Director P. O. Box 1904 Service Engineering Operations Dearborn, Michigan Ford Customer Service Division

Transcription

1 Michael A. Berardi Ford Motor Company Director P. O. Box 1904 Service Engineering Operations Dearborn, Michigan Ford Customer Service Division TO: All U.S. Ford and Lincoln Dealers August 6, 2013 SUBJECT: Safety Recall 13S01 - Supplement #1 Certain 2004 through 2007 Model Year Freestar and Monterey Vehicles Operated in Corrosion States 3 rd Row Seat Latch Striker Corrosion Repair REF: DEMONSTRATION / DELIVERY HOLD - Safety Recall 13S01 Dated March 5, 2013 New! REASON FOR THIS SUPPLEMENT Additional VINs that were not originally identified as part of this program are being added. These VINs will be activated in OASIS and show on FSA VIN lists on August 6, Technical information and claiming instructions for related damage has been added as follows: o Attachment IV Technical Information has been added to provide instructions for repairs when corrosion perforation in a wheel well extends beyond the overlay panel. o Claiming instructions for the procedure in Attachment IV have been added. Prior approval will not be required when the repair can be accomplished within 1.0 hour per side and up to $50 in additional material allowance. Dealer Q & A has been added to address common questions related to this recall. AFFECTED VEHICLES Certain 2004 through 2007 model year Freestar and Monterey vehicles built at the Oakville Assembly Plant from Job # through Job Last 2007 and originally sold in, or currently registered in the following states: Connecticut Iowa Minnesota Ohio Wisconsin Delaware Maine Missouri Pennsylvania District of Columbia Maryland New Hampshire Rhode Island Illinois Massachusetts New Jersey Vermont Indiana Michigan New York West Virginia Affected vehicles are identified in OASIS. In addition, for a list of vehicles assigned to your dealership, visit This information will be available on March 5, Copyright 2013 Ford Motor Company

2 REASON FOR THIS SAFETY RECALL In some of the affected vehicles that are operated in high corrosion areas for an extended period, the sheet metal that supports the folding 3 rd row seat latch strikers could experience corrosion and may compromise the mounting point for the forward portion of the 3 rd row seat. Initially, this condition may result in seat movement when passengers sit on or put weight on the seat, or difficulty latching the front of the seat when in its seating position. If corrosion is severe, the seat latch strikers may become detached from the vehicle. The seat belts and the permanent mounting attachment at the rear of the seat are unaffected. New! SERVICE ACTION Dealers are to install new 3 rd row seat latch striker mounting brackets which will relocate the seat latch strikers away from the potentially corroded area. In addition, dealers are to install overlay panels in the exterior of the wheel wells to prevent the entry of water and corrosive elements. If corrosion perforation extends beyond the coverage of the overlay panels, dealers are to use the procedure in Attachment IV to complete the repairs. This service must be performed on all affected vehicles at no charge to the vehicle owner. NOTE: For customers in non-corrosion areas whose Freestar or Monterey is not covered under this program but exhibits symptoms consistent with this condition, dealers can call the Special Service Support Center at to request the same service action. OWNER NOTIFICATION MAILING SCHEDULE Parts to repair this condition are currently not available in sufficient quantities to service all of the affected vehicles. Therefore, to ensure an ample supply of parts are available, owners of affected vehicles will be notified in multiple mailings. Mailings will begin the week of March 25, 2013, and are expected to be complete by April 30, Dealers should repair any affected vehicles that arrive at their dealership, whether or not the customer has received a letter. PLEASE NOTE: Federal law requires dealers to complete this recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $7,000 per vehicle. Correct all vehicles in your new vehicle inventory before delivery. New! ATTACHMENTS Attachment I: Administrative Information Attachment II: Labor Allowances and Parts Ordering Information Attachment III: Technical Information Standard Repair Attachment IV: Additional Technical Information Repair for Corrosion that Extends Past Overlay Panel Attachment V: Dealer Q & A Owner Notification Letter Recall Reimbursement Plan QUESTIONS & ASSISTANCE Special Service Support Center (Dealer Assistance Only) Special Service Support Center (Parts Ordering) Sincerely, Michael A. Berardi Copyright 2013 Ford Motor Company

3 ATTACHMENT I Page 1 of 2 Safety Recall 13S01 Supplement #1 Certain Model Year Freestar and Monterey Vehicles Operated in Corrosion States 3 rd Row Seat Latch Striker Corrosion Repair OASIS ACTIVATED? Yes, OASIS will be activated on March 5, FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through on March 5, Owner names and addresses will be available by May 3, NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall. STOCK VEHICLES Use OASIS to identify any affected vehicles in your used vehicle inventory. SOLD VEHICLES Owners of affected vehicles will be directed to dealers for repairs. Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this recall. New! RELATED DAMAGE Dealers are authorized to repair corrosion perforation in a wheel well that extends beyond the overlay panel (described in Attachment IV) without contacting the Special Service Support Center for prior approval. For this repair, dealers can claim up to an additional: 1.0 hour per side (2 hours total) in related damage labor $50 in related damage parts If a related damage condition exists that exceeds these amounts, call the Special Service Support Center to request approval prior to the repair of any additional related damage. Requests for approval after completion of the repair will not be granted. Copyright 2013 Ford Motor Company

