Transcription

1 Page 1 of 10 SAFETY RECALL 98S37 Front Suspension Lower Control Arm Ball Joint Replacement - Certain 1990 through 1999 Ford Crown Victoria Police, Fleet, Taxi, Natural Gas Vehicles (NGV), and Lincoln Town Cars Equipped with Limousine Package To: All Dealership Service Manager/Directors All Dealership Parts Managers Subject: Safety Recall 98S37, Lower Control Arm Ball Joint Replacement Certain 1990 Through 1999 Ford Crown Victoria and Lincoln Town Cars The attached Safety Recall 98S37 covers the front suspension lower control arm ball joint replacement on certain 1990 through 1999 Ford Crown Victoria police, fleet, taxi, natural gas vehicle (NGV), and Lincoln Town Cars equipped with the limousine package. The recall has been divided into two affected vehicle universes; 1995 and forward models using service part kit F8AZ-3050-AA, and 1994 and prior models using a service part kit to be announced in early Please note that this represents a small number of vehicles (approximately 2,000) which may have been serviced with affected ball joints. The owners of 1995 and forward models will be notified with the attached letter now while the owners of 1994 and prior models will be notified when parts are available in early Ford Customer Service Division Recall Department will supplement this bulletin announcing the notification of owners of 1994 and prior vehicles and will, at that time, provide service part kit information and claiming instructions. Ford Customer Service Division Recall and Service Programs Department December, 1998 To: All Ford and Lincoln-Mercury Dealers Subject: Safety Recall 98S37 - Front Suspension Lower Control Arm Ball Joint Replacement - Certain 1990 through 1999 Ford Crown Victoria Police, Fleet, Taxi, Natural Gas Vehicles (NGV), and Lincoln Town Cars Equipped with Limousine Package AFFECTED VEHICLES Certain 1990 through 1999 model Ford Crown Victoria police, fleet, taxi, natural gas vehicles (NGV), built at the St. Thomas Assembly Plant from March 15, 1996 through December 14, 1998 and Lincoln Town Cars equipped with the limousine package built at the Wixom Assembly Plant March 15, 1996 through December 18, 1998; in addition, approximately 2, through 1996 model vehicles are included which may have been serviced with affected ball joints. Check OASIS to assure specific vehicle inclusion in the universe of affected vehicles and to determine the service procedure to provide. REASONS FOR RECALL The front suspension lower control arm ball joint may wear and subsequently separate. If a ball joint should separate partial steering control may be lost potentially resulting in a collision. SERVICE ACTION To correct this condition, dealers are to replace the front suspension lower control arm ball joints on both sides of the vehicle. If you have knowledge of vehicles built in the affected period which were serviced with an affected ball joint and outside vehicle warranty (includes vehicles serviced under any service protection plan), contact the owner, provide a copy of the attached owner notification letter and schedule a service appointment. In these instances, it will be necessary to call the recall tollfree number to obtain approval to submit the claim. REFUNDS Refunds are available for owner-paid front suspension lower control arm ball joint replacement made before the date on the Owner Letter (or after the date of the letter if an emergency repair was made away from the servicing dealer). QUESTIONS? Claims Information Other Recall Questions Attachments Attachment I Administrative Information Refund Codes Attachment II Labor Allowances Parts Ordering Information Attachment III Technical Information

