Customer Satisfaction Program 05E16 - 6.0L Diesel - Engine Control Modules RECALIBRATION (05E16)

SUBJECT

Voluntary Emission Recall 05E16 

Certain 2004-2006 Model Year F-250/350, Excursion, and E350 Vehicles Equipped with 6.0L Diesel Engines

Engine Control Modules Recalibration

AFFECTED VEHICLES

Group 1: Certain Vehicles Under 14,000# GVW and Equipped With a Calibration That Requires Compliance with OBD Regulations:

• 2005-2006 model year E350 vehicles equipped with 6.0L diesel engines built from 3/4/2005 through 8/7/2005.
• 2005 model year Excursion vehicles equipped with 6.0L diesel engines built from 1/19/2005 through 9/30/2005.
• 2005-2006 model year F-250/350 vehicles equipped with 6.0L diesel engines built from 1/19/2005 through 7/31/2005.

Group 2: A small number of vehicles that were repaired with an incomplete calibration between July 5, 2005 and July 18, 2005 (prior to the temporary suspension of Voluntary Emissions Recall 05E15 ) will also be serviced in Voluntary Emission Recall 05E16:

• Certain 2004 model year E350 vehicles equipped with 6.0L diesel engines built from 12/9/2003 through 5/28/2004.
• Certain 2004 model year F-250/350 and Excursion vehicles equipped with 6.0L diesel engines built from 12/1/2003 through 5/31/04.
• Certain 2004 model year F-250/350 and Excursion vehicles equipped with 6.0L diesel engines built from 9/29/2003 through 11/30/2003.

Affected vehicles are identified in OASIS. In addition, for a list of vehicles assigned to your dealership, visit https://web.fsavinlists.dealerconnection.com. This information will be available on January 9, 2006.

REASON FOR THIS PROGRAM

On some of the affected vehicles, the on-board diagnostic (OBD) system may not properly monitor the performance of the emissions control systems, which may prevent a required illumination of the "check engine" light.

SERVICE ACTION

Dealers are to recalibrate (reflash) the engine control modules with the latest level software. This must also be performed on all of the affected vehicles in your inventory prior to delivery.

Be sure that your Worldwide Diagnostic System (WDS) is updated using WDS release B40.7 and higher or B41.1 and higher. THIS NEW CALIBRATION IS NOT INCLUDED IN THE B41 CD. Calibration files may also be obtained at www.motorcraft.com. (refer to Attachment III for software levels).

CUSTOMER VEHICLES AFFECTED BY OTHER FIELD SERVICE ACTIONS

PLEASE NOTE:  It is possible that a vehicle affected by this program may also be affected by other programs. Affected owners will receive one mailing explaining all applicable programs. The owner letter sample posted with this bulletin, however, will reflect only program 05E16. PLEASE CONSULT OASIS TO BE SURE YOU ARE ADMINISTERING THE CORRECT PROGRAM(S) AND, IF POSSIBLE, COMPLETE ALL OPEN PROGRAMS IN ONE CUSTOMER VISIT.

PLEASE NOTE:  The sale of uncorrected new vehicles to customers could lead to penalties under applicable state and Federal regulations. Correct all vehicles in your new vehicle inventory prior to delivery.

ATTACHMENTS

1. Attachment I: Administrative Information
2. Attachment II: Labor Allowances and Parts Ordering Information
3. Attachment III: Technical Information
4. Customer Notification Letter

QUESTIONS?

1. Claims Information: ... 1-800-423-8851
2. Special Service Support Center (Dealer Only) Questions: ... 1-800-325-5621
3. Parts Support Center (Dealer only) Questions: ... 1-800-207-2444

OASIS ACTIVATED?

Yes. OASIS will be activated by January 9, 2006.

FSA VIN LIST ACTIVATED?

Yes.

Available through FMCDealer.com or at https://web.fsavinlists.dealerconnection.com by January 11, 2006. Owner names and addresses will be available by January 26, 2006.