4 ATTACHMENT I Page 2 of 2 Safety Recall 13S01 Supplement #1 Certain Model Year Freestar and Monterey Vehicles Operated in Corrosion States 3 rd Row Seat Latch Striker Corrosion Repair OWNER REFUNDS This safety recall must still be performed, even if the owner has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. Owners are directed to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Noncovered repairs, or those judged by Ford to be excessive, will not be reimbursed. Refunds will only be provided for the cost associated with repair of 3 rd row seat latch striker due to corrosion damage. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. New! CLAIMS PREPARATION AND SUBMISSION Enter claims using Direct Warranty Entry (DWE). Refer to ACESII manual for claims preparation and submission information. Submit refunds on a separate repair line. - Program Code: 13S01 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. Provision for Locally Procured Supplies: Includes specified urethane sealer, undercoating, and up to two zip ties. Submit on the same repair line as the repair. - Program Code: 13S01 - Misc. Expense: OTHER - Misc. Expense: Claim Actual Cost up to $42.00 Related damage for repairs of corrosion perforation that extend past an overlay panel as described in Attachment IV must be claimed on a repair line that is separate from the FSA repair, with the related damage flag checked. The following can be claimed without prior approval: - Program Code: 13S01 - Labor Operation: MT13S01 Claim Actual Time up to 2.0 Hours - Misc. Expense: OTHER - Misc. Expense: Claim Actual Cost up to $50.00 "MT" labor related to concerns other than what is described in Attachment IV requires prior approval from the Special Service Support Center. Copyright 2013 Ford Motor Company

5 ATTACHMENT II Page 1 of 2 Safety Recall 13S01 Supplement #1 Certain Model Year Freestar and Monterey Vehicles Operated in Corrosion States 3 rd Row Seat Latch Striker Corrosion Repair LABOR ALLOWANCES Description Labor Operation Labor Time Install 3 rd row seat latch striker corrosion repair kit 13S01B 3.1 Hours PARTS REQUIREMENTS / ORDERING INFORMATION Part Number Description Quantity 4F2Z A 3 rd Row Seat Latch Striker Corrosion Repair Kit 1 PM-4-A Motorcraft Metal Brake Parts Cleaner (Aerosol) 1 WA-14-SBA a/ Zip Ties (can also use equivalent outside part c/ ) 2 Urethane Seam b/ c/ Sealer - Black (Procure Locally) b/ c/ Undercoating (Procure Locally) 3M #08367 Urethane Seam Sealer (10.5 Oz. Tube) OR Lord Fusor #803EZ or #805HD Urethane Sealant (10.5 Oz. Tube) VALUGARD #VG140AEA Aerosol Undercoat (Aerosol) OR 3M #08883 Rubberized Undercoating (Aerosol) a/ This part # includes 50 zip ties. Two are needed per repair. b/ Chemicals have a shelf life/expiration date. Use only current, non-expired products for proper repair results. c/ Claim as MISC OTHER. See Attachment I (CLAIMS PREPARATION AND SUBMISSION). The DOR/COR number for this recall is One-time Seed Stock To ensure parts are available at dealers prior to owner notification, there will be a one-time seed stock of repair kit part number 4F2Z A during the week of March 18, Dealer Affected Vehicles Seed Stock # of Kits Provided 1 to 19 1 Kit 20 to 49 5 Kits 50 to Kits 100 & up 20 Kits 1 1 Copyright 2013 Ford Motor Company

6 ATTACHMENT II Page 2 of 2 Safety Recall 13S01 Supplement #1 Certain Model Year Freestar and Monterey Vehicles Operated in Corrosion States 3 rd Row Seat Latch Striker Corrosion Repair PARTS REQUIREMENTS / ORDERING INFORMATION (Continued) Dealers will need to access to determine the total number of affected vehicles assigned to their dealership in order to calculate the number of parts that they will receive under the Seed Stock Program. NOTE: Additional 3 rd Row Seat Latch Striker Corrosion Repair Kits may be ordered by contacting the Special Service Support Center parts order line at Please be prepared to provide the dealer P&A code, VIN, RO# and customer name. Dealers will be notified via a DOES II communication if circumstances warrant a change in part supply strategy and when open ordering begins. Questions regarding parts should be directed to the Special Service Support Center Parts Order Line ( ) or ed to: Ford@Renkim.com. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for Parts Retention and Return Procedures. EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin Copyright 2013 Ford Motor Company

7 ATTACHMENT III PAGE 1 OF 18 CERTAIN 2004 THROUGH 2007 MODEL YEAR FREESTAR AND MONTEREY VEHICLES OPERATED IN CORROSION STATES 3RD ROW SEAT LATCH STRIKER CORROSION REPAIR OVERVIEW In some of the affected vehicles that are operated in high corrosion areas for an extended period, the sheet metal that supports the folding 3rd row seat latch strikers could experience corrosion and may compromise the mounting point for the forward portion of the 3rd row seat. Initially, this condition may result in seat movement when passengers sit on or put weight on the seat, or difficulty latching the front of the seat when in its seating position. If corrosion is severe, the seat latch strikers may become detached from the vehicle. The seat belts and the permanent mounting attachment at the rear of the seat are unaffected. Dealers are to install new 3rd row seat latch striker mounting brackets which will relocate the seat latch strikers away from the potentially corroded area. In addition, dealers are to install overlay panels in the exterior of the wheel wells to prevent the entry of water and corrosive elements. See 3rd Row Seat Latch Striker Corrosion Repair Kit components (below). This service must be performed on all affected vehicles at no charge to the vehicle owner. LH AND RH LOWER STRIKER BRACKET REINFORCEMENT PLATES AND HARDWARE LH 3rd ROW SEAT STRIKER BRACKET RH 3rd ROW SEAT STRIKER BRACKET LH REAR WHEEL WELL OVERLAY PANEL AND HARDWARE RH REAR WHEEL WELL OVERLAY PANEL AND HARDWARE 1209W 12Z0003

