Safety Recall 11S20 - Fuel Tank Replacement (11S20)

Publication date: 2011-09-30
Reference number: 11S20

SAFETY RECALL 11S20 - FUEL TANK REPLACEMENT

SERVICE CAMPAIGN BULLETIN

Reference Number(s): 11S20 - Supplement #2, Date of Issue: September 30, 2011

FORD:	2007 Five Hundred
MERCURY:	2007 Montego

Superceded Bulletin(s): 11S20 - Supplement #1, Date of Issue: August 17, 2011

SAFETY RECALL 11S20

SUBJECT

Safety Recall 11S20 - Supplement #2

Certain 2007 Model Year Five Hundred and Montego Vehicles

Fuel Tank Replacement

REF

Safety Recall 11S20 - Supplement #1

Dated August 17, 2011

REASON FOR THIS SUPPLEMENT

Advise dealers of an update to Attachment III (Technical Information) that changes the orientation of the fuel pump module lock ring and shield.
Announce updated claiming information and labor operations.

AFFECTED VEHICLES

Certain 2007 model year Five Hundred and Montego vehicles built at the Chicago Assembly Plant from September 5, 2006 through September 11, 2006. Affected vehicles are identified in OASIS. In addition, for a list of vehicles assigned to your dealership, visit https://web.fsavinlists.dealerconnection.com. This information was made available on July 8, 2011.

REASON FOR THIS SAFETY RECALL

In some of the affected vehicles, the fuel tank may have an improper weld between the plastic fuel tank and the plastic fuel filler inlet device. In the event of a severe rear impact to the vehicle, the weld may not provide the expected strength and could result in a fuel leak. A sufficient fuel leak in the presence of an ignition source may result in a fire.

SERVICE ACTION

Dealers are to replace the fuel tank in the affected vehicles. This service must be performed on all affected vehicles at no charge to the vehicle owner.

OWNER NOTIFICATION MAILING SCHEDULE

Owner Letters were mailed the week of August 15, 2011. Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

ATTACHMENTS

Attachment I: Administrative Information
Attachment II: Labor Allowances and Parts Ordering Information
Attachment III: Technical Information
Owner Notification Letter
Recall Reimbursement Plan

QUESTIONS & ASSISTANCE

Special Service Support Center (Dealer Assistance Only) ... 1-800-325-5621

ATTACHMENT I

Safety Recall 11S20 - Supplement #2

Certain 2007 Model Year Five Hundred and Montego Vehicles

Fuel Tank Replacement

OASIS ACTIVATED?

Yes, OASIS was activated on July 8, 2011.

FSA VIN LIST ACTIVATED?

Yes, FSA VIN list was made available through https://web.fsavinlists.dealerconnection.com on July 8, 2011. Owner names and addresses were made available on August 31, 2011.

NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall.

SOLD VEHICLES

Owners of affected vehicles have been directed to dealers for repairs.
Immediately contact any of your affected customers whose vehicles are not on your VIN list but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date.
Correct other affected vehicles identified in OASIS which are brought to your dealership.

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this recall.

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. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis.

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

This safety recall must still be performed, even if the owner has paid for a previous repair. Claiming a refund will not close the recall on the vehicle.
Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. Owners are directed to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121-6251.
Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed.
Refunds will only be provided for the cost associated with the fuel tank replacement.

RENTAL VEHICLES

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

CLAIMS PREPARATION AND SUBMISSION

Enter claims using Direct Warranty Entry (DWE).
Refer to ACESII manual for claims preparation and submission information.
Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center.
"MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center.
Submit refunds on a separate repair line.
1. - Program Code: 11S20
2. - Misc. Expense: ADMIN
3. - Misc. Expense: REFUND
4. - Misc. Expense: 0.2 Hrs.
Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim.
Claiming information for four zip-ties. Submit on same repair line as repair. Applies to labor operations 11S20F and 11S20G.
- Program Code: 11S20
- Misc. Expense: OTHER
- Misc. Expense: $1.00

ATTACHMENT II

Safety Recall 11S20 - Supplement #2

Certain 2007 Model Year Five Hundred and Montego Vehicles

Fuel Tank Replacement

LABOR ALLOWANCES

Description	Labor Operation	Labor Time
Install Fuel Tank Kit (Front Wheel Drive Vehicles)	11S20F	2.5 Hour(s)
Install Fuel Tank Kit (All Wheel Drive Vehicles)	11S20G	3.0 Hour(s)

PARTS REQUIREMENTS / ORDERING INFORMATION

Order your parts requirements through normal order processing channels.