2 Page 2 of 10 ATTACHMENT I Safety Recall 98S37 DEALER-OWNER CONTACT Owners of affected vehicles according to Ford Motor Company records will be notified with the attached letter. If you have knowledge of an owner with an affected vehicle that did not receive a notification letter, contact that owner, provide a copy of the attached letter and schedule a service appointment. OASIS 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 delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. REGIONAL CONTACT Advise regional office if: an owner cannot be contacted. an owner does not make a service date. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. If towing is required, submit per ACES II Manual section 3-8. REFUNDS See ACESII Manual, Section 3-63 for submission procedures. For owner-paid front suspension lower control arm ball joint replacement made before the date of the Owner Letter (or after the date of the letter if an emergency repair was made away from the servicing dealer), enter using DWE; Program Code - 98S37 Misc. Expense - REFUND Misc. Expense - ADMIN Misc. Expense Hrs. ATTACHMENT II Safety Recall 98S37 LABOR ALLOWANCES Operation Description Labor Allowances Labor Operation Replace Front Suspension Lower Control Arm Ball Joints (both sides) to 1999 Model Years 1.7 Hrs. 98S37B Replace Front Suspension Lower Control Arm Ball Joints (both sides) to 1994 Model Years 1.7 Hrs. 98S37C Administrative Allowance 0.1 Hrs. Misc. Expense Code "ADMIN" PARTS REQUIREMENTS Part Number Description Order Information F8AZ-3050-AA 1995 to 1999 Vehicles Kit A, Front Suspension Lower Control Arm Ball Joint Replacement DEALER PRICE For latest prices, check or call your: Order through normal channels XW7Z-3050-BA 1990 to 1994 Vehicles Kit B, Front Suspension Lower Control Arm Ball Joint Replacement Kits can only be ordered by calling the Recall Hotline at (800) Order Processing Center DOES II Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000.

3 Page 3 of 10 ATTACHMENT III Safety Recall 98S37 LOWER BALL JOINT REPLACEMENT AFFECTED VEHICLES: CERTAIN 1995 MODEL YEAR AND FORWARD CROWN VICTORIA AND TOWN CAR SERVICE PROCEDURE The following service procedure will replace the left side lower ball joint. Repeat the procedure to replace the right side lower ball joint. 1. Open hood. 2. Disconnect front wheel ABS sensor electrical connector. See Figure 1. Figure 1 3. Route front wheel ABS sensor wiring into wheel well. 4. Raise and support vehicle. 5. Remove left front tire and wheel assembly. 6. Remove caliper anchor bracket retaining bolts. See Figure 2. Figure 2 Do not let caliper assembly hang from brake hose. 7. Remove caliper and caliper anchor bracket as an assembly. Using wire, secure assembly away from steering knuckle. 8. Remove brake rotor from hub. Place mark on rotor and hub to aid in assembly. 9. Using 1/4 inch drill, drill out rivets securing brake rotor dust shield. 10. Remove brake rotor dust shield. 11. Remove retaining nut, then separate upper part of stabilizer bar link from steering knuckle. 12. Remove cotter pin from tie-rod castle nut. 13. Remove tie-rod castle nut, then separate tie-rod from steering knuckle. 14. Position jack stand under lower control arm. 15. Completely remove lower ball joint stud nut. 16. Reinstall lower ball joint stud nut a maximum of two (2) turns. 17. Remove jack stand supporting lower control arm. 18. Separate ball joint stud from steering knuckle. 19. Position jack stand under lower control arm. 20. Remove lower ball joint stud nut. 21. Using a block of wood for support, position steering knuckle away from lower control arm. See Figure 3.

4 Page 4 of 10 Figure Install Ball Joint Remover D89P-3010-A, Receiving Cup D84P-3395-A4 and U-Joint Tool T74P-4635-C on lower ball joint. See Figure 4. Figure 4 Use only hand tools to press ball joint out of lower control arm. 23. Using installed tools and a breaker bar, press ball joint out of lower control arm. 24. Remove tools and ball joint from lower control arm. 25. Install Ball Joint Replacer T80T-3010-A3, Receiving Cup D84P-3395-A4, U-Joint Tool T74P-4635-C and new ball joint on lower control arm. See Figure 5. Figure 5 Use only hand tools to press ball joint into lower control arm. 26. Using installed tools and a breaker bar, press ball joint into lower control arm. 27. Remove tools from lower control arm. 28. Reposition jack stand toward end of control arm. 29. Position steering knuckle on lower ball joint stud. Raise jack stand as necessary to fully seat steering knuckle on ball joint stud. 30. Install ball joint stud nut. Tighten to Nm ( lb-ft). 31. Remove jack stand supporting lower control arm.

