Attachment III - Technical Information
OVERVIEWThis program involves inspecting for the lower fuel tank protection brackets on 2008 and 2009 model year vehicles. On 2009 model year vehicles only, also inspect for the upper fuel tank protection bracket and make sure it is in the intended location.
^ All affected vehicles require 2 lower fuel tank protection brackets.
^ The 2009 model year affected vehicles also require an upper fuel tank protection bracket.
^ The 2009 model year vehicles may have the upper fuel tank protection bracket installed in an unintended location, too close to the rear fuel tank strap.
NOTE:
All 2009 model year vehicles that are affected by recall 09C08 are also affected by recall 09S08 - Fuel Tank Protection Bracket Relocation. Because the service procedure for recall 09C08 incorporates the repair for recall 09S08, vehicles that are affected by both recalls only require recall 09C08 to be performed. The claim submission for recall 09C08 will also close recall 09S08, and a separate claim should not be submitted.
INSPECTION
1. 2008 and 2009 model year- Inspect the bottom of the LH frame rail below the rear spring shackle for the 2 lower fuel tank protection brackets. See Figure 1.
2. 2009 ONLY - Inspect the top of the LH frame rail just above the rear spring shackle for the proper location of the upper fuel tank protection bracket. See Figure 2.
^ The intended location for the upper fuel tank protection bracket is approximately 1 inch to the rear of the fuel tank strap. If the bracket is closer to the fuel tank strap, it is in the unintended location. See Figure 2.
3. Refer to the chart for the actions to take.
INSTALL LOWER FUEL TANK PROTECTION BRACKET(S)
NOTE:
The school bus body, axle and spring have been removed for clarity.
1. Install the protection bracket J-nut(s) onto the lower LH frame rail for the missing fuel tank protection bracket(s). See Figure 3.
2. Install the appropriate protection bracket(s) on to the frame rail. See Figure 3.
NOTE:
The 2009 model year E-350 is shown, 2008 model year E-350 and 2009 model year E-450 are similar.
3. To position the fuel tank protection bracket correctly, place a non-marring tool, such as a plastic trim tool, between the bracket and the fuel tank lip. See Figure 4.
4. Torque the fuel tank protection bracket bolt to 47 Nm (30 lb-ft).
^ Continue to hold the non-marring tool between the bracket and the fuel tank lip while applying torque.
5. NOTICE: There MUST be clearance between the fuel tank protection bracket and the fuel tank.
Visually check for clearance between the fuel tank protection bracket and the fuel tank lip.
6. If the fuel tank protection bracket is touching the fuel tank, slightly loosen the protection bracket bolt and repeat Steps 3 through 5.
INSTALL OR RELOCATE THE UPPER FUEL TANK PROTECTION BRACKET
NOTE:
The school bus body, fuel filler neck and body mounts have been removed for clarity.
NOTE:
The 2009 model year E-350 is shown in all figures, 2009 model year E-450 is similar.
NOTE:
If the upper fuel tank protection bracket is missing, proceed to Step 2.
1. If the upper fuel tank bracket is not in the intended location:
^ remove and discard the fuel tank protection bracket bolt. See Figure 5.
^ position the fuel tank protection bracket toward the front of the vehicle.
^ remove and discard the J-clip from the frame rail. The J-clip will NOT reach the intended bolt hole location. See Figure 5.
2. Install the fuel tank protection bracket onto the LH frame rail in the intended location. See Figure 6.
3. Place a new flagnut onto a loose fitting open-end wrench. Using a rubber band, secure the flagnut to the open-end wrench. See Figure 7.
4. Position the open-end wrench with the attached flagnut between the inside of the frame rail and the fuel tank protection bracket. Align a new bolt with the flagnut and hand-start the bolt. Remove the open-end wrench. See Figure 8.
5. Tighten the fuel tank protection bracket bolt until the bolt is snug. Then loosen the bolt to allow slight movement in the bracket.
6. NOTE: Applying torque to the fuel tank protection bracket bolt will tend to move the bracket toward the fuel tank and not allow for proper clearance between the fuel tank protection bracket and the fuel tank.
Position and snug a C-clamp to make sure that the fuel tank protection bracket remains seated squarely up to the inside frame rail while applying torque to the fuel tank protection bracket bolt. See Figure 9.
7. Torque the fuel tank protection bracket bolt to 47 Nm (30 lb-ft).
8. Remove the C-clamp.
9. NOTICE: There MUST be at least a 6 mm (1/4 in) clearance between the fuel tank protection bracket and the fuel tank. Any clearance less than 6 mm (1/4 in) will increase the risk of damage to the fuel tank.
Using a tool, such as a 6 mm (1/4 in) drill bit, check the clearance between the outside of the fuel tank protection bracket and the fuel tank. See Figure 10.
10. If a 6 mm (1/4 in) clearance is not achieved in this step, the fuel tank protection bracket is not seated correctly. Slightly loosen the fuel tank protection bracket bolt and repeat Steps 6 through 9.