Safety Recall 05S28 - Speed Control System Modification (05S28)

SUBJECT

Safety Recall 05S28 - Supplement #16 

Certain 1992-2004 Multiple Vehicle Lines

Speed Control System Modification

REASON FOR THIS SUPPLEMENT

Advise dealers that the allowance for claiming Motorcraft XG-15-A Electrical Grease II has been increased. 

AFFECTED VEHICLES

Affected vehicles are identified in OASIS. In addition, for a list of vehicles assigned to your dealership, visit https://web.fsavinlists.dealerconnection.com  .

REASON FOR THIS RECALL

The underhood Speed Control Deactivation Switch (SCDS) may overheat, smoke, or burn, which could result in an underhood fire. The potential for a fire exists regardless of whether speed control is being used or the engine is running.

SERVICE ACTION

At no charge to the vehicle owner, dealers are to inspect the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination on all affected vehicles. After the inspection, dealers are to perform the repairs as specified in the "Vehicle Parts Application & Labor Operation Chart"  in Attachment II.

OWNER NOTIFICATION MAILING SCHEDULE

CAR VEHICLES: Part availability letters were mailed to all car vehicle owners in the February through March, 2008 timeframe. The letters informed owners that service parts to perform permanent repairs on their vehicles were available, and encouraged them to contact their dealer to have the permanent repair performed at their earliest convenience.

TRUCK VEHICLES: Part availability letters will be mailed to all truck vehicle owners beginning in mid-April, 2008. The letters will inform owners that service parts to perform permanent repairs on their vehicles are available, and encourage them to contact their dealer to have the permanent repair performed at their earliest convenience. The letters will be mailed in phases through the end of May, 2008.

PLEASE NOTE: 

Federal law requires dealers to complete this recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $6,000 per vehicle. Correct all vehicles in your new vehicle inventory before delivery. 

ATTACHMENTS

1. Attachment I: Administrative Information
2. Attachment II: Labor Allowances, Parts Ordering Information, & Obsolete FJH Usage
3. Attachment III: Technical Information
4. Attachment IV: FJH Parts Application Chart
5. Attachment V: Dealer Q & A
6. Owner Communications

QUESTIONS & ASSISTANCE

For questions and assistance, contact the Special Service Support Center (SSSC) via the SSSC Web Contact Site. The SSSC Web Contact Site can be accessed through the Professional Technician Society (PTS) website using the SSSC link listed at the bottom of the OASIS VIN report screen or listed under the SSSC tab.

OASIS ACTIVATED?

Yes, OASIS was activated August, 2007.

FSA VIN LIST ACTIVATED?

Yes. FSA VIN list is available through https://web.fsavinlists.dealerconnection.com. 

STOCK VEHICLES

Correct all affected units in your vehicle inventory before delivery.

SOLD VEHICLES

• Owners of affected vehicles will be directed to dealers for repairs.
• Correct other affected vehicles identified in OASIS which are brought to your dealership.

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this Field Service Action.

RELATED DAMAGE

If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed within a reasonable period of time after receiving notification.

ADDITIONAL LABOR TIME

If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted.

OWNER REFUNDS

• Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121-6251.
• Dealers are also authorized to refund owner-paid emergency  repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed.
• Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines.
• This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close out the VIN for this recall. 
• Refund Claiming Information (Submit on separate repair line.)
  1. - Program Code: 05S28
  2. - Misc. Expense: ADMIN
  3. - Misc. Expense: REFUND
  4. - Misc. Expense: 0.2 Hrs.

RENTAL VEHICLES

The use of rental vehicles is not authorized for this program.

CLAIMS PREPARATION AND SUBMISSION

• It is no longer necessary for dealers to manually enter labor operation times for vehicles built prior to the 1997 model year.
• Enter claims using Direct Warranty Entry (DWE) or One Warranty Solution (OWS).
  • DWE: refer to ACESII manual for claims preparation and submission information.
  • OWS: when entering claims in DMS software, select claim type 31: Field Service Action. The FSA number (05S28) is the sub code.
• Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from Special Service Support Center.
• "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center.
• Claiming Information for Electrical Grease II (Submit on same repair line as repair.)
  1. - Program Code: 05S28
  2. - Misc. Expense: OTHER
  3. - Misc. Expense: $13.50 
  NOTE: Electrical Grease II can only be claimed when Labor Operation 05S28XE, 05S28XX, or 05S28XB is claimed. (Do not claim as "Normal Shop Supplies".)

LABOR ALLOWANCES

PARTS REQUIREMENTS / ORDERING INFORMATION

DEALER PRICE

For latest prices, refer to DOES II.

PARTS RETENTION AND RETURN

After the claim is submitted, the Ford Warranty Parts Analysis Center (WPAC) may initiate an FCS 700 tag for the return of Speed Control Deactivation Switches. Do not return any removed parts unless you receive notice from PEARS (Parts Entry And Return System). Refer to your daily PEARS register for part disposition and return instructions.

Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures".

EXCESS STOCK RETURN

To preserve the inventory of the Universal Fused Jumper Harness parts, dealers are requested to exhaust their existing inventories of the non-universal Fused Jumper Harness parts (4W1Z-14A411-BC and 8W7Z-14A411-BB) on the approved vehicle applications specified in Attachment IV, prior to using the Universal Fused Jumper Harness parts on those applications. 

Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000.

FJH Parts Application Chart

Remaining dealer inventories of the 8W7Z-14A411-BB and 4W1Z-14A411-BC non-universal Fused Jumper Harnesses are approved for use on only  the vehicle applications identified below.

SPEED CONTROL DEACTIVATION SWITCH (SCDS) IDENTIFICATION AND LOCATION

SCDS Identification

The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1.

Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS.

FUSED JUMPER HARNESS (FJH) IDENTIFICATION

The new  universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2.

PARTS APPLICATION CHART

SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION

Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid.

• All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness.
  • On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector.
• If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors.

FUSED JUMPER HARNESS (FJH) INSTALLATION

1. Connect the fused jumper harness to the SCDS and the vehicle harness.
2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4.

SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT

1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level.
   NOTE: DO NOT apply fluid to the electrical connector or damage to the connector may occur.
   NOTE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle.
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5.
   NOTE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed.
   NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed.
   NOTE: If the new  SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program.
3. Remove the SCDS.
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS.
5. Tighten the new  SCDS as follows:
   • 18 Nm (159 lb-in) - all vehicles except 1994 Capri.
   • 13 Nm (115 lb-in) - 1994 Capri.
6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap.
7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6.
   • If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step.
   • If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions.
8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors.
9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip.
10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7.
11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness.
    NOTE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module.
12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8.
13. Reconnect the servo connector.
14. Release the vehicle.

DEALER Q & A

Q1. What is the Universal Fused Jumper Harness? 

A. The Universal Fused Jumper Harness contains a fuse in each side of the circuit to accommodate polarity complexity across vehicle lines, and a connector hardshell that is compatible with all Speed Control Deactivation Switches.

Q2. Why are the Speed Control Deactivation Switches not interchangeable on all vehicle applications? 

A. Differences in Speed Control Deactivation Switch (SCDS) activation pressures make it essential  that the correct SCDS is installed in the specified vehicle application.

Q3. Can I just remove the fuse for the Speed Control System circuit? 

A. No. Removing the fuse will disable more systems on the vehicle than just the Speed Control System.

Q4. Can the customer disconnect the Speed Control Deactivation Switch connector? 

A. No. To ensure that the correct connector is disconnected, a dealership technician should perform this service.

Q5. Is the Speed Control Deactivation Switch located on the vehicle steering wheel? 

A. No. The Speed Control Deactivation Switch is typically mounted to the brake master cylinder under the hood. On some of the earlier built vehicles, the SCDS was mounted to a junction block or brake proportioning valve located below the master cylinder on or near the frame rail.

Q6. Can customers avoid overheating the switch by not using the Speed Control System? 

A. No. The electrical circuit to the Speed Control Deactivation Switch is always energized, so not using the Speed Control System doesn't reduce the potential for overheating of the switch.

LETTER: CAR OWNERS - SERVICE PARTS ARE AVAILABLE MESSAGE

LETTER: TRUCK OWNERS: INTERIM REPAIR MESSAGE

POSTCARD: '01/'02 RANGER W/ INTERIM REPAIR - SERVICE PARTS ARE AVAILABLE MESSAGE

POSTCARD: TRUCK W/ INTERIM REPAIR - PARTS DELAY MESSAGE

Ford Motor Company Recall Reimbursement Plan for 05S28

Ford Motor Company has historically reimbursed customers for expenses to remedy a safety recall defect or noncompliance that were incurred before the customer was notified of the recall. These reimbursements have been processed through our dealer network, because our dealers are in the best position to quickly and efficiently satisfy these requests. We will continue to provide this service to our customers. However, new federal legislation now requires all motor vehicle manufacturers to establish processes through which customers may alternatively seek recall reimbursement directly from the manufacturer as well as from the dealers. 

Regarding the specific reimbursement plan for Recall # 05S28, owners who have paid for service to remedy the defect or noncompliance must have had that service performed prior to October 10, 2007 (the "ending date" referred to in the letter below). After this date, if repairs related to this recall are performed by a non-Ford repair facility in an emergency situation, customers must submit any refund requests through their dealership. As required by this federal regulation, Ford Motor Company submitted the details of its General Recall Reimbursement Plan in a letter to the National Highway Traffic Safety Administration (NHTSA) in February 2003. The following is the text of that letter and the Plan: 

General Recall Reimbursement Plan (As submitted to the NHTSA)

Pursuant to the requirements set forth in 49 CFR Part 573 and Part 577 of the Code of Federal Regulations, Ford Motor Company (Ford) is submitting required information pertaining to our general reimbursement plan for the cost of remedies paid for by vehicle owners before they are notified of a safety recall.

As the agency is aware, prior to this rule Ford has routinely reimbursed owners for the cost of such pre-notification remedies. Our practice will continue under the new rule with a few minor modifications. Set forth below is Ford's general reimbursement plan to reimburse owners and purchasers for costs incurred for remedies in advance of notification of potential safety-related defects or noncompliance pursuant to Part 573.6(c)(8)(i).