The NextGen PI Sedan – PI Utility Operation and Service
training is a two-day course with the same content as dealership tech training.
Some police-unique material is covered, specifically the All Wheel Drive systems. However, the
Ford Tech Training is not a police-specific, police-interface course. It may be
conducted in a police garage, but the content is virtually the same as given to
The training is divided into six major sections: Vehicle
Overview; Electrical-Electronics; Engine Operation-Components; Engine
Diagnostic-Service; Automatic Transaxle; All Wheel Drive.
On the first day, the big differences between these two
NextGen vehicles and the Ford CVPI are pointed out and explained. This is
obviously the All Wheel Drive
components, the Ti-VCT engines, and the 6-speed transaxle. But it also includes
an overview of the optional EcoBoost engine, and the High Speed-CAN, i.e., the
totally different electrical architecture.
Same But Different
The first day also includes an overview of both new
vehicles, the PI Sedan and the PI Utility, again, both the differences and the
similarities. The PI Sedan and PI Utility share common service parts including
tires, wheels, oil, oil filter, brake pads and brake rotors. Other common
components include the battery, alternator, brake calipers, rear differential
unit and seats. That means the first day is good for the fleet manager, shop
superintendent and foreman. It is also worthwhile for members of the police
admin on the operations and special service side and for upfitters.
The second day is quite different. It is very
diagnostic-oriented, very hands-on, and very tech-oriented. This aspect is
essential for the tech, of course, but just doesn’t apply to those not directly
involved with the vehicles. Shop foremen and techs who raise the hood and grab
the scan tools to fix driveability issues will find this two-day course
extremely valuable. If you are moving from the Ford CVPI to either/both the PI
Sedan or PI Utility, this course will keep you up to speed on Ford’s 30-year
jump in technology.
The training has a perfect 50:50 balance between classroom
and hands-on. However, the hands-on is strictly fingers on a keyboard, not
hands on a wrench. In fact, not a bolt or nut was turned either day. While this
is definitely mechanic-focused, it assumes two things about the tech. First, it
assumes the tech is already familiar with Ford’s diagnostic tools and systems.
Second, it assumes that the tech knows what to remove/replace once the proper
diagnosis has been made.
This two-day course is, by design, geared for diagnostics on
the new PI Sedan and PI Utility. As such, it is ideally suited for techs who do
significant fleet maintenance, whether or not their shop is a warranty repair
facility. While this is a drivability diagnostics course, the only tool used is
a laptop. No parts are replaced/removed with wrenches.
This course is perfect for, and should be required for,
police shops that go beyond preventative maintenance jobs of oil, tire and
brake changes. If you do PM but send all the other work to the local dealer,
this two-day course may be more tech-oriented than you need.
The course quickly touches on some of the police-specific
harnesses, modules and connectors important to upfitters. Another nod to
upfitters during the course was the emphasis on the Ford Modifier’s Guide. This
is available for all years, including the 2013 police cars, online in an
unrestricted area of Ford’s website. Go to www.fleet.ford.com, click Police
Cars, and then look at the right side of the screen.
The online Modifier’s Guide has 300 megs of information,
which is more than twice the content of the older Modifier’s Guides. The Guide
has five sections: General Information; Electrical; Installation
considerations; Trunk Mounting Considerations; Reference Information.
Ford’s world of automotive maintenance may be guided by two
very different manuals. The Workshop Manual (WSM)
contains detailed repair information on components and systems. It contains
diagnostic information on non-OBD II automotive systems. On the other hand, the
Powertrain Control / Emissions Diagnosis (PC/ED) manual contains drivability
and OBD II systems diagnostic information. The companion to both these manuals
is wiring diagrams. These show wiring charts, component and connector locations,
and connector face views.
Each tech was given a 300-page manual with all the PDFs used
in the course. The manual has three pages of Ford-speak acronyms and what they
mean. Frankly, this is critical because each automaker has their own terms.
Walk Around (and
The classroom portion began with a quick overview of the base
3.5L and 3.7L base engines and the optional 3.5L EcoBoost (twin turbo) engine.
Then a walk-around (and walk under) was conducted with the PI Sedan and PI
Both the PI Sedan and PI Utility operate as FWD vehicles
unit wheel slip is detected. Only then does power transfer to the rear wheels. Of
the most importance, the transaxle with water-cooled (police-only) AWD Power
Transfer Unit was located. And then the rear axle-mounted Active Torque
Coupling Unit attached to the Rear Differential Unit was pointed out. On these
AWD vehicles, power is continually fed to both the front half-shafts and the
rear driveshaft. The driveshaft is constantly engaged and rotating even if
power is not fed to the rear wheels.
