Extended Coverage Program 05N04 - 4.6L 2V - Extended Coverage For Composite Intake Manifold (05N04)

SUBJECT

Extended Coverage Program 05N04 

Certain 1996 through 2002 Vehicles Equipped with 4.6L 2V Engine:

• 1996-2001 Grand Marquis
• 1996-2001 Town Car
• 1996-2001 Crown Victoria
• 1997 Cougar, Thunderbird
• 1997-2001 Mustang
• 2002 Explorer and Mountaineer

Extended Coverage for Composite Intake Manifold

PROGRAM TERMS

This program is being provided as a settlement to a class action lawsuit. The terms of the settlement extend the coverage of the all-composite intake manifold to 7 years from the original warranty start date of the vehicle, with no limit on the number of miles that the vehicle has been driven. Coverage is automatically transferred to subsequent owners.

VEHICLES COVERED BY THIS PROGRAM

Affected vehicles are identified in OASIS.

REASON FOR PROVIDING ADDITIONAL COVERAGE

Some of the all-composite intake manifolds used on 4.6L SOHC engines may develop fatigue cracks at the coolant crossover duct which could result in external coolant leakage. Drivers may be alerted of this potential leakage by the coolant level and/or coolant temperature warning systems.

SERVICE ACTION

ATTACHMENTS

1. Attachment I: Administrative Information
2. Attachment II: Labor Allowances and Parts Ordering Information
3. Attachment III: Technical Information regarding how to inspect vehicles for customers that seek reimbursement without a receipt. (Refer to shop manual for intake manifold replacement instructions)
4. Notice of Proposed Settlement of Class Action and Settlement Fairness Hearing  (This document contains the declaration page that needs to be signed by the customer and attached to repair orders that are processed for refunds without receipts)

QUESTIONS?

1. Special Service Support Center (Dealer Only) Questions: ... 1-800-325-5621
2. Parts Support Center (Dealer only) Questions: ... 1-800-207-2444

OASIS ACTIVATED?

Yes. Affected vehicles will be activated in OASIS on December 14, 2005.

FSA VIN LIST ACTIVATED?

No.

STOCK VEHICLES

Do not perform this program unless the affected vehicle exhibits the covered condition (fix only if the coolant crossover duct is leaking). Stock vehicles are not eligible for refunds without an original receipt.

SOLD VEHICLES

Owners with affected vehicles that exhibit the covered condition will be directed to dealers for repairs. Owners who have paid for this repair within seven years of the warranty start date will also be directed to dealers to submit for reimbursement. Repairs that were performed after December 16, 2005, will not be eligible for a refund unless an emergency repair was needed and a Ford or Lincoln Mercury dealer was not available.

TITLE BRANDED / SALVAGED VEHICLES

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

RELATED DAMAGE

It is highly unlikely that you will encounter related damage while performing this repair, but 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. Components such as ignition coils, engines, alternators, spark plugs and spark plug wires are examples that are not covered by this program. Requests for approval after completion of the repair will not be granted.

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.
• If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center.