8 ATTACHMENT III PAGE 2 OF 18 SERVICE PROCEDURE 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Workshop Manual (WSM) Section Disconnect the battery cable to ground. For additional information, refer to WSM Section Note the position of the customer's 2nd and 3rd row seats, so they can be returned to that position after the repair. 4. If in the stowed position, raise the 3rd row seat out of the floor. 5. Remove 3rd row seat plastic floor trim panel. See Figure 1. Use care not to damage mounting tabs. See Figure 1. PLASTIC FLOOR TRIM PANEL x x x x MOUNTING TABS 1209A FIGURE 1 12Z0003

9 ATTACHMENT III PAGE 3 OF Position/remove the 2nd and 3rd row seat(s), as follows: a. Place the 3rd row seat into the stowed position. b. If equipped with 2nd row captains chairs, position the seats into the fold flat/forward cargo position. c. If equipped with a 2nd row bench seat, remove the seat from the vehicle. 7. Remove the RH and LH rear quarter trim panels. For additional information, refer to WSM Section If equipped, remove LH heating duct. See Figure 2. a. Remove the two bolts, two scrivets, and the nut. b. Position the heating duct aside and detach the wire harness retainer and the electrical connector. c. Remove the LH heating duct. LH HEATING DUCT SCRIVETS NUT BOLTS 1209B FIGURE 2 12Z0003

10 ATTACHMENT III PAGE 4 OF 18 NOTICE: The wiring harness must be positioned up and off the wheel well and toward the side of the vehicle to prevent damage by sheet metal screws that will be installed later in the procedure. 9. Reposition the LH wheel well wire harness. See Figure 3. a. Remove the bolt from the LH liftgate module. Detach the clip and slide the module forward to position aside. b. Remove the wire harness from the retainers. c. Secure the wire harness to the speaker bracket with a zip tie. d. Position the LH liftgate module back onto the mounting bracket with the wiring harness positioned on top of the module. Install the bolt (do not over tighten). BOLT CLIP ZIP TIE SECURING WIRE HARNESS TO SPEAKER BRACKET WIRE HARNESS ROUTED OVER LH LIFTGATE MODULE 1209D1 FIGURE 3 12Z0003

11 ATTACHMENT III PAGE 5 OF 18 NOTICE: The wiring harness must be positioned up and off the wheel well and toward the side of the vehicle to prevent damage by sheet metal screws that will be installed later in the procedure. 10. Position aside the RH wheel well wire harness. See Figure 4. a. Remove the three RH speaker bolts and position the RH speaker aside. b. Remove the wire harness from the retainers. c. Secure the wire harness to the seat belt retractor bracket with a zip tie. d. Reposition the wire harness behind the speaker tab and install the three bolts (do not over tighten). BOLT BOLT RH SPEAKER ZIP TIE SECURING WIRE HARNESS TO SEAT BELT RETRACTOR BRACKET BOLT POSITION WIRE HARNESS BEHIND THE SPEAKER TAB FIGURE C1 11. Position the carpet away from the RH and LH wheel wells. 12. Cover the carpet to protect it while performing any cutting, drilling, or grinding. 12Z0003

12 ATTACHMENT III PAGE 6 OF Note the orientation of the RH and LH 3rd row seat strikers. The top of the strikers are marked with "UP" for installation reference. Remove the two nuts and the 3rd row seat strikers from the RH and LH wheel wells. See Figure 5. Do not discard the nuts or 3rd row seat strikers, they will be used during reassembly. NOTE: LH side shown, RH side similar. NUTS FIGURE Using a suitable angle grinder, cut off the RH and LH 3rd row seat striker mounting studs (four total, 2 each side), flush with the wheel well panel. See Figure 6. NOTE: LH side shown, RH side similar. 3rd ROW SEAT STRIKER 1209E 3rd ROW SEAT STRIKER MOUNTING STUD 3rd ROW SEAT STRIKER MOUNTING STUDS CUT OFF FLUSH WITH WHEEL WELL PANEL 1209F FIGURE 6 12Z0003

13 ATTACHMENT III PAGE 7 OF By using the contour of the original wheel well panel and the location of the original 3rd row seat striker studs as a guide, place the new RH and LH 3rd row seat striker brackets into their approximate positions on each side of the vehicle. Scribe the perimeter of the brackets on floor. See Figure 7. NOTE: LH side shown, RH side similar. NEW 3rd ROW SEAT STRIKER BRACKET FOAM INSULATION STRIP MASTIC SOUND DEADENER PERIMETER 1209H1 FIGURE Use a suitable chisel or gasket remover to remove the mastic sound deadener and foam insulation strip from the floor, in the areas where the new RH and LH 3rd row seat striker brackets will attach to the floor. See Figure 7. Make sure enough material is removed to allow the bracket to sit directly on the floor sheet metal and not on top of the mastic sound deadener. Use caution not to penetrate though the floor sheet metal. Use a suitable shop vacuum to clean up the material that was removed. 12Z0003

14 ATTACHMENT III PAGE 8 OF Position the new RH and LH 3rd row seat striker brackets back into the mounting position. Ensure that the locating tab on the striker bracket fits into the existing locating hole in the floor panel. See Figure 8. NOTE: It is important to position the back of the new RH and LH 3rd row seat striker brackets so they fit tight against the existing wheel wells to provide proper clearance for the seat latch hardware. If necessary, bend the locating tab slightly to achieve proper fit/position of the brackets. See Figures 8 and Mark and center-punch the four (two each side) attachment bolt hole locations on the floor. See Figure 8. NOTE: LH side shown, RH side similar. NEW 3rd ROW SEAT STRIKER BRACKET LOCATING TAB INSTALLED INTO EXISTING LOCATING HOLE BOLT HOLE LOCATIONS 1209I FIGURE 8 NEW 3rd ROW SEAT STRIKER BRACKET TIGHT AGAINST EXISTING WHEEL WELL 1209V FIGURE 9 12Z0003

