Technical & Administrative Information - Attachment II: Overview
Attachment II Page 1 of 4
Safety Recall 87S38
(Technical and Administrative Instructions)
Technical Instructions:
Inspection instructions, inspection forms as well as installation instructions for the various heat protection, fuel venting and emissions control system modification kits are packaged with the kits. Additional inspection procedures and forms are available from your District Offices or from Service Recalls, Ford International Export Sales.
A special training videotape (VHS Format), covering the inspection procedure and installation of the various modification kits is being supplied to all involved dealers at no charge.
Dealership service personnel should also refer to the supplemental technical notes shown on Exhibit I of this attachment. These supplemental notes cover a variety of technical issues and are intended to clarify certain situations that may be encountered when servicing vehicles covered by this program. Topics covered include:
^ Warning not to use silicone lubricant on rubber parts;
^ What to do about disabled thermactor systems;
^ When to install the thermactor air bypass kit;
^ Warning to cap fuel lines when installing fuel venting kits;
^ Special instructions for installing fuel venting kit on 176" wheelbase vehicles.
^ What to do if the vehicle is equipped with non-Ford fuel tanks and/or fuel filler pipes;
^ Special instructions for installing fuel venting kits on some motorhomes built by Fleetwood Enterprises, Inc.;
Special Tool Requirements:
Completion of the modification kit installation procedure requires a fuel system pressurization test. In order to perform this test, it is necessary to use a Rotunda 134-00003 fuel tank assembly leak tester. Each involved dealer is being supplied with a leak tester kit, at no charge. (Dealers participating in the ambulance safety recall have already been supplied with this leak tester kit.) This kit contains the test assembly as well as four (4) special filler test caps and several aluminum plugs (needed to cap vent lines). If required, additional leak test kits are available through the normal Rotunda tool order channel. Orders for any additional leak tester kits will be charged to the dealer.
NOTE
This test procedure requires a tank of C02, Argon or Nitrogen Gas; if not already available, make necessary arrangements to obtain a tank of one of these inert gases, (SHOP AIR CANNOT BE USED SINCE INTRODUCTION OF OXYGEN DURING THIS TEST PROCEDURE PRESENTS A FIRE HAZARD.) Additionally, most dealers will need to obtain a step-down regulator valve for this tank to reduce the gas pressure down to a maximum of 150 lbs. PSI. The cost of the inert gas and the regulator is factored into the labor time allowances.
Parts Requirements:
Parts will not be "direct shipped" for this recall. A maximum order quantity has been established to preclude unnecessary stockpiling. Do not order recall parts from Windsor Export Supply. Order all requirements directly from Wixom using the mailing address on page No. 1 of this Bulletin. For more urgent handling, use cable address "RECALLS - FORDEX, WIXOM, MICHIGAN". For locations having telex facilities, our telex Ford private line code is FED and commercial telex code is 669777 answerback Ford FIES WIX. Our telephone number in Wixom, Michigan, is area code (313) 344-5641. Please give the part number, description, quantity and recall number when ordering. Modification kit ordering information is as follows:
Basic Part Kit Applications
E5UZ-9000-C - Fuel Venting Kit - Use for vehicles with Repair Codes A, B
E5UZ-9000-D - Fuel Venting Kit - Use for vehicles with Repair Code C
Basic Part Kit Applications
E6UZ-9000-B - Fuel Venting Kit - Use for vehicles with Repair Codes D, or, E, or F, or G
E6UZ-9000-C - Fuel Venting Kit - Use for vehicles with Repair Code H
E3UZ-9000-D - Fuel Venting Kit - Use for vehicles with Repair Codes J, or K, or L, or M
E3UZ-9000-E - Fuel Filler Pipe Kit - Use for vehicles with Repair Codes A, or D, or E, or J, or K
E3UZ-9000-L - Fuel Filler Pipe Kit - Use for vehicles with Repair Codes B, or F, or G, or L, or M
E3UZ-9000-F - Altitude Compensation Kit - Use for vehicles with Repair Codes A, or B, or C if operated over 4,000 feet altitude
E3UZ-9000-J - Altitude Compensation Kit - Use for 7.5 liter California vehicles if operated over 4,000 feet altitude
E5UZ-9000-G - Altitude Compensation Kit - Use for 5.8 liter 4V over 8,500 GW if operated over 4,000 feet altitude
E3TZ-9000-B - Thermactor Air Idler Kit - Use only if vehicle is equipped with a throttle kicker device to allow operation of the engine at extended high idle. Requires vehicle to be equipped with electrically controlled throttle kicker device. (Conversion to an electrically controlled throttle kicker device, if required, is at the owner's expense.)
NOTES:
^ The Fuel Filler Pipe Kit contains an inspection form and inspection instructions; A fuel filler pipe kit is not included for cutaway units with single 40 gallon fuel tanks; inspection forms are included in the fuel venting kit for these vehicles.
^ 176" wheelbase vehicles also require the following parts to mount the muffler shield on vehicles equipped with a front fuel tank: (1) E8UZ-9U61-A Frame Stringer, (1) E8UZ-5N203-A Muffler Shield Bracket, (2) 56760-S101 Bolt, and (2) 382400-S2 Nut.
Additionally, to assist dealership personnel, the specific kit combinations required to modify vehicles covered by this program (detailed by engine and vehicle configuration) are summarized on Exhibit II of this attachment.
Labor Allowances
Due to the many variations in vehicle configurations and the resulting large number of possible labor operation codes/times, a summary of specific codes/times by application is shown on Exhibit II of this attachment.
Claims Preparation Instructions
^ Only a dealer generated claim Form 1864 will be accepted for this Recall.
^ REFER TO ATTACHMENT II, EXHIBIT II. TO ASSIST IN THE PREPARATION OF CLAIMS. "REPAIR CODES" HAVE BEEN DEVELOPED FOR THE VARIOUS VEHICLE/ENGINE CONFIGURATIONS. OBTAIN THE APPROPRIATE CODE FROM THE ATTACHED EXHIBIT. THE CODE IS ALSO PRINTED ON THE LETTER MAILED TO THE OWNERS.
^ Copies of the Claim Form 1864 must be kept in dealership service files together with the dealership's copy of the completed Econoline inspection sheet.
^ It is important that only Claim Forms 1864 for the inspections and modifications that are authorized by Ford in this instruction be submitted for payment.
^ Submit claims to FIES Warranty Claim Processing, Wixom and provide a copy of each claim and the original inspection sheet to:
Ford International Export Sales
P.O. Box 600
Wixom, Michigan 48096 U.S.A.
Attention: Service Recall Unit
NOTE
CLAIMS WILL BE CHARGED-BACK IF COPIES OF THE CLAIMS AND THE ORIGINAL INSPECTION SHEETS ARE NOT RECEIVED BY THE FIES SERVICE RECALL UNIT.