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The chip in the key is part of the anti-theft system and immobilizer. Did the vehicle start after the fuel pump was changed? It is normal to disconnect the battery when removing fuel pump, and after a battery disconnect, the anti-theft system need to be reset.
Insert the key into the driver's side door lock.
Turn the key once, but not all the way to unlock the door. Leave the key in this position for 40-60 seconds. ...
Do this again, but turn the key in the opposite direction.
Remove the key from the door, get into your Ford, and start the engine. The system should be reset.
there is a max speed limit to engage and use 4 wheel low. try to engage while rolling 5mph and do not exceed 20mph in this "power" gear. also make sure the all drive components are well greased. lack of grease throws off drive alignment and may not easily engage.
GEAR SELECTOR LEVER - INCREASED EFFORT TO SHIFT FROM DRIVE TO PARK
Publication Date: November 1, 2004
FORD:
2002-2005 Explorer, Mountaineer
ISSUE:
Some 2002-2005 Explorer 4dr/Mountaineer vehicles, may require a greater effort to move the gear selector lever (shift lever) from drive to park. This may be due to a time delay with the brake shift interlock (BSI) pin retraction. ACTION:
To service, replace the BSI switch. Refer to the following Service Procedure. SERVICE PROCEDURE
Remove the two (2) fasteners supporting the instrument panel knee bolster from below the steering column and remove the cover (Figure 1).
Figure 1 - Article 04-22-12
Remove the three (3) fasteners supporting the steering column lower shroud and remove the cover (Figure 2).
Figure 2 - Article 04-22-12
Remove the three (3) wiring bundle carrier fasteners from the bottom of the steering column to allow movement while removing the BSI switch. It may be necessary to release the connectors from the multifunction switch (Figure 3).
Figure 3 - Article 04-22-12
Remove the BSI fasteners (T-30 on the side and T-20 on the bottom) (Figure 4).
Figure 4 - Article 04-22-12
Pull the BSI tab on the bottom of the column downward to help free the BSI from the column housing.
Break the two (2) side tabs off the BSI by the white wiring connector (Figure 5).
Figure 5 - Article 04-22-12
Push the locking tab on the white connector towards the wiring to release the connector from the BSI. Be careful not to damage the connector or wiring. If the connector does not free easily, a very small flat screwdriver may be used to help lift the locking tab (Figure 6).
Figure 6 - Article 04-22-12
Connect the wiring to the new BSI. Ensure all clips are fully engaged to prevent the connector from pulling free.
Reinstall the BSI onto the steering column and reinstall fasteners (Figure 7).
Figure 7 - Article 04-22-12
Check BSI function. With the key in the accessories or run position, press the brake pedal. The BSI pin should retract on brake application, and spring up one (1) second after releasing the brake pedal. Repeat several times.
Reinstall fasteners to connect wiring bundle carrier to the steering column. Make sure all connections to the multifunction switch unit are secured properly.
Reassemble steering column in reverse order. Ensure rubber gap hider around shift lever is properly seated on the shroud.
Cycle the shift lever from park to drive and drive back to park several times to verify improved shift effort.
Go to the engine compartment where the relays are located with the fuses. Check or replace the 4 wheel auto engage relay , maybe is not working. Is very clearly mark, I believe is the top right one looking at the bost front front of vehicle to the back. There is a diagram drawing of each relay in the cover, so you can't go wrong.
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