Recalls for '80-96 Broncos & F-series

[Steve83]

I've been adding a LOT of stuff to my signature link lately, including several more Technical Service Bulletins (TSBs) & Field Service Actions (FSAs - Recalls). Some are common problems that many people need to address - some I just found interesting for whatever reason. Some have their own album with several diagrams & the full text in the captions; others are a single diagram with the text in the caption. A few are only excerpts from the full article. They're all at the bottom of my album list, so scroll WAAAAAY down to find them.

Those with no images will be posted directly in this thread, so search it or scroll down this page (& any following) to see them. Press CTRL+F (or pulldown Edit>Find on this page...) and try a keyword until you get some results. To make searching easier, I'm trying to standardize the numbers as "TSB ##-##-##". FSA numbers are too random to standardize, so use keywords for them. I'm posting each one separately so that they can be directly linked by their post numbers.

If there's a particular TSB or FSA that several people need, post the name/number here & I'll work on getting it uploaded. Or, ANYONE who wants to upload a TSB or recall can put it or its link in this thread, to make them all easier to find.


CHECK THE TSB & FSA ALBUM in my signature link for additional articles.

[Steve83]

95S28 Ignition Switch '88-91
Note that this is a safety recall, and any included vehicle will be repaired free, no matter how old it is, how long the owner waits to present it for repair, or how many times it has been sold.

Ford Motor Company has decided that a defect which relates to motor vehicle safety exists in all 1988-90 Model Escort; 1988 Model EXP; 1988-93 Model Mustang built through September 30, 1992; 1988-93 Model Tempo and Topaz built through September 30, 1992; 1988-93 Model Thunderbird and Cougar built through September 30, 1992; 1988-89 Model Crown Victoria and Grand Marquis; 1988-89 Model Lincoln Town Car; 1988-91 Model Aerostar; and 1988-91 Model Bronco and F-Series trucks.

Safety Defect
On a small number of the affected vehicles, a short circuit could develop in the ignition switch that could lead to overheating, smoke, and possibly fire in the steering column area of your vehicle. The condition may occur while the vehicle is in use or unattended.

Repairs
At no charge to you, your Ford or Lincoln-Mercury dealer will replace the ignition switch with a revised design switch. Dealers currently have instructions and parts ordering information. The dealer will also check the wiring in the upper steering column area and will inspect for the installation of any aftermarket electrical accessories. If an improper installation is noted that is not part of this recall, you will be advised to have it corrected.

How Long Will It Take?
The time needed for this service is less than one hour. However, due to service scheduling times, your dealer may need your vehicle for a longer period. Call your dealer without delay. Ask for a service date and whether parts are in stock for Safety Recall 95S28. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your vehicle in, show the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge.

Refunds
If you paid to have this service done before the date of this letter, Ford is offering a full refund. For the refund, please give your paid original receipt to your Ford or Lincoln-Mercury dealer. To avoid delays, please do not send receipts to Ford Motor Company.
If the dealer doesn't make the repair promptly and without charge, you may contact:
Ford Customer Assistance Center
300 Renaissance Center
P.O. Box 43360
Detroit, Michigan 48243
or you may contact the Customer Ignition Switch Information Hotline toll free at 1-800-323-8400. This number will be active
for a limited time. You also may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590 or call the toll free Auto Safety Hotline 1-800-424-9393 (Washington, D.C. area residents may call 366-0123).

Parts Usage & Dealer Cost
F29Z-11572-D (Motorcraft SW-2472) Ignition Switch $2.92 [This switch is used on approximately 70% of affected vehicles]
88-90 Escort, 88 EXP, 88-93(a) Mustang, 88-93(b) T-Bird/Cougar, 88-89 Crown Vic./Grand Marq., 88-89 Town Car, 88-91 Aerostar, 88-93(c) Tempo/Topaz
F2TZ-11572-E (Motorcraft SW-2472) Ignition Switch $3.61 [This switch is used on approximately 30% of affected vehicles]
88-91 Bronco/F-Series(d)
(a) - Built through September 30, 1992
(b) - Built through September 30, 1992
(c) - Built through September 30, 1992
(d) - Excluding F53 and F59 models

Parts Purge
All of the ignition switches listed below are to be withdrawn from your inventory and immediately returned, freight prepaid using the least expensive transportation, to your facing PDC within 30 days:
E4UZ-11572-A (SW 1916)
E4TZ-11572-A (SW 1562A)
E6FZ-11572-A (SW 1744B)
E7TZ-11572-A (SW 2101)
F0LY-11572-A (SW 2219)
F2TZ-11572-A (SW 2300)

Safety Recall 95S28: Ignition Switch Replacement
1. Connect Rotunda Memory Saver 014-R1064 or equivalent.
2. Disconnect battery negative cable.
NOTE: Access to the ignition switch varies depending on the vehicle line. In all cases the switch is mounted on the steering column and certain items will need to be removed to gain access. Examine the components around the ignition switch to determine what may need to be removed or positioned out of the way. Refer to the appropriate service repair manual for removal and installation procedures. Once access is gained, proceed as follows.
NOTE: The new ignition switch is shipped in the LOCK position. Keep the ignition lock cylinder (ignition key) in the lock position during this procedure.
3. Disconnect electrical connector from the ignition switch.
4. Remove ignition switch retaining screws.
5. Disengage switch from the actuator pin and remove switch from vehicle.
6. Remove the positioning clip from the new ignition switch if so equipped, and install the switch onto the actuator pin. Align the switch mounting holes with the column lock housing threaded holes.
7. If supplied, install new retaining screws. If re-installing original screws, apply Ford Threadlock and Sealer E0AZ-19554-AA (CXC-70) or equivalent to the threads. Tighten to 6-8 N-m (53-70 in-lb).
8. Connect electrical connector to the ignition switch. Ensure that the connections are tight and fully seated.
9. Connect battery negative cable and remove Rotunda Memory Saver.
10. Check ignition switch for proper function, including START and ACC positions.
11. Check the wiring in the area of the upper steering column. If abrasion or exposure of bare wires is found, repair as necessary. If aftermarket accessory wiring is improperly connected, advise the vehicle owner. Advise also that repairs of such faults are at customer expense.
12. Install any components previously removed for access ensuring that no wires are pinched and the components are properly seated. Refer to appropriate service repair manual as required.

Dealers Questions and Answers
Q1. Is this a voluntary safety recall?
A. Yes. We have been working in cooperation with Transport Canada and NHTSA to investigate reported concerns with the subject switch.

Q2. How many vehicles are involved?
A. 8.5 million vehicles in the Unites States and Canada. The total when you add the previous Canadian recalled vehicles is 8.7 million vehicles.

Q3. What vehicles are involved?
A. 1988-1990 Escort
1988 EXP
1988-1992 and early build 1993 Mustang
1988-1992 and early build 1993 Tempo/Topaz
1988-1992 and early build 1993 Thunderbird/Cougar
1988-1989 Crown Victoria/Grand Marquis
1988-1989 Lincoln Town Car
1988-1991 Aerostar
1988-1991 Bronco/F-Series Light Trucks

Q4. Why are vehicles NOT included in this recall?
A1. Many Ford and Lincoln-Mercury cars and trucks built between 1984 and 1993 are excluded from this action for the following three reasons:
1) Some were built prior to a supplier manufacturing process change;
2) Some vehicles have low electrical load through the switch; or
3) Other vehicles are equipped with ignition switches that are of a completely different design.

Q5. What do you mean by "electrical load?"
A. Electrical load is the amount of current that passes through the switch when the vehicle is started. Electrical load is impacted by standard and optional
equipment, electrical circuitry, as well as cold weather operation.

Q6. What about vehicles built before 1988?
A. We believe that a manufacturing process change made by our switch supplier caused a change in internal switch dimensions. We have determined that as a result, a small number of switches are more susceptible to the potential for internal short circuits. Certain models with low electrical loads are not affected by the change. Vehicles produced prior to the 1988 model year are not included in the recall, because they are not equipped with ignition switches that are subject to this dimensional change. Ford has based this conclusion on an in-depth engineering analysis, and data supplied to us by our supplier.

CUSTOMER ISSUES
Q7. What about people who have had a vehicle fire, their vehicle would be included in the recall population, but they no longer own the vehicle? Will they be compensated?
A. Fires happen in vehicles for a number of reasons. For example, a fire could be the result of an improper vehicle modification (aftermarket accessories), arson, prior accident damage, or a faulty repair. Generally, vehicle losses are covered by insurance.

Q8. What about people who had a vehicle fire, still own the car, but it isn't being recalled?
A. Fires happen in vehicles for a number of reasons. For example, a fire could be the result of an improper vehicle modification (aftermarket accessories), arson, prior accident damage, or a faulty repair. Generally, vehicle losses are covered by insurance.

Q9. What about people who have/had property damage -- how will they be compensated?
A. Fires happen in vehicles for a number of reasons. For example, a fire could be the result of an improper vehicle modification (aftermarket accessories), arson, prior accident damage, or a faulty repair. Generally, vehicle losses are covered by insurance.

WHAT SHOULD CUSTOMER DO?
Q10. When did you notify dealers? When will customers be notified? What can they do in the meantime?
A. Dealers have been notified via Combat on 4/25/96 and will receive a Recall Bulletin on 4/26/96 via FedEx. Customers will be notified through the mail. Should an owner wish to have the switch replaced in advance of being notified by mail, dealers have been provided instructions and can replace the switch at no cost.

