This Field Service Action expired on January 31, 2001.

Size: px

Start display at page:

Download "This Field Service Action expired on January 31, 2001."

Derick Edwards
5 years ago
Views:

1 This Field Service Action expired on January 31, OWNER NOTIFICATION PROGRAM 99B28 Certain 1999 & 2000 Model Year F-250 Super Duty Through F-550 Super Duty, 1999 F-Super Duty Stripped Chassis & 1999 E-150 Through E-450 Super Duty Vehicles with 5.4L or 6.8L Engines-Engine Oil Cooler Inspection/Replacement December, 1999 To: All Ford and Lincoln-Mercury Dealers Subject: Owner Notification Program 99B28 - Certain 1999 and 2000 Model Year F-250 Super Duty Through F-550 Super Duty, 1999 F-Super Duty Stripped Chassis and 1999 E-150 Through E-450 Super Duty Vehicles with 5.4L or 6.8L Engines-Engine Oil Cooler Inspection/Replacement OASIS: Yes OWNER LIST: Yes PARTS RETURN: Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". PROGRAM TERMS: This program will be in effect until January 31, 2001, regardless of mileage. AFFECTED VEHICLES Certain model year F-250 Super Duty through F-550 Super Duty vehicles with 5.4L or 6.8L engines built at the Kentucky Truck Plant and the Cuautitlan Assembly Plant from March 24, 1999 through April 14, Certain 1999 F-Super Duty Stripped Chassis vehicles with 6.8L engine built at the Industrias Metalicas de Monterrey, South America (IMMSA) Assembly Plant from March 24, 1999 through April 14, Certain 1999 E-150 through E-450 Super Duty vehicles with 5.4L or 6.8L engines built at the Lorain

2 Assembly Plant from March 24, 1999 through April 14, REASON FOR PROGRAM In less than 10% of the affected vehicles, the engine oil cooler may develop an internal leak allowing engine oil and coolant to cross mix in the cooling and lubrication systems. The mixing of oil and coolant could result in engine overheating, loss of lubrication and eventual engine damage if the condition is not corrected. SERVICE ACTION The dealer will inspect oil cooler build dates on all of the affected vehicles. Engine oil coolers built from the 76th day of 1999 (March 17, 1999) through the 91st day of 1999 (April 1, 1999) will be replaced. Also, the dealer will check the coolant and engine oil for cross contamination. Contaminated engine oil and coolant will be replaced at no cost to the owner. NOTE: The replacement of suspect engine oil coolers will protect the engine against permanent damage. In rare cases where engine damage has occurred, the dealer must call for engine repair or replacement prior approval. Claims for engine repair or replacement without prior approval will not be accepted for payment. Attachments Attachment I Administrative Information Attachment II Labor Allowances Parts Ordering Information Attachment III Technical Information QUESTIONS? Claims Information Other Recall Questions ATTACHMENT I Owner Notification Program 99B28

3 Certain 1999 and 2000 Model Year F-250 Super Duty Through F-550 Super Duty, 1999 F-Super Duty Stripped Chassis and 1999 E-150 Through E-450 Super Duty Vehicles with 5.4L or 6.8L Engines Engine Oil Cooler Inspection/Replacement 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 Promptly correct all affected vehicles on the enclosed VIN list (if provided) or the VIN list in the Ford Dealer Consolidated Communicator (FDCC) and other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS PREPARATION AND SUBMISSION Enter claims using DWE. Refer to ACESII Manual for claims preparation and submission information. ENGINE DAMAGE In rare cases where engine damage has occurred, you must call for engine repair or replacement prior approval. Claims for engine repair or replacement without prior approval will not be accepted for payment. OWNER REFUNDS Ford Motor Company will only refund owner-paid oil cooler repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer.) Refer to ACESII Manual for Refund information. Program Code: 99B28 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. Refer to ACESII Manual for refund information. RENTAL CARS If an oil cooler requires replacement, Ford will pay for a loaner or rental vehicle except for fuel

4 which will be at the owner's expense. Rentals should be provided only while the vehicle is at the dealership for the oil cooler replacement. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days the vehicle was used in the Miscellaneous Expense area of the claim. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". To properly return an oil cooler and to prevent damage to parts being returned together, please adhere to the following requirements: Oil cooler inlet and outlet tubes need to be capped to prevent leakage. Oil cooler should be packed in a sealed plastic bag. ATTACHMENT II Owner Notification Program 99B28 Certain 1999 and 2000 Model Year F-250 Super Duty Through F-550 Super Duty, 1999 F-Super Duty Stripped Chassis and 1999 E-150 Through E-450 Super Duty Vehicles with 5.4L or 6.8L Engines Engine Oil Cooler Inspection/Replacement LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Operation Description Parts will not be direct shipped for this program. Oil cooler availability will be controlled through 4/30/00. Dealers must call and be prepared to provide the VIN, your Parts and Accessories code, the oil cooler build date code and oil cooler part number to the hotline analyst. Table 1 - Use with Labor Operation 99B28B Only Labor Allowances Labor Operation Inspect Engine Oil Cooler Build Date and Release Vehicle. 0.2 Hours 99B28A Inspect Engine Oil Cooler Build Date, Replace Oil Cooler, Check Oil and Coolant for Contamination and Top Off Oil and Coolant. Inspect Engine Oil Cooler Build Date, Replace Oil Cooler, Check Oil and Coolant for Contamination, Change Oil and Flush Cooling System. Emergency/Interim/Stock Orders BEFORE 04/30/00 Call Emergency/Interim/Stock Orders After 04/30/00 Normal order process 0.5 Hours 99B28B 1.2 Hours 99B28C Part Number Description Quantity