The Front Wheel
Drive system and the Power Transfer Unit send
torque back to the rear clutch pack all the time. Any time the vehicle is
moving, the driveshaft to the rear is turning. The Active Torque Coupling
mounted on the Rear Differential Unit only passes on torque when needed. But it
is literally right there when it is needed.
The Powertrain Control Module sends a signal to partially or
fully engage or disengage the Rear Wheel Drive part of the AWD. Based on input
from the four wheel sensors feeding the ABS
module, the steering angle sensor module and the instrument cluster module, the
PCM sends a signal to the AWD relay (?) module
and the 4x4 lock solenoid in the Active Torque Coupling. As this progressively locks
up, power is sent to the Rear Differential Unit and on to the rear wheels.
Since the Power Transfer Unit operates all the time to spin
the driveshaft to the rear, the PTU can get hot. On the police version, a
number of steps are taken to assure reliability and durability in police use. First,
a cooler is added to the front of the PTU housing. The police-only PTU housing
has an integral water jacket connected with water lines that run to the bottom three
coils of the radiator. The jacket receives engine coolant from the radiator to
maintain the correct PTU oil temperature.
Second, the PTU has a gear-lube temperature sensor. A module
keeps track of the gear lube temp, and how long/how often it was at that
temperature. When a threshold is reached, a change PTU Oil light activated.
Finally, the AWD system has a two-stage way to protect
itself from damage during extreme, prolonged use. The ATC has a heat protection
strategy based on a number of factors, including wheel speed and duration of
activity, to determine if overheating is occurring. If the ATC detects
overheating, it will lock the clutches together to cool them. Clutches that
slip to provide partial torque transfer get hot from the friction of the
slippage. Locking the clutches stops the slip and cools the entire unit. In a
locked condition, power is transferred to the rear wheels.
The ATC/RDU used on the Police Interceptors uses
fluid-filled “wet” clutch packs. The retail Taurus and Explorer use dry
clutches. The PI wet clutches can withstand higher temps and withstand higher
temps longer than the retail unit. The ATC and RDU are not field serviceable.
In case of a problem with either system, the whole unit is replaced.
After the walk-around, came the first of many hands-on
exercises. The class of 18 techs was divided into three groups that rotated from
task to task. The first was to find a wide variety of solenoids, sensors,
modules and components on either the PI Sedan or PI Utility.
Where is the PTU? Right-hand side of the transaxle. A PTU
leak is suspected. Fluid is visible on the right-hand half-shaft. What else
could it be? A trans seal leak and vice versa. This can be confusing since the
right half shaft goes through the transaxle. Check the color of the fluid.
Trans fluid is red, while the heavy PTU lube is brown.
Where is the Police
Center? Left-hand side of
the trunk. Where is the Powertrain Control Module? Engine side of the firewall,
right side, under the wiper mesh fascia. There were two dozen other modules,
sensors and relays to find.
The next exercise was going online, pulling up the
Modifier’s Guide, and answering common upfit questions. What is the maximum
output of the alternator during ideal ambient conditions? 220 amps. What color
are the circuits that run between the Lighting/Siren Control Module and the
siren speaker? Yellow and Blue with White stripe.
The next exercise was looking up Ford’s diagnostic tools,
accessing some information, and selecting other programmable parameters from
various menus. In Ford-speak, that means attaching the Rotunda Vehicle
Communication Module (VCM) that uses Ford’s proprietary Integrated Diagnostics
The hands-on exercise was to check for Diagnostic Trouble
Codes (DTC). The brand-new PI
Sedan and PI Utility had none. Go to the Tools Menu; select Electrical-Charging
System Test. What IDS component is
required to perform this test? Vehicle Measurement Module (VMM). Go to the
Module Programming Menu, select Interior Lighting. Place the vehicle in Dark
Car mode. This feature is enabled through which control module? Body Control
Unlike the Dodge Charger Pursuit and Chevy Caprice PPV tech
training, Ford’s NextGen Police Interceptor tech training is fee-based. A
charge is required due to contractual clauses with the dealership franchise and
Ford intellectual property. The two-day course has a flat fee of $4,200 with a
class size ranging from 12 to 18 techs. That is about $280 per tech. Since it
is a flat fee, it is possible for fleet managers and police admin to sit in on
the first day. They can audit the vehicle overview, walk around but pass on the
The host department should have both a PI Sedan and a PI
Utility on hand, and it is best if they have vehicles with the 3.7L V6 and the 3.5L
EcoBoost V6 available. These vehicles are for scanning exercises only; none are
For more information, contact Chris Keady, Ford Commercial
Vehicle Operations at firstname.lastname@example.org. You may also contact your regional
government account manager.