STOCK VEHICLES

Correct all affected units in your new vehicle inventory before delivery.

SOLD VEHICLES

• Owners of affected vehicles will be directed to dealers for repairs.
• Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date.
• 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.

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.
• If you encounter aftermarket equipment or modifications to the vehicle which would cause the technician to expend additional labor time to complete the repair, actual time (MT05E16) may be used. (See Claims "Preparation and Submission"). No approval is required.

OWNER REFUNDS

• Ford Motor Company will only refund owner-paid repairs covered by this program if the repair was performed before the date of the Customer Notification Letter (or after the date of the letter if an emergency repair was made away from the servicing dealer.) Refund claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement.
• This recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. Refund Claiming Information. (Submit on separate repair line.)
  1. - Program Code: 05E16
  2. - Misc. Expense: REFUND
  3. - Misc. Expense: ADMIN
  4. - Misc. Expense: 0.2 Hrs.

RENTAL VEHICLES

Ford Motor Company will pay for a rental vehicle up to $50/day, except for fuel and insurance, which will be at the owner's expense. Enter the word "RENTAL", the number of days the vehicle was used, and the dollar amount in the Miscellaneous Expense area of the claim form.

CLAIMS PREPARATION AND SUBMISSION

• Enter claims using Direct Warranty Entry (DWE).
• 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 approval from Special Service Support Center.
• "MT" labor should be submitted on a separate repair line with the related damage flag checked.
• The use of actual time (MT05E16) must comply with warranty and policy guidelines as outlined in the Warranty and Policy Manual. "Actual time" repairs require technician time stamps on the repair order. (See "Time Recording Procedure" in Section 1, page 14 of the Warranty and Policy Manual.)
• 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 SUPPORT CENTER

The Recall Parts Support Center can be contacted via:

• Phone: 1-800-207-2444
• E-mail: Ford@Renkim.com
• FAX: 1 (734) 374-1030

Please be prepared to provide the following information:

• Dealer Name and P & A code
• Contact Name
• Phone number and E-mail address
• FSA # 05E16
• VIN#

DEALER PRICE

For latest prices, refer to DOES II.

PARTS RETENTION AND RETURN

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

IF UNABLE TO REPROGRAM PCM

• Prior to disconnecting WDS from the vehicle and closing the session, call the Special Service Support Center at 1-800-325-5621.
• PCM Replacement will not be covered under this program.

VEHICLE EMISSION RECALL PROOF OF CORRECTION CERTIFICATE

Describe the modification completed, your P & A code, date of repair, etc. Provide the owners of vehicles registered in California and Massachusetts with a completed Vehicle Emission Recall Proof of Correction Certificate. This certificate can be obtained through your Regional Office.

MODULE RECALIBRATION

1. Connect a battery charger to the vehicle.
2. Using Worldwide Diagnostic System (WDS), recalibrate the modules to the latest level calibration.
3. VERIFY THE WDS IS LOADED WITH SOFTWARE VERSION B40.7 OR HIGHER, OR B41.1 OR HIGHER.
4. Select Module Configuration Programming (MCP) and follow the WDS display instructions.
   • If unable to recalibrate the modules:
     1. - module replacement will not be covered under this program.
     2. - prior to disconnecting the WDS from the vehicle and closing the session, call the Special Service Support Center at 1-800-325-5621.
5. Perform a self-test to verify there are no further concerns.

AUTHORIZED MODIFICATIONS LABEL INSTALLATION

1. Obtain and prepare the Authorized Modifications Label. Describe the modification performed, and enter your P & A Code, date of repair and the program type and program number. See Fig 1.

Fig 1: Authorized Modifications Label

PROOF OF CORRECTION CERTIFICATE

1. Provide the owners of vehicles registered in California and Massachusetts with a completed "Vehicle Emissions Recall - Proof of Correction" certificate. See Fig 2.

Fig 2: Proof Of Correction Certificate