Campaign - Starter Solenoid Inspection/Replacement
December, 1993TO: All Ford Dealers
SUBJECT:
Owner Notification Program 93B35 - Certain 1992/1993 Model Year F-Series Trucks equipped with Manual Transmissions and the 4.9L, 5.8L or 7.5L engines. Also Certain 1992 Model Year Broncos equipped with Manual Transmissions and the 4.9L Engine - Starter Solenoid Inspection and Possible Replacement.
OASIS - Yes
OWNER LIST - Yes
PARTS RETURN - No
PROGRAM TIMING - Through 36 month / 36,000 mile Bumper-to-Bumper
warranty, or through December 31, 1994, whichever provides greater coverage.
AFFECTED VEHICLES
Certain 1992 Model Year F-Series trucks equipped with manual transmissions and 4.9L, 5.8L or 7.5L engines, built from August 1, 1991 through July 31, 1992; also certain 1993 Model Year F-Series trucks equipped with manual transmissions and 4.9L, 5.8L or 7.5L engines, built from August 1, 1992 through January 15, 1993. Additionally, certain 1992 Model Year Broncos equipped with manual transmissions and the 4.9L engine built from August 1, 1991 through July 31, 1992.
REASONS FOR THIS PROGRAM
The starter solenoid (11390) may continue to keep the starter pinion engaged and the starter motor energized after the ignition key is returned from the "start" position. Depending on driver response, this condition may result in one of the following situations:
If the driver continues to run the engine with the starter engaged, or drives the vehicle with the starter engaged, the starter motor commutator will fail. The starter typically will not crank on subsequent attempts, causing a "No-Start" condition.
If the driver turns off the ignition key while the starter is engaged to the running engine, the starter motor will continue to "crank" the engine until the battery is disconnected, the battery runs down, or the commutator fails.
SERVICE ACTION
To correct this condition, the starter will be inspected and, if built before December 16, 1992, the starter solenoid will be replaced.
REFUNDS
Only for owner-paid repairs made before date of Owner Letter.
ATTACHMENTS
Attachment I
- Administrative Information
- Refund Codes
Attachment II
- Labor Allowances
- Parts Ordering Information
Attachment III
- Technical Information
ATTACHMENT I
B Program
OASIS
YOU MUST USE OASIS TO DETERMINE IF A VEHICLE IS ELIGIBLE FOR THIS PROGRAM.
PLEASE NOTE
CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY
PROMPTLY CORRECT
- Affected vehicles on the enclosed list.
- Other eligible vehicles which are brought to your dealership.
DEALER-OWNER CONTACT
Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date.
FCSD CONTACT
Talk with your FCSD Service Zone Manager about program concerns.
FORM 1863
Enter 1863 claims using DWE (or mail direct)
See Warranty and Policy Manual:
- Section 5.6 - 1/Section 6.1 - 24 (Owner Notification Programs)
OWNER REFUNDS
See Warranty and Policy Manual:
- Section 6.1 - Pages 25 through 26 (Owner Refund)
For owner-paid repairs made before date of Owner Letter:
- Submit on separate Form 1863 using the codes shown below:
Program Code Box - 93B35
Causal Basic Part Number - 11390
Condition Code - 79
Labor Operation (1st line) - REFUND
Labor Operation (2nd line) - ALLOW
Administrative Allowance - 0.2 Hrs.
Customer Concern Code - N99
ATTACHMENT II
B Program
OWNER NOTIFICATION PROGRAM 93B35
F-Series / Bronco Trucks - Starter Solenoid Replacement
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels.
Parts prices current until next issue of Master Price Book. For latest prices, check or call your:
- Order Processing Center
- DOES II
- Updated Price Book
CLAIMS PREPARATIONS
- Use Form 1863
- Enter using DWE (or mail)
- Use code information shown below:
Program Code - 93B35
Causal Basic Part Number - 11390
Condition Code - 79
Labor Operation - As Appropriate Above
Customer Concern Code - N99
ATTACHMENT III
B Program
OWNER NOTIFICATION PROGRAM 93B35
F-Series/Bronco Trucks - Starter Solenoid Replacement
ATTENTION: PARTS MANAGER
DEALER STOCK INSPECTION
NOTE:
SEE INSPECTION BELOW FOR METHOD OF READING DATE CODE.
If claim is processed electronically via DOES II, use return code "GB", otherwise complete a separate FPS-340 claim 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 IS INSTALLED OVER THE TERMINAL AND IS REINSTALLED AFTER SERVICE.
INSPECTION
The red starter assembly label will have the date the assembly was made as illustrated.
Starter assemblies with a production date equal to or less than 2M15 (December 15, 1992) are affected by this program.
OWNER NOTIFICATION PROGRAM 93B35
F-Series / Bronco Trucks - Starter Solenoid Replacement
REMOVAL
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 TERMINAL AND IS REINSTALLED AFTER SERVICE.
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. 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.
Serial Number 1FMCA11S6XYZ12345 January, 1994
Mr. John Sample
123 Main Street
Anywhere, USA 12345
Ford Motor Company is providing a no-charge Service Program, Number 93B35, 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
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.
CHANGED ADDRESS OR SOLD THE TRUCK?
Please fill out the enclosed prepaid postcard and mail it to us if you have changed your address or sold the truck.
We are taking this action as part of our ongoing efforts to maintain owner confidence in our products. We hope this program will confirm your continued satisfaction in your Ford built truck.