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 Park Mechanism To: All Ford Dealers Reference: Mailgram, same subject, dated October 23, 1991 Subject: 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 Vehicle`s Park Mechanism Reason For Recall WARNING: THE AUTOMATIC TRANSMISSION PARK MECHANISM IN THE VEHICLES SOMETIMES MAY NOT PREVENT THE VEHICLE FROM ROLLING EVEN IF THE TRANSMISSION SHIFT LEVER IS FIRMLY PLACED IN THE "PARK" POSITION. WARNING: IF A DRIVER PARKS THE VEHICLE WITHOUT SETTING THE PARKING BRAKE, IT COULD ROLL FREELY CREATING THE POSSIBILITY OF A CRASH OR PERSONAL INJURY. The automatic transmission park mechanism sometimes may not hold the vehicle in a parked position. Parking on a slope such as a driveway, inclined parking lot or any non-level parking area without firmly setting the parking brake, may result in the vehicle freely rolling down the incline or slope without warning. To correct this condition, dealers are to replace the park pawl spring in the transmission and install a spring on the transmission shift cable on each of the affected vehicles.
Page 2 of 17 Affected Vehicles Certain 1990 Ranger, 1990-91 Aerostar and 1991 Explorer trucks equipped with A4LD automatic transmissions. Specific vehicle information is as follows: AFFECTED VEHICLES ASSEMBLY PLANT VEHICLE PRODUCTION DATES 1990 Ranger * Louisville Twin Cities 8/14/89 to 8/24/90 1990-1991 Aerostar(*) St. Louis 8/21/89 to 8/09/91 1991 Explorer Louisville 2/05/90 to 7/26/91 * Some 1989 model year transmissions were installed in the early built 1990 Rangers and 1990 Aerostars. These vehicles DO NOT require the modification. The park pawl spring in the kit will not fit the 1989 model year park pawl and is not needed. Please check the transmission identification tag to determine the transmission model year. Attachments Attachment I Administrative Information Attachment II Labor Allowances Parts Ordering Information Attachment III Technical Information ATTACHMENT I Safety Recall 91S41 OASIS You must use OASIS to determine if a vehicle is eleigible for this recall. Please Note
Page 3 of 17 Correct all vehicles in stock before delivery. 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. District Contact Advise district office if: an owner cannot be contacted. an owner does not make a service date. FPSD Contact Talk with your FPSD 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. ATTACHMENT II Safety Recall 91S41 Labor Allowances OPERATION DESCRIPTION Inspect 1990 Ranger and 1990 Aerostar Transmission Identification Tag For Transmission Model Year LABOR TIME LABOR CODE 0.2 Hrs. Insert in Box "A" on Replace park pawl spring and install a spring on transmission shift cable. (Includes Inspection) Aerostar (2WD) 1.6 Hrs. Insert in Box "B" on Aerostar (AWD) 2.4 Hrs. Insert in Box "C" on Ranger/Explorer (4X2) 1.6 Hrs. Insert in Box "B" on
Page 4 of 17 Ranger/Explorer (4X4) 2.6 Hrs. Insert in Box "C" on Administrative Allowance 0.1 Hrs. NOTE: Add 0.1 hour Administrative Allowance to the total repair time. Special Parts Ordering Instructions Parts will be available for dealer ordering on the dates shown below. Back orders will be cancelled if parts are ordered before availability dates. After these dates, parts will be shipped as orders are received. VEHICLES Parts Requirements PART NUMBER ORDER DATE Ranger/Explorer 4x4 Only F1TZ-7331-B Feb. 21, 1992 Ranger/Explorer 4x2 Only F1TZ-7331-A March 6, 1992 Aerostar 4x2 Only F1TZ-7331-C March 20, 1992 Aerostar 4x4 Only F1TZ-7331-D March 27, 1992 Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. PART NUMBER VEHICLE DESCRIPTION QUANTITY CLASS DEALER PRICE F1TZ-7331-A (Ranger/Explorer 4X2) Kit-Park Pawl 1 AG $1.52 F1TZ-7331-B (Ranger/Explorer 4X4) Kit-Park Pawl 1 AG $2.14 F1TZ-7331-C (Aerostar 2WD) Kit-Park Pawl 1 AG $2.01 F1TZ-7331-D (Aerostar AWD) Kit-Park Pawl 1 AG $3.56 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 Safety Recall 91S41 Inspection Park Mechanism Modifications Technical Instructions
