Recall - Fuel Cross-Flow Extended Coverage 01M05 OWNER NOTIFICATION PROGRAM

Technical Service Bulletin # 01M05 Recall - Fuel Cross-Flow Extended Coverage 01M05 OWNER NOTIFICATION PROGRAM All 1990, 1991, 1992 and 1993 Model Year F-Series Vehicles equipped with Dual Fuel Tanks and 4.9, 5.0, 5.8 or 7.5 Liter Engine Fuel Cross-Flow Extended Coverage Page 1 Date: 010601

Page 2 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: When a claim is submitted under an "M" program the VIN number will remain in OASIS until the terms of the program expire. CLAIMS PREPARATION AND SUBMISSION Enter claims using DWE. Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund the cost of repairs for the fuel cross-flow condition 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). Refunds only apply to repairs made to correct a fuel cross-flow condition. All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII Manual for Refund information. Enter claims using DWE: Program Code: 01M05 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. RENTAL VEHICLES Rental vehicles are not approved for this program. Attachment II - Labor and Parts Information

Page 3 Labor Allowances Parts Requirements Parts Ordering Information Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels as noted. Dealers will need to call 1-800-325-5621 for emergency orders for 60 days after campaign launch. NOTE: ONLY A VERY SMALL PERCENTAGE OF VEHICLES WILL NEED THIS REPAIR BECAUSE IT IS ONLY FOR VEHICLES THAT HAVE HAD THE ORIGINAL RECALL (93S68 OR 00S57) COMPLETED AND HAVE HAD A SUBSEQUENT CROSS FLOW CONDITION. The part is used only for 90-91 vehicles requiring repairs. See Attachment III. (Owner Letters for this vehicle population will be mailed sometime in late July 2001).

Page 4 FOR CHASSIS CAB vehicles with 137" WB or 161" WB, ALSO ORDER THE PART BELOW. (only one check valve must be installed on the forward/mid-ship tank; the check valve will not fit on the rear tank) Dealers MUST install a fuel delivery module on the rear tank. DOR/COR NUMBER DOR/COR for this program is 50243. This number identifies parts ordered for this campaign through the Special Service Support Center (1-800-325-5621). DEALER PRICE For latest prices, check or call your: 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. Attachment III - Technical Information FUEL CROSS FLOW WARRANTY EXTENSION AFFECTED VEHICLES: ALL 1990, 1991, 1992 AND 1993 MODEL YEAR F-SERIES VEHICLES EQUIPPED WITH 4.9, 5.0, 5.8 OR 7.5 LITER ENGINES AND DUAL FUEL TANKS TABLE OF CONTENTS

Page 5 FLOWCHART SERVICE PROCEDURE FUEL PRESSURE REGULATOR REPLACEMENT EXTERNAL CHECK VALVE INSTALLATION AND RETURN LINE INSPECTION - REAR TANK (NON-CHASSIS CAB VEHICLES) EXTERNAL CHECK VALVE INSTALLATION AND RETURN LINE INSPECTION - FRONT TANK (ALL VEHICLES) FUEL DELIVERY MODULE REPLACEMENT AND RETURN LINE INSPECTION - REAR TANK (CHASSIS CAB VEHICLES) NOTE: Check OASIS to see if either Safety Recall 00S57 or 93S68 is open. If either recall is open, do not continue with this procedure. Instead, perform the appropriate safety recall and return vehicle to the owner. SERVICE PROCEDURE 1. Attach an EFI/CFI fuel pressure gauge to the Schrader valve on the engine fuel rail.