15 ATTACHMENT III PAGE 9 OF Position the new 3rd row seat striker brackets aside and drill four 12.7 mm (1/2 in) holes at the four locations (two each side) marked in Step 18. Use a suitable shop vacuum to clean the metal shavings. Apply a light application of undercoating to the drilled holes. 20. Raise the vehicle. 21. Remove both rear wheel and tire assemblies. For additional information, refer to WSM Section Remove three screws, 2 pin-type retainers and the LH rear wheel well inner splash shield. 23. Place the new RH and LH rear wheel well overlay panels into position. Use a suitable paint pen to mark the position around the perimeter of the panels on the surface of the wheel wells. See Figure 10. The rear wheel overlay panels should fit tight into the radius of the original panel. The features along the lower edge of the new panel should match up to the features of the original panel. It is important the panels fit tight against the existing sheet metal for proper sealing. NOTE: LH side shown, RH side similar. RADIUS PERIMETER SURFACE MARKS NEW REAR WHEEL WELL OVERLAY PANEL FIGURE G 12Z0003

16 ATTACHMENT III PAGE 10 OF Inspect the RH and LH wheel well surface for excess undercoating on or within the perimeter where the new overlay panels will be installed. Use a suitable chisel to remove the excess undercoating to provide a smooth mounting surface for the overlay panels. See Figure 11. EXCESS UNDERCOATING FIGURE Using a suitable brush, scuff/clean the original undercoating from inside the perimeter of the RH and LH markings made in Step 23 and across the bottom of the wheel wells. See Figure 12. Clean so that there is at least 25 mm (1 in) of scuffed/cleaned surface around the perimeter of where the new overlay panel will attach to the wheel well panel. See Figure 12. NOTE: LH side shown, RH side similar. 1209Q APPROXIMATELY 25 MM (1 IN) FIGURE P 12Z0003

17 ATTACHMENT III PAGE 11 OF Perform a final cleaning of the original RH and LH wheel well undercoating surface: Spray the wheel well surface using Motorcraft Metal Brake Parts Cleaner, or equivalent to remove any material that may have been loosened. Using compressed air blow off any additional loose material and dry the wheel well surface. 27. Using Motorcraft Metal Brake Parts Cleaner, clean the new RH and LH wheel well overlay panels, in the areas where urethane seam sealer will be applied. See Figure 13. NOTE: Complete the LH wheel well overlay panel installation prior to starting installation on the RH wheel well overlay panel, this should be done to prevent the urethane seam sealer from curing before the overlay panel is installed. 28. Apply a continuous 9.4 mm (3/8 in) bead of urethane seam sealer around the outer edge of the new LH wheel well overlay panel. Apply additional sealer to the notched out area on the bottom of the overlay panel and apply a bead around the dimples in the center of the panel. See Figure 13. NOTE: LH side shown, RH side similar. URETHANE SEAM SEALER APPLY EXTRA SEAM SEALER FIGURE R 12Z0003

18 ATTACHMENT III PAGE 12 OF Place the new LH wheel well overlay panel in position and press it into the original panel. Align the new panel to fit tightly into the original wheel well radius so that the features of the panels match. See Figure 14. a. Press the panel tightly around the perimeter to squeeze the urethane between the panels. b. Use a ball-peen hammer and tap lightly, if necessary, to help the new panel conform to the original. c. Use suitable Vise-Grips to hold the panel in position at the bottom. NOTE: LH side shown, RH side similar. NEW WHEEL WELL OVERLAY PANEL VISE-GRIPS VISE-GRIPS 1209S FIGURE 14 12Z0003

19 ATTACHMENT III PAGE 13 OF Using the self-tapping screws, secure the new LH overlay panel to the original panel in the order shown in Figure 15. Use care not to over-tighten and strip the screw attachments. NOTE: To ensure a tight fit to the original panels, it is important to install the screws in the order shown in Figure 15. a. Install screw at locations marked as 1. b. Press the panel firmly into the radius area, use a ball-peen hammer if necessary to draw panels together, and install screws at locations marked 2. c. Install screws at locations marked 3. Remove Vise-Grips. d. Install screws at locations marked 4 and then 5. NOTE: A pilot hole may be required before installing the self-tapping screws in areas where spot welds exist. The spot welds are located mostly along the bottom edge of the wheel wells. LH SIDE RH SIDE 1209T FIGURE Using a suitable putty knife, apply urethane seam sealer, over each of the self-tapping screw heads and in any areas where sealer did not seal the perimeter. 32. Repeat Steps for the RH side. 33. Lower the vehicle. 12Z0003

20 ATTACHMENT III PAGE 14 OF Working from inside the vehicle, inspect the position of the installed self-tapping screws. Use a suitable angle grinder to cut off the ends of the self-tapping screws that will interfere with installation of the new 3rd row seat striker bracket upper attachment (See Figure 16) or with the mounting of any modules, wire harnesses or trim panels. NOTE: LH side shown, RH side similar. SELF-TAPPING SCREW ENDS CUT OFF SELF-TAPPING SCREWS FIGURE 16 STRIKER BRACKET UPPER ATTACHMENT 1209U 35. Clean the wheel well to floor panel seam in the area where the new RH and LH 3rd row seat striker brackets will be installed. Apply a bead of urethane seam sealer to the seam and to the existing bracket locating hole. See Figure 17. NOTE: LH side shown, RH side similar. WHEEL WELL TO FLOOR PANEL SEAM EXISTING BRACKET LOCATING HOLE FIGURE J 12Z0003

