Safety Recall 13S04 - Fuel Delivery Module Replacement (13S04)

SUBJECT

DEMONSTRATION / DELIVERY HOLD - Safety Recall 13S04 - Supplement #5 

Certain 2013 Model Year Explorer, Taurus, MKS, Flex, MKT, Fusion, MKZ, and Police Interceptor Utility and Sedan Vehicles

Fuel Delivery Module Replacement

REF

DEMONSTRATION / DELIVERY HOLD - Safety Recall 13S04 - Supplement #4 

Dated August 19, 2013

REASON FOR THIS SUPPLEMENT

• Affected Vehicles: The population has been expanded to include additional vehicles. 
• Parts List: The parts requirements list has been updated to simplify parts ordering. 

AFFECTED VEHICLES

Affected vehicles are identified in OASIS and FSA VIN Lists.

REASON FOR THIS SAFETY RECALL

In the affected vehicles, over time, some of the fuel delivery modules in the fuel tank may develop a crack in the outlet port fitting that could result in a fuel leak. If a leak occurs, a customer may report symptoms of a fuel odor or liquid fuel leak. Fuel leakage in the presence of an ignition source may result in a fire.

SERVICE ACTION

Before demonstrating or delivering any of the vehicles involved in this recall, dealers are to replace the fuel delivery module. This service must be performed on all affected vehicles at no charge to the vehicle owner.

OWNER NOTIFICATION MAILING SCHEDULE

Explorer, Taurus, MKS, Flex, MKT, and Police Interceptor Utility and Sedan vehicles: 

Original owner letters mailed July 19, 2013. Owner letters for the additional vehicles are expected to be mailed the week of December 14, 2015. 

Fusion and MKZ vehicles: 

Owner letters mailed the week of August 19, 2013.

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 $7,000 per vehicle. Correct all vehicles in your new vehicle inventory before delivery. 

ATTACHMENTS

Attachment I: Administrative Information 

Attachment II: Labor Allowances and Parts Ordering Information 

Attachment III: Technical Information

Attachment IV: Dealer Q & A

Attachment V: Fuel Delivery Module Cross Reference Chart (Removed) 

Attachment VI: Lincoln Owner Special Handling (Lincoln Dealers Only)

Owner Notification Letters

Recall Reimbursement Plan 

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 ACTIVATION

Yes, OASIS was activated on May 30, 2013. OASIS will be activated for the additional vehicles on December 2, 2015. 

FSA VIN LISTS ACTIVATION

Yes, FSA VIN list was available through https://web.fsavinlists.dealerconnection.com  on May 30, 2013. FSA VIN list for the additional vehicles will be available on December 2, 2015. Owner names and addresses will be available by January 5, 2016. 

Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall.

STOCK VEHICLES

• Correct all affected units in your new vehicle inventory before delivery.
• Use OASIS to identify any affected vehicles in your used vehicle inventory.

SOLD VEHICLES

• Owners of affected vehicles will be directed to dealers for repairs.
• Immediately contact any of your affected customers whose vehicles are not on your VIN list but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) 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 recall.

ADDITIONAL LABOR TIME AND/OR PARTS

• Some vehicles may require additional parts to complete the repair, such as exhaust flange gaskets, single-use fasteners, and other parts that are not listed in the parts table in Attachment II. Refer to the Workshop Manual to identify these parts. Additional parts identified by the Workshop Manual do not require prior approval. 
• Submit a request to the SSSC Web Contact Site prior to the repair if you have any of the following:
  • Damage that you believe was caused by the covered condition.
  • A condition that requires additional labor and/or parts to complete the repair.
  • Aftermarket equipment or non-Ford modifications to the vehicle which might prevent the repair of the covered condition.

Requests for approval after completion of the repair may 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 on a timely basis. Additional related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC).

OWNER REFUNDS

• This safety recall must still be performed, even if the owner has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. 
• 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. Owners are directed 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 pre-approved 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. 
• Refunds will only be provided for the cost associated with fuel delivery module replacement related to fuel leaks. 

