2002 Ford ZX2 AutomaticFACTORY OEM SERVICE PROCEDURE

Functional Test

NOTE: If the retractor of a new safety belt assembly has been bolted into a damaged or distorted mounting area, the new retractor could be warped and may not function. If this is the case, reshape the sheet metal back to original shape and structural integrity and install another new complete safety belt assembly.
  1. Determine the type(s) of safety belt assembly(s) that have been replaced. Then functionally test the new safety belt assembly using the following procedure:
  2. The driver will buckle up and proceed to a safe test area. A passenger should be buckled into the seat where the belt is to be tested.
    3. WARNING: The driver and passenger must be prepared to brace themselves in the event the retractor does not lock.
  3. After reaching a safe area to perform sudden stops, the driver will attain a speed of approximately 8 km/h (5 mph). The driver should inform the passenger that he is preparing to make a severe brake application. At this time, both driver and passenger should grasp their respective shoulder harnesses and prepare to lean slightly forward at the moment the brake application is made.
  4. The driver will make a maximum brake application (approximately 9.75m/sec 2 [32 ft/sec 2 ]) without tire skid. (The maximum brake application should be on dry concrete or equivalent hard road surface, never on a wet or gravel road.) The driver and passenger should lean forward slightly into the shoulder harnesses. At this instant, the safety belts should lock up without belt webbing payout.
  5. If there is a lockup of both shoulder straps, the safety belt assemblies are functioning correctly. Should either or both retractors fail to lock up at the 8 km/h (5 mph) speed, the test should be repeated at a constant 24 km/h (15 mph).
  6. If either or both shoulder safety belts do not lock up at the 24 km/h (15 mph) test, repair the malfunctioning safety belts. Remove the retractor and rework the sheet metal back to its original shape and structural integrity of the retractor's mounting surface. Install the retractor assembly and test the safety belt assembly(s).
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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