5 Page 5 of Install tie-rod end into steering knuckle. Tighten castle nut to Nm (35-46 lb-ft). Continue to tighten castle nut until slot for cotter pin is aligned. 33. Install new cotter pin in tie-rod castle nut. 34. Install upper part of stabilizer bar link into steering knuckle. Tighten retaining nut to Nm (20-25 lb-ft). 35. Using rivets, install brake rotor dust shield. 36. Install brake rotor on hub. 37. Install caliper and caliper anchor bracket as an assembly. Tighten anchor bracket mounting bolts to Nm ( lb-ft). 38. Route the front wheel ABS sensor wiring into engine compartment. 39. Install left front tire and wheel assembly. 40. Lower vehicle. 41. Connect front wheel ABS sensor electrical connector. 42. Repeat procedure for right side lower ball joint. 43. With engine OFF, pump up brake system. AFFECTED VEHICLES: CERTAIN 1994 MODEL YEAR AND PRIOR CROWN VICTORIA AND TOWN CAR SERVICE PROCEDURE LOWER BALL JOINT REPLACEMENT The following service procedure will replace the left side lower ball joint. Repeat the procedure to replace the right side lower ball joint. 1. Open hood. 2. Disconnect front wheel ABS sensor electrical connector, if applicable. See Figure 1. Figure 1 3. Route front wheel ABS sensor wiring into wheel well, if applicable. 4. Raise and support vehicle. 5. Remove left front tire and wheel assembly. 6. Remove caliper anchor bracket retaining bolts. See Figure 2. Figure 2 Do not let caliper assembly hang from brake hose. 7. Remove caliper and caliper anchor bracket as an assembly. Using wire, secure assembly away from steering knuckle. 8. Remove brake rotor from hub. Place mark on rotor and hub to aid in assembly. 9. Using 1/4 inch drill, drill out rivets securing brake rotor dust shield. 10. Remove brake rotor dust shield. 11. Remove retaining nut and bolt, then separate upper part of stabilizer bar link from steering knuckle. 12. Remove cotter pin from tie-rod castle nut. 13. Remove tie-rod castle nut, then separate tie-rod from steering knuckle. 14. Position jack stand under lower control arm. 15. Remove cotter pin and loosen castle nut one (1) or two (2) turns. 16. Remove jack stand supporting lower control arm.

6 Page 6 of Separate ball joint stud from steering knuckle. 18. Position jack stand under lower control arm. 19. Remove lower ball joint stud castle nut. 20. Using a block of wood for support, position steering knuckle away from lower control arm. See Figure 3. Figure Install Ball Joint Remover D89P-3010-A, Receiving Cup D84P-3395-A4 and U-Joint Tool T74P-4635-C on lower ball joint. See Figure 4. Figure 4 Use only hand tools to press ball joint out of lower control arm. 22. Using installed tools and a breaker bar, press ball joint out of lower control arm. 23. Remove tools and ball joint from lower control arm. 24. Install Ball Joint Replacer T80T-3010-A3, Receiving Cup D84P-3395-A4, U-Joint Tool T74P-4635-C and new ball joint on lower control arm. See Figure 5. Figure 5 Use only hand tools to press ball joint into lower control arm. 25. Using installed tools and a breaker bar, press ball joint into lower control arm.