[Steve83]

FSA 93S65 1993 F-Series and Bronco 4x4 Vehicles with the Touch-Drive Electric Shift-on-the-Fly Transfer Case (ESOF)
Note that this is a safety recall, and any included vehicle will be repaired free, no matter how old it is, how long the owner waits to present it for repair, or how many times it has been sold.

Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1993 Model Year F-Series and Bronco 4x4 vehicles equipped with the Touch-Drive electric shift transfer cases.

Safety Defect
Some of the affected vehicles may have an electronic transfer case that contains a prior level electric shift motor. In the four-wheel drive "high" mode of operation, the transfer case may shift to "neutral" without input from the driver. This condition may occur while the vehicle is coasting in a forward direction or while engine power is being applied in reverse. The vehicle can be operated normally in the two-wheel drive modes and in the four-wheel drive "low" mode.
WARNING: IF A DRIVER PARKS THE VEHICLE IN THE FOUR-WHEEL DRIVE "HIGH" MODE WITHOUT FULLY SETTING THE PARKING BRAKE, IT COULD ROLL FREELY AS IF IN NEUTRAL CREATING THE POSSIBILITY OF A CRASH OR PERSONAL INJURY.
As stated in the Owner's Guide for your vehicle, Ford recommends that a vehicle operator always set the parking brake when leaving the vehicle unattended.

Repairs
At no charge to you, your dealer will inspect the transfer case and, if necessary, replace it. Dealers currently have instructions and parts ordering information. When you bring your truck in, show the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. If the dealer doesn't make the repair promptly and without charge, you may contact the Ford Customer Assistance Center, 300 Renaissance Center, P.O. Box 43360, Detroit, Michigan 48243. You also may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590 or call the toll free Auto Safety Hotline 1-800-424-9393 (Washington, D.C. area residents may call 366-0123).

How Long Will It Take?
The time needed for the inspection is approximately one half (1/2) hour. However, due to service scheduling times, your dealer may need your vehicle for one full working day. If the inspection reveals that a new transfer case is needed, it may be necessary for your dealer to order it. Call your dealer without delay.

Courtesy Cars
Should the transfer case of your vehicle require replacement, your dealer will provide you with a free (except for fuel) courtesy car until parts arrive and repairs are completed.

Affected Vehicles:
1993 Model F- Series and Bronco 4x4 Vehicles

Technical Instructions
1. Inspect the electronic transfer case wiring harness (the wiring harness may need to be cleaned for inspection). If the harness is GRAY, DO NOT REPLACE THE TRANSFER CASE. Claim inspect time only.
2. If the harness is BLACK, replace the transfer case as outlined in the appropriate shop manual.
3. Return the removed transfer case, freight prepaid, to:
Warranty Parts Return Center
1285 South Mill Street
Plymouth, MI 48170
c/o Safety Recall 93S65

Labor Allowances
Inspect transfer case wiring harness 0.3 Hrs.
Remove/Install transfer case (includes inspection) 1.5 Hrs.
Order your parts requirements by calling 1-800-325-5621 (Renkim Corporation). When confirmed that a transfer case replacement is required, Renkim will submit the order to have one direct shipped to you.
When calling this number, be prepared to give the following information:
VIN Number
P & A Code
Program Number 93S65
Warranty Repair Order Number
Dealer Name, Address, and Zip Code
Name of contact at dealership
Telephone Number
Color of the wiring harness

[Steve83]

FSA 93B35 Starter Solenoid Inspection & Possible Replacement

1992 / 1993 F-Series Trucks (equipped with 4.9, 5.8, or 7.5L engines) & Certain 1992 Broncos (4.9L engine) All Equipped with Manual Transmissions - Starter Solenoid Inspection & Possible Replacement
Note that this is a safety recall, and any included vehicle will be repaired free, no matter how old it is, how long the owner waits to present it for repair, or how many times it has been sold.

Ford Motor Company is providing a no-charge Service Program to owners of certain 1992 Broncos and 1992 and 1993 F-Series Trucks to inspect the starter assembly, and, if necessary, replace the starter solenoid.

Reason For This Program
The starter solenoid may continue to keep the starter engaged after the ignition key is returned from the "start" position. This may result in overheating of the starter as it continues to run with the engine. The starter typically will not crank on subsequent attempts, causing a "No-Start" condition.

No Charge Service
At no charge to you, your dealer will inspect the starter and, if necessary, replace the starter solenoid. This program is available through 36 month / 36,000 mile Bumper-to-Bumper warranty, or through December 31, 1994, whichever provides greater coverage.

How Long Will It Take?
The time needed for this service is one (1) hour. However, due to service scheduling times, your dealer may need your truck for one full working day. Call your dealer and ask for a service date and if parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your truck in, give the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge.

Refunds
If you paid to have this service done before the date of this letter, Ford is offering a full refund. For the refund, please show your paid work-order to your Ford dealer.

Affected Vehicles: 1992-93 F-Series / Bronco Trucks

Parts Purge
F2TZ-11002-A Starters built prior to 12/16/92 MOTORCRAFT (SA 793)
F2TZ-11002-C Starters built prior to 12/16/92 MOTORCRAFT (SA 795)
E9OZ-11390-B Solenoids MOTORCRAFT (SW 2207)

If claim is processed electronically via DOES II, use return code "GB" otherwise complete a separate FPS-340 claims for these parts. Indicate reason "J" on claims. In remarks section write "returned per Recall 93B35". Returns must be received within thirty (30) days from the date of this recall. Returns are restricted to the subject parts. Parts returned must have been purchased from FCSD in accordance with Policy and Procedure Bulletin 4000. Credit for parts and prepaid freight costs will be issued.

Technical Instructions
WARNING: WHEN SERVICING STARTER OR PERFORMING ANY MAINTENANCE IN THE AREA OF THE STARTER, NOTE THE HEAVY GAUGE INPUT LEAD CONNECTED TO THE STARTER SOLENOID IS HOT AT ALL TIMES. DISCONNECT THE BATTERY NEGATIVE CABLE BEFORE PERFORMING ANY SERVICE, MAKE SURE THE RED SOLENOID SAFETY CAP IN INSTALLED OVER THE TERMINAL AND IS REINSTALLED AFTER SERVICE.



Inspection
Starter assemblies with a production date equal to or less than 2M15 (December 15, 1992) are affected by this program. The red starter assembly label will have the date the assembly was made as illustrated below:
Motorcraft
11000 12V USA
F2TUAA or F2TUCA 2M15B (Build Date)
2 = calendar year, i.e. 1992, 3 = 1993
M = month (December), L = November, A = January
15 = day
B = shift on which starter was assembled
WARNING: WHEN SERVICING STARTER OR PERFORMING ANY MAINTENANCE IN THE AREA OF THE STARTER, NOTE THE HEAVY GAUGE INPUT LEAD CONNECTED TO THE STARTER SOLENOID IS HOT AT ALL TIMES. DISCONNECT THE BATTERY NEGATIVE CABLE BEFORE PERFORMING ANY SERVICE. MAKE SURE THE RED SOLENOID SAFETY CAP IS INSTALLED OVER THE TERMNAL
AND IS REINSTALLED AFTER SERVICE.

Removal
1. Disconnect the battery negative cable.
2. Raise the vehicle on a hoist.
3. Disconnect the starter cable and push-on connector from the starter solenoid.
CAUTION: WHEN DISCONNECTING HARDSHELL CONNECTOR AT S-TERMINAL, GRASP THE PLASTIC SHELL AND PULL OFF. DO NOT PULL ON WIRE. BE CAREFUL TO PULL STRAIGHT OFF TO PREVENT DAMAGE TO THE CONNECTION AND S-TERMINAL. IF ANY PART OF THE CONNECTION IS DAMAGED, REPLACE THE DAMAGED COMPONENTS.
4. NOTE: The 5.8L engine starter has a heat shield. Carefully SLIDE the heat shield away from the mounting bolts before removing the starter assembly.
5. Remove upper and lower bolts, and remove starter assembly from engine.
6. Remove starter solenoid from starter assembly.

Installation
1. Position solenoid to housing, ensuring that the solenoid plunger is attached through the drive lever. Bottom solenoid terminal (M) should have a metal strip attached to it. Tighten solenoid bolts to 5-10 N-m (45-89 in-lb).
2. Attach motor connector to solenoid (bottom terminal). Tighten nut to 9-14 N-m (80-124 in-lb).
3. Position starter motor to engine and install upper and lower bolts finger-tight.
4. Tighten upper and lower bolts to 20-27 N-m (15-20 ft-lb).
5. Be sure that solenoid heat shield (5.8L engine) is properly positioned over solenoid. Connect starter solenoid connector. Be careful to push straight on and make sure connector locks in position with a noticeable click or detent.
6. Install starter cable nut to starter terminal. Tighten to 9-14 N-m (80-124 in-lb).
7. Replace solenoid safety cap.
8. Lower vehicle to floor and connect battery negative cable.

