Attachment A


Ford Fuel System Recalls


NHTSA ID No.: 78V-143
Date of Company Notification: 6-15-78
Make: Ford
Model: Pinto
Model Year: 1971-76
Make: Mercury
Model: Bobcat
Model Year: 1975-76
Number of Vehicles: 1,400,000
Mfg. Campaign No. 293. Fuel/tank. Fuel tanks and filler necks installed on these vehicles are subject to failure when vehicles are struck from rear. Such failure can result in fuel leakage, which in presence of external ignition sources can result in fire, and "based on our investigation, it has been initially determined that defect which relates to motor vehicle safety exists in these 1971-1976 Ford Pintos and 1975-1976 Mercury Bobcats (except station wagons)." Correct by replacing existing fuel filler pipe and seal with longer pipe and improved seal. Also, install polyethylene shield on front of fuel tank.

NHTSA ID No.: 84V-082
Date of Company Notification:
Make: Ford
Model: Ranger
Model Year: 1983-84
Number of Vehicles: 302,500
Mfg. Campaign No. (N/A). Fuel/tank. If truck is struck from side, cap on fuel tank could become unsealed, allowing unsafe leakage of fuel, failing to comply with FMVSS 301, "Fuel System Integrity." Leakage can be caused by an orange-colored plastic diesel fuel information ring which is found around fuel tank neck, or by the tether. Correct by removing diesel fuel information ring or replacing tethers.

NHTSA ID No.: 87V-139
Date of Company Notification: 9-1-87
Make: Ford
Model: Taurus, Mustang, Thunderbird, Escort
Make: Mercury
Model: Sable, Crown Victoria, Cougar, Gran Marquis, Lynch
Make: Lincoln
Model: Continental, Town Car Mark VII
Make: Ford Truck
Model: Econoline, Ranger, Bronco II, Bronco, Aerostar F-100, F-150 F-250, F-350
Model Year: 1986-87
Number of Vehicles: 3,600,000
Mfg. Campaign No. (N/A)-Fuel Line Coupling. DOM:7/85-8/87. Spring lock fuel line coupling may not be properly engaged. Coupling could disengage due to fuel pressure, vibration, and engine movements; this would cause loss of fuel which, in presence of an ignition source, creates a fire risk. Correct by installing retainer clips over the couplings to prevent coupling separation and fuel leakage.

NHTSA ID No.: 87V-144
Date of Company Notification: 9-9-87
Make: Ford Truck
Model: E-250, E-350, Econoline, Club Wagon
Model Year: 1983-87
Number of Vehicles: 188,000
Mfg. Campaign No. (N/A)-Fuel Tank Venting. DOM:8/83-8/87. Vehicles are subject to excessive underhood temperatures and fuel system pressures in severe duty applications. This creates potential for fuel expulsion from the fuel filler pipe which in the presence of an ignition source, could result in a fire. Correct by installing modification kits to minimize possibility of fuel expulsion and to shield underbody components from exhaust system heat.

NHTSA ID No.: 91V-146
Date of Company Notification: 9-4-91
Make: Ford
Model: Econoline
Model Year: 1989-91
Model: F-150, F-250, F-350
Model Year: 1989
Number of Vehicles: 350,000
Mfg. Campaign No. 91S39. Fuel tank, auxiliary. DOM: 2/89-2/91. Dual function fuel reservoir may malfunction and cause an overfill condition in one of the fuel tanks, resulting in an overflow of fuel past filler cap. Overflow of fuel past filler cap causes a fuel leakage, which can result in fire when exposed to a source of ignition. Correct by replacing dual function fuel reservoirs with new reservoirs containing o-rings of a revised material.

NHTSA ID No.: 93V-125
Date of Company Notification: 08-02-93
Make: Ford Truck
Model: F Super Duty
Model Year: 1991-93
Model: F-150
Model Year: 1990-93
Model: F-250
Model Year: 1990-93
Model: F-350
Model Year: 1990-93
Number of Vehicles: 1,131,000
Fuel tank assembly. DOM: 7/89-12/92. Light trucks and chassis cabs with gasoline engines and dual fuel tanks. A malfunctioning check valve within the fuel pump assembly causes a portion of the unused fuel from one tank to be returned to the second tank. When this occurs, the capacity of the second tank can be exceeded, causing fuel spillage which can result in a fire. Correct by replacing the fuel pressure regulator and installing redundant check valves.

NHTSA Identification Number: 95V-063
Date of Company Notification: 3-21-95
Make: Ford
Model: Crown Victoria
Model Year: 1995
Make: Lincoln
Model: Town Car
Model Year: 1995
Make: Mercury
Model: Grand Marquis
Model Year: 1995
Number of Vehicles: 100,000
Fuel tank assembly and filler neck. DOM: 6/94-12/94. The seal material between the fuel filler pipe and fuel tank may not have been fully cured during the molding process which could allow fuel to leak and result in fire. Correct by replacing the fuel filler pipe-to-fuel tank seal with a new seal of different material.

NHTSA ID No.: 95V-232
Date of Company Notification: 11-30-95
Make: Ford
Model: Contour
Model Year:
Make: Mercury
Model: Mystique
Model Year: 1995
Number of vehicles: 167,784
Fuel system. DOM: 7/94 - 4/95. Fuel tank filler pipe opening reinforcement, constructed from two separately molded pieces, can leak at the weld and result in a fire. Correct by replacing the fuel tank assemblies with units containing one-piece molded reinforcements.