PARTS INFORMATION

Part Number	Description	Quantity
7G1Z-9B210-A	Fuel Tank Kit	1
Obtain Locally	Zip-Ties (approximately 3-5 inches or 75-125 mm in length)	4 per vehicle

NOTE: The previous fuel tank should no longer be ordered for 11S20 repairs.

The DOR/COR number for this recall is 50441.

Questions regarding parts should be directed to the Special Service Support Center (1-800-325-5621) or E-mailed to: Ford@Renkim.com.

DEALER PRICE

For latest prices, refer to DOES II.

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

Safety Recall 11S20 - Supplement #2

Certain 2007 Model Year Five Hundred and Montego Vehicles

Fuel Tank Replacement

OVERVIEW

NOTE: At the time of this supplement, the fuel tank kit includes duplicate parts (O-rings and nuts) that are not required to complete this repair.

SERVICE PROCEDURE

WARNING: Do not carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable vapors are always present and can ignite. Failure to follow these instructions can result in personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.

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 system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

WARNING: This procedure involves fuel handling. Be prepared for spillage at all times and always observe fuel handling precautions. Failure to follow these instructions can result in personal injury.

All Vehicles

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to WSM Section 100-02.
Release the fuel system pressure. For additional information, refer to WSM Section 310-00.
Drain the fuel tank. For additional information, refer to WSM Section 310-00.
NOTE: Do not discard the exhaust system Torca clamp, it may be reused during reassembly.
Remove the muffler and tailpipe. For additional information, refer to WSM Section 309-00.

All Wheel Drive Vehicles

NOTE: Do not discard the driveshaft flange bolts, they may be reused during reassembly.
Remove the driveshaft. For additional information, refer to WSM Section 205-01.

All Vehicles

Disconnect the fuel vapor control tube assembly valve-to-fuel vapor tube quick connect coupling. For additional information, refer to WSM Section 310-00.

NOTICE: The fuel tubes and fuel filter may have some fuel remaining after the fuel system pressure is released. Upon disconnecting the fuel supply tubes or removing the fuel filter, carefully drain the residual fuel into a suitable container.

Disconnect the fuel supply tube-to-fuel filter quick connect coupling. For additional information, refer to WSM Section 310-00.
NOTICE: The fuel tank filler pipe may have some residual fuel remaining after draining. Upon disconnecting the fuel tank filler pipe hose, carefully drain the residual fuel into a suitable container.
Release the fuel tank filler pipe hose clamp and disconnect it from the fuel tank. See Fig 1.

Fig 1: Fuel Tank Filler Pipe Hose Clamp
Place a suitable lifting device under the fuel tank.
Remove the 4 fuel tank strap bolts and discard.
Lower the fuel tank slightly and detach the push pin retainer for the electrical connector and the rear fuel vapor tube-to-fuel vapor control tube assembly.
Lower the fuel tank and position it forward.
Disconnect the fuel vapor tube-to-fuel vapor control tube assembly valve quick connect coupling. For additional information, refer to WSM Section 310-00.
Disconnect the fuel tank wiring harness electrical connector at the rear of the fuel tank.
Remove the fuel tank.
Remove the stone shield from the fuel vapor tube. See Fig 2.
- Do not discard.
Fig 2: Stone Shield On Fuel Vapor Tube
Using a suitable cutting tool, remove the fuel tank filler pipe hose crimp ring and the filler pipe hose. See Fig 3.

Fig 3: Fuel Tank Filler Pipe Hose And Crimp Ring
Disconnect the 2 quick connect coupling fittings from the fuel pump module. See Fig 4. For additional information, refer to WSM Section 310-00.