Page 5 of 17 On 1990 Ranger and 1990 Aerostars, raise the vehicle on a hoist and check the model year of the transmission on the identification tag. Modify only those transmissions built in 1990. If the transmission model is 90GT-XXX, perform the recall following the procedures described below. If the transmission model is 89GT-XXX, the vehicle does NOT require modification, release the vehicle. Park Pawl Spring Replacement Aerostar, Ranger And Explorer (4X2) 1. Raise the vehicle on a hoist. 2. Remove the driveshaft. Make scribe marks on driveshaft end yoke and rear axle companion flange to assure proper positioning of driveshaft during assembly. 3. Support transmission with a transmission jack. 4. Remove speedometer cable from extension housing. 5. Remove rear support-to-crossmember attaching bolts and nuts. 6. Raise transmission slightly and remove rear support from extension housing. 7. Remove transmission shift cable bracket. 8. Loosen extension housing bolts and allow the transmission fluid to drain. 9. Remove bolts and extension housing. 10. Remove the parking pawl and return spring. See Figure 1. Discard the spring. Figure 1 - Park Mechanism Modification 11. Install original park pawl and new return spring (from kit) in the extension housing and preload. 12. Using a new gasket, position extension housing on the case, making sure to correctly seat the park pawl actuating rod in the guide cup bore in the extension. 13. Install six extension housing retaining bolts. Tighten to 37-52 N-m (27-38 ft-lbs). 14. Install rear support and lower transmission. 15. Install attaching bolts. Torque to 20-30 ft-lbs. Remove the transmission jack. 16. Install transmission shift cable bracket. 17. Install the speedometer cable. Refer to Section 13-02 of the appropriate shop manual for the procedures. 18. Install driveshaft using scribe marks as a guide to assure correct balance. Refer to Section 05-00 of the appropriate shop manual for the procedures. 19. Lower vehicle and fill transmission with fluid, adding as required while running engine. 20. Check extension housing area for fluid leaks. Aerostar (AWD), Ranger And Explorer (4X4)
Page 6 of 17 1. Raise the vehicle on a hoist. 2. If so equipped, remove the nuts, bolts and skid plate from the frame. 3. Remove the damper from the transfer case, if necessary. 4. On vehicles equipped with a electronic shift transfer case, remove the wire connector from the feed wire harness at the rear of the transfer case. First squeeze the locking tabs, then pull the connector apart. CAUTION Do not pull directly on the wires or pull outwardly on the locking tabs. 5. On vehicles equipped with a electronic shift transfer case, remove the connector for the transfer case motor from the mounting bracket. 6. On vehicles equipped with a manual shift transfer case, disconnect the shift linkage as described in Section 07-06 of the appropriate shop manual. NOTE: For detailed instructions on front and rear driveshaft removal and installation, refer to Section 05-01, Driveshaft. 7. On Ranger and Explorer vehicles, disconnect the front driveshaft from the transfer case front output shaft yoke and wire the driveshaft out of the way. On Aerostar vehicles, remove the band clamp from the front driveshaft slip yoke and pull the boot away from the transfer case so the transfer case can be removed with the driveshaft still connected to the front drive axle. 8. On Ranger and Explorer vehicles, disconnect the rear driveshaft from the transfer case rear output shaft flange and wire the driveshaft out of the way. On Aerostar vehicles, remove the rear driveshaft. 9. Disconnect the speedometer driven gear from the transfer case rear cover. 10. On Aerostar vehicles, remove the transfer case strut which is connected to the engine block and transfer case. 11. On Ranger and Explorer vehicles, disconnect the vent hose from the mounting bracket. CAUTION The catalytic converter is located beside the transfer case. Be careful when working around the catalytic converter because of the high temperatures generated by the converter. 12. Support the transfer case with a suitable transmission jack, Rotunda Number 077-00019 or equivalent. 13. Remove the five bolts retaining the transfer case to the transmission extension housing. 14. Slide the transfer case rearward off the transmission output shaft. Remove the transfer case from the vehicle. Remove and discard the gasket between the transfer case and extension housing. 15. Support the transmission with a transmission jack. 16. Remove rear support-to-crossmember attaching bolts or nuts. 17. Raise transmission slightly and remove rear support from extension housing. 18. On Ranger and Explorer vehicles, remove transmission shift cable bracket. 19. Loosen extension housing bolts and allow the transmission fluid to drain. 20. Remove the bolts and the extension housing. 21. Remove the parking pawl and return spring. See Figure 1. Discard the spring. 22. Install original park pawl and new return spring (from kit) in the extension housing and preload. 23. Using a new gasket from the kit, position the extension housing on the case, making sure to correctly seat the park pawl actuating rod in the guide cup bore in the extension.