Labor
Inspect Starter Only 0.3 Hrs.
Inspect and replace starter solenoid 0.6 Hrs.
F3PZ-11390-A Starter Solenoid Dealer Price $12.31

[Steve83]

FSA 95B79 1994-95 RKE Transmitter Mail-In Service

Ford Motor Company is providing a special no-charge Service Program to owners of certain 1994 and 1995-model vehicles equipped with the Ford Remote Keyless Entry System.

Reason For This Program:
Battery contact corrosion inside the small rectangular shaped Ford Remote Keyless Entry System transmitters (with your vehicle's keys) may cause the system to operate intermittently and possibly result in unnecessary battery replacement.

No Charge Service With Drop-In-The-Mailbox Convenience:
At no charge to you, Ford Motor Company will upgrade your remote transmitters for proper trouble-free operation via a special mail-in service program. This special mail-in program is designed to provide you with a quick, convenient way to upgrade your remote transmitters and is available to you through October 31, 1996. (If you desire, you could have this service performed by your Ford or Lincoln-Mercury dealer.)

Return Transmitters In Special Prepaid Mailer:
Use the enclosed prepaid mailing envelope to return all of your remote transmitters for the vehicle identified by the serial number above. Just drop the envelope (with the transmitters enclosed) in the mail. For your security and protection, the prepaid mailer does not require your name or address. The bar-coding on the label will enable us to identify you. Please return the remote transmitters only. Detach them from the large key ring. (During the time that your transmitters are being upgraded, remember that you will have to use your key; we apologize for this inconvenience.)

Processing Time:
Counting mail time to and from our service center, we expect your transmitters will be returned to you within 10 working days. If you have not received your transmitters back by this time, please call the following toll-free number: 1-800-490-4288.

Questions?
A special toll-free number (1-800-490-4288) is available if you have questions on this program. Ford representatives are available weekdays from 7:30 a.m. to 7:30 p.m. and on Saturdays from 8:00 a.m. to 3:00 p.m. Eastern time. Have your vehicle serial number (VIN) ready when you call.

Remote Keyless Entry Transmitter Reprogramming
1. Locate the 2-pin RKE programming connector. Refer to RKE Programming Connector Location list below.
2. Turn ignition switch to the RUN position.
3. Using a jumper wire or alligator clip momentarily short the two terminals within the 2-pin program connector. On Econoline models you will need to short these terminals for the duration of the reprogramming procedure. The doors will lock then unlock on all models except Contour and Mystique. On Contour and Mystique models only the horn will sound and the exterior lights will flash.
4. Press any button on the remote keyless entry transmitter. All doors will lock then unlock to verify transmitter has been programmed. The horn will sound and the exterior lights will flash on the Contour and Mystique.
NOTE: Programming in the first transmitter will erase all other previously programmed transmitters. All transmitters that are to operate with the vehicle (up to four transmitters) must be programmed during Steps 4 and 5.
5. Repeat Step 4 for any additional remote transmitters to be reprogrammed.
6. Turn ignition switch OFF. All doors should lock then unlock. On Contour and Mystique models the horn will sound and the exterior lights will flash.
7. Remove short (Econoline models only).
8. Install any trim previously removed.
9. Verify transmitter operation.

The Two-Pin RKE Programming Connector is located…
Taurus/Sable Wagons: behind the left side trim panel inside the cargo area. Remove the trim panel for access to the connector.
Taurus/Sable Sedans: under the left side of the package tray.
Contour/Mystique: under the right side of the instrument panel, behind right side of glove compartment. Reach up behind the glove compartment for access to the connector.
Probe: in the trunk behind the subwoofer on the right side of the vehicle. Remove the subwoofer (if so equipped) for access to the connector.
Mark VIII, Crown Victoria, Grand Marquis and Town Car: behind the glove compartment. Open the glove compartment, compress the sides to allow it to fully open and let it hang for access to the connector.
F-Series and Bronco: under the driver's side of the instrument panel above the drivers right foot area.
Mustang: in the trunk behind the left side trim panel. Loosen the lining board (convertibles only) and the rear and left side trim covers to gain access to the connector.
Thunderbird/Cougar: behind the left side trim panel inside the trunk. Remove the trim panel for access to the connector.
Explorer: behind the left quarter utility compartment access panel. Remove the panel for access to the connector.
Windstar: behind and to the right of the glove compartment, compress the sides to allow it to fully open and let it hang for access to the connector.
Econoline: under the instrument panel to the left of the steering column.
Continental: under the right side of the instrument panel near the glove compartment. Remove the panel from beneath the instrument panel for access to the connector.

For further information regarding connector location and color-coding refer to the appropriate Electrical Vacuum and Troubleshooting Manual (EVTM). See also TSB 97-24-13.

[Steve83]

FSA 96S49 Rear Tire Pressure

96S49 Compliance Recall on Certain 1996 and 1997 Model Year Light and Medium Trucks Supplementary Tire Information Label
Note that this is a safety recall, and any included vehicle will be repaired free, no matter how old it is, how long the owner waits to present it for repair, or how many times it has been sold.

Ford Motor Company has decided that certain 1996 and 1997 model year light and medium trucks fail to conform to Federal Motor Vehicle Safety Standard No. 120., "Tire Selection and Rims for Motor Vehicles other than Passenger Cars". Note that while the rear tire pressure designated on the Certification Label is incorrect, your vehicle was produced with the rear tires inflated to the correct pressure.

Non-Compliance
The Safety Compliance Certification Label on affected vehicles have incorrect rear tire inflation pressures designations. Federal Motor Vehicle Safety Standard No. 120 requires that a label affixed to the vehicle show the tire size designation and the recommended inflation pressure for those tires, such that the tires on each axle are appropriate for the GAWR (Gross Axle Weight Rating) indicated on the label.

Supplementary Label
Please affix the enclosed supplemental tire information label adjacent to the Safety Certification Label found on the frame of the driver's door opening. The label is visible when you open the door. Before applying the label, wipe the area with a dry cloth. Check that the tire air pressure of all tires on your vehicle are set to the pressures shown on the supplemental Safety Certification Label.

Call Your Dealer
If you prefer that your dealer affix the label, call and ask for a service date for Safety Recall 96S49. Please bring the attached label with you to your service appointment. The time needed for this service is less than one half hour. However, due to service scheduling times, your dealer may need your vehicle for a longer period. If you misplace this letter, your dealer will still do the work, free of charge. If the dealer doesn't make the repair promptly and without charge, you may contact the Ford Customer Assistance Center, 300 Renaissance Center, P. O. Box 43360, Detroit, Michigan 48243. You also may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S. W., Washington, D. C. 20590 or call the toll free Auto Safety Hotline 1-800-424-9393 (Washington, D. C. area residents may call 366-0123).

Labor
Install Supplementary Tire Information Label 0.2 Hrs.

Parts Requirements
Supplemental tire information labels and installation instructions will be mailed to the vehicle owner for installation, or the owner at his/her option may have the dealership personnel install the label. Labels and instructions for vehicles not reported sold will be included in the Ford Dealership Consolidated Communicator (FDCC) package. If the customer no longer has the labels, call Renkim Corp. (1-800-325-5621).When calling this number, be prepared to give the recall number 96S49 and the kit code shown at the top of the owner letter.

[Steve83]

TSB 95-08-08 4.9L Engine Knocking on Cold Start

AFFECTED VEHICLES:
LIGHT TRUCK: 1984-95 BRONCO, ECONOLINE, F-150-350 SERIES

This TSB is being republished in its entirety to include the 1995 model year.

ISSUE: An engine knock of about 3-5 seconds may be heard on initial start-up, after an extended soak time (eight hours or more). This may be due to insufficient oil at the engine bearings, caused by engine oil drainback from the engine oil filter.
ACTION: Install an anti-drainback engine oil filter adapter. Refer to the following procedure for service details.

SERVICE PROCEDURE
1. Drain and discard engine oil.
2. Remove and discard engine oil filter.
3. Remove and discard engine oil filter adapter insert.
4. Install the service replacement anti-drainback engine oil filter adapter insert (E4TZ-6890-A).
5. Tighten the anti-drainback insert to 15-35 lb-ft (20-48 N-m).
6. Lightly lubricate the gasket surface of the new oil filter (FL-1A).
7. Install the new engine oil filter to the cylinder block and rotate the engine oil filter one-half turn after the gasket contacts the sealing surface.
8. Fill the engine with the proper grade and amount of engine oil, as specified in the appropriate Owner Guide.

Parts Usage:
E4TZ-6890-A Engine Oil Filter Mounting Insert
Labor: 0.4 Hr.
SUPERSEDES: 94-11-22
************************************************
As of the posting date, there is only 1 insert available for sale in the US, and its list price is ~$250. Wholesale is ~$160.