21 ATTACHMENT III PAGE 15 OF Place the new RH and LH 3rd row seat striker brackets in position. Make sure the bracket locating tab is engaged in the bracket locating hole and that the bracket is flush with the existing wheel well sheet metal. Install two (one each side) new ganged bolt assemblies through the holes on each side of the vehicle. See Figure 18. NOTE: RH side shown, LH side similar. NEW 3rd ROW SEAT STRIKER BRACKET NEW GANGED BOLT ASSEMBLY FIGURE Position the new RH and LH lower striker bracket reinforcement plates and install two new nuts. See Figure 19. Use caution not to push the new ganged bolt assemblies out while installing the new reinforcement plates. Tighten to 62 Nm (46 lb-ft). NOTE: RH side shown, LH side similar. NEW LOWER STRIKER BRACKET REINFORCEMENT PLATE 1209K FIGURE 19 NEW NUTS 1209L 12Z0003

22 ATTACHMENT III PAGE 16 OF Hold the new RH and LH 3rd row seat striker brackets tight against the wheel wells. Center-punch and drill four (two per side) mm (3/8 in) holes in the center of each of the 3rd row seat striker bracket upper mounting attachment locations. See Figure 20. Apply a light application of undercoating to the drilled holes. NOTE: RH side shown, LH side similar. NEW 3rd ROW SEAT STRIKER BRACKET UPPER MOUNTING ATTACHMENT LOCATIONS 1209M FIGURE Slide the new J-nuts onto each of the four new RH and LH 3rd row seat striker bracket upper mounting attachment locations. See Figure 21. NOTE: RH side shown, LH side similar. NEW RH AND LH 3rd ROW SEAT STRIKER BRACKET NEW J-NUTS FIGURE N 12Z0003

23 ATTACHMENT III PAGE 17 OF Raise the vehicle. 41. Install four (two per side) new 3rd row seat striker bracket upper mounting attachment bolts. See Figure 22. Tighten to 30 Nm (22 lb-ft). NOTE: RH side shown, LH side similar. NEW 3rd ROW SEAT STRIKER BRACKET UPPER MOUNTING ATTACHMENT BOLTS FIGURE O 42. Spray the new overlay panels and the lower striker bracket reinforcement plates with one coat of undercoating. 43. Install the LH rear wheel well inner splash shield and 2 pin-type retainers. Install and tighten the three screws. 44. Install both rear wheel and tire assemblies. For additional information, refer to WSM Section Lower the vehicle. 46. Position the carpet back into its original position. 47. Install original 3rd row seat strikers onto the studs of the new 3rd row seat striker brackets, using original nuts. a. Make sure the strikers are installed in their original orientation. The top of the strikers are marked with "UP" for installation reference. See Figure 5. b. Use the alignment marks that are stamped into the bracket to help align the strikers before tightening fully. c. Tighten to 20 Nm (15 lb-ft). 12Z0003

24 ATTACHMENT III PAGE 18 OF If equipped, install LH heating duct. See Figure 2. a. Install the heating duct. b. Connect the wire harness retainer and the electrical connector. c. Install the two bolts, two scrivets, and the nut. 49. Install the RH and LH rear quarter trim panels. For additional information, refer to WSM Section Operate the 3rd row seat to check the 3rd row seat latch striker for correct adjustment. Adjust horizontally and vertically, as needed. To adjust: a. Remove the striker trim cover(s) from the quarter trim panel. b. Loosen the 2 nuts enough to allow movement of the striker. c. Gently lower the 3rd row seat down to the striker and align the striker to the latch. d. Tighten the nuts. e. Tighten to 20 Nm (15 lb-ft). f. Make sure both 3rd row seat latches latch fully and evenly to the strikers. Reinstall striker covers when complete. NOTE: If the seat is not centered on the strikers, loosen the four nuts that secure the seat to the floor hinge and reposition as necessary. Once centered, tighten the seat hinge nuts to 55 Nm (41 lb-ft). 51. Position the 2nd and 3rd row seats back to the customer's initial position. 52. Install the 3rd row seat plastic floor trim panel. See Figure 1. Use care not to damage mounting tabs. See Figure Connect the battery cable to ground. For additional information, refer to WSM Section Return vehicle to customer. 12Z0003

25 ATTACHMENT IV PAGE 1 OF 3 CERTAIN 2004 THROUGH 2007 MODEL YEAR FREESTAR AND MONTEREY VEHICLES OPERATED IN CORROSION STATES VEHICLES NEEDING ADDITIONAL REPAIR FOR CORROSION THAT EXTENDS PAST THE OVERLAY PANEL(S) OVERVIEW Installation of the new 3rd row seat latch striker mounting brackets relocates the seat latch strikers away from the potentially corroded area. The sheet metal overlay panels provided in the kit prevent intrusion of water and corrosive materials into the vehicle. For vehicles where corrosion extends past the provided overlay panels, additional sheet metal should be added using the same preparation and attachment methods used to install the overlay panels in 3rd Row Seat Latch Striker Corrosion Repair Kit P/N 4F2Z A. While each vehicle may exhibit different areas and amounts of corrosion, these instructions can be used as a guide for fabrication, preparation, and attachment of the additional sheet metal. ADDITIONAL MATERIALS NEEDED The following additional materials are expected for repairs that require the fabrication and installation of additional sheet metal to repair corrosion that extends past the overlay panel: Additional sheet metal (18-22 gauge steel) Urethane sealer (1 additional tube) 1/2 Self-tapping sheet metal screws (as required) Rust preventative paint (1 aerosol can) REPAIR PROCEDURE NOTE: The following repair instructions are to be used in conjunction with Recall 13S01 Technical Instruction Attachment III. 24-A. Perform Recall 13S01 Technical Instruction Attachment III Steps 1 through 24 to prepare the vehicle for installation of the seat latch striker brackets and overlay panels. At step 24, inspect for and remove any excess undercoating that may be present in the area where the additional fabricated sheet metal panel will be installed. Note that any fabricated panel should extend approximately mm (2 to 2½ inches) beyond any corrosion perforation. See Figure 1. CORROSION PERFORATION EXTENDING BEYOND OVERLAY PANEL OVERLAY PANEL PERIMETER SURFACE MARKS 1301IV1 FIGURE 1 Bosch 12Z0035