5 F8UZ-6A642-HA * F7UZ-6A642-EA ** *A total of 11,800 vehicles will need to be inspected and only 1390 vehicles will require oil cooler replacement. **A total of 5800 vehicles will need to be inspected and only 280 vehicles will require oil cooler replacement. Table 2 - Use with Labor Operation 99B28C Only *A total of 11,800 vehicles will need to be inspected and only 1390 vehicles will require oil cooler replacement. **A total of 5800 vehicles will need to be inspected and only 280 vehicles will require oil cooler replacement. ***Claim only actual amount of coolant used. DEALER PRICE For latest prices, check or call your: DOES II Updated Price Book EXCESS STOCK RETURN Oil Cooler Assembly (All 6.8L Engines and F-250 through F L Engines) Oil Cooler Assembly (E-150 through E L Engines 1 per vehicle 1 per vehicle F1AZ-6731-BD Oil Filter (FL-820S) 1 XO-5W30-QSP SAE 5W30 Oil 1 Quart E2FZ AA Premium Engine Coolant (Not for Sale In Oregon) 1 Quart F5FZ CC Premium Engine Coolant (For Sale in Oregon Only) 1 Quart Part Number Description Quantity F8UZ-6A642- HA * F7UZ-6A642- EA ** Oil Cooler Assembly (All 6.8L Engines and F-250 through F L Engines) Oil Cooler Assembly (E-150 through E L Engines F1AZ-6731-BD Oil Filter (FL-820S) 1 XO-5W30-QSP SAE 5W30 Oil F1AZ-19A503-A Ford Premium Cooling System Flush 1 E2FZ AA Premium Engine Coolant (Not for Sale in Oregon) F5FZ CC Premium Engine Coolant (For Sale in Oregon Only) 1 per vehicle 1 per vehicle 6 Quart 17 Quart (Max.) *** 17 Quart (Max.) *** Excess stock returned for credit must have been purchased from Ford Customer Service Division in

6 accordance with Policy Procedure Bulletin ATTACHMENT III Owner Notification Program 99B28 OIL COOLER REPLACEMENT AFFECTED VEHICLES CERTAIN MODEL YEAR F-250 SUPER DUTY THROUGH F-550 SUPER DUTY VEHICLES WITH 5.4L AND 6.8L ENGINES CERTAIN 1999 MODEL YEAR E-150 THROUGH E-450 SUPER DUTY VEHICLES WITH 5.4L AND 6.8L ENGINES CERTAIN 1999 MODEL YEAR F-SUPER DUTY (STRIPPED CHASSIS) VEHICLES WITH 5.4L AND 6.8L ENGINES OVERVIEW When performing this procedure, you will: inspect the build date on the engine oil cooler. replace the oil cooler, if necessary. On vehicles that require oil cooler replacement, you will also: inspect the engine oil and the coolant for cross contamination. replace the engine oil and flush the cooling system, if necessary. OIL COOLER BUILD DATE INSPECTION 1. Turn off the air suspension switch (if equipped). 2. Raise the vehicle on the hoist. 3. Inspect the build date on the oil cooler. If the first three numbers of the build date are 9-76 through 9-91,replace the engine oil cooler. Refer to Oil Cooler Replacement on Page 3. If not, return the vehicle to the customer. See Figure 1.

7 FIGURE 1 OIL COOLER REPLACEMENT 1. Remove the engine oil filter. 2. Clamp the oil cooler hoses by the radiator. See Figure 2. FIGURE 2 3. Disconnect the oil cooler hoses from the oil cooler. See Figure 3.

8 FIGURE 3 4. Insert a 14 mm hex key (Allen) wrench into the hollow oil filter mounting stud. Remove the stud from the center of the oil cooler. See Figure Remove the oil cooler and oil cooler-to-adapter seal. FIGURE 4 6. Making certain the new oil cooler-to-adapter seal is in place, install the new oil cooler. Make sure the notch in the oil cooler is lined up with the tang on the oil filter adapter. See Figure 5. Tighten the hollow oil filter mounting stud to 57 Nm (42 lb-ft).

