Recall - Cross Tank Fuel Flow Condition RECALL NUMBER: 93S68

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1 1990 Ford Truck F 150 2WD Pickup V L Copyright 2013, ALLDATA 10.52SS Page 1 Technical Service Bulletin # 93S68 Date: Recall - Cross Tank Fuel Flow Condition RECALL NUMBER: 93S68 Date: Sept At Dealers By as Req'd. At PDC by Date in Owner Letter 0% of Parts Direct Shipped to Dealers TO: All Ford Dealers SUBJECT: Safety Recall 93S68 - All 1990, 1991, 1992 and certain 1993 Model Year F-Series Vehicles equipped with 4.9, 5.0, 5.8 or 7.5 Liter Engines and Dual Fuel Tanks. AFFECTED VEHICLES All 1990, 1991, 1992 and certain 1993 model F-series vehicles equipped with 4.9, 5.0, 5.8 or 7.5 Liter engines and dual fuel tanks. REASONS FOR RECALL Some of the affected vehicles may experience a cross tank fuel flow condition due to a damaged check valve in the fuel pump/sender assembly. Fuel may be supplied from one tank and some or all of the unused fuel may be returned to the other tank. Should this occur, the capacity of the receiving tank may be exceeded and fuel may overflow from the filler cap. Fuel spillage in the presence of an ignition source could potentially result in a fire. To correct this condition, the fuel pressure regulator will be replaced and a check valve will be installed between each fuel supply line and fuel tank. FREE FUEL LINE REMOVAL TOOL Standard fuel line removal tools can be used to disconnect fuel lines. However, because of the number of vehicles to be serviced, two free tools (# T93T-9550-AH) will be provided to each Ford dealer. These tools will be in your next Dealer Mail System (DMS) shipment (DMS packing slip # ). PARTS KIT CODES The required parts kit code for each vehicle will be shown on the attached VIN listing and will be printed at the top of each Owner Letter. Ask owners for the kit code shown on their letter when the owner calls for a service appointment. ATTACHMENTS Attachment I - Administrative Information Attachment II - Labor Allowances - Parts Ordering Information Attachment III - Technical Information Attachment I - Administrative Information OASIS YOU MUST USE OASIS TO DETERMINE IF A VEHICLE IS ELIGIBLE FOR THIS RECALL. PLEASE NOTE CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY. FEDERAL LAW REQUIRES DEALERS TO COMPLETE ANY OUTSTANDING SAFETY RECALL SERVICE BEFORE A NEW VEHICLE IS

2 1990 Ford Truck F 150 2WD Pickup V L Copyright 2013, ALLDATA 10.52SS Page 2 DELIVERED TO THE BUYER OR LESSEE. VIOLATION OF THIS REQUIREMENT BY A DEALER COULD RESULT IN A CIVIL PENALTY OF UP TO $1,000 PER VEHICLE. 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 and arrange a service date. DISTRICT CONTACT Advise district office if: - an owner cannot be contacted. - an owner does not make a service date. FCSD CONTACT Talk with your FCSD Service Zone Manager about all matters. FORM 1863/64 Submit 1864 claims using DWE for all completed vehicles. You may use your original 1863 for your record file copy. WARRANTY AND POLICY MANUAL See Section 6.3 pages 5 through 8 of your Warranty and Policy Manual for claims preparation. (REFUNDS, USE "CUSTOMER CONDITION CODE" X99 FOR SAFETY RECALLS) Attachment II - Labor and Parts Information and certain 1993 Model Year F-Series Vehicles With 4.9, 5.0, 5.8, or 7.5 liter engines and Dual Fuel Tanks LABOR ALLOWANCES Install new fuel pressure regulator and check valves (or new fuel lines with built-in check valves): NOTE Add 0.1 hour Administrative Allowance to the total repair time.