RENTAL VEHICLES

With proper parts ordering and service appointment scheduling, rental vehicles should not be required. However, if you have a unique circumstance which may require a rental vehicle, please contact the SSSC via the SSSC Web Contact Site.

LINCOLN CLIENT SPECIAL HANDLING

See Attachment VI  for instructions related to Lincoln Owner Special Handling.

CLAIMS PREPARATION AND SUBMISSION

• 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 (13S04) is the sub code.
• Some vehicles may require additional parts to complete the repair, such as exhaust flange gaskets, single-use fasteners, and other parts that are not listed in the parts table in Attachment II. Refer to the Workshop Manual to identify these parts, and claim on the same repair line on which the FSA is claimed. Additional parts identified by the Workshop Manual do not require prior approval from the SSSC. 
• Additional labor and/or parts that are not identified in the Workshop Manual must be claimed as related damage on a repair line that is separate from the repair line on which the FSA is claimed. Additional labor and/or parts not identified in the Workshop Manual require prior approval from the SSSC via the SSSC Web Contact Site. 
• For rental vehicle claiming, follow Extended Service Plan (ESP) guidelines for dollar amounts. Enter the total amount of the rental expense under Miscellaneous Expense code "Rental". 
• Submit refunds on a separate repair line.
  • - Program Code: 13S04
  • - Misc. Expense: ADMIN
  • - Misc. Expense: REFUND
  • - Misc. Expense: 0.2 Hrs.
• 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.
• On applicable Fusion and MKZ vehicles, if an inspection was performed and the Inspection Failed  , labor operation 13S04FF must  be submitted for payment before  a final repair (13S04E) is submitted for payment. Note that labor operation 13S04AA is a final repair and will close  the safety recall for the specified VIN.
• See Attachment VI for claiming instructions related to Lincoln Owner Special Handling.

LABOR ALLOWANCES

PARTS REQUIREMENTS / ORDERING INFORMATION

The DOR/COR number for this recall is 50506.

Order your parts through normal order processing channels.

For questions regarding parts, contact SSSC via the SSSC Web Contact Site.

DEALER PRICE

For latest prices, refer to DOES II.

PARTS RETENTION AND RETURN

Follow the provisions of the Warranty and Policy Manual, Section 1 "WARRANTY PARTS RETENTION AND RETURN POLICIES."

EXCESS STOCK RETURN

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

OVERVIEW

In some of the affected vehicles, over time, the Fuel Delivery Module (FDM) in the fuel tank may develop a crack in the outlet port fitting that could result in a fuel leak. If a leak occurs, a customer may report symptoms of a fuel odor, fuel puddle on the ground, hard or no start, engine stall and/or illumination of the "Service Engine Soon" warning indicator. Fuel leakage in the presence of an ignition source may result in a fire. Before demonstrating or delivering any of the vehicles involved in this recall, dealers are to inspect and/or replace the FDM as directed.

SERVICE PROCEDURE

Explorer, Taurus, MKS, Flex, MKT and Police Interceptor Utility and Sedan Vehicles 

1. Replace the FDM. For additional information, refer to Workshop Manual (WSM) Section 310-01.

   Fusion/MKZ Vehicles Only 

   NOTE: A small number of Fusion/MKZ vehicles having specific December 2012 through February 2013 build dates may have been built with updated parts. An inspection can be performed on vehicles within the identified build dates to determine if they can be removed from this program. Refer to the Fusion/MKZ FDM Inspection Chart in Step 2 for applicable vehicle build dates and inspection information for vehicles that qualify for this inspection option.
2. Determine the vehicle build date. Refer to the Fusion/MKZ FDM Inspection chart below.
   • - Fusion/MKZ vehicles produced between the "Built From" and "Built Through" dates can be inspected to determine if the FDM needs to be replaced. Proceed to Step 3.
   • - For Fusion/MKZ vehicles built before the dates indicated in the chart, replace the FDM. For additional information, refer to WSM Section 310-01.
   FUSION/MKZ FDM INSPECTION CHART
   
