Skillet wrote:How difficult is it to remove and replace the passenger seat?
It's not too difficult. Basically four bolts, which you can reach fairly easily (the Ford seat base is "hollow" underneath). Then the seat and its slanted base come out together (along with the seat belt pre-tensioner, which is attached to the seat as well). You have to unplug the pre-tensioner, but that is also easy (is on floor under center of seat).
Here is where it got complicated for me, but would be simple for anyone else:
Researching this ahead of time, I found that if you "just" unplug the airbag from the passenger seat, then the system will register an error code, the airbag light will come on, and now you have no airbags at all. Unacceptable for me.
Well, then ensued tons of research, but it's a bit tricky. Because I mean you can't just call up Ford, say you want to disable the passenger airbag, and would they mind helping you out. Ha, right.
And also, different generations of airbags work differently (they seem the same in a 2003 cutaway as in my '99 tho). Newer ones (past the Chinook era) can be turned off, etc.
Anyway, long story, including following a Ford bulletin and replacing the crash sensor module as directed. No, that didn't work. Finally it turned out to be super simple! The airbag sensor under the passenger seat just wants to see a certain resistance. I think I could just have plugged a resistor into it and been fine. But I wanted something slightly more official and "repeatable" without wearing out. So I ordered a "dummy plug" that is used in the industry for isolating the seat vs. the plug in order to do repairs. I'm sure it's just a resistor, but it's inside something with electrical contacts that you can easily use. As a side bonus, the company that sells them double checked my research (he had a diagram of the system) and agreed it would work. And the dummy plug was only like $29. So I bought it. Then I went one step further and attached it to the "seat end" of a spare (junkyard) airbag plug. So now I can easily either have the seat plugged in (seat in place) or the dummy plug in (seat out). Either way the airbag system works just as it is supposed to. No lights, no codes, no loss of function.
(Side note is that the same company also has an airbag switch, that can be used by itself or in conjunction with the plug. The use for the switch alone would be with seat in, but no airbag desired [child in seat, etc.] I don't have that situation, so no need for switch.)
You'd want to make sure your system was the same, but a buddy with a 2003 E-450 cutaway has the exact same system (the pure vans might have advanced at a different rate than the cutaways that we have).
So to summarize:
1) Four bolts to remove seat+base.
2) Unplug airbag plug on floor (leads to seatbelt pre-tensioner).
3) Pull seat/base/pre-tensioner out side door in one piece.
4) Plug in pre-made dummy plug.
5) In my case, put in custom tool/whatever box with upper map/snack tray
Standard warning: Do any of this at your own risk, I'm not an expert, I don't work for Ford, etc.