LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Lincoln >> 2004 >> Aviator AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1406 (Supplemental Inflatable Restraint System) >> Removal And Installation >> Occupant Classification Sensor >> Removal
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Occupant Classification Sensor: Removal

WARNING: This page is about a different car, the 2005 Lincoln Town Car. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not separate the components.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, or an OCS service kit is installed. A diagnostic tool is used to trigger the active command to carry out rezeroing of the OCS system.
CAUTION: If only installing a new front passenger seat cushion trim cover, the occupant classification sensor (OCS) must be rezeroed.
CAUTION: While positioning the seat cushion frame and occupant classification sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure.
NOTE: Occupant classification sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and electronic control unit) must be installed as an assembly.
NOTE: To identify between a production OCS system and a service OCS system (OCS service kit) inspect the electronic control unit (ECU) electrical connector. A production OCS system allows the disconnect of the ECU electrical connector. A service OCS system (OCS service kit) has the ECU electrical connector glued to the ECU. It cannot and should not be disconnected or altered. An OCS system service kit also has an in-line 18-pin connector between the OCS ECU and the seat wiring harness.
NOTE: The heated seat element on the front passenger seat cushion is not serviceable separately. If a new heated seat element is needed on the front passenger seat cushion, a new occupant classification sensor (OCS) service kit and a new heated seat element must be installed.
NOTE: If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer.

    All seats 

  1. Position the front passenger seat to access the fasteners.
  2. Depower the system. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING .
  3. Remove the front passenger seat. For additional information, refer to SEATING .
  4. Remove the front seat backrest. For additional information, refer to SEATING .
  5. Remove the seat track. For additional information, refer to SEATING .

    6. Heated seats 

  6. Disconnect the cushion heated seat element electrical connector.
    Fig 1: Disconnecting Cushion Heated Seat Element Electrical Connector
    G03880459Courtesy of FORD MOTOR CO.

    7. Seats with manual recline 

  7. Remove the seat backrest recliner handle.
    Fig 2: Removing Seat Backrest Recliner Handle
    G03880385Courtesy of FORD MOTOR CO.

    8. Seats with power lumbar 

  8. Release the tabs at the front and back, separate the power lumbar switch and bezel from the seat cushion pan and disconnect the electrical connector.
    Fig 3: Identifying Power Lumbar Switch
    G03880363Courtesy of FORD MOTOR CO.

    9. All seats 

  9. Disconnect the power lumbar switch electrical connector (if equipped) and release the remaining cushion trim cover J-clips.
    Fig 4: Disconnecting Power Lumbar Switch Electrical Connector
    G03881275Courtesy of FORD MOTOR CO.
    10. CAUTION: If replacing only the front passenger seat cushion trim cover, the occupant classification sensor (OCS) must be rezeroed.
    CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed or an OCS service kit is installed. A diagnostic tool is used to trigger the active command to carry out rezeroing of the OCS system.
    CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam.
    Fig 5: Separating Hook & Loop Strips
    G03881276Courtesy of FORD MOTOR CO.
  10. Separate the hook and loop strips. Position the seat cushion trim cover out of the way.
  11. Bend the retaining tab holding the pressure sensor in place downward and away.
    Fig 6: Bending Retaining Tab
    G03881277Courtesy of FORD MOTOR CO.

    12. Seats with an original equipment OCS 

  12. Remove the seat cushion pad from the seat cushion frame.
    Fig 7: Removing Seat Cushion Pad From Seat Cushion Frame
    G03881278Courtesy of FORD MOTOR CO.
  13. If necessary, remove the two pin-type retainers and the mat. Otherwise, position the mat out of the way.
  14. Remove the electronic control unit (ECU) and separate the pressure sensor from the seat cushion frame bracket.
    1. Release the pressure sensor hose.
    2. Disconnect the electrical connector and slide the pressure sensor from the bracket.
      3. CAUTION: Do not oversize the seat cushion frame holes used to rivet the ECU in place.
    3. Using a 5-mm (3/16-inch) drill, remove the three rivets.
    4. Remove the ECU bracket.
    5. Disconnect and remove the ECU.
    Fig 8: Removing ECU
    G03881279Courtesy of FORD MOTOR CO.
  15. Remove the pin-type retainers holding the OCS bladder to the seat cushion pan.
    Fig 9: Removing Pin-Type Retainers Holding OCS Bladder To Seat Cushion Pan
    G03881280Courtesy of FORD MOTOR CO.
    16. NOTE: Make note of the opening that the pressure sensor and hose are being fed through on the seat cushion support assembly for installation purposes.
    Fig 10: Separating OCS Bladder And Pressure Sensor From Seat Cushion Frame
    G03881281Courtesy of FORD MOTOR CO.
  16. Separate the OCS bladder and pressure sensor from the seat cushion frame.
    • Feed the pressure sensor and hose through the seat cushion support assembly.

    17. Seats with an OCS service kit 

  17. Separate the OCS components from the seat cushion frame.
    1. Release the pressure sensor hose.
    2. Slide the pressure sensor from the bracket.
    3. Cut the tie straps.
      4. CAUTION: Do not oversize the seat cushion frame holes used to rivet the ECU in place.
    4. Using a 5-mm (3/16-inch) drill, remove the three rivets.
    5. Remove the ECU bracket.
    6. Disconnect the ECU.
    Fig 11: Separating OCS Components From Seat Cushion Frame
    G03881282Courtesy of FORD MOTOR CO.
    18. NOTE: Make note of the opening that the OCS components are being fed through on the seat cushion support assembly for installation purposes.
    Fig 12: Removing OCS From Seat Cushion Frame
    G03881283Courtesy of FORD MOTOR CO.
  18. Remove the OCS from the seat cushion frame.
    • Feed the hose, pressure sensor, wire harness, electrical connector and ECU through the seat cushion frame support assembly.
  19. If necessary, remove the two pin-type retainers and the mat.
scientia non olet · About LEMON Manuals