Fig 4: Quick Connect Coupling Fittings And Electrical Connectors On Fuel Pump Module
Disconnect the electrical connectors from the fuel pump module and the fuel level sensor module. See Fig 4.
Using special tool 310-123. Remove the fuel pump module and the fuel level sensor module lock rings. See Fig 5.
NOTE: Fuel pump module shown, fuel level sensor module similar.

Fig 5: Fuel Pump Module Lock Ring Removal
Lift the fuel pump module slightly out of the tank and disconnect both quick connect fittings from the fuel pump module. See Fig 6. For additional information, refer to WSM Section 310-00.

Fig 6: Quick Connect Fittings On Fuel Pump Module
Remove the fuel pump module.
Lift the fuel level sensor module slightly out of the tank and disconnect the fuel transfer tube quick connect fitting from the fuel level sensor module. See Fig 7. For additional information, refer to WSM Section 310-00.

Fig 7: Fuel Transfer Tube Quick Connect Fitting On Fuel Level Sensor Module
Remove the fuel level sensor module.

FUEL LEVEL SENDER REPLACEMENT

NOTE: Review the fuel level sender wire routing prior to disassembly. This fuel level sender replacement service procedure applies to the fuel pump and fuel level sensor modules. See Fig 8 and Fig 9 .

Remove one of the fuel level sender retention screws. See Fig 8 and Fig 9 .

Fig 8: Fuel Pump Module

Fig 9: Fuel Level Sensor Module
Cut the existing yellow wire between the shrink wrap and sender to allow better access to the terminal connection. See Fig 10.

Fig 10: Existing Yellow Wire Between Shrink Wrap And Sender
Remove old fuel level sender.
Using a utility knife or razor blade, carefully cut the shrink wrap tubing that surrounds the terminal connection lengthwise starting slightly more than half way to access the terminal lock above the yellow wire. See Fig 11.

Fig 11: Cutting Shrink Wrap Tubing That Surrounds Terminal Connection
Disengage the fuel level sender terminal locking tab from the yellow wire and separate the connection. See Fig 12.

Fig 12: Sender Terminal Locking Tab On Yellow Wire
Slide new shrink wrap tube over the new fuel level sender yellow wire.
Reconnect the new fuel level sender yellow wire terminal connection. Check that the locking tab is engaged by lightly pulling on the wire.
Slide new shrink wrap tube over the new fuel level sender yellow wire connection. Secure the new shrink wrap tube with 2 zip-ties, 1 above and 1 below the fuel level sender yellow wire connection, close to the wire crimp area. Pull the zip-ties tightly to ensure the connection will stay insulated and trim the tail end of the zip-ties. See Fig 13.

Fig 13: Shrink Wrap Tube Secured With Zip-Ties
NOTE: The fuel level sender ground circuit will have an extra eyelet connection under the fuel level sender retention screw. Check the routing of the fuel level sender wiring to ensure it is away from the float arm travel.
Install the new fuel level sender to the fuel pump module or the fuel level sensor module and install the fuel level sender retention screw. See Fig 8 and Fig 9 .
Ensure float rod moves freely through full float travel.
Repeat steps 25-34 for the remaining module.
Position the fuel level sensor module into the new fuel tank and connect the fuel transfer tube quick connect, fitting inside the fuel tank. See Fig 7. For additional information, refer to WSM Section 310-00.
Position the fuel pump module into the new fuel tank and connect both quick connect fittings. See Fig 6. For additional information, refer to WSM Section 310-00.
Align the fuel level sensor and fuel pump module arrows to the new fuel tank alignment arrows. See Fig 14.
NOTE: Fuel pump module shown, fuel level sensor module similar.

Fig 14: Fuel Pump Module Alignment
NOTE: A new fuel pump module lock ring is included in the fuel tank kit. This locking ring contains studs for mounting the fuel pump module shield, and must be used for this repair.
NOTICE: The alignment arrow stamped into the new fuel pump module lock ring is in the incorrect location for this application. As a result, the lock ring must be installed in accordance with the following instructions to ensure proper orientation of the fuel purnp module shield, which mounts onto the lock ring.