OWNER REFUNDS

• Program 05N04 covers one intake manifold replacement per vehicle. Program 46B01 covers one refund per vehicle. The replacement program will show on OASIS as 05N04 and the refund program will show as 46B01. If you receive a refund request for a vehicle that no longer has 46B01 open on OASIS, call the Special Service Support Center for prior approval.
• Ford Motor Company will only refund owner-paid repairs covered by 46B01 if the repair was performed prior to December 16, 2005. (or after December 16, 2005 if an emergency repair was made when a Ford, Lincoln or Mercury dealer was not available.)
• The repair must have been completed within 7 years of the warranty start date to be eligible for a refund.
• The dealer must submit for reimbursement to Ford by March 16, 2006. This refund period was specified by the court settlement. Refund claims will not be accepted after March 16, 2006. Dealers have until March 20, 2006 to submit corrections for claims that were submitted on or before March 16, 2006.
• Refund claims that include other non-covered repairs will not be accepted for reimbursement.
• Engine replacement and other engine repairs are not covered under this program.
• Customers with receipts:
  • The customer must present the original, a photocopy of or a duplicate of the original receipt to receive the same amount of money that they paid for the repair.
  • Refund claims with supporting receipts over $900 will require prior approval from the Special Service Support Center.
• Customers without receipts:
  • If a customer claims that he or she paid to have the intake manifold replaced due to a cracked coolant crossover duct leak but no longer has the receipt, there is an inspection process to determine refund eligibility. Refer to attachment III for inspection instructions. The vehicle must still be within 7 years of the warranty start date to be eligible for a refund without a receipt.
  • Customers submitting for a refund without a receipt must provide the dealer with a signed declaration page from the class action notification (copy attached). The dealer must attach this completed document to the refund repair order.
  • Customers that are eligible for reimbursement without a receipt will receive the court settlement determined amount of $735.00.

RENTAL VEHICLES

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

CLAIMS PREPARATION AND SUBMISSION

• Enter claims using Direct Warranty Entry (DWE).
• Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. (Requires prior approval)
• "MT" labor should be submitted on a separate repair line with the related damage flag checked. (Requires prior approval)
• Refer to ACESII manual for claims preparation and submission information.

LABOR ALLOWANCES

PARTS REQUIREMENTS / ORDERING INFORMATION

Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels.

RECALL PARTS ASSISTANCE

There are three methods to use for questions or assistance regarding recall parts:

• Parts Support Center: 1-800-207-2444
• E-mail: ford@renkim.com
• FAX Number: 1-888-374-8040

When contacting the Parts Support Center via phone, FAX, or E-mail for a question, or concern, please provide:

• Dealer Name and P & A code
• Contact Name
• Phone number and E-mail address
• FSA #: Customer Satisfaction Program 05N04
• Include a VIN#
• Part number that you have a question / concern with

DEALER PRICE

For latest prices, refer to DOES II.

PARTS RETENTION AND RETURN

Affected intake manifolds are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions.

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

OVERVIEW

This program involves either:

1. inspecting the intake manifold part number to determine if the owner is eligible for reimbursement for a previous intake manifold replacement repair without a receipt, or
2. inspecting the intake manifold coolant crossover directly behind the alternator for leakage in the event the owner reports a suspected coolant leak. If a leak in this specific area is verified, the intake manifold must be replaced.

Proceed to the appropriate inspection procedure.

PART NUMBER INSPECTION

1. Remove the engine appearance cover, if equipped.
2. Locate the area on the intake manifold where the part number is to be found. See Figure 1.
   Fig 1: Intake Manifold Part Number Location

   
3. NOTE:  Thorough cleaning of the area is required in order to accurately read the part number prefix and suffix. Wrap a shop towel around the end of either a long screwdriver or long extension to reach the affected area to wipe after spraying with cleaner.

   Clean the area between the two (2) runners by first blowing any dirt or foreign material away using compressed air. Then spray the area with Motorcraft Metal Brake Parts Cleaner, PM-4 or equivalent, and using a shop towel, wipe the area clean.

4. Read and record the intake manifold part number.
   • If the part number on the manifold matches the part numbers listed below, the vehicle is not eligible for a refund without a receipt.
   • If the part number is different than the numbers listed below, the vehicle is eligible for a refund without a receipt.

COOLANT LEAKAGE INSPECTION

1. NOTE:  To properly inspect the intake manifold you must look down behind the alternator.

   Inspect the coolant crossover area of the intake manifold as shown in Figure 2 for engine coolant leakage.

   • If seepage IS present, the intake manifold MUST be replaced. Refer to the appropriate Workshop Manual, Section 303-01 for 1996 through 1998 model year vehicles and Section 303-01 for 1999 through 2002 model year vehicles for replacement procedures for intake manifold.
   • If seepage is NOT present, no service action is required.

Fig 2: Area To Inspect For Leakage