   

   Vehicle Application	Powertrain	Vehicle Built From and Including	Vehicle Built Through and Including
   Fusion	1.6L EcoBoost	1/14/2013	1/21/2013
   Fusion / MKZ FWD	2.0L EcoBoost	1/14/2013	1/21/2013
   Fusion / MKZAWD	2.0L EcoBoost	1/22/2013	2/11/2013
   Fusion / MKZFWD	2.0L Hybrid	1/18/2013	1/26/2013
   Fusion	2.5L	12/13/2012	1/8/2013
   MKZ	3.7L	1/21/2013	2/25/2013

3. Remove the fuel tank. For additional information, refer to WSM Section 310-01.
4. Inspect the color of the fuel outlet port fitting on top of the FDM. See Figure 1.
   • - If the color of the fuel outlet port fitting is black, replace the FDM. For additional information, refer to WSM Section 310-01.
   • - If the color of the fuel outlet port fitting is gray/silver, no further action is necessary. Reinstall the fuel tank. For additional information, refer to WSM Section 310-01.

DEALER Q & A

Q1. What is the issue? 

A.  Ford is voluntarily recalling certain 2013 Model Year Explorer, Taurus, MKS, Flex, MKT, Fusion, MKZ, and Police Interceptor Utility and Sedan vehicles to address concerns relating to the fuel delivery module. In the affected vehicles, over time, some of the fuel delivery modules in the fuel tank may develop a crack in the outlet port fitting that could result in a fuel leak. If a leak occurs, a customer may report symptoms of a fuel odor or visible fuel leak. Fuel leakage in the presence of an ignition source may result in a fire.

Q2. Are vehicles safe to drive? What if a customer calls and reports a fuel odor? 

A.  The vehicle is safe to drive if it does not exhibit a fuel odor or leak. If a customer reports a fuel odor or visible fuel leak, they should contact the dealer to arrange for repairs.

Q3. Is this a condition that can occur when the vehicle is turned off? 

A.  Because the fuel delivery module outlet port is above the fuel tank, if a crack occurs, only a small amount of fuel can potentially leak once the vehicle is turned off.

Q4. Are there any early warning signs or symptoms a customer would notice that would indicate a problem? 

A.  If a leak occurs, a customer may report symptoms such as a fuel odor or visible fuel leak.

Q5. Are parts available to repair all affected vehicles? How long will the repair take? 

A.  Parts are available in sufficient quantities to repair all affected vehicles. Order the parts needed for scheduled repairs through normal parts ordering channels  . The repair procedure can generally be completed in less than one-half day.

Q6. What about Dealer Stock vehicles? 

A.  Parts are available to repair affected stock vehicles in addition to vehicles that have been sold to owners. Refer to Parts Requirements and Ordering Information in Attachment II for instructions on ordering parts. 

Q7. How can a customer see if their vehicle is affected by this recall? 

A.  Customers can see if they are affected by the recall by:

• Logging onto www.FordOwner.com, click "Recall Notices" in the "Service" tab and input their VIN to determine if their vehicle is part of the recall;
• Calling 866-436-7332 in the U.S. or 888-222-7814 in Canada; or
• Contacting a Ford dealer

Q8. Is Fusion Energi (Plug-in Hybrid) affected by this recall? 

A.  Fusion Energi (plug-in hybrid) is not affected by this recall. Although it has similar 2.0L I4 engine and electric motor as the hybrid; it uses a different fuel delivery module design.

Q9. When the part arrives, how can I reference what vehicle it was ordered for? 

A.  When looking up the parts information with the DOR/COR# 50506; the Order Detail screen will list the first 3 & last 8 characters of the VIN.

