Safety Recall 17S01 - Passenger Airbag Inflator Replacement

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NHTSA Campaign Number: 17V024
Manufacturer Ford Motor Company
Components AIR BAGS
Potential Number of Units Affected 654,695

Passenger Frontal Air Bag Inflator May Rupture

An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.

Summary

Ford Motor Company (Ford) is recalling certain 2012 Ford Fusion and Mustang and Lincoln Zephyr and MKZ vehicles originally sold, or ever registered, in Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands, or “Zone A.”

Additionally, unless included in “Zone A” above, Ford is recalling certain 2009 Ford Ranger, Edge, Fusion and Mustang, Lincoln MKX, MKZ and Zephyr and Mercury Milan vehicles originally sold, or ever registered, in Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia and West Virginia, or “Zone B.”

Additionally, unless included in “Zone A” or “Zone B” above, Ford is recalling certain 2007-2008 Ford Ranger, Edge and Lincoln MKX, 2006-2008 Ford Fusion, Mercury Milan, Lincoln Zephyr and MKZ, 2005-2008 Ford Mustang and 2005-2006 Ford GT vehicles originally sold, or ever registered, in the states of Alaska, Colorado, Connecticut, Idaho, Iowa, Maine, Massachusetts, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, Oregon, Rhode Island, South Dakota, Utah, Vermont, Washington, Wisconsin and Wyoming.

These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the passenger frontal air bag, these inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.

Remedy

Ford will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. Interim letters informing owners of the recall and that parts are not yet available began mailing March 1, 2017. Owners will receive a second notice when remedy parts become available. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 17S01.

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

Check if your Vehicle has a Recall

August 9, 2018

TO: All U.S. Ford and Lincoln Dealers

SUBJECT: Safety Recall 17S01 – Supplement #5
Certain 2005-2006 Ford GT, 2005-2009 and 2012 Mustang, 2006-2009 Milan,
2006-2009 and 2012 Fusion and MKZ/Zephyr, 2007-2009 Edge and MKX, and
2007-2009 Ranger Vehicles
Passenger Airbag Inflator Replacement

New! REASON FOR THIS SUPPLEMENT

Repair instructions, warranty claiming information, and parts ordering information have been added for 2006-2009 Fusion and Milan. Parts to repair these vehicles are anticipated to be available starting in mid to late September.
Parts and service staff should review the Parts Ordering Information in Attachment II to become familiar with the parts ordering and distribution strategy for each part number.

REASON FOR THIS SAFETY RECALL

NHTSA and Takata have determined that the propellant in certain Takata airbag inflators can experience an alteration over time with exposure to certain climate conditions. A combination of time, high temperature fluctuations, and humidity contribute to the degradation of the propellant in the inflators. This degradation can cause the propellant to burn too quickly, creating high pressure inside the inflator, and in extreme cases causing the inflator to rupture in the event of a crash necessitating airbag deployment. A ruptured inflator can send inflator parts toward vehicle occupants resulting in serious injury or death. Additional information regarding Takata recalls can be found at www.nhtsa.gov and www.safercar.gov.

AFFECTED VEHICLES

Vehicles included in this safety recall were originally sold or at some point registered in certain states. Affected vehicles are identified in OASIS and FSA VIN Lists.

New! REPAIRS ARE CURRENTLY AVAILABLE FOR THE FOLLOWING VEHICLES ONLY

Vehicle	Zone A* Model Year	Zone B* Model Year	Zone C* Model Year	Assembly Plant
Mustang	2012	2009	2005-2008	Flat Rock
Ford GT	N/A	N/A	2005-2006	Wixom
Ranger	N/A	2009	2007-2008	Twin Cities
MKZ/Zephyr	N/A	2009	2006-2008	Hermosillo
Fusion/Milan	N/A	2009	2006-2008	Hermosillo

*Refer to Figure 1.