Page 7 of 17 24. Install six extension housing retaining bolts. Tighten to 37-52 N-m (27-38 ft-lbs). 25. On Ranger and Explorer vehicles, install transmission shift cable bracket. 26. Install rear support and lower transmission. 27. Install attaching bolts. Torque to 20-30 ft-lbs. Remove the transmission jack. 28. Place a new gasket (from kit) on the front mounting face of the transfer case assembly. If necessary, apply a small amount of grease to the gasket to hold it in place during assembly. 29. On Aerostar vehicles, clean the splines of the front output shaft. Apply 5-8 grams of Long-Life Lubricant, C1AZ-19590-BA (ESA-M1C75-B) or equivalent to the splines. 30. Raise the transfer case with the transmission jack so that the transmission output shaft aligns with the splined transfer case input shaft. On Aerostar vehicles, be sure to align the front driveshaft to the transfer case front output shaft. Slide the transfer case forward onto the transmission and dowel pin. Install the five transfer case retaining bolts to the extension housing. Tighten the bolts to 34-48 N-m (23-35 ft-lbs). Refer to Section 07-07 of the appropriate shop manual for the bolt torque sequence. 31. Remove the transmission jack from the transfer case. 32. On Ranger and Explorer vehicles, install the vent hose. Make sure the white marking on the hose aligns with the notch in the mounting bracket. 33. Connect the speedometer driven gear to the transfer case rear cover. Tighten the screw to 2.3-2.8 N- m (20-25 in-lb). 34. On Ranger and Explorer vehicles, connect the rear driveshaft to the transfer case output shaft flange. Tighten the bolts to 83-118 N-m (61-87 ft-lb). On Aerostar vehicles, install the rear driveshaft and tighten the bolts to 83-118 N-m (61-87 ft-lb). 35. On Aerostar vehicles, install the boot on the driveshaft. Be sure to use the new dust boot-to-transfer case clamp (from kit). Refer to Section 05-01 of the appropriate shop manual for the procedures. 36. On vehicles equipped with a electronic shift transfer case, attach the connector for the transfer case motor to the mounting bracket. 37. On vehicles equipped with a manual shift transfer case, reconnect the shift linkage as described in Section 07-06 of the appropriate shop manual. 38. On vehicles equipped with a electronic shift transfer case, connect the electrical connectors to the rear of the transfer case. Make sure the tabs on the connectors are in the locked position. 39. Remove the transfer case fill plug and check the fluid level. Add Motorcraft Mercon XT-2-QDX or DDX Automatic Transmission fluid E4AZ-19582-B (ESP-M2C-166-H) or equivalent to the bottom of the fill hole, if required. 40. On Ranger and Explorer vehicles, install the damper, (if previously removed). Tighten the bolts to 34-48 N-m (25-35 ft-lb). 41. On Aerostar vehicles, install the transfer case strut. Tighten the bolt at the engine block end of the strut to 61-81 N-m (45-60 ft-lb) and the nut at the transfer case end to 75-88 N-m (55-65 ft-lb). 42. Install the skid plate, if so equipped. Tighten the bolts and nuts to 20-27 N-m (15-20 ft-lb). 43. Lower the vehicle. 44. Check transmission fluid level. Add fluid as required. Shift Cable Spring Installation The shift cable is to be modified by the addition of a spring to remove cable free-play from the adjustment procedure. Aerostar (4X2 And AWD) 1. From inside the vehicle, place the console shift selector lever into the (OVERDRIVE) position. 2. From below the vehicle, remove the shift cable end fitting from the transmission manual control lever ball stud. See Figure 2.
Page 8 of 17 Figure 2 - Park Mechanism Modifications Aerostar 3. Remove the shift cable adjusting screw securing the transmission shift control cable (slotted end) to the black nylon end fitting. Discard the screw. 4. Thoroughly clean the black nylon end fitting of all dirt and debris. If the nylon end fitting is broken or the nut stripped, replace it with service part F29Z-7329-A. 5. Remove the shift cable spring and adjusting screw from the kit. Insert the spring into the black nylon end fitting cavity with the two spring hooks facing up. See Figure 2. Slide the slotted shift cable end on top of the spring. Be sure the two spring hooks are positioned over the slotted cable end. Install the new adjusting screw. Tighten the screw just enough for the shift cable spring to move back and forth. Do not fully tighten the screw at this time. 6. Connect the shift cable end fitting to the transmission manual control lever ball stud. Apply thumb
Page 9 of 17 pressure on the shift cable spring to keep the spring seated in the nylon end fitting cavity. 7. With the shift cable end fitting installed on the manual control lever ball stud, release the pressure from the shift cable spring to allow the spring to self-adjust the cable. Tighten the adjustment screw to 5-7 N-m (42-62 in-lb). 8. Check the transmission console shift selector lever in all detent positions with the engine running to ensure correct detent/transmission action. 9. In the event that the detent and transmission action do not correspond, readjust the system as follows: From inside the vehicle, place the console shift selector lever in the (OVERDRIVE) position. Disconnect the shift cable from the transmission manual control lever at the transmission. Position the transmission manual control lever in the overdrive position by moving the lever all the way rearward (counterclockwise) and then moving it three detents forward (clockwise). Loosen the shift cable adjusting screw and repeat steps 6, 7 and 8. Ranger And Explorer (4X2 And 4X4) 1. From below the vehicle, use a screwdriver and pry the shift cable end fitting from the transmission manual control lever ball stud. See Figure 3.
