Customer Satisfaction Program 04N03 - Additional Warranty Coverage For Anti-Lock Brake System Module (04N03)

SUBJECT

Customer Satisfaction Program 04N03:

Certain 2003 and 2004 Model Year E-Series Vehicles

Additional Warranty Coverage for Anti-Lock Brake System Module

REF

DEMONSTRATION / DELIVERY HOLD:  Safety Recall 04S22 Dated October 2004 - Anti-Lock Brake System (ABS) Module Service

PROGRAM TERMS

This program extends the coverage of the Anti-Lock Brake System (ABS) Module to 10 years of service or 150,000 miles from the warranty start date of the vehicle, whichever occurs first. If a vehicle has already accumulated more than 150,000 miles, this coverage will last until September 30, 2005. This program provides one-time replacement coverage, and is automatically transferred to subsequent owners.

VEHICLES COVERED BY THIS PROGRAM

Certain 2003 model year E-Series vehicles built at the Lorain Assembly Plant from April 23, 2002 through September 19, 2003 and certain 2004 model year E-Series vehicles built at the Lorain Assembly Plant from May 06, 2003 through November 19, 2003. Affected vehicles are identified in OASIS.

REASON FOR PROVIDING ADDITIONAL COVERAGE

In a very small percentage of the affected vehicles, a diode in the Anti-Lock Brake System (ABS) Module may experience an electrical short. An electrical short may cause an ABS malfunction that would illuminate the ABS warning light, and in some cases, the module may overheat resulting in burning odor, smoke, and/or fire. Since battery power is always present at the module, this condition may occur when the vehicle ignition switch is in the off position, creating the potential for unattended vehicle fires.

Safety Recall 04S22 dated October 2004 - Anti-Lock Brake System (ABS) Module Service was issued to address the above concern. This program provides additional warranty coverage should the ABS Module need replacement.

SERVICE ACTION

If an affected vehicle experiences a short in the ABS Module, dealers are to replace (one time) the ABS Module. This repair will be performed at no charge to the vehicle owner.

ATTACHMENTS

1. Attachment I: Administrative Information
2. Attachment II: Labor Allowances and Parts Ordering Information
3. Attachment III: Technical Information
4. Customer Notification Letters

QUESTIONS?

1. Claims Information: ............................................................ 1-800-423-8851
2. Special Service Support Center (Dealer Only) Questions: .......... 1-800-325-5621

OASIS ACTIVATED?

Yes, OASIS will be activated by 10/01/2004.

FSA VIN LIST ACTIVATED?

No

STOCK VEHICLES

Do not perform this program unless the affected vehicle exhibits the covered condition.

SOLD VEHICLES

Only owners with affected vehicles that exhibit the covered condition will be directed to dealers for repairs.

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this Field Service Action.

RELATED DAMAGE

If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior  to the repair of any related damage. Requests for approval after completion of the repair will not be granted.

ADDITIONAL LABOR TIME

• If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior  to performing any additional labor. Requests for approval after completion of the repair will not be granted.
• If you encounter aftermarket equipment or modifications to the vehicle, which might prevent the repair of the covered condition, call the Special Service Support Center.

OWNER REFUNDS

• Ford Motor Company will only refund owner-paid repairs covered by this program if the repair was performed prior to the date of the Customer Notification Letter (or after the date of the letter if an emergency  repair was made away from the servicing dealer). Refund claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement.
• Refund Claiming Information. (Submit on separate repair line.)
  1. - Program Code: 04N03
  2. - Misc. Expense: ADMIN
  3. - Misc. Expense: REFUND
  4. - Misc. Expense: 0.2 Hrs.

RENTAL VEHICLES

The use of rental vehicles is not authorized for this program.

CLAIMS PREPARATION AND SUBMISSION

• Enter claims using Direct Warranty Entry (DWE).
• Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed.
• "MT" labor should be submitted on a separate repair line with the related damage flag checked.
• Refer to ACESII manual for claims preparation and submission information.

LABOR ALLOWANCES

PARTS REQUIREMENTS / ORDERING INFORMATION

Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels.

DOR/COR NUMBER

The DOR/COR for this program is 50331. This number identifies parts ordered for this Customer Satisfaction Program through the Special Service Support Center (1-800-325-5621).

MANDATORY PARTS RETENTION

Return all replaced ABS Modules to Warranty Parts Analysis Center, 15090 Commerce Drive North, Dearborn, MI 48120. Follow normal shipping instructions described in the Warranty and Policy Manual.

DEALER PRICE

For latest prices, refer to DOES II.

PARTS RETENTION AND RETURN

Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures."

EXCESS STOCK RETURN

Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000.

OVERVIEW

This program involves replacement of the ABS module. The module is secured to the ABS hydraulic control unit (HCU) located in the engine compartment.

REMOVAL

1. Remove the heat shield (if equipped).
2. Remove the three (3) screws attaching the radiator coolant reservoir and position the reservoir aside.
3. Disconnect the module wire harness connector by releasing the lock tab and pulling the connector from the module. See Figure 1.
4. Remove the four (4) Torx head screws securing the module to the HCU. See Figure 2.
5. Lift the module slightly and disconnect the ABS pump motor connector, then remove the module from the vehicle. See Figure 3.

INSTALLATION

1. Position the new  module above the HCU and connect the ABS pump motor connector.
2. Carefully position the new  module onto the HCU and install the four (4) screws. Tighten to 4 Nm (35 lb-in).
3. Connect the module wire harness connector and engage the lock tab.
4. Position and install the radiator coolant reservoir. Tighten the three (3) screws to 12 Nm (106 lb-in).
   NOTE: The new  ABS Module does not contain the suspect diode, therefore, the heat shield that may have been installed for Safety Recall 04S22 is no longer required.
5. Turn the ignition key to ON and verify the ABS indicator light on the instrument panel goes out after approximately five (5) seconds.

Owner Letter - Safety Recall 04S22, Customer Satisfaction Program 04N03

Owner Letter - Safety Recall 04S22, Safety Recall 04S23, Customer Satisfaction Program 04N03