NOTE: Safety Recall 17S01 Repairs are only available for Ranger, Mustang, Ford GT, 2006-2009 MKZ/Zephyr and (starting in mid to late September) 2006-2009 Fusion and Milan. Repairs for most other vehicles affected by this safety recall are expected to become available throughout the third quarter of 2018. Dealers are encouraged to refer to the Takata Airbag Inflator Recall Information for Dealers document on the FMC dealer homepage for the latest parts status for all Takata airbag recalls. The dealer bulletin will also be updated as repair-information becomes available for other affected vehicles.

NOTE: Parts are not interchangeable between different vehicle models so a repair should not be attempted on vehicles that repairs are not currently published for.

Due to owner relocations and vehicle resale activity, dealers in Zones B and C may have some vehicles assigned to their FSA VIN list. All vehicles affected by this safety recall must be repaired, regardless of the vehicle’s current location. Always use OASIS to identify affected vehicles.

The Takata airbag recall zones have been defined by the NHTSA, based on temperature and humidity.

FIGURE 1

SERVICE ACTION

Dealers are to replace the passenger airbag inflator or passenger airbag module as directed in the Technical Information attachments. This service must be performed on all affected vehicles at no charge to the vehicle owner.

For Mustang and Ford GT vehicles, dealers should check OASIS to determine if safety recall 15S21 is open for the driver side airbag. If safety recall 15S21 is open, then it should be completed in addition to safety recall 17S01. Parts are readily available to complete safety recall 15S21.

NOTE: This is a final / permanent repair. All 2005-2006 Ford GT vehicles that were previously serviced under Safety Recall 14S28 must have this repair performed.

New! OWNER NOTIFICATION MAILING SCHEDULE

Owner letters for Ranger, Mustang, Ford GT, and 2006-2009 MKZ/Zephyr vehicles have been mailed. Owner letters for 2006-2009 Fusion and Milan vehicles are anticipated to be mailed by the end of September 2018. Dealers should repair any affected vehicles that repairs are available for, whether or not the customer has received a letter.

PLEASE NOTE:

Federal law requires dealers to complete this recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $21,000 per vehicle. Correct all vehicles in your new vehicle inventory before delivery.

New! ATTACHMENTS

Attachment I: Administrative Information
Attachment II: Labor Allowances and Parts Ordering Information
Attachment III: Technical Information – 2012 Mustang and 2005-2006 Ford GT
Attachment IV: Technical Information – 2005-2009 Mustang
Attachment V: Technical Information – 2007-2009 Ranger
Attachment VI: Technical Information – 2006-2009 MKZ/Zephyr
Attachment VII: Technical Information – 2006-2006 Fusion/Milan (NEW!)
Attachment VIII: Regional Core Recovery Center – Airbag Inflator Return Process – Parts with Core Charges
Attachment IX: Dealer Q & A
Attachment X: Takata Airbag Recall Rental Vehicle Reimbursement Process
Attachment XI: Restricted Vehicle Use Agreement
Owner Notification Letters

QUESTIONS & ASSISTANCE

For questions and assistance, contact the Special Service Support Center (SSSC) via the SSSC Web Contact Site. The SSSC Web Contact Site can be accessed through the Professional Technician Society (PTS) website using the SSSC link listed at the bottom of the OASIS VIN report screen or listed under the SSSC tab. Sincerely,

David J. Johnson

ATTACHMENT I

Safety Recall 17S01 – Supplement #5
Certain 2005-2006 Ford GT, 2005-2009 and 2012 Mustang, 2006-2009 Milan, 2006-2009 and
2012 Fusion and MKZ/Zephyr, 2007-2009 Edge and MKX, and 2007-2009 Ranger Vehicles
Passenger Airbag Inflator Replacement

OASIS ACTIVATION

OASIS was activated on February 22, 2017.

New! FSA VIN LISTS ACTIVATION

FSA VIN Lists were made available through https://web.fsavinlists.dealerconnection.com on August 9, 2018, for vehicles that can be repaired at this time.

NOTE: Your FSA VIN Lists 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 will be 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.
Dealers are to prioritize repairs of customer vehicles over repairs of used vehicle inventory.

STOCK VEHICLES

Dealers should use OASIS to identify any affected vehicles in your used vehicle inventory and perform the repair.

