1996 FORD F SUPER DUTY Recalls (2)

Campaign:
96V146000 on 08/07/1996
Component:
Structure:frame and members
Manufactured:
02/07/1996 - 02/08/1996
Affected:
200
Defect:
The crossmember frame gussets were installed with undersized threaded fasteners following a breakdown of the production rivet gun that is generally used. this gusset is the attachment point for the rear strap of the mid-ship fuel tank.
Consequence:
The subject fasteners can separate causing in the rear strap of the affected fuel tank to become disconnected. a loose or disconnected rear strap allows the fuel tank to possibly contact the road surface increasing the risk of a vehicle fire.
Correction:
Dealers will replace the crossmember gusset fasteners with the specified alternative fasteners (bolts).
Notes:
Owner notification: owner notification is expected to begin august 26, 1996. note:owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact ford at 1-800-392-3673.also contact the national highway traffic safety administration's auto safety hotline at 1-800-424-9393.
Campaign:
97V209000 on 11/19/1997
Component:
Engine and engine cooling:exhaust system:emission control:gas recirculation valve (egr valve)
Manufactured:
02/28/1993 - 10/27/1997
Affected:
64,000
Defect:
Vehicle description: motor home chassis. hot exhaust gasses can leak from the exhaust gas return (egr) tube on the engine. a hole can develop in the flexible section of the tube. heat damage to the passenger compartment floor and floor covering can occur.
Consequence:
Depending on the materials used in the construction of the completed vehicle, ignition of these materials could occur resulting in a vehicle fire.
Correction:
Dealers will replace the egr tube.
Notes:
Owner notification began january 19, 1998. owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact ford motorhome customer service at 1-800-444-3311.also contact the national highway traffic safety administration's auto safety hotline at 1-800-424-9393.

1996 FORD F SUPER DUTY TSBs (104)

Bulletin:
95212
Component:
036000 service brakes, hydraulic:antilock
Summary:
the use of petroleum-based grease as a lubricant in servicing disc brakes is no longer acceptable because it may be incompatible with the rubber material used in the disc brake system. if petroleum-based grease is used to lubricate any par
Bulletin:
BC0693961023
Component:
185000 vehicle speed control:cruise control
Summary:
Investigating 7.3l irregular idle. *tt
Bulletin:
BC0821961010
Component:
100000 power train
Summary:
Concerns w/ the speedometer/odometer indication plus transmission shift concerns due to failure of the speedometer drive gear (e8tz-2n598-a) located within the transmission mounted parking brake assy. *tt
Bulletin:
BC0844961008
Component:
102000 power train:manual transmission
Summary:
E4od trans may emit a tick/rattle noise when driving at light loads in 1st gear at 1100 to 1800 rpm rpm. *tt
Bulletin:
BC5166961001
Component:
100000 power train
Summary:
Concerns w/ the speedometer/odometer indication plus trans shift concerns due to a failure of the speedometer drive gear (e8tz-2n598-a) located within the trans mounted parking brake assy. *tt
Bulletin:
BC5191961001
Component:
103000 power train:automatic transmission
Summary:
For concerns of stalling, reflash pcm w/ 1996 calibration (r11 level). *tt
Bulletin:
BC5195961001
Component:
190000 tires
Summary:
Firestone p235 tires may exhibit a high frequency vibration at 65-75 mph. *tt
Bulletin:
BC9688961001
Component:
353000 equipment:electrical
Summary:
Information for when diagnosing concerns w/ factory installed cellular phones. *tt
Bulletin:
BC0001196110
Component:
011000 steering:wheel and handle bar
Summary:
A 'clunk' noise may be heard/felt through the steering column when maneuvering in parking lots, driving in stop and go traffic or driving over bumps. *tw
Bulletin:
96249
Component:
103700 power train:automatic transmission:torque converter
Summary:
Torque converter - leak test procedure - service tip. *tw
Bulletin:
962413
Component:
022000 suspension:rear
Summary:
Suspension - front or rear - side-toside leveling procedures and attitude service kits for f53 rv basic stripped chassis. *tw
Bulletin:
962418
Component:
103000 power train:automatic transmission
Summary:
Transmission - e40d - revised design forward planet thrust washer - service tip. *tw
Bulletin:
96221
Component:
131000 visibility:windshield
Summary:
Windshield and interior glass - fog/film. *tw
Bulletin:
96222
Component:
034000 service brakes, hydraulic:foundation components
Summary:
Brakes - elimination of sanding rotors and drums - service tip. *tw
Bulletin:
962213
Component:
063200 engine and engine cooling:exhaust system:manifold/header/muffler/tail pipe
Summary:
Exhaust - exhaust leak at exhaust manifolds - vehicles equipped with 7.0l or 7.5l engine. *tw
Bulletin:
962521
Component:
011000 steering:wheel and handle bar
Summary:
Steering - clunk noise from steering column on accelerating and braking. *tw
Bulletin:
962612
Component:
103700 power train:automatic transmission:torque converter
Summary:
Transaxle - torque converter replacement guidelines and torque converter/transaxle cooling system cleaning procedures - service tip. *tw
Bulletin:
BC0256970201
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
A running change for the 7.3l to allow better definition on cylinder contribution tests in process. *jd
Bulletin:
97215
Component:
980000 unknown or other
Summary:
Diagnostic guides for out-of-warranty vehicles to be used as a master copy - diagnostic guides no longer available from adistra. *tw
Bulletin:
97216
Component:
061000 engine and engine cooling:engine
Summary:
Leak - oil leakat engine valley pan and/or high pressure oil pump - vehicles equipped with 7.3l diesel engine. *tw
Bulletin:
BC0053972301
Component:
104000 power train:transfer case (4-wheel drive)
Summary:
Some 1995 and all 1996 and 1997 vehicles with e4od transmissions have been built with a reusable elastomeric transmission fluid pan gasket. *jd
Bulletin:
97310
Component:
021242 suspension:front:springs:leaf spring assembly:hanger,bracket
Summary:
Noise- "popping/creaking"- front frame or suspension brackets- frame- "popping/creaking"- fastener replacement. *jd
Bulletin:
9747
Component:
160000 structure
Summary:
Frame- rivet replacement with bolts- service tips. *jd
Bulletin:
BC3130970221
Component:
061200 engine and engine cooling:engine:diesel
Summary:
Diesel exhaust smell in passenger cabin may be due to poor connection at the inlet or outlet to/from the turbo. *tw
Bulletin:
BC3212970213
Component:
980000 unknown or other
Summary:
Camshaft position sensor information . *tw
Bulletin:
BC3241970210
Component:
063200 engine and engine cooling:exhaust system:manifold/header/muffler/tail pipe
Summary:
Exhaust leaks or noise at the joint between the y-pipe and the exhaust manifold. *tw
Bulletin:
9778
Component:
121000 exterior lighting:headlights
Summary:
Headlamp- headlamp housing melts- ambulance and emergency vehicles only. *jd
Bulletin:
9779
Component:
114100 electrical system:wiring:front underhood
Summary:
Wiring- aftermarket wiring alterations- service tip. *jd
Bulletin:
97511
Component:
103000 power train:automatic transmission
Summary:
Fluid- transmission fluid usage charts. *jd
Bulletin:
9768
Component:
980000 unknown or other
Summary:
Fuel economy- customer expectations versus vehicle usage. *jd
Bulletin:
97617
Component:
015100 steering:hydraulic power assist:pump
Summary:
Steering- high effort during highway driving- f super duty motorhome chassis vehicles built from 7/1/93 through 8/9/96. *jd
Bulletin:
97618
Component:
061000 engine and engine cooling:engine
Summary:
Low rpm- 7.3l dit engine fails to start- code 340 stored in memory and/or engine fails to achieve rated speed for 2-3 minutes after extended cold soak- f-series built through 2/9/96 and all econolines. *jd
Bulletin:
97619
Component:
072100 fuel system, gasoline:delivery:fuel pump
Summary:
Fuel pump- availability of new style fuel pump and sender- f super duty motorhome chassis- service tip. *jd
Bulletin:
BC2297970501
Component:
075000 fuel system, gasoline:carburetor system
Summary:
When the air cleaner is being replaced, the drain mechanism on the bottom of the air cleaner case is to be cleaned of obstructions. *tw
Bulletin:
97050110621
Component:
500000 child seat
Summary:
Part number information for the use of a child seat tether. *tw
Bulletin:
985A5
Component:
034530 service brakes, hydraulic:foundation components:disc:rotor
Summary:
Hub-mount brake rotor machining equipment from rotunda is now approved for warranty and service use. *yc
Bulletin:
985A11
Component:
034000 service brakes, hydraulic:foundation components
Summary:
Service tip information regarding elimination of sanding rotors and drums. *yc
Bulletin:
985A13
Component:
034500 service brakes, hydraulic:foundation components:disc
Summary:
The use of petroleum-based grease as a lubricant in servicing disc brakes is no longer acceptable. *yc
Bulletin:
9888
Component:
103000 power train:automatic transmission
Summary:
Information on a new transmission fluid usage chart. *yc
Bulletin:
9845
Component:
045300 service brakes, air:disc:rotor
Summary:
Availability of hub-mount brake rotor machining equipment. *yc
Bulletin:
98419
Component:
980000 unknown or other
Summary:
Some vehicles may exhibit a flashing transmission control indicator lamp (tcil) and diagnostic trouble codes (dtcs) 62,628, and/or 1728. *yc
Bulletin:
9852
Component:
190000 tires
Summary:
Information on tire company telephone numbers for customer assistance. *yc
Bulletin:
9864
Component:
063000 engine and engine cooling:exhaust system
Summary:
Information on a buzzing or rattle noise from the exhaust system. *tt
Bulletin:
9873
Component:
353400 equipment:electrical:radio/tape deck/cd etc.
Summary:
Experiencing a whining / buzzing noise in the speakers of the entertainment radio or two-way radio. *tt
Bulletin:
982119
Component:
103000 power train:automatic transmission
Summary:
Some vehicles may exhibit erratic 4-3 shift hunting while ascending a grade and/or no 3-4 upshift after cresting a grade. *yc
Bulletin:
982120
Component:
010000 steering
Summary:
Steering wheel alignment- vehicles with motorhome chassis.
Bulletin:
982010
Component:
063000 engine and engine cooling:exhaust system
Summary:
Experiencing a " buzzing " or " rattling " noise from the exhaust system. *yc
Bulletin:
982310
Component:
063100 engine and engine cooling:exhaust system:emission control
Summary:
Mass air flow (maf)- sensor contamination- service tip. *ak
Bulletin:
982313
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Some vehicles with a 7.3l direct injection (di) turbo diesel engine, one or more of the following concerns may be present: rough idle, stalling, hesitation/ stumble, loss / lack of power, poor fuel economy, and excessive oil consumption.
Bulletin:
982314
Component:
061110 engine and engine cooling:engine:gasoline:belts and associated pulleys
Summary:
Premature wear of the belt tensioner may occur on some vehicles. *yc
Bulletin:
982321
Component:
020000 suspension
Summary:
Service procedures and vehicle attitude service kits have been developed to assist customers and vehicle modifiers with side -to- side leveling concerns related to weight distribution. *yc
Bulletin:
98246
Component:
110000 electrical system
Summary:
Ford motor company has released a new electrical grease ( f8az - 19g208-aa ) to reduce the possibility of moisture corrosion at the terminals. *yc
Bulletin:
9943
Component:
100000 power train
Summary:
Information regarding reprogramming powertrain control modules (pcms). *tt
Bulletin:
98123
Component:
103000 power train:automatic transmission
Summary:
Some vehicles may exhibit a flashing transmission control indicator lamp (tcil) and diagnostic trouble codes (dtcs) 62, 628, and / or 1728 may be stored in memory. *tt
Bulletin:
99816
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Ford motor company now recommends sae 5w-30 viscosity grade for servicing any ford gasoline-powered vehicle regardless of model year. *tt
Bulletin:
99129
Component:
353400 equipment:electrical:radio/tape deck/cd etc.