7 Page 7 of Remove tools from lower control arm. 27. Reposition jack stand toward end of control arm. 28. Position steering knuckle on lower ball joint stud. Raise jack stand as necessary to fully seat steering knuckle on ball joint stud. 29. Install ball joint stud castle nut. Tighten castle nut to Nm ( lb-ft). Continue to tighten castle nut until slot for cotter pin is aligned. 30. Install new cotter pin in lower ball joint castle nut. 31. Remove jack stand supporting lower control arm. 32. Install tie-rod end into steering knuckle. Tighten castle nut to Nm (35-46 lb-ft). Continue to tighten castle nut until slot for cotter pin is aligned. 33. Install new cotter pin in tie-rod castle nut. 34. Install upper part of stabilizer bar link into steering knuckle. Tighten retaining nut to Nm (30-40 lb-ft). 35. Using rivets, install brake rotor dust shield. 36. Install brake rotor on hub. 37. Install caliper and caliper anchor bracket as an assembly. Tighten anchor bracket mounting bolts to Nm ( lb-ft). 38. Route the front wheel ABS sensor wiring into engine compartment, if applicable. 39. Install left front tire and wheel assembly. 40. Lower vehicle. 41. Connect front wheel ABS sensor electrical connector, if applicable. 42. Repeat procedure for right side lower ball joint. 43. With engine OFF, pump up brake system. December, 1998 Serial Number: S37 Mr. John Sample 123 Main Street Anywhere, USA And Forward Vehicles 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 certain 1995 through 1999 Ford Crown Victoria and Lincoln Town Cars. SAFETY DEFECT The front suspension lower control arm ball joint may wear and subsequently separate. If a ball joint should separate partial steering control may be lost potentially resulting in a collision. At no charge to you, your dealer will replace both lower control arm ball joints. HOW LONG WILL IT TAKE? The time needed for this service is less than one-half day. However, due to service scheduling times, your dealer may need your vehicle for a longer period. Please call your dealer for a service date. CALL YOUR DEALER Call your dealer without delay. Ask for a service date and whether parts are in stock for Safety Recall 98S37. 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. At the time of repair, show 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 the front suspension lower control arm ball joints replaced before the date of this letter, Ford is offering a full refund. You will still need to have the ball joint service offered by this recall performed on your vehicle. For the refund, please show 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? Please fill out the enclosed prepaid postcard and mail it to us if you have changed your address or sold the vehicle. If the dealer doesn't make the repair promptly and without charge, you may contact the Ford Customer Assistance Center, Executive Plaza Drive, P.O. Box 6248, Dearborn, 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 product.

8 Page 8 of 10 SAFETY RECALL 98S37 Early 1999 Serial Number: S37 Mr. John Sample 123 Main Street Anywhere, USA And Prior Vehicles 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 certain 1990 through 1994 Ford Crown Victoria and Lincoln Town Cars. SAFETY DEFECT Our records indicate that one or both of the front suspension lower control arm assemblies on the vehicle identified by serial number shown above may have been replaced prior to this notice. The ball joint on these service parts may wear and subsequently separate. If a ball joint should separate partial steering control may be lost potentially resulting in a collision. REPAIRS At no charge to you, your dealer will replace both lower control arm ball joints. HOW LONG WILL IT TAKE? The time needed for this service is less than one-half day. However, due to service scheduling times, your dealer may need your vehicle for a longer period. Please call your dealer for a service date. CALL YOUR DEALER Call your dealer without delay. Ask for a service date and whether parts are in stock for Safety Recall 98S37. 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. At the time of repair, show 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 the front suspension lower control arm ball joints replaced before the date of this letter, Ford is offering a full refund. You will still need to have the ball joint service offered by this recall performed on your vehicle. For the refund, please show 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? Please fill out the enclosed prepaid postcard and mail it to us if you have changed your address or sold the vehicle. If the dealer doesn't make the repair promptly and without charge, you may contact the Ford Customer Assistance Center, Executive Plaza Drive, P.O. Box 6248, Dearborn, 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 product. SAFETY RECALL 98S37 SAFETY RECALL 98S37 Front Suspension Lower Control Arm Ball Joint Replacement - Certain 1993 through 1999 Ford Crown Victoria Police, Fleet, Natural Gas Vehicles (NGV),