DEALER-OPERATED RENTAL VEHICLES

The Fixing America’s Surface Transportation (FAST) Act law effective June 2016 prohibits a rental company from selling, renting or leasing vehicles subject to a safety or compliance recall. Please consult your legal counsel for legal advice.

TITLE BRANDED / SALVAGED VEHICLES

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

QUICK LANE REPAIRS

At the dealer’s discretion, dealers with Quick Lanes may now use Quick Lane service bays and Quick Lane technicians to perform Takata Airbag Recalls.
Claim processing, hazardous material handling and parts returns MUST be processed through the main dealership’s warranty submission process and parts department.
No other warranty or recall repairs are allowed at Quick Lanes at this time.

OWNER REFUNDS

Refunds are not approved for this program.

New! RENTAL VEHICLES

For Edge, MKX, 2012 MKZ, and 2012 Fusion vehicles, if the customer requires the use of their vehicle’s passenger seat and requests a rental vehicle while waiting for parts to become available, refer to the Takata Airbag Recall Rental Vehicle Reimbursement Process for rental reimbursement guidelines and the process for requesting rental vehicle reimbursement.

For Ford GT, Mustang, Ranger, and 2006-2009 MKZ/Zephyr vehicles, parts are readily available to complete the recall on these vehicles. With proper dealer parts ordering and service appointment scheduling, rental vehicles should not be required. Parts for 2006-2009 Fusion and Milan vehicles will be available by mid to late September.

Dealers should contact vehicle owners that are currently in rental vehicles to schedule a repair as soon as parts are available to repair their vehicle.

FORD GT SPECIAL HANDLING

Dealers are authorized to claim up to a maximum combined value of $200 to provide unique services to Ford GT owners under this recall. Examples of potential services include:

Technician travel to vehicle location for remote repair
Vehicle transportation (towing/flatbed) to dealership
Vehicle re-delivery to the owners location after repairs have been completed
Ford and Lincoln Dealerships are authorized to claim the special handling allowance.

In some cases, $200 may not be sufficient to tow the vehicle to the dealership and redeliver to the customer. Dealers are encouraged to consider remote repairs at the vehicles location in these scenarios.

ADDITIONAL REPAIR (LABOR TIME AND/OR PARTS)

Additional repairs identified as necessary to complete the FSA should be managed as follows:

For vehicles that the airbags have deployed or that have other modifications preventing the recall repair from being completed:
- Submit a VIN specific request to the SSSC Web Contact Site prior to attempting a repair.
- Attach pictures of the vehicles airbag modules to the request.
For related damage and access time requirements, refer to the Warranty and Policy Manual – Section 6 – Ford/Lincoln Program Policies – Field Service Actions (FSA) – Related Damage.
Submit an Approval Request to the SSSC Web Contact Site prior to completing the repair.

CLAIMS PREPARATION AND SUBMISSION

Enter claims using Dealer Management System (DMS) or One Warranty Solution (OWS) online.
- When entering claims, select claim type 31: Field Service Action. The FSA number 17S01 is the sub code.
- For additional claims preparation and submission information, refer to the Recall and Customer Satisfaction Program (CSP) Repairs in the OWS User Guide.
Additional labor and/or parts must be claimed as related damage on a separate repair line from the FSA. IMPORTANT: Click the radio button on the Related Damage Indicator.

New! CLAIMS PREPARATION AND SUBMISSION (continued)

NOTE: The serial number of the new passenger airbag inflator or module must be provided to Ford for the claim to be processed. The Technical Information in this bulletin advises technicians to document the serial number from the new airbag inflator on the repair order. The passenger airbag inflator serial number is 11 characters for Ranger, Mustang, and GT and 13 characters for 2006-2009 MKZ/Zephyr and 20062009 Fusion and Milan. Enter the serial number of the new airbag inflator or module in the claim as follows:

For claims submitted using DMS or OWS on-line, enter the serial numbers in the Test Results Section.

- Select DTC REQUIRED MEASUREMENT OR RESULTS from the drop down list.
- Enter the serial number in the CODE field.
- The serial number must entered without spaces or dashes.