Summary:
Experiencing a whine / buzz type noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump. *tt
Bulletin:
99139
Component:
125000 exterior lighting:brake lights
Summary:
Conditions with the brake lamps inadvertently disabling the brake shift interlock. *tt
Bulletin:
99222
Component:
114000 electrical system:wiring
Summary:
Subject on a wire harness terminal repair kit available for repairing electrical wiring harnesses. *tt
Bulletin:
99194
Component:
034000 service brakes, hydraulic:foundation components
Summary:
Information for servicing and diagnosing brake vibration, brake inspection, and brake friction material replacement. *tt
Bulletin:
99196
Component:
353600 equipment:air conditioner
Summary:
Information on identifying non-approved / alternate refrigerants which could cause safety, and performance concerns if installed in ford a/c systems. *tt
Bulletin:
99236
Component:
102000 power train:manual transmission
Summary:
Subject regarding 4r100 transmission flexplate replacement for vehicles with 7.3l diesel engine. *tt
Bulletin:
13412
Component:
103000 power train:automatic transmission
Summary:
Some vehicles may exhibit a condition of no 4x4 low range engagement or a stuck in 4x4 low range, with no (dtc) diagnostic trouble code stored in the gem. *tt
Bulletin:
98168
Component:
103000 power train:automatic transmission
Summary:
Transmission- e40d/4r100-1989-99-main controls, separator plates and separator plate gaskets usage chart. yd
Bulletin:
0015
Component:
103000 power train:automatic transmission
Summary:
Information regarding the new transmission cooler flusher- service tip. *mjs
Bulletin:
0038
Component:
103600 power train:automatic transmission:cooling unit and lines
Summary:
Vehicles may experience solid particle contaminants from prior transmission concerns or excess wear, may be trapped in the transmission fluid cooling system is not properly flushed, fluid in-line filter kit. *mjs
Bulletin:
96715
Component:
171100 latches/locks/linkages:doors:latch
Summary:
Subject regarding a new single key locksets installed on certain trial vehicles. *tt
Bulletin:
96720
Component:
020000 suspension
Summary:
Experiencing front end shimmy occurring at various driving speeds and is usually induced when hitting bumps such as large potholes or rough railroad crossings. *tt
Bulletin:
96723
Component:
980000 unknown or other
Summary:
On some vehicles, the malfunction indicator lamp (mil) may illuminate and code p1411 may be stored in memory. *tt
Bulletin:
96728
Component:
101000 power train:clutch assembly
Summary:
Service tip information regarding the reverse clutch piston and piston seal usage. *tt
Bulletin:
985A12
Component:
354600 equipment:mechanical:wrecker and wheel lift devices
Summary:
Recommended guidelines for towing behind recreational vehicles. *tt
Bulletin:
98-4722
Component:
185000 vehicle speed control:cruise control
Summary:
Repeat message, no change- rough idle/miss. *ak
Bulletin:
98-4726
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Repeat message, no change: hard start/ no start. *ak
Bulletin:
98-4734
Component:
061120 engine and engine cooling:engine:gasoline:turbo-charger
Summary:
Lack of power due to failure of engine turbo boost
Bulletin:
98-4742
Component:
116000 electrical system:ignition
Summary:
Vehicle stalls upon acceleration. *ak
Bulletin:
4614
Component:
185000 vehicle speed control:cruise control
Summary:
Information on vehicles exhibiting rough idle / miss. *tt
Bulletin:
4616
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Brief information vehicles exhibiting hard start / no start condition. *tt
Bulletin:
4617
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Brief information on vehicles exhibiting lack of power condition. *tt
Bulletin:
4625
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Brief information on vehicles exhibiting a stall on deceleration condition. *tt
Bulletin:
4626
Component:
980000 unknown or other
Summary:
Information on vehicles exhibiting and o/d off lamp flashing with diagnostic trouble code 62 / 628 / 1728. *tt
Bulletin:
4629
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Brief information concern vehicles exhbiting external oil leaks. *tt
Bulletin:
4633