9 Page 9 of 10 Supplement #1 - February, 1999 Lincoln Town Car Equipped with Limousine Packages - Clarification of Lower Control Arm replacement as it relates to this recall. February, 1999 To: All Ford and Lincoln-Mercury Dealers Subject: Safety Recall 98S37 Supplement #1 - Front Suspension Lower Control Arm Ball Joint Replacement - Certain 1993 through 1999 Ford Crown Victoria Police, Fleet, Natural Gas Vehicles (NGV), Lincoln Town Car Equipped with Limousine Packages - Clarification of Lower Control Arm replacement as it relates to this recall. VEHICLES AFFECTED BY THIS SUPPLEMENT This supplement applies to only the 1996 through 1998 model years for the vehicles listed in the subject heading above. BACKGROUND Recall 98S37 covers replacement of the lower control arm ball joints. Some dealers have found it necessary to also replace lower control arms on the affected vehicles. The control arms are not covered by Recall 98S37 unless the ball joint caused the control arm to fail. ISSUE Certain control arms in the Ford service parts system do not contain ball joints of the design installed in Recall 98S37. Use of a control arm not containing the recall-level ball joint on a vehicle involved in Recall 98S37 will remove the recall remedy from the vehicle. USE THE CORRECT CONTROL ARM When replacing lower control arms on a vehicle included in Recall 98S37, use only: 1. XW1Z-3078-BA and XW1Z-3079-BA - These control arms have the recall-level ball joints already installed. 2. F8VZ-3078-BA and F8VZ-3079-BA - Can be used for police, limousine, and NGV vehicles only if the metal cap on the bottom of the ball joint is gold in color. If the ball joint "cap" is not gold, it can be used only for non-police, non-limousine, and non-ngv applications. QUESTIONS? Claims Information Other Recall Questions SAFETY RECALL 98S37 Supplement #2 - April, 1999 Announcing the Availability of Parts for 1994 and Prior Affected Vehicles April, 1999 To: All Ford and Lincoln-Mercury Dealers Subject: Safety Recall 98S37 Supplement #2: Announcing the Availability of Parts for 1994 and Prior Affected Vehicles Reference: Front Suspension Lower Control Arm Ball Joint Replacement - Certain 1990 through 1999 Ford Crown Victoria Police, Fleet, Natural Gas Vehicles (NGV), Lincoln Town Car Equipped with Limousine Packages This bulletin announces the availability of parts for 1990 through 1994 vehicles that may have been serviced with the recalled ball joint. Owners of vehicles have already been notified and asked to return their vehicles to a dealership for the service provided by this supplement. The service kits for 1990 to 1994 vehicles are extremely limited, so kit "B" can only be ordered by calling the Recall Hotline at Please refer to the Revised Attachment II which contains the new labor operations and service part information for the vehicles affected by this supplement. Replace the original Attachment II from Safety Recall bulletin 98S37 with the attached Revised Attachment II.

10 Page 10 of 10 QUESTIONS? Claims Information Other Recall Questions Attachments Attachment II Labor Allowances Parts Ordering Information ATTACHMENT II Revised Attachment II - 98S37 - Supplement #2 - Revised April, 1999 LABOR ALLOWANCES Operation Description Labor Allowances Labor Operation Replace Front Suspension Lower Control Arm Ball Joints (both sides) to 1999 Model Years 1.7 Hrs. 98S37B Replace Front Suspension Lower Control Arm Ball Joints (both sides) to 1994 Model Years 1.7 Hrs 98S37C Administrative Allowance 0.1 Hrs Misc. Expense Code "ADMIN" Part Number Description Order Information F8AZ-3050-AA 1995 to 1999 Vehicles Kit A, Front Suspension Lower Control Arm Ball Joint Replacement Order through normal channels XW7Z-3050-BA 1990 to 1994 Vehicles Kit B, Front Suspension Lower Control Arm Ball Joint Replacement Kits can only be ordered by calling the Recall Hotline at (800) DEALER PRICE For latest prices, check or call your: Order Processing Center DOES II Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin CPR 1998 FORD MOTOR COMPANY Published By: Recall/Service Programs Department Ford Customer Service Division