For Ford GT Special Handling claim up to a maximum of $200. All Special Handling must be on the same repair line the FSA is claimed. Claim Special Handling under Misc. Expense Code “OTHER.”
Rental Vehicle Reimbursement:
- Claim should be submitted under long-term rental program 18A02.
- A new approval code is required from the SSSC every 30 days.
- Dealers are eligible to claim a $25 administrative fee for any long-term rental claims that are submitted after June 13, 2018. This includes long-term rental claims that were originally approved by the SSSC after May 12, 2018 but processed for warranty payment after June 13, 2018.
  - Claim the rental reimbursement administrative fee of $25 per claim on a separate RO line under Misc. Expense code FSAEXP.
- Customers that were placed into a long-term rental vehicle prior to June 13, 2018 are eligible for the increased dollar per day rental reimbursement rates back to the date the most recent longterm rental approval code was approved from the SSSC. To request the increased rates on a pre-existing approval code, update the existing approved contact and attach the rental invoice showing the dollar per day amounts.
- If the customer has paid for a rental vehicle for the purpose of this recall, they are eligible for reimbursement within the guidelines outlined in the Takata Airbag Recall Rental Vehicle Reimbursement Process. Dealers should follow the same process for claiming rental vehicle reimbursement and then refund the customer.
- Reference the Takata Airbag Recall Rental Vehicle Reimbursement Process for further detail on rental vehicle reimbursement.

ATTACHMENT II

New! LABOR ALLOWANCES (only vehicles that repairs are currently available for are listed)

Description	Labor Operation	Labor Time
Replace Passenger Airbag Inflator – 2005-2009 and2012 Mustang	17S01B	0.5 Hours
Replace Passenger Airbag Inflator – 2005-2006 Ford GT	17S01C	0.6 Hours
Replace Passenger Airbag Inflator – 2007-2009 Ranger	17S01D	0.5 Hours
Replace Passenger Airbag Module – 2006-2009 MKZ/Zephyr	17S01E	0.5 Hours
Replace Passenger Airbag Module – 2006-2009 Fusion/Milan	17S01F	0.4 Hours

Performing the supplemental restraint depower procedure and clearing DTCs was included in previous airbag inflator recall 14S28, but is no longer required.

New! PARTS REQUIREMENTS / ORDERING INFORMATION

Repairs are currently only available for Mustang, Ranger, Ford GT, 2006-2009 MKZ/Zephyr and (starting in mid to late September) 2006-2009 Fusion and Milan vehicles covered under safety recall 17S01. Repairs for most other vehicles affected by this safety recall are expected to become available throughout the third quarter of 2018. Dealers are encouraged to refer to the Takata Airbag Inflator Recall Information for Dealers document on the FMC dealer homepage for the latest parts status for all Takata airbag recalls. The dealer bulletin will also be updated as repair information becomes available for other affected vehicles.

Note: The parts used in this safety recall may physically appear to be identical, but they have differing operating characteristics. It is crucial that parts are NOT interchanged or substituted.

New! PARTS REQUIREMENTS (only vehicles that repairs are currently available for are listed)

Description	Order Quantity	Claim Quantity	Part Number
Passenger Airbag Inflator – 2012 Mustang and 2005-2006 Ford GT	1	1	6G7Z-63044A74-A
Passenger Airbag Inflator – 2005-2009 Mustang	1	1	5R3Z-63044A74-B
Passenger Airbag Inflator – 2007-2009 Ranger	1	1	8L5Z10044A74-E
Passenger Airbag Module – 2006-2009 MKZ/Zephyr (Light Stone color)	1	1	7H6Z-54044A74-AD
Passenger Airbag Module – 2006-2009 MKZ/Zephyr (Charcoal Black color)	1	1	7H6Z-54044A74-AE
Passenger Airbag Module – 2006-2009 MKZ/Zephyr (Sand color)	1	1	7H6Z-54044A74-AF
Passenger Airbag Module – 2006-2009 Fusion/Milan (Dark Stone color)	1	1	8E5Z-54044A74-AC
Passenger Airbag Module – 2006-2009 Fusion/Milan (Charcoal Black color)	1	1	8E5Z-54044A74-AD

The DOR/COR number for this recall is 51115.