26 ATTACHMENT IV PAGE 2 OF 3 24-B. Temporarily attach the provided overlay panel in position using ViseGrip pliers and a few screws as required. 24-C. Measure and assess the size of the additional sheet metal panel to be fabricated. As a general rule, the fabricated panel should extend approximately mm (2-2½ inches) beyond the opening in the corroded area, and should overlap the overlay panel where the two meet by approximately 25 mm (1 inch). Making a cardboard template of the panel may be helpful in the fabrication process. See Figure 2. AREA TO BE COVERED BY FABRICATED PANEL OVERLAP OVERLAY PANEL BY 25 MM (1 INCH) EXTEND MM (2-2½ INCHES) BEYOND CORROSION PERFORATION OVERLAY PANEL FIGURE IV2 24-D. Draw or transfer the outline of the panel to be fabricated onto the gauge sheet metal. Cut out the panel. 24-E. Pre-form any radii or other shapes in the fabricated panel. Test fit and make adjustments to the panel until it fits snug against the original wheel well and the overlay panel. 24-F. Once the sheet metal is formed and desired fit is attained, drill two pilot holes where it will attach to the overlay panel. Drill the holes 13 mm (½ inch) in from the edge of the fabricated panel. Temporarily attach the fabricated panel to the overlay panel using two screws. 24-G. Re-mark the perimeter of the combined panel assembly on the wheel well as described in Technical Instruction Attachment III Step H. Remove the combined overlay panel from the wheel well. 24-I. Remove the fabricated sheet metal panel from the overlay panel. 24-J. Pre-drill additional pilot holes for sheet metal screws around the perimeter of the sheet metal. Holes should be placed in each corner and spaced so they are 13 mm (½ inch) in from the edge of the sheet metal, with holes spaced between approximately 50 and 75 mm (2 and 3 inches) apart. This includes the area where the fabricated panel attaches to the overlay panel. Bosch 12Z0035

27 ATTACHMENT IV PAGE 3 OF 3 24-K. Clean the fabricated panel with Motorcraft Metal Brake Parts Cleaner and dry. 24-L. Complete Technical Instruction Attachment III Steps 25 through 30 to install the appropriate side overlay panel. 30-A. On the inside of the vehicle, inspect for any wiring harnesses or components that may be damaged when the additional sheet metal is installed using the self-tapping screws. Re- locate/protect any harnesses or other components that may be damaged by drilling or installing sheet metal screws to attach the fabricated sheet metal in the wheel well in step B. Apply a continuous 9.4 mm (3/8 inch) bead of urethane seam sealer around the outer edge of the fabricated sheet metal where it will attach to the overlay panel and original wheel well. 30-C. Place and press the sheet metal in position in the wheel well. Start attachment using two self-tapping sheet metal screws in the locations previously used to temporarily attach the sheet metal to the overlay panel in Step 24-F above. The following additional steps should also be followed: ii. Install screws to attach the sheet metal in an order that provides a good fit to the original wheel well panel. ii. Apply and spread urethane sealer down the area where the sheet metal and overlay panel join, and around the perimeter of the combined panel assembly. iii. Spray unprotected sheet metal with a fast drying rust preventative paint such as RustOleum and allow to dry before applying undercoating. 30-D. Complete installation of the panels and the recall following Technical Instruction Attachment III Steps 31 through 54. Bosch 12Z0035

28 ATTACHMENT V Page 1 of 1 Safety Recall 13S01 Supplement #1 Certain Model Year Freestar and Monterey Vehicles Operated in Corrosion States 3 rd Row Seat Latch Striker Corrosion Repair New!! DEALER Q & A Q1. What if there is a hole in the wheel well of an affected vehicle? A. If the hole (corrosion perforation) in the wheel well of an affected vehicle can be sealed by the overlay panel in the service parts kit (4F2Z A), perform the normal 13S01 repair as instructed in Attachment III. If the hole (corrosion perforation) extends beyond the area sealed by the overlay panel, use the procedure in Attachment IV in combination with the procedure in Attachment III to repair the vehicle. Q2. Why are we using sheet metal screws instead of welding panels into the wheel wells of the affected vehicles? A. The rear wheel wells of the Freestar and Monterey are not a structural part of the vehicle. During the repair the 3 rd row seat striker is moved onto the new support bracket. The wheel well s function is to keep contaminants (water, dirt, exhaust, etc) out of the passenger compartment. The combination of adhesive, sheet metal screws, overlay panels, and under coating used in the repair provides a good seal against contaminants. Q3. How much corrosion is too much to repair the vehicle? A. 13S01 covers corrosion of the wheel well around the 3 rd row seat striker. Corrosion of spring mounts, floor pan, and other parts of the vehicle are not covered by recall 13S01. If the wheel well has perforation corrosion in the area where the new bracket mounts at the top, please call the Special Service Support Center (SSSC) for instructions. Copyright 2013 Ford Motor Company