[Steve83]

TSB 06-14-04 Transmission Fluid Chart
I edited this slightly:

FORD: 1980-1997 Crown Victoria
1981-1997 Mustang, Thunderbird
1981-2003 Escort
1986-1993 Festiva
1986-1997 Taurus
1989-1997 Probe
1994-1997 Aspire
1995-2000 Contour
1980-1996 Bronco
1981-2003 F-150
1981-2004 E-Series, F-Super Duty
1983-1996 Ranger
1986-1996 Aerostar
1991-1997 Explorer
1993-2004 F-53 Motorhome Chassis
1995-1998 Windstar
1997-2004 Expedition
2000-2005 Excursion
2001-2007 Escape
1987-2000 F- & B-Series
2000-2007 F-650, F-750
LINCOLN: 1980-1997 Town Car
1981-1997 Continental
1993-1997 Mark VIII
1998-2004 Navigator
2002-2003 Blackwood
MERCURY: 1980-1997 Grand Marquis
1981-1997 Cougar
1986-1997 Sable
1987-1999 Tracer
1995-2000 Mystique
1999-2002 Cougar
1993-2002 Villager
1997 Mountaineer
2005-2007 Mariner
MERKUR: 1985-1989 XR4TI

This article supersedes TSB 01-15-07 to update the vehicle application chart.

ISSUE: MERCON® Automatic Transmission Fluid is being replaced by MERCON® V as a service fluid.

ACTION: Beginning immediately all automatic transmission / transaxle applications requiring MERCON® can now be serviced using MERCON® V or MERCON® Automatic Transmission Fluid or dual usage fluids labeled MERCON® / MERCON® V. After July 1, 2007, MERCON® Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory.

SERVICE PROCEDURE
Service automatic transmissions requiring MERCON® with MERCON® V or MERCON® Automatic Transmission Fluid or dual usage fluids labeled MERCON® / MERCON® V. For proper fluid application on current and past model vehicles equipped with automatic transmissions / transaxles refer to the fluid usage chart.

CAUTION: AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON® V OR DUAL USAGE FLUID LABELED MERCON® / MERCON® V.
CAUTION: MERCON® SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE.
CAUTION: THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON® C WILL CAUSE FUNCTIONALITY CONCERNS AND
INTERNAL TRANSMISSION DAMAGE.
CAUTION: DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS.

PART NUMBER PART NAME
XT-2-QDX MERCON® (Quart)
XT-2-DDX MERCON® (55 Gal. Drum)
XT-5-QM MERCON® V (Quart)
XT-5-DM MERCON® V (55 Gal. Drum)

[Steve83]

TSB 96-10-07 California ReFormulated Gasoline (CaRFG)

ISSUE: California introduced CaRFG around March 1, 1996 and statewide it must be available at all service stations by June 1, 1996 to help reduce emissions and improve gasoline quality. It will replace the traditional gasoline sold in Northern California and improve the reformulated gasoline that has been sold in Southern California since January 1995. California Air Resources Board (CARB) projects smog forming emissions from motor vehicles to be reduced by about 15 percent.

ACTION: The following text is provided to give some answers to some commonly asked questions by our customers.

POSITION
Ford Motor Company recommends the use of CaRFG as a cost effective means of reducing emissions to provide cleaner air. We have participated in vehicle and laboratory testing of CaRFG to make sure it is acceptable for our customers' use. There are no unusual vehicle performance concerns expected based upon these studies. The use of CaRFG will not affect Ford's new vehicle and/or emissions warranty.

WHAT DOES CaRFG CONSIST OF?
CaFRG consists of the same basic components as other gasolines, but it reduces pollution because of its cleaner burning components. Features are:
> reduced aromatic hydrocarbons to form less smog emissions
> added oxygenates to reduce emissions
> decreases the amount of fuel evaporating from the vehicle
> lowered sulfur content to provide more efficient operation of the vehicle's catalytic converter
> reduced benzene by about one-half

IS CaRFG MORE HAZARDOUS THAN CONVENTIONAL GASOLINES?
CaRFG is a hazardous substance like convential gasoline. Precautions should continue to be taken to avoid exposure to vapors or liquid when it is pumped or handled. It should never be siphoned or swallowed.

HOW WILL CaRFG AFFECT VEHICLE PERFORMANCE?
Properly blended CaRFG should have no adverse effect on vehicle performance or the durability of engine and fuel system components. Its basic properties are not significantly different than other cleaner burning gasolines that have been used in the U.S. for several years. If the vehicle is a certified California calibration 1996 or later model year, it was designed to operate on CaRFG gasoline. The vehicle will operate satisfactorily on gasolines in the other 49 states, but emission control system performance may be affected. Using gasolines other than CaRFG have substantially increased emissions from motor vehicles.

WILL THE USE OF CaRFG AFFECT CALIFORNIA VEHICLE WARRANTY?
No. The coverage of Ford's new vehicle warranty is not affected. In fact, Ford Owner Guides have consistently approved the use of properly blended reformulated gasolines containing oxygenates. Further information about properly fueling your vehicle is included in the Owner Guide.

WILL FUEL ECONOMY BE AFFECTED?
A very small reduction in fuel economy of less than one-half mile per gallon is possible if the customer was using gasoline without oxygenates. This is attributed to the lower energy content of oxygenates which have been in all Southern California gasolines since January of 1995 and in some gasolines since the 1970's. Many factors affect fuel economy like driving habits, vehicle maintenance, weather conditions, etc. Fuel economy can vary by more than a mile per gallon from one fill-up to the next with the same gasolines. For further details see TSB Article «95-12-2» for customer expectations regarding fuel economy.

ARE SPECIAL ADDITIVES NECESSARY FOR CaRFG?
No. It is not necessary to add anything to the vehicle fuel tank after the gasoline is purchased from the service station. California regulations require deposit control additives in CaRFG to minimize port fuel injector and intake valve deposits.

WILL OLDER VEHICLES OPERATE SATISFACTORILY WITH THE NEW CaRFG?
Older vehicles are expected to operate satisfactorily on CaRFG because vehicles have been operating on gasolines similar to CaRFG for a number of years. However, considerable testing indicates that older, high mileage vehicles are more susceptible to fuel system problems due to age and normal wear and tear regardless of whether they are operated on conventional or CaRFG gasolines. Owners of these older vehicles are encouraged to follow their vehicle manufacturer's recommendations regarding vehicle maintenance.

WILL THE SMELL BE DIFFERENT THAN CONVENTIONAL GASOLINE?
CaRFG is not expected to smell different than the gasoline most vehicles are currently using. If an unusual odor is noticed, it would probably be from oxygenates. Most service stations use vapor recovery systems to minimize the release of gasoline vapors while refueling. The use of CaRFG should result in little or no "rotten egg" smell from the exhaust because CaRFG has much lower sulfur than conventional gasoline.

WAS CaRFG TESTED BEFORE INTRODUCTION?
It was tested for over five million miles in more than 800 vehicles under the guidance of CARB including experts representing automobile manufacturers, gasoline suppliers, fleet operations and government. There was no increase in problems identified with the use of CaRFG.

DOES CaRFG COST MORE?
The price at the pump cannot be accurately predicted, although a modest increase is likely. The price of CaRFG is subject to the competitive forces in the marketplace. Many factors including production costs, supply and demand, weather, crude oil prices, and taxes affect gasoline prices.

WHERE CAN I GET MORE INFORMATION ON CaRFG?
Additional information within the state of California on CaRFG is available from the California Air Resources Board toll-free at 1-800-922-7349 (within California only).

OTHER APPLICABLE ARTICLES: 95-12-02

[Steve83]

TSB 98-26-02 Fuel Volatility Tips

ISSUE: Some vehicles using winter blend fuels may exhibit a stall on start up and a no restart, hard start condition or a no start condition in unseasonably hot weather (greater than 27°C/80°F). These concerns may be related to fuel volatility from winter blend fuels during winter-spring and autumn-winter transitions and may result in a fuel pump vapor lock condition. This condition may appear to be a fuel pump failure but may be caused by winter blend fuel.

ACTION: Explain to the customer that this concern may be due to a low tank level of winter blend fuel combined with unseasonably warm weather. Advise customer that filling the fuel tank to full may be effective in resolving this concern. Also, advise customer to use the recommended octane grade per their Owner Manual and not a higher grade.
NOTE: FUEL TANK ADDITIVES WILL NOT RESOLVE THESE CONCERNS BECAUSE VAPOR FORMS FROM CAVITATION WITHIN THE FUEL PUMP. FILLING THE TANK TO FULL MAY BE EFFECTIVE. ADVISE CUSTOMER TO USE THE RECOMMENDED OCTANE GRADE PER OWNER MANUAL AND NOT A HIGHER GRADE.

BACKGROUND
Gasolines are seasonally adjusted, meaning they have higher volatility (vaporize easier) in the winter and lower volatility in the summer. Government mandates to improve air quality have resulted in significant changes to gasolines, such as the mandatory use of oxygenates (ethanol, methyl tertiary butyl ether (MTBE), and others) in the winter or the reduction of Reid Vapor Pressure (RVP) in the summer. The addition of oxygenates (especially ethanol) increases volatility while the reduction of RVP reduces volatility.
Gasoline distribution practices often do not allow branded marketers to have much control over their gasoline's volatility other than RVP. Oxygenate (e.g., ethanol, MTBE) use is more dependent on local gasoline markets, rather than specific marketers practice. Therefore, it is difficult to recommend specific brands to avoid volatility related complaints.

OTHER APPLICABLE ARTICLES: 91-08-13
SUPERSEDES: 96-05-04

[Steve83]

TSB 91-08-13 Tips to Avoid Lean Conditions

ISSUE: Rough idle, hesitation, poor throttle response, induction backfire and stalls during cold start/warm up may be caused by the poor volatility of some high octane premium grade unleaded fuels (91 octane or higher (R+M)/2). When compared to regular grade unleaded fuel (87 octane (R+M)/2), high octane premium grade unleaded fuel may cause long crank time.