New! PARTS ORDERING INFORMATION

Due to the varying levels of part inventories, the parts ordering procedure and the distribution strategy for this recall will vary by part number and vehicle line. Refer to the vehicle lines listed below for the part ordering procedure and distribution strategy. Once sufficient parts inventory is available, parts strategy will move to open ordering. Dealers will be notified via a DOES II communication if circumstances warrant a change in part supply strategy and when open ordering begins.

NOTE: Because some parts used in this recall being shipped directly from the supplier, inventory that is readily available for ordering may not show available in dealer part ordering interfaces.

2006-2009 Fusion and Milan

Part numbers 8E5Z-54044A74-AC and 8E5Z-54044A74-AD for 2006-2009 Fusion and Milan will be seed stocked to dealers starting in mid to late September. Dealers will receive a percentage of parts based on the number of 2006-2009 Fusion and Milan vehicles assigned to them on their FSA VIN list. Dealers that have 2006-2009 Fusion and Milan vehicle owners currently in a rental vehicle will also be shipped parts to repair those vehicles. If additional parts are required after receiving the seed stock shipment, submit a VIN-specific Part Order contact via the SSSC Web Contact Site to order additional parts.

Mustang, GT, and Ranger

Passenger airbag inflators 6G7Z-63044A74-A (2012 Mustang and GT), 5R3Z-63044A74-B (2005-2009 Mustang), and 8L5Z-10044A74-E (Ranger) were previously seed stocked to dealers that had vehicles assigned to them on their FSA VIN list. If additional parts are required, order your parts through normal order processing channels. To guarantee the shortest delivery time, an emergency order for parts should be placed. There are still a significant number of unrepaired Ranger, Mustang, and Ford GT vehicles and dealers are encouraged to maintain stock of these parts to be prepared to repair vehicles as they arrive for repairs. Dealers should reference their FSA VIN list to monitor the number of unrepaired vehicles assigned to them.

2006-2009 MKZ/Zephyr

To place an order for a passenger airbag module for 2006-2009 MKZ/Zephyr part numbers 7H6Z-54044A74AD, 7H6Z-54044A74-AE, and 7H6Z-54044A74-AF, submit a VIN-specific Part Order contact via the SSSC Web Contact Site.

PARTS RETENTION AND RETURN

It is critical that all original passenger airbag inflators removed from vehicles are not allowed back into the market. Therefore, all passenger airbag inflators under this safety recall have been assigned a $100 core charge to ensure they will be properly returned.

The Regional Core Recover Center (RCRC), including dealers in Alaska and Hawaii, will pick up these airbag inflators along with all other core returns during your normal core retrieval visit.

For additional information, refer to Attachment VII: Regional Core Recovery Center – Airbag Inflator Return Process.

IMPORTANT: Old part number 5G7Z-63044A74-A for 2005-2006 Ford GT vehicles used under 14S28 must no longer be installed in vehicles, and can be returned via the FSA parts return process. Please use “CG” as the claim code and note in the shipper field the FSA bulletin number (17S01).

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

CERTAIN 2005-2006 FORD GT AND 2012 MUSTANG VEHICLES — PASSENGER AIRBAG INFLATOR REPLACEMENT

OVERVIEW

Takata has determined that the propellant wafers in some airbag inflators may experience an alteration over time, which could potentially lead to an over-aggressive combustion in the event of a crash that requires airbag deployment. This potential condition could create excessive internal pressure when the airbag is deployed, which could result in the body of the inflator rupturing upon deployment increasing the risk of injury to occupants.

Dealers are to replace the passenger airbag inflator. The serial number from the new airbag inflator must be recorded on the repair order. Place the replaced inflator into the packaging from the new part and provide to the appropriate dealership personnel for part returns.

NOTE: For vehicles that the airbags have deployed or that have other modifications preventing the recall repair from being completed, submit a VIN specific request to the SSSC Web Contact Site prior to attempting a repair. Attach pictures of the vehicles airbag modules to the request.