29 Ford Motor Company Ford Customer Service Division P. O. Box 1904 Dearborn, Michigan Safety Recall Notice 13S01 / NHTSA Recall 13V081 March 2013 Mr. John Sample 123 Main Street Anywhere, USA Your Vehicle Identification Number: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has decided that a defect which relates to motor vehicle safety exists in your vehicle, with the Vehicle Identification Number shown above. We apologize for this situation and want to assure you that, with your assistance, we will correct this condition. Our commitment, together with your dealer, is to provide you with the highest level of service and support. What is the issue? If your vehicle is operated in high corrosion areas for an extended period (where salt is used on the roadways during winter months), it is possible that the sheet metal that supports the folding 3 rd row seat latches could corrode and compromise the forward mounting point of the 3 rd row seat. The seat belts and the permanent mounting attachment at the rear of the seat are unaffected. Initially, this condition may result in seat movement when passengers sit on or put weight on the seat, or difficulty latching the seat in the seating position. As the corrosion progresses, the seat latch strikers may become detached from the vehicle and the 3 rd row seat may not fully latch into its seating position. In the event of an impact to the rear of the vehicle, an unlatched seat may increase the risk of personal injury. What will Ford and your dealer do? How long will it take? Ford Motor Company has authorized your dealer to install new 3 rd row seat latch striker mounting brackets which will re-locate the seat latch strikers away from the potentially corroded area. In addition, dealers will install overlay panels in the exterior of the wheel wells to prevent the entry of water and corrosive elements. This service will be performed on your vehicle free of charge (parts and labor). The time needed for this repair is less than one-half day. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time. Copyright 2013 Ford Motor Company

30 What should you do? Please call your dealer without delay and request a service date for Recall 13S01. Provide the dealer with the Vehicle Identification Number (VIN) of your vehicle. The VIN is printed near your name at the beginning of this letter. If you do not already have a servicing dealer, you can access for dealer addresses, maps, and driving instructions. Ford Motor Company wants you to have this safety recall completed on your vehicle. The vehicle owner is responsible for making arrangements to have the work completed. Ford Motor Company can deny coverage for any vehicle damage that may result from the failure to have this recall performed on a timely basis. Therefore, please have this recall performed as soon as possible. Please note: Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Have you previously paid for this repair? If you have previously paid for a repair that addresses the issue described in this letter, you still need to have this recall performed to ensure the correct parts and procedures are used. You may be eligible for a refund of previously paid repairs. Refunds will only be provided for service related to 3 rd row seat latch striker corrosion. To verify eligibility and expedite reimbursement, give your paid original receipt to your dealer. Refund requests may also be sent directly to Ford Motor Company. To request your refund from Ford, send the refund request with all required documentation, including your original repair receipt (no photocopies), to Ford Motor Company at P.O. Box 6251, Dearborn, Michigan Refund requests mailed to this address may take up to 60 days to process. Your original receipt will be returned to you. Detailed information regarding eligibility for Ford's reimbursement program and documentation requirements may be obtained by contacting the Ford Customer Relationship Center at What if you no longer own this vehicle? If you no longer own this vehicle, and have an address for the current owner, please forward this letter to the new owner. You received this notice because government regulations require that notification be sent to the last known owner of record. Our records are based primarily on state registration and title data, which indicate that you are the current owner. Can we assist you further? If you have difficulties getting your vehicle repaired promptly and without charge, please contact your dealership's Service Manager for assistance. RETAIL OWNERS: If you still have concerns, please contact the Ford Motor Company Customer Relationship Center at and one of our representatives will be happy to assist you. For the hearing impaired call (TDD). Representatives are available Monday through Copyright 2013 Ford Motor Company

31 Can we assist you further? (continued) Friday: 8:00AM - 5:00PM (Your Local Time). If you wish to contact us through the Internet, our address is: FLEET OWNERS: If you still have concerns, please contact the Fleet Customer Information Center at FLEET, Option #3 and one of our representatives will be happy to assist you. Representatives are available Monday through Friday: 8:00AM - 5:00PM (Your Local Time). Or you may contact us through the Internet at If you are still having difficulty getting your vehicle repaired in a reasonable time or without charge, you may write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave. S.E., Washington, D.C or call the toll free Vehicle Safety Hotline at (TTY: ) or go to Reference NHTSA Safety Recall 13V081. Thank you for your attention to this important matter. Ford Customer Service Division Copyright 2013 Ford Motor Company

32 Steve M. Kenner, Global Director Automotive Safety Office Sustainabilily, Environment & Safely Engineering Fairlane Plaza South, Suite Town Center Drive Dearborn, MI March 4, 2013 Ms. Nancy Lewis Associate Administrator for Enforcement National Highway Traffic Safety Administration 1200 New Jersey Avenue SE, Room W Washington, DC Dear Ms. Lewis: Subject: Ford Motor Company (Ford) Recall NO.13S01 - Certain 2004 through 2007 model year Ford Freestar and Mercury Monterey vehicles Equipped with a Fold Flat Third Row Seat Summary Ford Action - Ford is conducting a voluntary safety recall in high corrosion areas involving certain 2004 through 2007 model year Ford Freestar and Mercury Monterey vehicles equipped with a fold flat third row seat. This action is being taken to address corrosion in the rear wheel well area that could potentially affect the ability to secure the third row seat's forward latch when the seat is put into its seating position. Ford is not aware of any accidents or injuries related to this condition. Furthermore, the seat belt and permanent seat anchorage to the vehicle are unaffected. Ford has not determined that this concern in these vehicles constitutes a safety defect. Nevertheless, to avoid a protracted dispute with the agency, Ford has decided to conduct this field action as a Safety Recall, despite our belief that this condition does not present an unreasonable risk of accident or injury. $ Number of Vehicles Involved - Ford estimates that there are approximately 196,667 vehicles that were either originally sold in or are currently registered in Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin that are potentially affected Effect on Vehicle Operation - The third row seat's forward latches are attached to the vehicle near the rear whee! wells. If corrosion exists between the meta! panels in the rear wheel, in the area where the latch striker plate attaches, customers may experience

