TSBs & FSAs

[Steve83]

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

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[Steve83]

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 the 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.

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TSB 06-14-04 Transmission Fluid Chart

I edited this slightly:

Originally Posted by 92builtbronco

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 01-15-7 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)

trans stick slushbox auto automatic manual gear oil atf

[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.

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.

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.
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.

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: 00-3-8
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 02-21-1 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
Obtain service part E9TZ-7N171-A, F7TZ-19554-AA and general purpose degreaser such as Motorcraft Brake Parts Cleaner, PM-4.
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. 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.

trans transmission bellhousing engine bottom plug rubber stopper disk disc grommet grommett gromett hole drain

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