ACTION: Use a regular grade unleaded fuel in all vehicles, except where a premium unleaded fuel is recommended in the Owner Guide. If lean air-fuel type symptoms are experienced, determine the grade and brand of fuel used and offer the following service tips.
> Advise those using a higher octane grade fuel to switch to a regular grade unleaded fuel. For those using a regular grade fuel, advise them to try another brand.
> Do not advise using a higher octane unleaded fuel than is recommended for that specific engine. Ford engines are designed to perform best using a high quality regular grade unleaded fuel.
> Only advise using a higher octane unleaded fuel to avoid potentially damaging spark knock or ping, but do so only after mechanical fixes are ineffective.
NOTE: ALL UNLEADED GASOLINES USED SHOULD CONTAIN DETERGENT ADDITIVES THAT ARE ADVERTISED AS HAVING "KEEP CLEAN" OR "CLEAN UP" PERFORMANCE FOR BOTH INTAKE
VALVES AND FUEL INJECTORS.

[Steve83]

TSB 89-09-18 Introduction to the E4OD

LIGHT TRUCK: 1989 E-250, E-350, F SUPER DUTY, F-250, F-350

ISSUE: The E4OD is a new 4-speed automatic overdrive transmission. The E4OD transmission was derived from the C-6 automatic (3-speed) transmission.

ACTION: Use the following information to familiarize yourself with the various E4OD components. This information can help you explain the operation of the transmission to the customer.

The E4OD uses electronics to control shift points, pressure regulation and torque converter clutch control. This provides high quality shifts, good fuel economy and overall performance. The engine and transmission are monitored with diagnostic testing available through the EEC-IV Quick Test. The E4OD operations are provided by both operator selected positions of the manual selector lever and with an overdrive cancel switch located on the instrument panel.

FUNCTIONS
P (Park), R (Reverse), and N (Neutral) are the same as other Ford automatic transmissions.
D (Overdrive - normal driving position) provides all automatic shifts through fourth gear (overdrive) along with application and release of the converter clutch. The transmission may also be shifted manually between all forward ranges.
D (Overdrive - with overdrive cancel switch activated, amber light on. This position is selected by pushing the button on the instrument panel, or shift stalk on later models.) provides all automatic shifts, including the application and release of the converter clutch, except the shift into overdrive. It is used to provide additional engine braking for descending grades.
2 (Manual second) provides only second gear operation regardless of vehicle speed. It is useful for start-up on slippery surfaces or to provide engine braking on downgrades.
1 (Manual low) provides only low (1st) gear at start-ups. At higher speeds it results in a downshift to second gear followed by an automatic downshift to low which occurs when vehicle speed decreases enough. Once in low, the transmission will stay in low until the selector is moved to another position.

ELECTRONIC CONTROL
* The E4OD is electronically controlled by a microprocessor known as the EEC-IV processor (electronic control assembly, ECA). The EEC-IV processor controls both the engine and the transmission on gasoline engine applications in the same microprocessor. On diesels the ECA controls the transmission only.
* Electronic control also provides powertrain system diagnostic capabilities which will result in earlier and more accurate resolution of E4OD malfunctions.
* Service technicians can detect many types of transmission concerns if they occur during the standard EEC-IV "Quick Test" on both gas and diesel use.
* Additionally, the overdrive cancel switch indicator light will flash during certain conditions which will inform the driver to go to a Ford dealer for servicing.
* The processor gathers information from sensors located throughout the vehicle which are monitoring vehicle operating conditions. Using this information, the processor determines the best operating state for the transmission. A solenoid body assembly, containing five solenoids, receives the processor signals which in turn produces the desired mode of operation.
* Altitude compensation for shift quality and cold ambient warm-up strategy are also provided in the electronic controls. This eliminates the need for changes to the transmission for operating in mountainous regions. It also allows the E4OD to operate effectively even in extreme cold.
* An overdrive cancel switch allows lockout of overdrive with the push of a button. The switch is located on the instrument panel and is useful for providing increased engine braking on downhill grades. Depressing the switch will lock out overdrive (amber light turns on). Pressing it again, will change the system back to normal operation. Whenever the ignition key is turned on, the vehicle will automatically provide overdrive operation regardless of the switch position the last time the vehicle was running.

FUNCTIONAL COMPONENTS
Components from the intermediate brake drum rearward to the output shaft and extension housing seal are similar to the C-6 automatic transmission. However, the E4OD planetary gears have a higher contact ratio for quieter operation. Forward of the intermediate brake drum, the E4OD components are new. These new
parts are:
> Center support assembly
> Overdrive ring gear
> Coast clutch
> Overdrive sun gear and planet gear assembly
> Pump and support assembly
> Converter and clutch/damper assembly
The E4OD has wider forward gear ratios than the C-6 as shown below.
Gear - C6 - E4OD
1st - 2.46 - 2.71
2nd - 1.46 - 1.538
3rd - 1.00 - 1.00
OD - NA - 0.712
Rev - 2.18 - 2.18
Currently there are 12 E4OD models for use in F-250/350 (4x2 and 4x4), Econoline (5.8L/7.3L Diesel/7.5L) and F Super Duty (7.3L Diesel/7.5L). For details in diagnosing, testing, disassembling and assembling, see Section 17-09 of the 1989 Truck Shop Manual. Also see the E4OD Theory and Diagnosis Technical Training Manual (Order No. 1710-012). The E4OD, like the C-6, is filled with Mercon fluid. The fluid should be changed every 30,000 miles for severe service use. See the bottom of this page for proper fluid application.

[Steve83]

TSB 02-21-01 E4OD/4R100 Torque Converter Access External Dust Plug May Become Dislodged
Publication Date: October 11, 2002

Applicability:
1989-1996 BRONCO
1989-1997 F SUPER DUTY
1989-1998 F-250 LD, F-53 MOTORHOME
1989-2003 E SERIES, F-150
1997-2003 EXPEDITION
1999-2003 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS.
2000-2003 EXCURSION
LINCOLN: 1998-2003 NAVIGATOR
2002-2003 BLACKWOOD

ISSUE: Some vehicles equipped with the E4OD/4R100 transmission may exhibit the torque converter external access dust plug dislodging and falling out during severe duty use. This may be caused by a combination of stack up tolerance, material shrinkage over time, and loading being applied to the plug during usage or cleaning of the underside of the vehicle.

ACTION: Obtain new plug (E9TZ-7N171-A) and apply 1/4" bead of silicone sealant around entire perimeter of part and install plug into transmission case. The silicone is to be applied in the groove of the part such that when it is installed, the sealant will fill any gaps between the transmission case and the plug.

SERVICE PROCEDURE
1. Obtain service part E9TZ-7N171-A, F7TZ-19554-AA and general purpose degreaser such as Motorcraft Brake Parts Cleaner, PM-4.
2. Clean transmission case casting in the area of the plug using general purpose degreaser making sure the area is free from grease and other contaminants.
3. Apply a 1/4" bead of silicone sealant F7TZ-19554-AA to plug E9TZ-7N171-A making sure that the groove in the plug is filled with silicone sealant. Immediately install plug into the transmission case casting smoothing out any overflow that may occur during installation.

PART NUMBER PART NAME
PM-4 Motorcraft Brake Parts Cleaner
E9TZ-7N171-A Plug - Converter Access
F7TZ-19554-AA Ultra Silicone Sealant

OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage

OPERATION: 022101A
DESCRIPTION: Install Torque Converter Access External Dust Plug - 1989-1996 Bronco, 1989-1997 F-150, F250LD, F-Super Duty, E-Series, 1998-2003 F-150,
Lightning, Harley Davidson, F-250LD, Super Duty F-Series, E-Series, 2000-2003 Excursion, 1989-2003 Motor Home Stripped Chassis, 1997-2003 Expedition,
Navigator, 2002-2003 Blackwood
TIME: 0.2 Hr.
Searchability: trans transmission bellhousing engine bottom plug rubber stopper disk disc grommet grommett gromett hole drain

[Steve83]

TSB 96-22-01 Windshield and Interior Glass - Fog/Film
Publication Date: OCTOBER 21, 1996

FORD: 1984-1986 LTD
1984-1988 EXP
1984-1994 TEMPO
1984-1997 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD
1986-1997 TAURUS
1988-1993 FESTIVA
1989-1997 PROBE
1994-1997 ASPIRE
1995-1997 CONTOUR
LINCOLN-MERCURY: 1984-1986 MARQUIS
1984-1987 LN7, LYNX
1984-1992 MARK VII
1984-1994 TOPAZ
1984-1997 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR
1986-1997 SABLE
1987-1989 TRACER
1991-1994 CAPRI
1991-1997 TRACER
1993-1997 MARK VIII
1995-1997 MYSTIQUE
MERKUR: 1985-1989 XR4TI
1988-1990 SCORPIO
LIGHT TRUCK: 1984-1997 F-150-350 SERIES
1986-1990 BRONCO II
1986-1996 BRONCO
1986-1997 AEROSTAR, ECONOLINE, RANGER
1988-1997 F SUPER DUTY
1991-1997 EXPLORER
1993-1997 VILLAGER
1995-1997 WINDSTAR

ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog can be advised that Ford Motor Company has extensively tested this material and found that it is not a health hazard. The film is caused by some of the chemicals used during the manufacture of the interior trim.