Install fuel pump module lock ring over the fuel tank tabs so that the arrow stamped on the lock ring is oriented two slots clockwise from the fuel tank alignment arrow. Note that when the lock ring is installed correctly, the lock ring alignment arrow will be oriented approximately 90 degrees clockwise from the alignment arrows on the fuel tank and the fuel pump module assembly. See Fig 15.

Fig 15: Fuel Pump Module Lock Ring Installation
Install the fuel level sensor module lock ring onto the fuel tank.
Using special tool 310-123, tighten the fuel pump module and the fuel level sensor module lock rings. See Fig 5.
To aid in achieving proper orientation of the fuel pump module lock ring during future repairs, use a yellow paint pen to mark a line across the surfaces of the fuel pump module, the lock ring, and the fuel tank. See Fig 16.

Fig 16: Paint Mark Across Surfaces Of Fuel Pump Module, Lock Ring, And Fuel Tank
NOTE: When the new fuel pump module lock ring is properly installed, the tallest tab on the fuel pump module shield will face the front of the vehicle. See Fig 17.
Install the new fuel pump module shield onto the studs of the lock ring and install the 3 nuts. See Fig 17.
- Tighten to 9 Nm (80 lb-in).
Fig 17: Fuel Pump Module Shield Installation
Connect the electrical connector to the fuel pump and the fuel level sensor modules. See Fig 4.
Connect the 2 quick connect coupling fittings to the fuel pump module. See Fig 4. For additional information, refer to WSM Section 310-00.
Install the stone shield to the fuel vapor tube. See Fig 2.
Raise the new fuel tank up to the vehicle and connect the fuel tank wiring harness.
Connect the fuel vapor tube-to-fuel vapor control tube assembly valve quick connect coupling. For additional information, refer to WSM Section 310-00.
Attach the push pin retainer for the electrical connector and the rear fuel vapor tube-to-fuel vapor control tube assembly.
Install the 4 new fuel tank strap bolts.
- Tighten to 35 Nm (26 lb-ft).
Remove the jack from under the fuel tank.
Connect the fuel tank filler hose to the fuel tank filler pipe and tighten the hose clamp. See Fig 1.
Connect the fuel supply tube-to-fuel filter quick connect coupling. For additional information, refer to WSM Section 310-00.
Connect the fuel vapor control tube assembly valve-to-fuel vapor tube quick connect coupling. For additional information, refer to WSM Section 310-00.

All Wheel Drive Vehicles

NOTE: Clean the driveshaft flange bolts and apply threadlock and sealer prior to installing the driveshaft.
Install the driveshaft. For additional information, refer to WSM Section 205-01.

All Vehicles

Install the muffler and tailpipe. For additional information, refer to WSM Section 309-00.
Lower the vehicle.
Refill the fuel tank with the fuel that was previously drained.
Return the vehicle to the customer.

OWNER NOTIFICATION LETTER

Fig 18: Owner Notification Letter - Page 1

Fig 19: Owner Notification Letter - Page 2

RECALL REIMBURSEMENT PLAN FOR 11S20

Ford and Lincoln Mercury dealers are in the best position to quickly and efficiently process reimbursement requests. However, federal legislation requires all motor vehicle manufacturers to establish processes through which customers may seek recall reimbursement directly from the manufacturer or from the dealers.

Regarding the specific reimbursement plan for Recall # 11S20, owners who have paid for service to remedy the defect or noncompliance must have had that service performed prior to August 31, 2011. After this date, if repairs related to this recall are performed by a non-Ford repair facility in an emergency situation, customers must submit any refund requests through their dealership. As required by this federal regulation, Ford Motor Company submitted the details of its latest General Recall Reimbursement Plan in a letter to the National Highway Traffic Safety Administration (NHTSA) in February 2009. The following is the text of that letter and the Plan:

GENERAL RECALL REIMBURSEMENT PLAN (As submitted to the NHTSA)

Pursuant to the requirements set forth in 49 CFR Part 573 and Part 577 of the Code of Federal Regulations, Ford Motor Company (Ford) is submitting required information pertaining to our general reimbursement plan for the cost of remedies paid for by vehicle owners before they are notified of a related safety recall.