33 difficulty securing the third row seat's fornard latch or occupants may notice bounce or flexing in the rear seat cushion when the seat is occupied If the corrosion is allowed to progress, occupants may notice an increase in road and/or tire noise, Seat belt and permanent seat anchorages to the vehicle, which are at the rear of the seat, are unaffected. As of this date there are no reports of accidents or injuries related to this condition. Service Procedure - Owners will be notified by mail and instructed to take their vehide(s) to a Ford or Lincoln dealer who will install new third row seat latch striker brackets, which will relocate the seat's fornard latch strikers mounting locations to the floor of the vehicle. In addition, dealers are to install overlay panels on the exterior of the wheel wells to mitigate entry of water and corrosive elements. The detailed information required by the applicable portions of 49 CFR Part Defect and Non-Compliance Information Report is attached. ~ Steven M. Kenner Attachment

34 Ford Motor Company Recall Reimbursement Plan for 13S01 Ford and Lincoln dealers are in the best position to quickly and efficiently process reimbursement requests. However, federal legislation requires all motor vehicle manufacturers to establish processes through which customers may seek recall reimbursement directly from the manufacturer or from the dealers. Regarding the specific reimbursement plan for Recall # 13S01, owners who have paid for service to remedy the defect or noncompliance must have had that service performed prior to May 15, After this date, if repairs related to this recall are performed by a non-ford repair facility in an emergency situation, customers must submit any refund requests through their dealership. As required by this federal regulation, Ford Motor Company submitted the details of its latest General Recall Reimbursement Plan in a letter to the National Highway Traffic Safety Administration (NHTSA) in February The following is the text of that letter and the Plan: General Recall Reimbursement Plan (As submitted to the NHTSA) Pursuant to the requirements set forth in 49 CFR Part 573 and Part 577 of the Code of Federal Regulations, Ford Motor Company (Ford) is submitting required information pertaining to our general reimbursement plan for the cost of remedies paid for by vehicle owners before they are notified of a related safety recall. Set forth below is Ford's general plan to reimburse owners and purchasers for costs incurred for remedies in advance of notification of potential safely-related defects or noncompliances pursuant to Part (c)(8)(i). This plan has not changed since our February 24, 2011 submission. Reimbursement Notification Ford's notice to a vehicle owner in accordance with 49 CFR Part 577 will indicate that Ford is offering a refund if the owner paid to have service to remedy the defect or noncompliance prior to a specified ending date. In accordance with Part (c)(2), this ending date will be defined as a minimum of ten calendar days after the date on which Ford mailed the last of its Part 577 notifications to owners, and will be indicated in the specific reimbursement plan available to owners for an individual recall. This notice will direct owners to seek eligible reimbursement through authorized dealers or, at their option, directly through Ford at the following address: Ford Motor Company P.O. Box 6251 Dearborn, MI Ford notes that this rule allows for the identification of a beginning date for reimbursement eligibility. Under the rule, an owner who paid to remedy the defect or noncompliance prior to the identified beginning date would not be eligible for reimbursement. Ford generally has not established such a beginning date for reimbursement eligibility and does not presently anticipate changing this general policy. However, in any case where Ford determines a beginning date is appropriate, Ford will indicate that date in the owner notice. As permitted by (e), Ford may not include a reimbursement notification when all vehicles are well within the warranty period, subject to approval by the agency. Version

35 Costs to be Reimbursed For vehicles, reimbursement will not be less than the lesser of: The amount paid by the owner for the remedy that specifically addressed and was reasonably necessary to correct the defect or noncompliance that is the subject of the recall, or The cost of parts for the remedy (to be no more than the manufacturer's list retail price for authorized part(s), plus associated labor at local labor rates, miscellaneous fees (such as disposal of waste) and taxes. For replacement equipment, reimbursement will be the amount paid by the owner for the replacement item (limited by the amount of the retail list price of the defective or noncompliant item that was replaced, plus taxes, where the brand or model purchased by the owner was different than the brand or model that was the subject of the recall). If the item of motor vehicle equipment was repaired, the reimbursement provisions identified above for vehicles will apply. Ford notes that costs incurred by the owner within the period during which Ford's original or extended warranty would have provided for a free repair of the problem will not be eligible for reimbursement, as provided by Part (d)(1). Entities Authorized to Provide Reimbursement Ford will continue to use authorized dealers to reimburse owners under the specific reimbursement plans for a particular recall, and will encourage owners to pursue requests for reimbursement directly through dealers to expedite reimbursement. Ford will also provide a mailing address to which customers can, at their option, send requests for reimbursement directly to Ford, as previously noted. Requests for reimbursement sent directly to Ford may take up to 60 days to process. Whether the owner chooses to pursue reimbursement requests through a dealer or directly through Ford, the owner will be directed to submit the required documentation, upon which reimbursement eligibility will be determined. Required Documentation The reimbursement determination will depend upon the information provided by the customer. Consistent with Part (d)(4) the following information must be submitted: Claimant name and address Vehicle make, model, and model year Vehicle identification number (VIN) and, for replacement equipment, a description of such equipment or, for tires, the model, size and TIN (DOT code) Identification of the recall number (either the Ford recall number or the NHTSA recall number) Identification of the owner of the recalled vehicle at the time that the pre-notification remedy was obtained An original receipt for the pre-notification remedy that includes a breakdown of the amount for parts, labor, other costs and taxes, including costs for the replacement item. Where the receipt covers work other than to address the recall or noncompliance, Ford may require the claimant to separately identify costs that are eligible for reimbursement. If the remedy was obtained during the warranty period, documentation indicating that the warranty was not honored or the warranty repair did not correct the problem related to the recall. Failure to submit all of the above information may result in denial of the reimbursement request. Version