Page 10 of 17 Figure 3 - Park Mechanism Modifications Ranger / Explorer 2. Pull down the lock tab to unlock the adjuster body. 3. Slide the adjuster spring from the kit over the shift cable end fitting (large end first) and push it up to the spacer cap. 4. Work the adjuster spring coils over the spacer cap until the spring is in place between the spacer cap and the adjuster body. See Figure 3. 5. Move the shift cable back and forth the full adjustment length four or five times to remove any dirt. Be sure the adjuster body moves freely. 6. From inside the vehicle, place the column shift selector lever in the (OVERDRIVE) position. Hang a 3 pound weight on the selector lever. 7. From below the vehicle, position the transmission manual control lever in the (OVERDRIVE) position by moving the lever all the way rearward (counterclockwise) and then moving three detents forward (clockwise). 8. Holding the cable end fitting, push the cable rearward until the end fitting lines up with the manual
Page 11 of 17 control lever ball stud. Connect the cable end fitting to the ball stud. 9. Push up on the lock tab to lock the adjuster body in the correctly adjusted position. Be sure locator tab is properly seated in the bracket. 10. Remove the 3 pound weight from the column shift selector. 11. After adjustment, check for P (PARK) engagement. Check the transmission control lever in all detent positions with the engine running to ensure correct detent/transmisssion action. Readjust if required. Date here Serial Number: 12345678901234567 91S41 Mr. John Sample 123 Main Street Anywhere, USA 12345 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 some 1990 Rangers, 1990 and 1991 Aerostars and 1991 Explorers equipped with an automatic transmission. A letter notifying you of this safety recall was mailed to you in October 1991. At that time, service parts and repair instructions were not available to the dealer. The purpose of this letter is to advise you that dealers now have repair instructions and parts to perform the recall service on your vehicle. Safety Defect The automatic transmission park mechanism sometimes may not hold your vehicle in a parked position. Parking on a slope such as a driveway, inclined parking lot or any non-level parking area without firmly setting the parking brake, may result in your vehicle freely rolling down the incline or slope without warning. WARNING: THE AUTOMATIC TRANSMISSION PARK MECHANISM SOMETIMES MAY NOT PREVENT YOUR VEHICLE FROM FREELY ROLLING EVEN IF THE TRANSMISSION SHIFT LEVER IS FIRMLY PLACED IN THE "PARK" POSITION. WARNING: IF YOU PARK YOUR VEHICLE WITHOUT SETTING THE PARKING BRAKE, IT COULD ROLL FREELY CREATING THE POSSIBILITY OF A CRASH OR PERSONAL INJURY.
Page 12 of 17 Repairs At no cost to you, your dealer will inspect your vehicle and, if necessary, replace the park pawl spring in the transmission and install a spring on the transmission shift cable. How Long Will It Take? The time needed to repair your vehicle is less than 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. 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 in approximately one week When you bring your vehicle 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 Vehicle? If you have, please fill out enclosed prepaid postcard and mail it to us. If the dealer doesn't make the repair promptly and without charge, you may contact the Ford Customer Assistance Center, 300 Renaissance Center, P.O. Box 43360, Detroit, MI., 48234. You also may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, SW, Washington, DC 20590 or call the toll free Auto Safety Hotline 1-800-424-9393 (Washington DC area residents may call 366-0123). 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 vehicle. SAFETY RECALL 91S41 SAFETY RECALL Identifies Additional Vehicles Involved
Page 13 of 17 91S41 Supplement - May, 1992 To: All Ford Dealers Reference: Safety Recall Bulletin 91S41, dated February 21, 1992 Subject: Safety Recall 91S41 Supplement #1 - Additional Units Please provide copies of this bulletin to the Parts Manager and to the Service Manager. The purpose of this bulletin is to advise you that some additional trucks have been added to the population of the referenced recall. According to our records, the additional involved vehicle (s) shown on the enclosed listing have been delivered to your dealership. Notification Of Owners Vehicle owners whose names and addresses are shown on the enclosed listing are being notified by First Class Mail. If the owner of any vehicle cannot be contacted or does not make an appointment to have his vehicle corrected, advise your FPSD District Office of the owner's name and address so that we can handle further notification. Affected Vehicles All 1990 Bronco II and 1991 Rangers with standard A4LD transmissions. Certain 1989 Aerostars built from July 21, 1989 through end of 1989 model year with 1990 model Western Region (California, Oregon, Washington, Alaska and Hawaii) A4LD transmissions. NOTE: Approximately 2,300 1990 model year transmissions were installed in late built 1989 Aerostars. For 1989 Aerostar vehicles, dealers need to check the model year of the transmission on the identification tag. If the transmission model is 90GT-XXX, perform the recall.