Set forth below is Ford's general plan to reimburse owners and purchasers for costs incurred for remedies in advance of notification of potential safely-related defects or noncompliances pursuant to Part 573.6 (c)(8)(i). This plan has not changed since our February 28, 2007 submission.

Reimbursement Notification

Ford's notice to a vehicle owner in accordance with 49 CFR Part 577 will indicate that Ford is offering a refund if the owner paid to have service to remedy the defect or noncompliance prior to a specified ending date. In accordance with Part 573.13 (c)(2), this ending date will be defined as a minimum of ten calendar days after the date on which Ford mailed the last of its Part 577 notifications to owners, and will be indicated in the specific reimbursement plan available to owners for an individual recall. This notice will direct owners to seek eligible reimbursement through authorized dealers or, at their option, directly through Ford at the following address:

Ford Motor Company
P.O. Box 6251
Dearborn, MI 48121-6251

Ford notes that this rule allows for the identification of a beginning date for reimbursement eligibility. Under the rule, an owner who paid to remedy the defect or noncompliance prior to the identified beginning date would not be eligible for reimbursement. Ford generally has not established such a beginning date for reimbursement eligibility and does not presently anticipate changing this general policy. However, in any case where Ford determines a beginning date is appropriate, Ford will indicate that date in the owner notice. As permitted by 577.11 (e), Ford may not include a reimbursement notification when all vehicles are well within the warranty period, subject to approval by the agency.

Costs To Be Reimbursed

For vehicles, reimbursement will not be less than the lesser of:

The amount paid by the owner for the remedy that specifically addressed and was reasonably necessary to correct the defect or noncompliance that is the subject of the recall, or
The cost of parts for the remedy to be no more than the manufacturer's list retail price for authorized part(s), plus associated labor at local labor rates, miscellaneous fees (such as disposal of waste) and taxes.

For replacement equipment, reimbursement will be the amount paid by the owner for the replacement item (limited by the amount of the retail list price of the defective or noncompliant item that was replaced, plus taxes, where the brand or model purchased by the owner was different than the brand or model that was the subject of the recall). If the item of motor vehicle equipment was repaired, the reimbursement provisions identified above for vehicles will apply.

Ford notes that costs incurred by the owner within the period during which Ford's original or extended warranty would have provided for a free repair of the problem will not be eligible for reimbursement, as provided by Part 573.13 (d)(1).

Entities Authorized to Provide Reimbursement

Ford will continue to use authorized dealers to reimburse owners under the specific reimbursement plans for a particular recall, and will encourage owners to pursue requests for reimbursement directly through dealers to expedite reimbursement. Ford will also provide a mailing address to which customers can, at their option, send requests for reimbursement directly to Ford, as previously noted. Requests for reimbursement sent directly to Ford may take up to 60 days to process. Whether the owner chooses to pursue reimbursement requests through a dealer or directly through Ford, the owner will be directed to submit the required documentation, upon which reimbursement eligibility will be determined.

Required Documentation

The reimbursement determination will depend upon the information provided by the customer. Consistent with Part 573.13 (d)(4) the following information must be submitted:

Claimant name and address
Vehicle make, model, and model year
Vehicle identification number (VIN) and, for replacement equipment, a description of such equipment or, for tires, the model, size and TIN (DOT code)
Identification of the recall number (either the Ford recall number or the NHTSA recall number)
Identification of the owner of the recalled vehicle at the time that the pre-notification remedy was obtained
An original receipt for the pre-notification remedy that includes a breakdown of the amount for parts, labor, other costs and taxes, including costs for the replacement item. Where the receipt covers work other than to address the recall or noncompliance, Ford may require the claimant to separately identify costs that are eligible for reimbursement.
If the remedy was obtained during the warranty period, documentation indicating that the warranty was not honored or the warranty repair did not correct the problem related to the recall.

Failure to submit all of the above information may result in denial of the reimbursement request.

Additional Information

The Part 577 required owner notice will provide a toll-free telephone number through which specific information about the reimbursement plan can be requested from Ford. This general reimbursement plan will be incorporated into notifications pursuant to Part 573.6 by reference. Information specific to an individual recall also may be incorporated into the Part 573.6 notification.

ADDITIONAL INFORMATION

Fig 20: Background Summary