SERVICE PROCEDURE

Recommended Tools:

1/4″ Drive Deep Socket – 7mm

1/4″ Drive Ratchet

1/4″ Drive Extension – 6″ (152mm)

1/4″ Drive Shallow Socket – 8mm

1/4″ Drive Impact Driver

1/4″ Drive Torque Wrench

Side Cutters

Utility Knife

Needle Nose Pliers

AIRBAG INFLATOR REPLACEMENT

NOTE: The following repair instructions only apply to 2012 Mustang and 2005-2006 Ford GT vehicles. Repair instructions will be published in separate attachments for the other vehicle lines included in this recall as parts become available for those vehicles.

NOTE: The parts used in this safety recall may physically appear to be identical, but they have differing operating characteristics. It is crucial that parts are not interchanged or substituted.

WARNING: Failure to follow the instructions and warnings in the Workshop Manual (WSM) may result in injury.

NOTE: If the Airbag Readiness light indicates no Supplemental Restraint System (SRS) faults are present, it is not necessary to follow the WSM SRS Depowering and Repowering steps. Turn the ignition to OFF and wait 1 minute, then it is safe to proceed with airbag inflator replacement.

NOTE: The ignition must remain OFF until this service procedure is completed.

NOTE: Mustang airbag shown in this procedure, Ford GT similar.

NOTE: To view a video demonstration of this repair procedure, click the video icon.

NOTE: For Mustang vehicles equipped with SYNC, it is not necessary to remove the Accessory Protocol Interface Module (APIM) retainers to access the passenger airbag module. Unclip the APIM mounting bracket and position the APIM aside.

Remove the passenger airbag from the vehicle. Please follow the WSM procedures in Section 501-20B.
Set the airbag face down onto a surface that will not scratch or damage the airbag face.
Remove the wiring harness connector retainer from the passenger airbag assembly.
See Figure 1.

FIGURE 1

NOTE: Carry out this step on the longer wire on the end opposite of the airbag inflator retaining bracket. See Figure 2.

Remove approximately 100 mm (3.93 in) of the yellow conduit from the passenger airbag assembly wire harness. See Figure 2.

FIGURE 2

Position the shorting clip onto the harness wires, and crimp the shorting clip together one side at a time using pliers. See Figure 3.

FIGURE 3

Cut the harness wires between the shorting clip and the harness connector. See Figure 4.

FIGURE 4

Remove and discard the four passenger airbag inflator retaining bracket nuts and the retaining bracket.
See Figure 5.

FIGURE 5

WARNING: Do not allow any debris on or around the airbag once the inflator is removed.

With an assistant holding the passenger airbag assembly, remove the inflator from the assembly by pushing outward on the inflator. Set the airbag inflator aside for return shipping. See Figure 6.
- If required, use of a brass punch is permitted (only at the location shown) to free the inflator from its mounted position.

FIGURE 6

NOTE: The serial number of the new airbag inflator must be provided to Ford for the warranty claim to be processed.

Record the 11 character serial number of the new airbag inflator on the repair order. See Figure 7.

FIGURE 7

NOTE: Both new inflator end caps are specific to their respective end of the inflator and must be
fully seated.

NOTE: The tail end cap does not have an alignment tab and may be installed in any orientation.

Install both new inflator end caps making sure the alignment feature on the cap nearest the inflator retaining bracket is properly oriented. See Figure 8.

FIGURE 8

Install the inflator into the passenger airbag assembly with the orange connector end facing out. Align the three tabs on the cap nearest the inflator retaining bracket with the airbag module lower channel (facing down). See Figure 9.

FIGURE 9

NOTE: If the inflator retaining bracket is unable to be installed, ensure the inflator tail end cap is fully seated.

Install the new passenger airbag inflator retaining bracket and new nuts. See Figure 10.
- Torque the new retaining nuts in the sequence shown below to 4 Nm (35 Ib.in).

FIGURE 10

Install the new wiring harness onto the passenger airbag module and connect to both sides of the inflator. See Figure 11.

FIGURE 11

Insert black the inflator wiring harness connector tabs. See Figure 12.

NOTE: Pull gently on the wiring harness to ensure it is properly seated.