3 1990 Ford Truck F 150 2WD Pickup V L Copyright 2013, ALLDATA 10.52SS Page 3 Add additional 0.3 hour if truck is equipped with fuel tank skid plates. Add additional 0.1 hour if truck is over 8,500 lbs. and equipped with a 5.8L engine. PARTS REQUIREMENTS Parts will not be direct shipped for this recall. For Kits AA, BB, CC, and DD, order your parts requirements through normal order processing channels. For Kits EE, FF, GG, and HH, order your parts by calling Renkim Corporation at When calling, be prepared to announce Recall 93S68, give your name, dealer name, P&A code, the VIN number of the vehicle to be serviced, and the kit part number required (do not order Kits AA, BB, CC or DD by calling this number). 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 Attachment III - Technical Information TECHNICAL INSTRUCTIONS: WARNING DO NOT SMOKE, CARRY LIGHTED TOBACCO OR ANY OPEN FLAME OF TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. WARNING FUEL SUPPLY LINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN. CAUTION: EACH KIT AND INSTRUCTION SHEET IS UNIQUE. BE SURE TO USE THE KIT AND INSTRUCTION SHEET THAT MATCHES THE VEHICLE TO BE SERVICED. DETAILED INSTRUCTIONS ARE NOT REPRODUCED HERE BUT ARE INCLUDED IN EACH KIT.

4 1990 Ford Truck F 150 2WD Pickup V L Copyright 2013, ALLDATA 10.52SS Page 4 FOLLOW ALL INSTRUCTIONS IN EACH KIT CAREFULLY. IN PARTICULAR, NOTE THE FOLLOWING ITEMS: 1. Be sure to leak test each truck before returning it to the customer. 2. Be careful not to kink fuel lines when reinstalling fuel tanks. 3. Do not mix parts. Some parts look similar. For example, some kits contain short check valve connectors (orange tag with part number imprinted); other kits contain long check valve connectors (white tag with part number imprinted). SEE KIT APPLICATION LIST - SELECT KIT CAREFULLY! KIT APPLICATION (See detailed instructions included in each kit) Owner Letter Serial Number: S68 Kit AA September, 1993 Mr. John Sample 123 Main Street Anywhere, USA This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in 1990, 1991, 1992 and certain 1993 Model Year F-Series vehicles equipped with 4.9, 5.0, 5.8 or 7.5 liter engines and dual fuel tanks. SAFETY DEFECT The dual fuel tanks have fuel delivery modules designed to direct fuel to the engine from one tank and to return unused fuel to the same tank. It is possible that one or both fuel delivery modules on your truck could allow a portion of the unused fuel to be directed to the tank other than from which it was drawn.

5 1990 Ford Truck F 150 2WD Pickup V L Copyright 2013, ALLDATA 10.52SS Page 5 Should this occur when one tank is at or near full capacity, fuel could overflow from the filler pipe past the cap. Fuel spillage in the presence of an ignition source could potentially result in a fire. To correct this condition, the fuel pressure regulator will be replaced and a check valve will be installed between each fuel supply line and fuel tank. REPAIRS At no charge to you, your dealer will replace the fuel pressure regulator and install the check valves. Dealers currently have instructions and parts or parts ordering information. HOW LONG WILL IT TAKE? The time needed for this service is about three hours. However, due to service scheduling times, your dealer may need your vehicle for one full working day. CALL YOUR DEALER Call your dealer without delay. Ask for a service date and whether parts are in stock. When calling, be prepared to tell the dealer the two letter parts kit code printed at the top of this letter (for example, "Kit AA"). 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. 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. If the dealer doesn't repair your vehicle promptly and without charge, you may contact the Ford Customer Assistance Center, 300 Renaissance Center, P. 0. Box 43360, Detroit, Michigan You also may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C or call the toll free Auto Safety Hotline (Washington, D.C. area residents may call ). We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Ford-built truck. Additional Information SAFETY RECALL 93S68 THE PURPOSE OF THIS COMMUNICATION IS TO PROVIDE ADDITIONAL INFORMATION REGARDING SAFETY RECALL 93S68. PLEASE FILE WITH YOUR 93S68 BULLETIN. SECTION I - MODIFIED INSTALLATION PROCEDURE FOR REAR TANK CHECK VALVE - KITS CC AND DD SECTION II - REVISED KITS TO REPLACE KITS EE, FF, GG, AND HH SECTION III - HELPFUL HINTS FOR KIT INSTALLATION TO: ALL FORD DEALERS THE PURPOSE OF THIS ANNOUNCEMENT IS TO PROVIDE ADDITIONAL INFORMATION REGARDING SAFETY RECALL 93S68: SECTION I - ADDITIONAL TECHNICAL INFORMATION. SECTION II - CANCELLATION OF PARTS KITS EE, FF, GG, AND HH AND INTRODUCTION OF PARTS KITS JJ AND KK. SECTION III - HELPFUL HINTS FOR KIT INSTALLATION. Section I SECTION I - MODIFIED INSTALLATION PROCEDURE FOR REAR TANK CHECK VALVE - KITS CC AND DD: ON 1992/93 F-SERIES EQUIPPED WITH A STEEL REAR FUEL TANK, TECHNICIANS MAY FIND IT DIFFICULT TO INSTALL THE CHECK VALVE ON THE REAR TANK. IF YOU ARE NOT CAREFUL WHEN LOWERING THE FUEL TANK, THE PORTS ON THE REAR TANK FUEL DELIVERY MODULE CAN BE BENT. THE FOLLOWING TECHNIQUE SHOULD BE FOLLOWED ON THE REAR TANK (NO CHANGE IN PROCEDURE IS NECESSARY ON THE FRONT TANK). NO CHANGE IN LABOR TIME IS REQUIRED:

6 1990 Ford Truck F 150 2WD Pickup V L Copyright 2013, ALLDATA 10.52SS Page 6 1. DRAIN REAR FUEL TANK IF NOT ALREADY NEAR EMPTY. THIS CAN BE DONE BY PUSHING A LARGE HOSE DOWN THE FILLER NECK AND SIPHONING AS MUCH FUEL AS POSSIBLE USING ROTUNDA FUEL STORAGE TANKER OR OR EQUIVALENT. 2. RAISE VEHICLE ON HOIST AND POSITION SUITABLE SAFETY STANDS UNDER VEHICLE. 3. POSITION SPARE TIRE OUT OF THE WAY (IT IS NOT NECESSARY TO COMPLETELY REMOVE THE TIRE AND CARRIER - JUST REMOVE FROM THE HOLD DOWN BOLT AND LET THE TIRE AND CARRIER CAREFULLY SWING DOWN OUT OF THE WAY). 4. LOOSEN HOSE CLAMP AT FUEL FILLER HOSE CONNECTION TO FUEL TANK AND REMOVE HOSE FROM TANK OR, ALTERNATIVELY, REMOVE THE THREE SCREWS ATTACHING THE FILLER NECK TO THE BODY SHEET METAL. 5. POSITION SUITABLE JACK STAND UNDER REAR FUEL TANK. 6. SUPPORT THE TANK AND REMOVE THE BOLTS ATTACHING THE TANK SUPPORTS TO THE FRAME. SLOWLY BEGIN TO LOWER THE TANK WHILE KEEPING THE FRONT OF THE TANK UP AS THE TANK IS LOWERED FROM THE REAR FIRST. SEE FIGURE # 1. MOVE THE TANK A FEW INCHES REARWARD AS THE TANK IS BEING LOWERED - BE SURE THAT THE FUEL LINES AT THE FRONT OF THE TANK ARE MOVING FREELY AND NOT BINDING ON THE CROSSMEMBER. DO NOT LOWER THE TANK MORE THAN 4-5 INCHES. THIS WILL PROVIDE ACCESS TO THE FUEL DELIVERY MODULE AT THE FRONT OF THE TANK. SEE FIGURE # 2. IF THE TANK IS LOWERED MORE THAN 4-5 INCHES, OR IF THE TANK IS LOWERED STRAIGHT DOWN WITHOUT ALSO MOVING IT A FEW INCHES REARWARD, THE FUEL DELIVERY MODULE PORTS COULD BE BENT. 7. DISCONNECT THE FUEL SUPPLY LINE FITTING AT THE FUEL DELIVERY MODULE (REFERENCE APPENDIX I OF