2. Page 6 WARNING: FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE, EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Start the engine and record the fuel pressure reading. Turn the ignition key to the OFF position. Then relieve the fuel system pressure by slowly opening the manual valve on the fuel pressure gauge. Remove the gauge from the fuel rail. ALL EXCEPT CHASSIS CAB 6-CYLINDER ENGINES If the fuel pressure is 55 PSI or less, perform all of the following: External Check Valve Installation And Return Line Inspection - Rear Tank. If the fuel pressure exceeds 55 PSI, perform all of the following: Fuel Pressure Regulator Replacement. External Check Valve Installation And Return Line Inspection - Rear Tank. 8-CYLINDER ENGINES If the fuel pressure is 39 PSI or less, perform all of the following: External Check Valve Installation And Return Line Inspection - Rear Tank. If the fuel pressure exceeds 39 PSI, perform all of the following: Fuel Pressure Regulator Replacement. External Check Valve Installation And Return Line Inspection - Rear Tank. CHASSIS CAB 6-CYLINDER ENGINES If the fuel pressure is 55 PSI or less, perform all of the following: Fuel Delivery Module Installation And Return Line Inspection - Rear Tank. If the fuel pressure exceeds 55 PSI, perform all of the following: Fuel Pressure Regulator Replacement. Fuel Delivery Module Installation And Return Line Inspection - Rear Tank. External Check Valve Installation And Return Line Inspection - Front Tank. 8-CYLINDER ENGINES If the fuel pressure is 39 PSI or less, perform all of the following: Fuel Delivery Module Installation And Return Line Inspection - Rear Tank.

If the fuel pressure exceeds 39 PSI, perform all of the following: Fuel Pressure Regulator Replacement. Fuel Delivery Module Installation And Return Line Inspection - Rear Tank. Page 7 FUEL PRESSURE REGULATOR REPLACEMENT NOTE: Perform only if fuel pressure exceeds levels specified earlier in this procedure. 1. Install a memory saver, then disconnect the battery negative cable. 2. Disconnect the vacuum line from the fuel pressure regulator, which is located on the fuel rail. 3. Remove the retaining screws from the fuel pressure regulator. 4. Remove and discard the fuel pressure regulator, gasket and 0-ring seal from the fuel rail manifold. 5. Lubricate the new fuel pressure regulator 0-ring with light oil (10W30 oil WSE-M2C903-A2 or equivalent). Install the new o-ring and the new gasket on the new regulator. 6. Position the new fuel pressure regulator with 0-ring and gasket onto the fuel rail and install the retaining screws. Tighten the screws to 4 Nm (35 lb-in). 7. Connect the vacuum line to the new fuel pressure regulator. EXTERNAL CHECK VALVE INSTALLATION AND RETURN LINE INSPECTION - REAR TANK (NON-CHASSIS CAB VEHICLES) 1. Install a memory saver, then disconnect the battery negative cable. 2. Drain the rear fuel tank, using Rotunda Fuel Storage Tanker 034-00002, 034-00014 or equivalent. 3. Raise the vehicle on a hoist. 4. Position the spare tire out of the way. 5. Loosen the hose clamp at the fuel filler hose connection to the rear fuel tank. 6. Position a safety stand under the rear fuel tank. 7. Remove the fuel tank support straps. 8. Access the fuel delivery module (FDM) at the top of the tank by lowering the tank while guiding the fuel filler hose from the tank. 9. NOTE: For vehicles equipped with stainless steel braided flex lines, proceed to the next step. Inspect the nylon fuel return lines for kinking. 10. 11. If the nylon fuel return line is not kinked or the vehicle is equipped with stainless steel braided flex lines, proceed to the next step. If the nylon return line is kinked, repair the line as necessary using Rotunda Tool 134-000001 (Plastic Fuel Line Fitting Connector Tool), before continuing this procedure. NOTE: Remove and discard the black hairpin clip on 1990 and 1991 model year vehicles. A new clip will be used when reconnecting the fuel supply line. Disconnect the fuel supply line at the FDM. See Figure 1. If equipped, remove and discard the old external check valve.

Page 8 12. Install the external check valve to the supply tube of the FDM. Install the fuel line clip onto the external check valve. See Figure 1. 13. Connect the fuel supply line to the external check valve. Install a new black hairpin clip on 1990 and 1991 model year vehicles. See Figure 1. 14. Raise the rear fuel tank back into position while guiding the fuel filler hose onto the fuel tank. 15. Install the fuel tank straps. Tighten bolts to 38 Nm (28 lb-ft). 16. Tighten the fuel filler hose clamp to 4 Nm (35 lb-in). 17. Remove the safety stand. 18. Reposition the spare tire. 19. Lower the vehicle. EXTERNAL CHECK VALVE INSTALLATION AND RETURN LINE INSPECTION - FRONT TANK (ALL VEHICLES) 1. Drain the front fuel tank, using Rotunda Fuel Storage Tanker 034-00002, 034-00014 or equivalent. 2. Raise the vehicle on a hoist. 3. Remove the skid plate if equipped. 4. Loosen the hose clamp at the fuel filler hose connection to the front tank. 5. Position a safety stand under the fuel tank.

