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If the airbag chime is the same as the one for the headlights on and key in ignition then it is located in the speedometer cluster--It looks like a round black button and is in the upper left hand corner (looking at cluster from drivers seat)--I removed mine 5 years ago and soldered in a jumper...
You will need torx head for the manifold bolts--(with an extension)--Also a mirror to get the ones in the back by the firewall--Unless you remove hood to get a bords eye view--You do not have to remove the bolts on the manifold, just back them out--They will stay in the manifold while you lift...
I recently did mine also--To break free the large nut for the EGR on the mainfold I actually removed the passenger side inner fenderwell and stuck a large pipe wrench thru there onto the nut--I only got a 1/4 turn at a time, but it worked!!
Chances are it is the blend door actuator--Mine made a loud clicking (almost banging) noise when it gave out--I actually had no problem changing mine, due to the excellent write ups and info from this site--I did have a dealer quote me $ 700.00 to do it (car was in for recall)--
I have an 03 (V6) with factory tow package and used it to tow a 4500lb boat--And like leftlane 36 said, on flats it was fine but slowed down when it saw a hill--Never failed or ran hot, however-
I wrapped the old belt around the pulley then clamped the pulley from the back with a vice grip--Then used a pipe wrench to free the fan--The vice grip acts as a "stop" when it catches on the pump--
I installed one in my 03' XLT--No Rear Air, and it didn't have a mounting plate or wiring there--I also have a moonroof I had to contend with--Best Buy said they couldn't install one in the car because of the lack of clearance--I removed the trim for the moonroof and found a metal crossbrace...
I removed the chime itself--It's in the back of the instrument cluster--I wear my seatbelt 100% of the time, but leave my key in the ignition and that's what got to me-
I did mine in my 2003 XLT 2 weeks ago and followed the hints in this post
http://www.explorerforum.com/forums/showthread.php?t=198271&highlight=blend+door
I have the same exact symptoms--ABS Light only comes on during hard acceleration--I have changed the sensor on the master cylinder and the one on the rear differential (2 easiest and least expensive) and still comes on--Time to go get the code read--
Funny, I did my brakes last Tuesday and was missing the drivers side lower caliper bolt--I thought the pads were worn , but the noise was the caliper rubbing on the rim when I applied thre brakes--I got a replacement bolt at Lowe's--The one by me has a pretty good hardware selection--.82 cents--
I actually removed the chime itself--It is soldered into the back of the speedometer cluster--The belt chime didn't annoy me because I wear my seat belt, but the same chime stays on when you leave your keys in the ignition ( I leave my keys in )--I just soldered in a jumper wire--
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