ACTION: At the present time, there is no known field fix to prevent the window fogging, however, glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for film removal.

PART NUMBER PART NAME
E4AZ-19C507-AA Ford Glass Cleaner

OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 86-13-06
WARRANTY STATUS: Information Only

[Steve83]

Note that, everywhere these TSBs say "electrolysis", the correct term is "Galvanic action".
************************************************** *************************
TSB 06-21-19 Heater Core Leakage and Electrolysis
Publication Date: 10/30/06

FORD: 1997-2002 Contour
1997 -2007 Crown Victoria, Mustang, Taurus
2000-2007 Focus
2002-2005 Thunderbird
2005-2007 Five Hundred, Freestyle
2006-2007 Fusion
1997-1999 F-2S0 Light Duty
1997 -2003 Windstar
1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger
2000-2005 Excursion
2001-2003 Explorer Sport
2001-2007 Escape, Explorer Sport Trac
2004 F-15O Heritage
2004-2007 Freestar
2005-2007 Escape Hybrid
1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental
1997-2007 Town Car
2000-2006 Lincoln LS
2006 Zephyr
2007 MKZ
1998-2007 Navigator
2002-2003 Blackwood
2003-2005 Aviator
2006-2007 Mark LT
MERCURY: 1997 -2002 Cougar, Mystique
1997-2005 Sable
1997-2007 Grand Marquis
2005-2007 Montego
2006-2007 Milan
1997-2002 Villager
1997-2007 Mountaineer
2005-2007 Mariner
2006-2007 Mariner Hybrid

This article supersedes TSB 01-15-06 to update the vehicle model years and Service Procedure.

ISSUE: The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred.

ACTION: If the heater core is leaking, review the location of the leakage and check the condition of the coolant.

SERVICE PROCEDURE
1. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate. Replace the heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412.
2. lf leaks are found in the body of the heater core itself, and they do not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis.

Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant, but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition or replacement. To keep more coolant from exiting the heater core, clamp off heater core lines and measure coolant in the engine block. Try not to
dilute the original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of DC voltmeter to engine ground and positive lead in the coolant.
NOTE: POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (VDC) OK, reconnect battery cables and proceed to Step 2.
d. lf greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on/off switch on the vehicle instrument panel; use a jumper wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. Less than or equal to 0.4V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until voltage drops to less than or equal to 0.4 V. Repair ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 VDC
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present, try turning off each accessory one at a time including blower motor and any fan motors.
n. If AC voltage is still present, shut engine off and remove B+ from the alternator and tape it up, then retest.
o. If voltage drops gradually to less than or equal to 0.4 VAC, the ground straps may simply be overloaded by added accessories. Test by using a heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck.
NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on, and off.
CAUTION: DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLYSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLYSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR IF THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

***********************************************

TSB 01-15-06 Repeat Heater Core Failure (SUPERSEDED)
Publication Date: JULY 26, 2001

FORD: 1985-94 TEMPO
1985-97 THUNDERBIRD
1985-2002 CROWN VICTORIA, ESCORT, MUSTANG
1986-2002 TAURUS
1988-93 FESTIVA
1993-97 PROBE
1994-97 ASPIRE
1995-2000 CONTOUR
2000-2002 ESCORT ZX2, FOCUS
2002 THUNDERBIRD
1985-90 BRONCO II
1985-96 BRONCO
1985-97 F-250 HD, F-350
1985-2002 ECONOLINE, F-150, RANGER
1986-97 AEROSTAR
1988-97 F SUPER DUTY
1991-2002 EXPLORER
1995-2002 WINDSTAR
1997-2002 EXPEDITION
1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION
2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 1985-92 MARK VII
1985-2002 CONTINENTAL, TOWN CAR
1993-98 MARK VIII
2000-2002 LS
1998-2002 NAVIGATOR
MERCURY: 1985-94 TOPAZ
1985-97 COUGAR
1985-2002 GRAND MARQUIS
1986-2002 SABLE
1991-99 TRACER
1995-2000 MYSTIQUE
1999-2002 COUGAR
1993-2002 VILLAGER
1997-2001 MOUNTAINEER

ISSUE: Some vehicles may exhibit (repeat) heater core leaks. This may be caused by a chemical reaction called electrolysis. Electrolysis involves an ion exchange between the heater core and engine coolant which can result in a breakdown of the heater core material. This is similar to the operation of a battery.

ACTION: Check for electrolysis on any vehicle with a heater core failure. If electrolysis is verified, flush the coolant and follow additional steps as required. Refer to the following Service Procedure for details.

SERVICE PROCEDURE - Electrolysis Inspection:
If there is a condition of a heater core leaking or repeat heater core leak, check for electrolysis using the following procedure:
1. To check for electrolysis use a DVOM set on DC volts. Place the positive probe of the meter in the engine coolant and the negative probe on the negative battery post.
2. Adjust engine throttle to 2000 RPM to properly get coolant flow and true electrolysis voltages.
3. If more than .4V is recorded, flush the coolant and recheck (follow guidelines in TSB 98-23-16 for Cougar). See Coolant Fill Procedure below to remove trapped air on 4.6/5.4/6.8L modular engines.
NOTE: EXPORT MARKETS, BE SURE THE WATER IS DESALINATED.
4. If there is still excessive voltage present in the coolant, check the engine to body/battery grounds. Also, verify proper grounding of any aftermarket electrical/electronic equipment which has been installed into the vehicle. Improperly grounded electrical devices can cause electrolysis to occur.
5. If the condition is still present after the grounds have been checked, it may be necessary to add extra grounds to the heater core and engine. A hose clamp can be used to secure a 16 AWG stranded copper wire to the heater core inlet tube. The other end should be secured to an EXISTING FASTENER on the body sheet metal. Extra grounds to the engine should be attached between EXISTING FASTENERS on the engine and body sheet metal. Verify continuity of any added grounds to the negative battery terminal.
6. If the condition is still present, add a restrictor (part F1UZ-18D406-A) on the inlet hose with the arrow facing the direction of coolant flow (toward heater core). Cut the line and install with 2 hose clamps. It is important that the restrictor be installed in the right direction of flow and as close to the engine block as possible (not near the heater core itself).

Coolant Fill Procedure
At times, in order to completely remove any trapped air in the cooling system of vehicles equipped with 4.6/5.4/6.8L modular engines, it may be necessary to use the following procedure:
1. Disconnect the heater hose at the right front or rear of the engine.
2. Remove the thermostat and housing.
3. Using the thermostat opening, carefully fill the engine with the proper clean coolant mixture until observed at the engine side heater hose connection.
4. Reconnect the heater hose and reinstall the thermostat and housing.
5. Fill the degas bottle to the coolant fill level mark.
6. Run the engine until it reaches normal operating temperatures.
7. Select max heat and max blower speed on the climate system.
NOTE: IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.

PART NUMBER PART NAME
F1UZ-18D406-A Restrictor

OTHER APPLICABLE ARTICLES: 98-23-16
WARRANTY STATUS: INFORMATION ONLY

***************************************
Note that everywhere these TSBs mention "electrolysis", the correct term is "galvanic action". Electrolysis is the breakdown of the molecules in an electrolytic solution into their component chemicals due to an electrical charge being applied to the solution. (Hydrogen being emitted from a battery under a hard charge is an example of electrolysis since the water is breaking down into Hydrogen & Oxygen.) Luigi Galvani studied the interaction of electricity & metals exposed to an electrolytic solution. Since the phenomenon described in the TSB deals with the metal of the heater core & not the chemistry of the coolant, it's a galvanic process.

[Steve83]

TSB 00-23-10 Transmission Fluid In-Line Filter Kit
Publication Date: NOVEMBER 6, 2000

FORD: 1980-1997 THUNDERBIRD
1980-2001 CROWN VICTORIA
1984-2001 MUSTANG
1985-1990 BRONCO II
1985-2001 RANGER
1987-1997 AEROSTAR
1989-1996 BRONCO
1989-1997 F SUPER DUTY, F-250 HD
1989-2001 ECONOLINE, F-150, F-250 LD, F-350, F-450
1991-2002 EXPLORER
1997-2001 EXPEDITION
1999-2001 F-250 HD, SUPER DUTY F SERIES
2000-2001 EXCURSION
LINCOLN: 1982-2001 TOWN CAR
2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1980-2001 GRAND MARQUIS
1987-1997 COUGAR
1997-2002 MOUNTAINEER

ISSUE: Contamination from prior transmission concerns or excess wear may be trapped in the transmission fluid cooling system. This debris must be removed by properly cleaning the transmission cooling system. After cleaning, some contamination may still remain. The remaining contamination may be reintroduced into the fluid cooling system of a repaired/replaced transmission causing premature or repeat failures.

ACTION: After every overhaul or transmission exchange, clean, flush and backflush the transmission fluid cooling system which includes: fluid cooler, auxiliary cooler, cooler lines, and Cooler Bypass Valve (CBV), if equipped. Perform the cooler flow test to ensure proper transmission fluid flow volume on the transmission return line through the cooling system. Once proper fluid flow volume is verified install the Transmission Fluid In-Line Filter Kit (XC3Z-7B155-AA) in the fluid cooler return line (transmission fluid flow coming out of the fluid cooler going into the transmission). Refer to the following Service Procedure for details.