FUEL DELIVERY MODULE REFERENCE CHART BY APPLICATION

Explorer, Flex, Lincoln MKT, Taurus, Lincoln MKS, Police Interceptor Utility and Sedan with 3.5L or 3.7L TiVCT Engines Only (Flex Fuel Applications) 

• NOTE: Refer to the Parts Requirements And Ordering Information Tables in Attachment II for all applications.
• Non-Flex Fuel FDMs can only  be used in non-Flex Fuel applications
• Flex Fuel Capable FDMs are compatible with the corresponding vehicles non-Flex Fuel applications

VIN Specific Parts List Tool: https://www.techhotline.dealerconnection.com/dealerpa/LookUp13S04.aspx 

FUEL DELIVERY MODULE REFERENCE CHART BY PART NUMBER

VIN Specific Parts List Tool: https://www.techhotline.dealerconnection.com/deal erpa/LookUp13S04.aspx 

LINCOLN OWNER SPECIAL HANDLING ALLOWANCE (Applies to sold vehicles only)

To "surprise & delight" Lincoln Owners; Lincoln Dealers are authorized to provide the following services to MKS, MKT and MKZ owners under Safety Recall 13S04.

• Lincoln Service Loaner (Rental) up to 2 days per ESP guidelines
• Fuel Fill (up to $75)
• Vehicle Pick-up and Delivery (up to $100)
• Vehicle Wash and Vacuum (this is expected as part of the Lincoln Commitment Program)

This program is exclusive to Lincoln Dealers. Ford Stand-alone Dealerships servicing Lincoln Owners are not authorized to claim the special handling allowance. Owners will not be notified of this service in owner mailings.

CLAIMS PREPARATION AND SUBMISSION

• 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 (13S04) is the sub code.
• Rental:  Follow Extended Service Plan (ESP) guidelines for dollar amounts. Enter the total amount of the Service Loaner (Rental) expense under Miscellaneous Expense Code "RENTAL". Expenses for more than two days require prior approval from the Special Service Support Center.
  • - Misc. Expense Code: RENTAL
  • - Misc. Expense Amount: Total amount
• Fuel Fill:  Enter Miscellaneous Expense Code "FUEL" with actual cost up to $75
  • - Misc. Expense Code: FUEL
  • - Misc. Expense Amount: Total amount
• Vehicle Pick-up and Delivery:  Enter Miscellaneous Expense Code "LCHP" with actual cost up to $100
  • - Misc. Expense Code: LCHP
  • - Misc. Expense Amount: Total amount
• Maintain supporting documentation for all Miscellaneous Expenses according to procedure as identified in the Warranty and Policy Manual.

FORD OWNER LETTER - FUSION

FORD OWNER LETTER - ALL EXCEPT FUSION

LINCOLN OWNER LETTER - MKZ

LINCOLN OWNER LETTER - ALL EXCEPT MKZ

SUPPLEMENT FORD OWNER LETTER (ALL EXCEPT FUSION)

SUPPLEMENT LINCOLN OWNER LETTER (ALL EXCEPT MKZ)

BACKGROUND SUMMARY

Ford Motor Company Recall Reimbursement Plan for 13S04

Ford and Lincoln dealers are in the best position to quickly and efficiently process reimbursement requests. However, federal legislation requires all motor vehicle manufacturers to establish processes through which customers may seek recall reimbursement directly from the manufacturer or from the dealers. 

Regarding the specific reimbursement plan for Recall # 13S04, owners who have paid for service to remedy the defect or noncompliance must have had that service performed prior to January 15, 2016. 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 latest General Recall Reimbursement Plan in a letter to the National Highway Traffic Safety Administration (NHTSA) in February 2015. 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 related safety recall.

Set forth below is Ford's general plan to reimburse owners and purchasers for costs incurred for remedies in advance of notification of potential safely-related defects or noncompliances pursuant to Part 573.6 (c)(8)(i). This plan has not changed since our February 20, 2015 submission.