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Home >> Lincoln >> 2006 >> Zephyr >> Repair and Diagnosis >> Body & Frame >> Seats >> Seating >> Disassembly And Assembly >> Seat Backrest - Front >> Assembly

Seat Backrest - Front: Assembly

    All seats 

  1. Route and install the backrest wiring harness, if removed.

    2. Seat with side air bag 

  2. Install the side air bag mounting bracket and 2 nuts, if removed.
    • Tighten to 6 Nm (53 lb-in).

    3. Seat with power recliner 

    NOTE: The recliners are synchronized. Avoid rotating the recliner shaft until fully installed.
  3. Install the recliner motor.
    1. Position the recliner shaft through the recliner motor and RH recliner.
    2. Install a new one-way push clip onto the recliner shaft at the RH recliner.
    3. Slightly turn the recliner motor to align the bolt hole with the hole in the RH recliner and install the recliner motor bolt.
      • Tighten to 6 Nm (53 lb-in).
    4. Connect the recliner motor electrical connector.

    4. Climate controlled seat 

    NOTE: Before assembly, inspect the climate controlled seat components for damage, crush, obstruction and debris and repair as needed.
  4. Install the upper support spring and TED assembly to the backrest frame.
    • Attach the TED and bracket to the backrest upper support spring as noted in disassembly, if removed.
  5. Connect the exhaust duct to the TED and install a new tie strap.
  6. Connect the TED electrical connector.

    7. All seats 

  7. Attach the lumbar assembly spring clips and install the lumbar assembly to the backrest frame.
    • Route the lumbar cable to the backrest as in disassembly, if equipped.
    • Connect the power lumbar motor electrical connector, if equipped.

    8. Seat with side air bag 

  8. Install the side air bag wiring harness.
    • Route the side air bag wiring harness to the backrest frame as noted in disassembly and install the pushpin-type retainers.

    9. All seats 

  9. Position the backrest foam pad to the backrest frame.
    • If removed, install a new backrest heater mat.
      • For installation, peel away the paper from the adhesive strips, align and apply the new heater mat to the backrest foam pad being sure to tuck the heater mat into the foam pad creases.
      • The heater mat must lay flat on the foam pad with no wrinkles.

    10. Climate controlled seat 

    NOTE: Inspect the climate controlled seat backrest manifold for crush and obstruction before installation. If damaged, install a new backrest manifold.
  10. If removed, align the backrest manifold and insert into the valleys of the foam pad.
    • Check for correct fit between the manifold, foam pad and TED assembly, to make sure there is no air flow obstruction or cushion crush.
      Fig 1: Locating Backrest Manifold Position
      G04683533Courtesy of FORD MOTOR CO.
  11. Install new hog rings to the upper support spring and foam pad.
    Fig 2: Locating Hog Rings
    G04683534Courtesy of FORD MOTOR CO.

    12. All seats 

    NOTE: A backrest trim cover for a seat with a side air bag module is different than a backrest trim cover for a seat without a side air bag module. Make sure the correct backrest trim cover is being installed.
  12. Position the backrest trim cover to the backrest frame and foam pad and install new rear upper hog rings to the backrest frame.
  13. Roll the backrest trim cover downward and attach the hook and loop strips.
    • If removed, install new hog rings as noted during disassembly.
      Fig 3: Attaching Hook And Loop Strips
      G04683535Courtesy of FORD MOTOR CO.
    14. NOTE: The head restraint guides are keyed to the backrest frame and are not interchangeable.
  14. Install the 2 head restraint guides to the backrest.
  15. Connect the inner and outer backrest trim cover J-strips.
  16. Install the 2 pin-type retainers and trim cover flaps to the recliners, if equipped.

    17. Seat with side air bag 

    WARNING: If the air bag cover has separated or the air bag material has been exposed, install a new side air bag module. Do not attempt to repair the air bag module. Failure to do so may result in personal injury in the event of an air bag deployment.
    WARNING: Inspect the mounting surfaces of the side air bag module for any foreign objects before installing the side air bag module. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment.
  17. Connect the side air bag module electrical connector and then slide and engage the side air bag electrical connector locking clip.
  18. Install the side air bag module to the mounting bracket on the backrest frame.
    • Position the side air bag module locator hook in the side air bag bracket the seat back frame.
  19. Align the bolt hole and install the side air bag bolt.
    • Tighten to 10 Nm (89 lb-in).
  20. Install the side air bag bolt cover.

    21. All seats 

  21. Install the front seat backrest. For additional information, refer to SEAT BACKREST - FRONT .
  22. Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this time.  For additional information, refer to SEAT - FRONT .

    23. Passenger seat 

  23. Carry out the OCCUPANT CLASSIFICATION SENSOR (OCS) SYSTEM ZERO SEAT WEIGHT TEST and prove out the SRS.
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