SERVICE PROCEDURE
NOTE: THIS IN-LINE TRANSMISSION FLUID FILTER KIT CAN BE INSTALLED ON ALL TRANSMISSIONS WITH 8mm (5/16") AND 9.5mm (3/8") TRANSMISSION FLUID COOLER LINES.
NOTE: THIS IN-LINE TRANSMISSION FLUID FILTER KIT WILL ALSO BE SUPPLIED WITH ALL E4OD/4R100 AND OTHER FORD QUALITY REMANUFACTURED (FQR) TRANSMISSIONS. AFTER ANY OVERHAUL OR TRANSMISSION EXCHANGE PRIOR TO CONNECTING THE TRANSMISSION FLUID COOLING SYSTEM TO THE TRANSMISSION, FOLLOW THE STEPS BELOW.
1. Clean, flush and backflush transmission fluid cooling system.
NOTE: VEHICLES EQUIPPED WITH STAND-ALONE OIL-TO-AIR (OTA) FLUID COOLERS CANNOT BE PROPERLY FLUSHED. ADDITIONALLY, 1998-2001 CROWN VICTORIA/GRAND MARQUIS AND TOWN CAR HAVE OIL-TO-AIR (OTA) FLUID COOLERS EQUIPPED WITH A TERMINAL BY-PASS VALVE. FOR ALL VEHICLES EQUIPPED WITH STAND-ALONE OTA COOLERS, THE OTA COOLER
MUST BE REPLACED ON EVERY OVERHAUL OR TRANSMISSION EXCHANGE. REFER TO THE APPROPRIATE SERVICE/WORKSHOP MANUAL FOR PROCEDURE
2. Once the fluid cooling system has been cleaned, flushed and backflushed, connect the cooler lines and perform the transmission fluid flow test to ensure proper fluid flow. Refer to the appropriate Service/Workshop Manual for procedure. If proper fluid flow volume is not obtained, refer to appropriate Service/Workshop Manual for repair procedure. The transmission fluid coolers, auxiliary cooler, OTA, cooler lines, CBV (if equipped), transmission fluid pump or internal filter may be restricted or damaged and require replacement.
CAUTION: FAILURE TO FOLLOW THE KIT INSTRUCTIONS MAY CAUSE INTERNAL TRANSMISSION ASSEMBLY DAMAGE AND REPEAT REPAIRS.
3. Only after proper transmission fluid flow volume is present, install the Transmission Fluid In-Line Filter Kit (XC3Z-7B155-AA). Follow the instructions provided with the kit.
4. Once the filter is installed: with the transmission fluid return line disconnected from the transmission, verify fluid flow through the filter. Once the fluid flow in-and-out of the filter is verified, connect the transmission fluid return line to the transmission. Check and adjust proper transmission fluid level to normal operating range at normal operating temperature and check for leaks, kinks and chafe points (refer to the "Do's and Don'ts" chart in the kit instructions).
NOTE: THE FILTER INCLUDED IN THIS KIT WILL ALSO BE AVAILABLE AS A SEPARATE PART (XC3Z-7B155-BA). IT IS RECOMMENDED THAT THIS IN-LINE FILTER BE CHANGED EVERY 48,000 KILOMETERS (30,000 MILES).

PART NUMBER PART NAME
XC3Z-7B155-AA Transmission Fluid In-Line Filter Kit (Complete)
XC3Z-7B155-BA In-Line Filter Only (Separate)

OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 00-03-08
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage

OPERATION DESCRIPTION TIME
002310AB Perform Flow Test And Install In-Line Fluid Filter 0.7 Hr.
002310A Additional Time To Retest Fluid Flow Before Installing In-Line Filter (To Be Used Only After Additional Repairs Are Performed) 0.3 Hr.

[Steve83]

TSB 98-5A-13 NEW SPECIFICATION - Silicone Brake Caliper Grease and Dielectric Compound to be used for Disc Brake Caliper Slides
Publication Date: MARCH 18, 1998

FORD: 1984-1994 TEMPO
1984-1996 MUSTANG, THUNDERBIRD
1985-1996 CROWN VICTORIA, ESCORT
1986-1996 TAURUS
1989-1996 PROBE
1994-1996 ASPIRE
1995-1996 CONTOUR
LINCOLN-MERCURY: 1982-1996 CONTINENTAL
1984-1994 TOPAZ
1984-1996 COUGAR
1985-1996 GRAND MARQUIS
1986-1996 SABLE, TOWN CAR
1987-1989 TRACER
1991-1994 CAPRI
1991-1996 TRACER
1993-1996 MARK VIII
1995-1996 MYSTIQUE
LIGHT TRUCK: 1983-1996 RANGER
1986-1996 AEROSTAR
1990-1996 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES
1991-1996 EXPLORER
1993-1996 VILLAGER
1995-1996 WINDSTAR
MEDIUM/HEAVY TRUCK: 1990-1991 C SERIES
1990-1996 F & B SERIES

ISSUE: The use of petroleum-based grease as a lubricant in servicing disc brakes is no longer acceptable because it may be incompatible with the rubber material used in the disc brake system. If petroleum-based grease is used to lubricate any part of the disc brake system, it could cause rubber parts to swell if lubricant contacts the rubber material.

ACTION: Refer to the following Servicing Procedures for details.

DISC BRAKE SERVICING
CAUTION: DO NOT USE PETROLEUM-BASED SERVICE GREASE (SUCH AS FORD DISC BRAKE CALIPER SLIDE GREASE D7AZ-19590-A) TO LUBRICATE DISC BRAKE CALIPER SLIDE PINS OR RUBBER DUST BOOTS. PETROLEUM-BASED GREASE MAY CAUSE EPDM RUBBER TO SWELL.
When servicing any disc brakes, lubricate necessary components by applying Silicone Brake Caliper Grease and Dielectric Compound (D7AZ-19A331-A (Motorcraft WA-10)) or an equivalent silicone compound meeting Ford Specification ESE-M1C171-A. Refer to the appropriate Service Manual for specific service details.

DRUM BRAKE SERVICING
When servicing drum brakes, apply Silicone Brake Caliper Grease and Dielectric Compound (D7AZ-19A331-A (Motorcraft WA-10)) or an equivalent silicone compound meeting Ford Specification ESE-M1C171-A to the contact points between the brake shoes and the drum backing plates for lubrication.
NOTE: DISC BRAKE CALIPER SLIDE GREASE D7AZ-19590-A SHOULD NO LONGER BE USED FOR DISC BRAKE CALIPER SLIDE LUBRICATION.

OTHER SERVICE APPLICATIONS
Existing inventory of D7AZ-19590-A may be used for all other Service Manual procedures. Once material is exhausted, all vehicle procedures specifying Disc Brake Caliper Slide Grease (D7AZ-19590-A) should use Silicone Brake Caliper Grease and Dielectric Compound (D7AZ-19A331-A).

PART NUMBER : PART NAME
D7AZ-19A331-A : Silicone Brake Caliper Grease And Dielectric Compound

OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 95-21-02

[Steve83]

TSB 98-24-06 New Electrical Terminal Grease Released for Service
Publication Date: NOVEMBER 25, 1998

FORD: 1981-1999 ESCORT
1983-1999 CROWN VICTORIA
1984-1988 EXP
1984-1994 TEMPO
1985-1999 TAURUS
1986-1997 PROBE
1988-1991 FESTIVA
1993-1999 MUSTANG
1994-1997 ASPIRE
1995-1999 CONTOUR
1996-1997 THUNDERBIRD
LINCOLN-MERCURY: 1983-1999 CONTINENTAL, GRAND MARQUIS
1984-1986 CAPRI
1984-1987 LN7
1984-1994 TOPAZ
1985-1999 SABLE
1988-1992 MARK VII
1991-1994 CAPRI
1993-1998 MARK VIII
1993-1999 TRACER
1995-1999 MYSTIQUE
1996-1997 COUGAR, TOWN CAR
1999 COUGAR
MERKUR: 1985-1988 XR4TI
1988 SCORPIO
LIGHT TRUCK: 1981-1996 BRONCO
1981-1997 F SUPER DUTY, F-250 HD, F-350
1981-1999 ECONOLINE, F-150, F-250 LD
1983-1999 RANGER
1984-1990 BRONCO II
1984-1997 AEROSTAR
1991-1999 EXPLORER
1993-1999 VILLAGER
1995-1999 WINDSTAR
1997-1999 EXPEDITION, MOUNTAINEER
1998-1999 NAVIGATOR
1999 SUPER DUTY F SERIES
MEDIUM/HEAVY TRUCK: 1984-1999 F & B SERIES
1988-1997 CARGO SERIES
1996-1998 AEROMAX, LOUISVILLE

ISSUE: Ford Motor Company has released a new Electrical Grease (F8AZ-19G208-AA) to reduce the possibility of moisture corrosion at the terminals.



ACTION: Add the new grease during electrical connection repair.
CAUTION: ELECTRICAL CONNECTOR GREASE SHOULD NOT BE USED IN HIGH VOLTAGE CONNECTIONS FOR SPARK PLUG AND COIL WIRE APPLICATIONS.