Page 9 6. Remove the fuel tank support strap bolts. 7. Access the FDM at the top of the tank by lowering the tank while guiding the fuel filler hose from the tank. 8. NOTE: For vehicles equipped with stainless steel braided flex lines, proceed to the next step. Inspect the nylon fuel return line for kinking. 9. If the nylon fuel return line is not kinked or the vehicle is equipped with stainless steel braided flex lines, proceed to the next step. If the nylon return line is kinked, repair the line as necessary using Rotunda Tool 134-000001 (Plastic Fuel Line Fitting Connector Tool), before continuing this procedure. NOTE: Remove and discard the black hairpin clip on 1990 and 1991 model year vehicles. A new clip will be used when reconnecting the fuel supply line. Disconnect the fuel supply line at the fuel delivery module. See Figure 2. 10. If equipped, remove and discard the old external check valve. 11. Install the external check valve to the supply tube of the fuel delivery module. Install the fuel line clip onto the external check valve. See Figure 2. 12. Connect the fuel supply line to the external check valve. Install a new black hairpin clip on 1990 and 1991 model year vehicles. 13. Reinstall the skid plate if removed. 14. Lower the vehicle. 15. Fill the fuel tanks.

Page 10 16. Connect the battery negative cable, then remove the memory saver. 17. Without starting the engine, turn the ignition key on and off several times to pressurize the fuel system and check for leaks. FUEL DELIVERY MODULE REPLACEMENT AND RETURN LINE INSPECTION - REAR TANK (CHASSIS CAB VEHICLES) 1. Install a memory saver, then disconnect the battery negative cable. 2. Drain the rear fuel tank, using Rotunda Fuel Storage Tanker 034-00002, 034-00014 or equivalent. 3. Raise the vehicle on a hoist. 4. Position the spare tire out of the way. 5. Loosen the hose clamp at the fuel filler hose connection to the rear fuel tank. 6. Position a safety stand under the rear fuel tank. 7. Remove the fuel tank support skid plate bolts. 8. Access the fuel delivery module (FDM) at the top of the tank by lowering the tank while guiding the fuel filler hose from the tank. 9. NOTE: Remove and discard the black hairpin clip. A new clip will be used when reconnecting the fuel supply line. Disconnect the fuel supply line, fuel return line and the electrical connector (not shown) from the FDM See Figure 3. 10. Disconnect the vapor line from the fuel tank. See Figure 3. 11. Lower the fuel tank while guiding the fuel filler hose out of the tank. 12. NOTE: For vehicles equipped with stainless steel braided flex lines, proceed to the next step. Inspect the nylon fuel return line for kinking. If the nylon fuel return line is not kinked or the vehicle is equipped with stainless steel braided flex lines, proceed to the next step. If the nylon return line is kinked, repair the line as necessary, using Rotunda Tool 134-000001 (Plastic Fuel Line Fitting Connector Tool) before continuing this procedure. 13. Clean any dirt from the top of the tank around the FDM. 14. Remove the locking ring from the FDM. 15. Remove the FDM, then remove and discard the gasket. 16. Clean the FDM mounting flange on the fuel tank, then install a new gasket onto the flange.

Page 11 17. Install the new FDM, then install the locking ring. Tighten the locking ring to 62 Nm (46 lb-ft). 18. Raise the tank up into the vehicle, leaving enough mom to make the connections on the top of the tank. 19. Connect the vapor line to the fuel tank. 20. Connect the fuel supply, fuel return and electrical connector to the FDM. Install a new black hairpin clip on the fuel supply line connection. 21. Raise the rear fuel tank into position while guiding the fuel filler hose into the tank. 22. Install the fuel tank support skid plate bolts. Tighten bolts 44 Nm (32 lb-ft). 23. Tighten the fuel filler hose clamp to 4 Nm (35 lb-in). 24. Remove the safety stand. 25. Reposition the spare tire. 26. Lower the vehicle.

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