7 1990 Ford Truck F 150 2WD Pickup V L Copyright 2013, ALLDATA 10.52SS Page 7 INSTRUCTION SHEET 8117 OR 8118 IN KIT CC OR DD FOR REMOVAL PROCEDURE). SEE FIGURE # 2 ABOVE. NOTE: FOR PURPOSES OF CLARITY, THE FUEL LINE SAFETY CLIPS ARE NOT SHOWN - THEY ARE REQUIRED. 8. WITH THE FUEL SUPPLY LINE STILL DISCONNECTED, CAREFULLY MOVE THE FUEL TANK BACK INTO POSITION BY LIFTING THE FRONT OF THE TANK FIRST. BE CAREFUL NOT TO KINK THE FUEL LINES AT THE FRONT OF THE TANK. SEE FIGURE # 3. POSITION FUEL TANK SUPPORTS AND INSTALL ATTACHING BOLTS AND NUTS. TIGHTEN TO N-m (27-37 FT.LB.). FOR ADDITIONAL INFORMATION, SEE TSB RECONNECT THE FUEL FILLER HOSE TO THE FUEL TANK AND TIGHTEN CLAMP TO 3-4 N-m (25-35 IN.LB.) OR, IF THE FILLER NECK WAS REMOVED AT THE BODY SHEET METAL, REATTACH WITH THE THREE SCREWS. 10. INSTALL CHECK VALVE CONNECTOR TO THE FUEL SUPPLY LINE FIRST (NOT TO THE FUEL DELIVERY MODULE). NOTE: MAKE SURE TO INSTALL THE SAFETY CLIP CONNECTING THE FUEL LINE AND THE CHECK VALVE AND TO POSITION IT SO THE LONG LEGS OF THE CLIP WILL BE HORIZONTAL TO THE GROUND WHEN ATTACHED TO THE FUEL DELIVERY MODULE IN STEP # PRE-POSITION THE SECOND SAFETY CLIP ON THE OTHER END OF THE CHECK VALVE CONNECTOR (IF NOT ALREADY PRE-POSITIONED - SEE NOTE IN STEP # 10).

8 1990 Ford Truck F 150 2WD Pickup V L Copyright 2013, ALLDATA 10.52SS Page CONNECT THE FUEL SUPPLY LINE AND CHECK VALVE CONNECTOR ASSEMBLY (WITH SAFETY CLIP PRE-POSITIONED) TO THE FUEL DELIVERY MODULE BY INSERTING THROUGH THE SPACE BETWEEN THE FRAME CROSSMEMBER AND THE PICKUP BOX BED SUPPORT. SEE FIGURE # 4 AND # 5 BELOW. DO NOT ATTACH UNTIL A SAFETY CLIP IS PRE-POSITIONED ON THE OPEN END OF THE CHECK VALVE CONNECTOR AND THE OTHER SAFETY CLIP IS ATTACHED BETWEEN THE CHECK VALVE AND THE FUEL SUPPLY LINE. (REFERENCE APPENDIX I OF INSTRUCTION SHEET 8117 OR 8118 IN KIT CC OR DD FOR INSTALLATION PROCEDURE). AFTER THE FUEL LINE AND CHECK VALVE CONNECTOR ARE ATTACHED TO THE FUEL DELIVERY MODULE, USE A LARGE FLAT BLADE SCREWDRIVER TO FULLY SEAT THE SAFETY CLIP ONTO THE SUPPLY LINE OF THE FUEL DELIVERY MODULE AND THE CHECK VALVE. MAKE SURE TO POSITION THE SAFETY CLIP SO THE LEGS OF THE CLIP WILL BE HORIZONTAL TO THE GROUND WHEN ATTACHED TO THE FUEL DELIVERY MODULE. BOTH SAFETY CLIPS MUST BE INSTALLED. 13. REMOVE JACK AND REPOSITION SPARE TIRE. 14. CONTINUE WITH INSTALLATION OF FRONT FUEL TANK CHECK VALVE AND FUEL PRESSURE REGULATOR PER THE INSTRUCTION SHEET PACKED WITH KITS CC AND DD. Section II