Component:
034000 service brakes, hydraulic:foundation components
Summary:
Rear brake drag or excessive wear on rear brakes. *tt
Bulletin:
99-8-15
Component:
162300 structure:body:door
Summary:
Subject regarding door trim panel replacement - service tip. *tt
Bulletin:
99111
Component:
980000 unknown or other
Summary:
Information designed to aid in the diagnosis, testing and repair of noise, vibration and harshness (nvh) concerns. *tt
Bulletin:
991210
Component:
980000 unknown or other
Summary:
Ford motor company has released a private labeled material to be used for iron particle / acid rain service repairs. *tt
Bulletin:
99152
Component:
103000 power train:automatic transmission
Summary:
Information on the new flush and fill tool available through rotunda. *tt
Bulletin:
98156
Component:
063200 engine and engine cooling:exhaust system:manifold/header/muffler/tail pipe
Summary:
Exhaust leak at exhaust manifolds--vehicle equipped with 7.0l 0r 7.5l engine. *ak
Bulletin:
002310
Component:
103600 power train:automatic transmission:cooling unit and lines
Summary:
Subject regarding contamination from prior transmission concerns or excess wear may be trapped in the transmission fluid cooling system. *tt
Bulletin:
01156
Component:
138120 visibility:defroster/defogger system:windshield:heater core
Summary:
Some vehicles may exhibit heater core leaks. *slc
Bulletin:
01157
Component:
980000 unknown or other
Summary:
Information regarding transmission fluid usage charts. *slc
Bulletin:
01181
Component:
103800 power train:automatic transmission:park/neutral start switch
Summary:
Brake shift interlock.*jb
Bulletin:
16697
Component:
061000 engine and engine cooling:engine
Summary:
Exhaust air rush noise and lower power. *tt *jb
Bulletin:
03148
Component:
103600 power train:automatic transmission:cooling unit and lines
Summary:
New transmission cooler flusher - service tips. 2003 escort and super duty f series included. *tt
Bulletin:
03211
Component:
061000 engine and engine cooling:engine
Summary:
Loss of power and malfunction indicator lamp may also illuminate with diagnostic trouble codes 128 and 845 or p0236 and p0238 stored in memory. *tt
Bulletin:
03213
Component:
061120 engine and engine cooling:engine:gasoline:turbo-charger
Summary:
A no-start or reduced power condition may occur intermittently. *tt
Bulletin:
03218
Component:
090000 fuel system, other
Summary:
The water-in-fuel lamp may stay on and the fuel may be slow to drain or not drain at all when the fuel drain valve is opened. *tt
Bulletin:
03219
Component:
061000 engine and engine cooling:engine
Summary:
Availability of new sealant for servicing 7.3l di turbo engine. *tt
Bulletin:
032111
Component:
061000 engine and engine cooling:engine
Summary:
No start/hard start and/or long crank time for vehicles with 7.3l di turbo diesel. *tt
Bulletin:
032112
Component:
100000 power train
Summary:
On vehicles with transmission build dates prior to 9/20/95, the overdrive cancel lamp may be illuminating and diagnostic trouble code (dtc) p1728 present and/or engine stall when reverse and/or manual low is selected. *tt
Bulletin:
032114
Component:
061110 engine and engine cooling:engine:gasoline:belts and associated pulleys
Summary:
The front end accessory drive (fead) belt may wear, shred and/or come off during deceleration. *tt
Bulletin:
032121
Component:
061000 engine and engine cooling:engine
Summary:
A high number of high pressure rexroth pumps and injection pressure regulators (ipr) are being replaced due to oil leaking, when all that is required is a new gasket or seal on either the pump or ipr. *tt
Bulletin:
032123
Component:
061000 engine and engine cooling:engine
Summary:
Low rpm, no start, runs poorly, stall. 7.3l dit engine. *tt
Bulletin:
032125
Component:
114000 electrical system:wiring
Summary:
Aftermarket wiring alterations - service tip. *tt
Bulletin:
032128
Component:
062000 engine and engine cooling:cooling system
Summary:
Coolant may leak at the rear oil header. *tt
Bulletin:
032145
Component:
061000 engine and engine cooling:engine
Summary:
External oil leak diagnosis for 7.3l dit engines. various models including 2003 super duty f series. *tt

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