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Home >> Ford >> 1992 >> Explorer 2D Utility, 4WD, Automatic >> Repair and Diagnosis >> Accessories & Equipment >> Cruise Control Systems >> Testing >> Control Switch & Circuit Test >> Aerostar, Explorer & Ranger

Aerostar, Explorer & Ranger

  1. Press brake pedal. Go to next step if stoplights operate properly. If stoplights do not operate properly, repair as necessary.
  2. Attempt to sound horn. Go to next step if horn operates properly. If horn does not operate properly, repair as necessary.
  3. Locate 6-pin connector at amplifier. See AMPLIFIER LOCATION table under REMOVAL & INSTALLATION. Using DVOM, check for continuity between circuit No. 57 (Black wire on vehicles with analog cluster) or circuit No. 397 (Black/White wire on Aerostar with electronic cluster) and ground. Repair amplifier ground circuit if necessary. If ground circuit is okay, go to next step.
  4. Turn ignition on. Check for battery voltage at circuit No. 296 (White/Purple wire on Aerostar) or circuit No. 302 (Dark Blue wire on Explorer and Ranger). If battery voltage is present, go to next step. If battery voltage is not present, check fuse and wiring back to fuse panel.
  5. Press brake pedal. Check for battery voltage at circuit No. 511 (Light Green wire) on Explorer and Ranger or circuit No. 810 (Red/Light Green wire) on Aerostar. If battery voltage exists, go to next step. If battery voltage does not exist, repair wiring between brakelight switch and amplifier and repair as necessary. If continuity exists between brakelight switch and amplifier, check amplifier. See AMPLIFIER TEST.
  6. Measure voltage at circuit No. 151 (Light Blue/Black wire). If meter indicates approximately 7.8 volts, go to next step. If meter indicates approximately 12 volts, service sticking speed control ON button or short to ground on circuit No. 151 (Light Blue/Black wire). If voltage is approximately zero, service shorted clockspring on Aerostar. If circuit No. 151 (Light Blue/Black wire) and ON-OFF buttons are both okay, substitute a known good amplifier and repeat test.
  7. Measure voltage at circuit No. 151 (Light Blue/Black wire) while turning steering wheel 1/4 turn left and right with specified control switch pressed. See CONTROL SWITCH VOLTAGE table.
    CONTROL SWITCH VOLTAGE

    Switch Position Approximate Voltage
    No Button Pressed 7.8
    ON 12.0
    OFF 0
    RESUME 6.5
    SET-ACCEL 4.5
    COAST 1.5
  8. If voltages are correct, cruise control switches are operating properly; go to step 15). If voltages are incorrect or fluctuate, go to next step.
  9. Turn ignition off. Unplug 6-pin connector at amplifier. Measure resistances between circuit No. 151 (Light Blue/Black wire) and amplifier ground with specified switch pressed. See CONTROL SWITCH RESISTANCE table. If values are correct, replace amplifier and retest. If values are incorrect, go to next step.
    CONTROL SWITCH RESISTANCE

    Switch Ohms
    OFF 0-1
    SET-ACCEL 646-714
    COAST 114-126
    RESUME 2090-2310
  10. Remove horn pad or air bag module (if equipped). Unplug 6-pin horn pad connector from steering wheel. Connect ohmmeter between circuits No. 151 (Yellow/Light Blue wire) and No. 6 (Dark Blue wire) on horn pad connector.
  11. Press ON button. If resistance is greater than one ohm, replace cruise control switch assembly. If resistance is okay, connect ohmmeter between circuits No. 151 (Yellow/Light Blue wire) and No. 57 (Black wire) on horn pad connector. Check for resistance values specified in CONTROL SWITCH RESISTANCE table.
  12. If values are correct, replace amplifier and retest. If resistance values are incorrect, remove steering wheel. Check circuits No. 151 (Light Blue/Black wire) and No. 57 (Black wire) for continuity between 6-pin connector and brush assembly (Explorer and Ranger) or clockspring (Aerostar).
  13. If continuity does not exist, check for continuity between 3-pin brush connector and brush assembly. Also check for continuity of each wire between 3-pin connector and amplifier 6-pin connector. Repair wiring or replace brush assembly as required.
  14. If continuity exists on both circuits, clean brush assembly (Explorer and Ranger) or clockspring (Aerostar) with solvent, then lubricate with Speed Control Slip Ring Grease (ESA-M1C122-A). Reinstall steering wheel and horn pad.
  15. Measure resistance between circuit No. 150 (Green/White wire) and circuit No. 397 (Black/White wire) on Aerostar, or between circuit No. 563 (Orange/Yellow wire) and circuit No. 397 (Black/White wire) on Explorer and Ranger. If resistance is not 180-250 ohms, check for continuity between 6-pin amplifier connector and 2-pin speed sensor connector at transmission. If wiring is okay, perform SPEED SENSOR TEST.
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