NHTSA Identification Number: 97V-159
Date of Company Notification: 9-17-97
Make: Ford
Model: Thunderbird
Make: Mercury
Model: Cougar
Model Year: 1992-1993
Number of Vehicles: 125,000
Mfg. Campaign No. 97S84-Fuel system. DOM: 08/91-09/93. Movement of fuel lines causes nylon fuel line jumper to chafe against floor pan. Wear can cause pin hole in one of the fuel lines, resulting in fuel leakage and possible fire. Correct by installing plastic shield around fuel lines. If they show leak, replace the lines first.

NHTSA Identification Number: 98V-060
Date Company Notification: 3-12-98
Make: Ford
Model: Explorer
Make: Mercury
Model: Mountaineer
Model Year: 1997-98
Number of Vehicles: 320,000
Mfg. Campaign No. (N/A)-Fuel line. DOM: 08/96-02/98. Engine fuel lines can be damaged if vehicle is jump started and ground cable is attached to fuel line bracket that is located near battery. Since bracket is not grounded, stainless steel fuel line braid could act as a ground, potentially overheating inner liner of fuel line and result in damage to fuel line and fire. Correct by obtaining a warning label for fuel line bracket advising not to use it for a jump start ground. Also install revised bolt in alternator bracket to provide convenient jump start ground location.

NHTSA Indentification Number: 98V-190
Date of Company Notification: 8-6-98
Make: Ford
Model: Aerostar
Model Year: 1988-90
Number of Vehicles: 140,000
Mfg. Campaign No. 98M03-Fuel tank. DOM: 10/87-11/89 Minivans registered in following states or portions of states: Alabama, Arizona, Arkansas, California (10 southern counties: Los Angeles, Orange, San Bernardino, San Diego, Riverside, Ventura, Santa Barbara, San Luis Obispo, Imperial, and Kern Counties), Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada (Clark County), Oklahoma, South Carolina and Texas, and in U.S. territories covered by federal statutes. Upper portion of fuel tank can develop cracks due to extended exposure to high ambient temperatures. Fuel vapor or leakage could occur at these cracks and result in fire. Correct by replacing fuel tank through March 31, 2002. This coverage will be only for structural cracks at top of tank and will not include other damage caused by crash or road debris.

NHTSA Identification Number: 99V-093.001
Date of Company Notification: 4-20-99
Model Year:1999
Number of Vehicles: 293,650
Mfg. Campaign No. 99S11-Fuel sytem/FMVSS301. DOM: 9/98-3/99. Vehicles fail to meet FMVSS 301 fuel spillage levels in static rollover test, due to pick-up box leaking. Correct by replacing tank locator brackets in all plus retaining cables in earlier made models.

NHTSA Identification Number:99V-311
Date of Company Notification: 10-29-99
Model Year:1999-00
Mfg. Campaign No. 99S32-Fuel sytem/FMVSS301. DOM: 1/98-7/99. In 30 mph frontal barrier crash test, fuel tank vapor recovery valve separates internally. During subsequent static rollover test, fuel spillage exceeded rate allowed by FMVSS 301. This could result in fire. Correct by installing stop plate assembly on frame to prevent recovery valve contact with frame crossmember during impact sequence.

NHTSA Identification Number: 00V-231
Date of Company Notification: 8-17-00
Make: Ford
Model: F-150
Model: F-250
Model Year: 1997
Number of Vehicles: 671,440

Mfg Campaign No. 00S22 - Fuel assembly. DOM 11/95-8/97. Front fuel line assembly could have hole rubbed through from improper installation of mounting brackets. Vehicles with manual 4x4 transfer case shifter, shifter linkage may contact steel fuel lines during shifting between 4H, 4L, 2L and Neutral. These conditions could result in fuel leakage and fire. Correct by inspecting and replacing front fuel line assembly if necessary.

NHTSA Identification Number: 00V-419.002
Date of Company Notification: 1-2-01
Make: Mercury
Model: Villager
Model Year: 1993-98
Number of Vehicles: 393,271

Mfg. Campaign No. 00S59 - Fuel tank. DOM: 11/91-6/98. Fuel tank vent hose allows air to vent from fuel tank during refueling. Cracks have developed in vent hose. If (1) fuel tank is overfilled, not allowing excess fuel in vent hose to flow back into tank, (2) vehicle is driven only short distance after refueling and, (3) there is significant heating of fuel tank, fuel in tank can expand into vent hose and leak fuel which can result in fire. Correct by replacing vent hose.

NHTSA Identification Number: 00V-424
Date of Company Notification: 12-18-00
Make: Ford
Model: F150
Model: F250
Model: F350
Model Year: 1993
Number of Vehicles: 275,000

Mfg. Campaign No. 00S57 - Fuel system. DOM: 12/92-8/93. On vehicles with gasoline engines and dual fuel tanks, carbon steel fuel pressure regulator in fuel system can wear out. If fuel pressure regulator malfunctions, it causes high fuel system pressure, which damages fuel pump check valve. This allows fuel to be transferred from one tank to other, overfilling non-operating tank and resulting in fuel overflow past filler cap which can cause fire. Correct by having stainless steel fuel pressure regulator installed.



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