9 1990 Ford Truck F 150 2WD Pickup V L Copyright 2013, ALLDATA 10.52SS Page 9 SECTION II - REVISED KITS TO REPLACE KITS EE, FF GG, AND HH: EFFECTIVE IMMEDIATELY, KITS EE, FF, GG, AND HH ARE CANCELLED (PART NUMBERS F4PZ-9155-E, -F, -G, AND -H). PARTS PRICES AND APPLICATIONS FOR KITS JJ AND KK: LABOR ALLOWANCES FOR KITS JJ AND KK: Note - Add 0.1 hour Administrative Allowance to the total repair time. - Add additional 0.1 Hour if truck is over 8,500 lbs. GVWR and equipped with a 5.8L engine. Section III SECTION III - RECALL 93S68 HELPFUL HINTS 1. Always be certain you have the correct kit. Each kit is different and has specific vehicle applications. DO NOT MIX COMPONENTS FROM DIFFERENT KITS. 2. Kits AA, CC, and JJ may contain a new design fuel pressure regulator gasket which appears to have 1/3 of the end cut off. This is normal. 3. When disconnecting Aeroquip fuel line connectors on 1992/1993 models (Kits CC and DD), it may be difficult to completely disengage the locking clip in the connector unless the connector is first pushed onto the male end of the line as far as possible. 4. If the locking clip in the Aeroquip fuel line connector is damaged in the removal of a 1992/1993 fuel line assembly, a new locking clip (basic part number 9B307) must be installed in the connector. Do not attempt to repair the damaged locking clip. 5. When servicing the aft-axle tank on the 1990/1991 models (Kits AA and BB), reinstallation of the fuel line after the check valve is installed on the supply side of the fuel delivery module may be difficult due to limited clearance to the crossmember. Installation may be easier if the installation sequence defined in the kit instructions for the aft-axle tank is reversed and the check valve is connected to the fuel line BEFORE attaching to the fuel delivery module. If necessary, the fuel line hold-down clip on the crossmember may be temporarily opened to allow the end of the supply line to be moved to the forward side of the crossmember for easier access. Reinstall all lines in the clip when completed. 6. If a plastic elbow connector is damaged on a 1990/1991 fuel line assembly, the line can be repaired by either of two methods: a) The damaged connector may be cut off and a replacement connector (part number N S19O) installed using Rotunda Tool OR b) the damaged connector and a section of fuel line may be cut off and a new section of fuel line including a connector (basic part number 9291) may be spliced onto the existing fuel line using Rotunda Tool Use connector N S to perform the splice. Trim the lines to the desired length before splicing.

10 1990 Ford Truck F 150 2WD Pickup V L Copyright 2013, ALLDATA 10.52SS Page Special precautions must be taken to prevent kinked fuel lines as pointed out in the kit instructions. BE SURE TO READ AND FAMILIARIZE YOURSELF WITH THESE PRECAUTIONS. For additional information, Technical Service Bulletin also addresses the issue of kinked fuel lines. 8. When reinstalling fuel lines after installation of the check valve connector from the kit, be sure that BOTH safety clips are properly reinstalled (one clip between check valve connector and the fuel delivery module; second clip between the fuel supply line and the check valve connector). 9. In the event that a fuel line is inadvertently damaged during kit installation, repair using parts, tools, and procedures found under Group 10 in the appropriate Shop Manual and Technical Service Bulletin

SAFETY RECALL 91S41. To: All Ford Dealers

SAFETY RECALL 91S41. To: All Ford Dealers Page 1 of 17 SAFETY RECALL 91S41 Certain 1990 Ranger, 1990-1991 Aerostar and 1991 Explorer Trucks Equipped With A4LD Automatic Transmissions for Inspection and, if Necessary, Modification of the Vehicles