9 FIGURE 5 7. Connect the cooler hoses. 8. Remove the clamps from the cooler hoses. 9. Install a new oil filter. 10. Lower the vehicle and go to Engine Oil and Coolant Condition Check. ENGINE OIL AND COOLANT CONDITION CHECK 1. Inspect the engine oil for signs of engine coolant, such as a white milky substance, by removing and inspecting the dipstick. Inspect the coolant recovery reservoir for signs of engine oil. If the cooling system is contaminated, the inside wall of the reservoir will be coated with engine oil, leaving a dark residue. If the engine oil or coolant is contaminated, change the engine oil. Go to Cooling System Flush. If NO sign of contamination is evident, top off the engine oil and the coolant. Return the vehicle to the customer. COOLING SYSTEM FLUSH (To be performed only if the engine oil or coolant is contaminated) WARNING: NEVER REMOVE THE PRESSURE RELIEF CAP WHILE THE ENGINE IS OPERATING OR WHEN THE COOLING SYSTEM IS HOT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE OR PERSONAL INJURY. TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE DEGAS BOTTLE WHEN REMOVING THE PRESSURE RELIEF CAP, WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE PRESSURE RELIEF CAP AND TURN IT SLOWLY. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN RELEASED, (STILL WITH A CLOTH) TURN AND REMOVE THE PRESSURE RELIEF CAP. 1. Release the pressure in the cooling system by slowly turning the pressure relief cap one-half turn counterclockwise. When the pressure is released, remove the pressure relief cap.

10 CAUTION Contaminated coolant must be recycled or disposed of properly. 2. Open the radiator draincock and partially drain the cooling system. 3. Remove the water thermostat. Remove the upper radiator hose. Remove the thermostat housing. Remove the thermostat. Install the thermostat housing without the thermostat. Install the upper radiator hose. 4. Refer to the cooling system Flush-All Flusher 164-R3673 or equivalent Operating Instructions for specific vehicle hookup. Use cooling system Flush-All, Flush Kit Hardware Package 164- R3658 and Drain Kit 164-R3662 to flush the engine and radiator. Use Ford Premium Cooling System Flush F1AZ-19A503-A or equivalent meeting Ford specification ESR-M14P7A with standard (green) coolant and flush the cooling system. 5. Install the water thermostat. Remove the upper radiator hose. Remove the thermostat housing. Install the thermostat. Install the thermostat housing. Tighten the bolts to 25 Nm (18 lb-ft). Install the upper radiator hose. 6. Fill the cooling system. 7. Start the engine and check operation of the cooling system. December, 1999 Serial Number: B28 Mr. John Sample 123 Main Street Anywhere, USA Ford Motor Company is providing a no-charge Service Program, Number 99B28, to owners of certain 1999 and 2000 model year F-250 Super Duty through F-550 Super Duty, 1999 F-Super Duty Stripped Chassis and 1999 E-150 through E-450 Super Duty vehicles with 5.4L or 6.8L engines. WHAT IS THE REASON FOR THIS PROGRAM? Some of the affected vehicles were assembled with engine oil coolers that may develop an internal leak allowing engine oil and coolant to cross mix in the cooling and lubrication systems. The mixing of oil and coolant could result in engine overheating, loss of lubrication and eventual engine damage if the condition is not corrected. NO CHARGE SERVICE At no charge to you, your dealer will inspect your vehicle's engine oil cooler. If it has a suspect build

11 date, your dealer will replace the oil cooler, check the coolant and engine oil for contamination and replace, if necessary. This program will be in effect until January 31, 2001, regardless of mileage. HOW LONG WILL IT TAKE? The time needed for this repair is less than one-half day. However, due to service scheduling issues, your dealer may need your vehicle for a longer period of time. CALL YOUR DEALER Call your dealer without delay. Ask for a service date for Owner Notification Program 99B28. 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. RENTAL VEHICLES If your engine oil cooler requires replacement, the oil cooler will need to be ordered. In these cases, your dealer is authorized to provide a free loaner vehicle (except for fuel) while your vehicle is at the dealership for the oil cooler replacement. 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, do not send receipts to Ford Motor Company. CHANGED ADDRESS OR SOLD THE VEHICLE? If you have changed your address or sold the vehicle, please fill out the enclosed prepaid postcard and mail it to us. 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 vehicle. OWNER NOTIFICATION PROGRAM 99B28 CPR В 1999 FORD MOTOR COMPANY

12 Published By: Recall/Service Programs Department Ford Customer Service Division

June 21, All U.S. Ford and Lincoln Dealers

June 21, All U.S. Ford and Lincoln Dealers Michael A. Berardi Director Service Engineering Operations Ford Customer Service Division TO: All U.S. Ford and Lincoln Dealers Ford Motor Company P. O. Box 1904 Dearborn, Michigan 48121 June 21, 2013