PROPER USES OF THE NEW ELECTRICAL GREASE INCLUDE:
Electrical Connectors
Battery Connections
Light Sockets
Starter Terminals

DO NOT USE ON:
Spark Plug Wires
Coil Wires
Spark Plug-to-Coil Connections
Low Current Flow Switches (12V Systems less than 0.1 amp)

[Steve83]

TSB 97-17-02 NEW PROCEDURE for Rear View Mirror Reattachment
Publication Date: AUGUST 18, 1997

FORD: 1990-1994 TEMPO
1990-1997 CROWN VICTORIA, MUSTANG, TAURUS, THUNDERBIRD
1990-1998 ESCORT
1992-1997 PROBE
1995-1998 CONTOUR
LINCOLN-MERCURY: 1990-1992 MARK VII
1990-1994 TOPAZ
1990-1997 COUGAR, GRAND MARQUIS, SABLE
1990-1998 CONTINENTAL, TOWN CAR
1991-1998 TRACER
1993-1997 MARK VIII
1995-1998 MYSTIQUE
LIGHT TRUCK: 1990-1996 BRONCO
1990-1997 AEROSTAR, ECONOLINE, F-150-350 SERIES, RANGER
1991-1997 EXPLORER
1993-1997 VILLAGER
1995-1998 WINDSTAR
1997 EXPEDITION, MOUNTAINEER
1998 NAVIGATOR

ISSUE: This TSB article introduces a new procedure and tool for reattaching the inside rear view mirror assembly in the event the mirror detaches.

ACTION: Utilize the new Rotunda Mirror Button Applicator (164-R3925) to bond the mirror button to the windshield. This preferred method provides improved adhesion performance. Refer to the following Service Procedure for details.

SERVICE PROCEDURE
CAUTION: DO NOT USE THIS PROCEDURE IF WINDSHIELD IS DAMAGED (E.G., CHIPPED, CRACKED, OR EXHIBITS STAR BREAKS) WITHIN 152mm (6") OF THE MIRROR BUTTON, AND IF PLASTIC FILMS HAVE BEEN APPLIED TO THE INSIDE SURFACE OF THE WINDSHIELD (SUCH AS ADDITIONAL GRADIENT BANDS) WITHIN 51mm (2") OF THE MIRROR BUTTON.
1. Mark original location of bracket on outside of windshield with any appropriate marking tool (e.g., white china marker) before you begin.
NOTE: SURFACES MUST BE CLEAN FOR PROPER BONDING TO OCCUR.
2. Use the following steps to ensure proper cleaning of windshield:
a. Carefully remove any adhesive residue from the windshield using a new single edge razor blade.
b. Spray the inside surface of the windshield with a glass cleaner and wipe with a clean, soft, lint-free cloth.
3. Remove the liner from the pre-applied tape and apply the button directly onto the windshield at the marked location.
Button sizes:
F7AZ-17698-AA Small Footprint Size (16mm X 33mm)
F7AZ-17698-BA Large Footprint Size (21mm X 29mm)
4. Center the curing head of the Rotunda Mirror Button Applicator (164-R3925) over the button. Hold the curing head in place and press the "ON" button to activate the vacuum pump. Press the "START" button of the time/temperature controller to begin the cure cycle. Immediately clean the mirror button location marks from the outside of the windshield. Do not release the curing head until the cycle is completed. The AUTOMATIC CYCLE (once the start button is pressed) is as follows:
a. Time of curing cycle will be displayed.
b. Time will stay constant until cure temperature 185°C (365°F) is reached.
c. Once the cure temperature is reached, display will reflect time remaining for complete cure.
CAUTION: THE HEATER BLOCK MAY STILL BE WARM. HANDLE WITH A GLOVE AND AVOID CONTACT WITH ANY SURFACE THAT MAY BE DAMAGED BY HIGH TEMPERATURE.
5. Turn the applicator off. Press the vacuum release button and remove the curing head from the windshield. Once the button has cooled to ambient temperature (about 5 minutes), reattach the mirror assembly.

PART NUMBER PART NAME
F7AZ-17698-AA Rear View Mirror Button (Small - 16mm X 33mm)
F7AZ-17698-BA Rear View Mirror Button (Large - 21mm X 29mm)

OTHER APPLICABLE ARTICLES: 94-17-02

[Steve83]

TSB 96-23-01 Clicking Heard When Turning Steering Wheel
Publication Date: NOVEMBER 4, 1996

FORD: 1990-1991 CROWN VICTORIA, TAURUS
LINCOLN-MERCURY: 1990-1991 GRAND MARQUIS, MARK VII, SABLE, TOWN CAR
1991 CONTINENTAL
LIGHT TRUCK: 1992-1996 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES
1995-1996 EXPLORER, RANGER, WINDSTAR

ISSUE: A "clicking" noise may be heard when turning the steering wheel. This condition may be caused by minor surface variations in the original stamped non-silver plated upper column bearings.

ACTION: Install an Upper Steering Column Bearing Kit if noise occurs during Diagnosis procedure. Refer to the following Service Procedure for installation details.
NOTE: THE CLICKING NOISE DOES NOT AFFECT STEERING OPERATION.

DIAGNOSIS
Before replacing the bearings, the following checks should be made:
1. Hold the steering wheel in the 3 and 9 o'clock positions and rock the wheel (without rotating it) about its center, checking for the clicking noise.
2. Repeat while holding the wheel in the 12 and 6 o'clock positions.

SERVICE PROCEDURE
If the noise does not occur with the above checks, the noise is due to another component such as the clockspring and this TSB article does not apply. If the noise does occur, install the Upper Steering Column Bearing Kit (F6AZ-3605-AA) which includes silver plated upper steering column bearings. Refer to Instruction Sheet 7162 provided in the Upper Steering Column Bearing Kit for replacement procedure.
The Upper Steering Column Bearing Kit (F6AZ-3605-AA) contains one (1) each of the following items:
Steel Tolerance Ring
Steel Sleeve (Stamped)
Bearing Pre-Load Spring
Upper Bearing Snap Ring
Steering Wheel Attaching Bolt
Small Upper Bearing (Silver Plated)
Large Upper Bearing (Silver Plated)
Instruction Sheet (I.S. 7162)

PART NUMBER PART NAME
F6AZ-3605-AA Upper Steering Column Bearing Kit

OTHER APPLICABLE ARTICLES: 89-25-03 , 90-25-08 , 91-03-01
SUPERSEDES: 92-12-03
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991 Lincolns And 1992-96 Vehicles, Basic Warranty Coverage For All Other Vehicle Lines

OPERATION DESCRIPTION TIME
962301A Install Steering Column Bearing Kit - 1990-91 Crown Victoria/Grand Marquis 1.9 Hrs.
962301B Install Steering Column Bearing Kit - 1990-91 Taurus (Manual Transmission) 1.4 Hrs.
962301C Install Steering Column Bearing Kit - 1990-91 Taurus/Sable (Automatic Transmission) 1.6 Hrs.
962301D Install Steering Column Bearing Kit - 1990-91 Mark VII 1.7 Hrs.
962301E Install Steering Column Bearing Kit - 1990-91 Town Car 1.8 Hrs.
962301F Install Steering Column Bearing Kit - 1991 Continental 1.6 Hrs.
962301G Install Steering Column Bearing Kit - 1995-96 Windstar (Without Tilt Wheel) 1.8 Hrs.
962301H Install Steering Column Bearing Kit - 1995-96 Windstar (With Tilt Wheel) 1.9 Hrs.
962301J Install Steering Column Bearing Kit - 1995-96 Ranger/Explorer (With Tilt Wheel) 1.8 Hrs.
962301K Install Steering Column Bearing Kit - 1995-96 Ranger/Explorer (Without Tilt Wheel) 1.7 Hrs.
962301L Install Steering Column Bearing Kit - 1992-96 Econoline (With SRS And Tilt Wheel) 2.0 Hrs.
962301M Install Steering Column Bearing Kit - 1992-96 Econoline (With SRS And Without Tilt Wheel) 1.9 Hrs.
962301N Install Steering Column Bearing Kit - 1992-96 Econoline (Without SRS And With Tilt Wheel) 1.8 Hrs.
962301O Install Steering Column Bearing Kit - 1992-96 Econoline (Without SRS Or Tilt Wheel) 1.7 Hrs.
962301P Install Steering Column Bearing Kit - 1992-96 F-150-350/Bronco (With SRS And Tilt Wheel) 1.8 Hrs.
962301Q Install Steering Column Bearing Kit - 1992-96 F-150-350/Bronco (With SRS And Without Tilt Wheel) 1.7 Hrs.
962301R Install Steering Column Bearing Kit - 1994-96 F-150-350/Bronco (Without SRS And With Tilt Wheel) 1.7 Hrs.
962301S Install Steering Column Bearing Kit - 1994-96 F-150-350/Bronco (Without SRS Or Tilt Wheel) 1.6 Hrs.
962301T Install Steering Column Bearing Kit - 1992-96 Aerostar 1.7 Hrs.

See this album for more info, including the full teardown procedure for the '92-up
steering column.


CHECK THE TSB & FSA ALBUM in my signature link for additional articles.