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
Make:Ford
Model:F-250
Model:F-350
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
Make:Ford
Model:F-250
Model:F-350
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 4×4 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.