Page 14 of 17 If the transmission model is 89GT-XXX, the vehicle does NOT require the modification. Two copies of a listing identifying affected dealers and involved vehicles in your district are enclosed with this mailing. Please inform district personnel of these additional units in the recall. If you have any questions, call the FPSD Safety Recall Office. Attachments Attachment I Labor Allowances Parts Requirements ATTACHMENT I Emissions Recall 91S41 Supplement 1 Labor Allowances OPERATION DESCRIPTION Inspect 1989 Aerostar Transmission Identification Tag For Transmission Model Year LABOR TIME LABOR CODE 0.2 Hrs. Insert in Box "A" on Replace park pawl spring and install a spring on transmission shift cable. (Includes Inspect Above) 1989 Aerostar (2WD) 1.6 Hrs. Insert in Box "B" on 1991 Ranger (4X2) 1.6 Hrs. Insert in Box "B" on 1991 Ranger (4X4) 2.6 Hrs. Insert in Box "B" on 1990 Bronco II (4X2) 1.9 Hrs. Insert in Box "B" on
Page 15 of 17 1990 Bronco II (4X4) 2.9 Hrs. Insert in Box "B" on Administrative Allowance 0.1 Hrs. NOTE: Add 0.1 hour Administrative Allowance to the total repair time. Parts Requirements PART NUMBER F1TZ-7331-A 1990 Bronco II (4X2) and 1991 Ranger (4X2) F1TZ-7331-B 1991 Ranger (4X4) and 1990 Bronco II (4X4) DESCRIPTION KIT CODE QUANTITY CLASS DEALER PRICE Kit-Park Pawl GG 1 AG $1.52 Kit-Park Pawl HH 1 AG $2.14 F1TZ-7331-C 1989 Aerostar (2WD) Kit-Park Pawl AA 1 AG $2.01 June, 1992 Serial Number: 12345678901234567 91S41 Mr. John Sample 123 Main Street Anywhere, USA 12345 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 certain 1990 Bronco II, 1991 Rangers and 1989 Aerostars equipped with an automatic transmission. Safety Defect The automatic transmission park mechanism sometimes may not hold your vehicle in a parked position. Parking on a slope such as a driveway, inclined parking lot or any non-level parking area without firmly setting the parking brake, may result in your vehicle freely rolling down the
Page 16 of 17 incline or slope without warning. WARNING: THE AUTOMATIC TRANSMISSION PARK MECHANISM SOMETIMES MAY NOT PREVENT YOUR VEHICLE FROM FREELY ROLLING EVEN IF THE TRANSMISSION SHIFT LEVER IS FIRMLY PLACED IN THE "PARK" POSITION. WARNING: IF YOU PARK YOUR VEHICLE WITHOUT SETTING THE PARKING BRAKE, IT COULD ROLL FREELY CREATING THE POSSIBILITY OF A CRASH OR PERSONAL INJURY. Repairs At no cost to you, your dealer will inspect your vehicle and, if necessary, replace the park pawl spring in the transmission and install a spring on the transmission shift cable. How Long Will It Take? The time needed to repair your vehicle is less than 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. 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 in approximately one week. When you bring your vehicle 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 Vehicle? If you have, please fill out enclosed prepaid postcard and mail it to us. If the dealer doesn't make the repair promptly and without charge, you may contact the Ford Customer Assistance Center, 300 Renaissance Center, P.O. Box 43360, Detroit, Mi., 48234. You also may send a complaint to the Administrator, National Highway traffic Safety Administration, 400 Seventh Street, SW, Washington, DC 20590 or call the toll free Auto Safety Hotline 1-800-424-9393 (Washington DC area residents may call 366-0123). 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 vehicle.
Page 17 of 17 SAFETY RECALL 91S41 CPR 1992 FORD MOTOR COMPANY Published By: Recall/Service Programs Department Ford Customer Service Division