FIGURE 12

Re-install the passenger airbag. Please follow WSM procedures in Section 501-20B.
Package the replaced inflator in the new part box and provide to the appropriate dealership personnel
for part returns.

ATTACHMENT IV

CERTAIN 2005-2009 MUSTANG VEHICLES — PASSENGER AIRBAG INFLATOR REPLACEMENT

OVERVIEW

SERVICE PROCEDURE

Recommended Tools:

1/4″ Drive Deep Socket – 7mm

1/4″ Drive Ratchet

1/4″ Drive Extension – 6″ (152mm)

1/4″ Drive Shallow Socket – 8mm

1/4″ Drive Impact Driver

1/4″ Drive Torque Wrench

AIRBAG INFLATOR REPLACEMENT

NOTE: The following repair instructions only apply to 2005-2009 Mustang vehicles. Repair instructions will be published in separate attachments for the other vehicle lines included in this recall as parts become available for those vehicles.

NOTE: The parts used in this safety recall may physically appear to be identical, but they have differing operating characteristics. It is crucial that parts are not interchanged or substituted.

WARNING: Failure to follow the instructions and warnings in the Workshop Manual (WSM) may result in injury.

NOTE: The ignition must remain OFF until this service procedure is completed.

NOTE: To view a video demonstration of this repair procedure, click the video icon.

Remove the passenger airbag from the vehicle. Please follow the WSM procedures in Section 501-20B.
Set the airbag face down onto a surface that will not scratch or damage the airbag face.
Remove the wiring harness connector retainer from the passenger airbag assembly.
See Figure 1.

FIGURE 1

NOTE: Carry out this step on the longer wire on the end opposite of the airbag inflator retaining bracket. See Figure 2.

Remove approximately 100 mm (3.93 in) of the yellow conduit from the passenger airbag assembly wire harness. See Figure 2.

FIGURE 2

Position the shorting clip onto the harness wires, and crimp the shorting clip together one side at a time using pliers. See Figure 3.

FIGURE 3

Cut the harness wires between the shorting clip and the harness connector. See Figure 4.

FIGURE 4

Remove and discard the four passenger airbag inflator retaining bracket nuts and the retaining bracket.
See Figure 5.

FIGURE 5

WARNING: Do not allow any debris on or around the airbag once the inflator is removed.

With an assistant holding the passenger airbag assembly, remove the inflator from the assembly by pushing outward on the inflator. Set the airbag inflator aside for return shipping. See Figure 6.
- If required, use of a brass punch is permitted (only at the location shown) to free the inflator from its mounted position.

FIGURE 6

NOTE: The serial number of the new airbag inflator must be provided to Ford for the warranty claim to be processed.

Record the 11 character serial number of the new airbag inflator on the repair order. See Figure 7.

FIGURE 7

NOTE: Both new inflator end caps are specific to their respective end of the inflator and must be fully seated.

NOTE: The tail end cap does not have an alignment tab and may be installed in any orientation. Make sure the tail end cap is fully seated or you will not be able to install the inflator retaining bracket.

Install both new inflator end caps making sure the alignment feature on the cap nearest the inflator retaining bracket is properly oriented. See Figure 8.

FIGURE 8

Install the inflator into the passenger airbag assembly with the orange connector end facing out. Align the three tabs on the cap nearest the inflator retaining bracket with the airbag module lower channel (facing down). See Figure 9.

FIGURE 9

NOTE: If the inflator retaining bracket is unable to be installed, ensure the inflator tail end cap is fully seated.

Install the new passenger airbag inflator retaining bracket and new nuts. See Figure 10.
- Torque the new retaining nuts in the sequence shown below to 4 Nm (35 Ib.in).

FIGURE 10

Install the new wiring harness onto the passenger airbag module and connect to both sides of the
inflator. See Figure 11.

FIGURE 11

Re-install the passenger airbag. Please follow WSM procedures in Section 501-20B.

NOTE: Pull gently on the wiring harness to ensure it is properly seated.

FIGURE 12

Re-install the passenger airbag. Please follow WSM procedures in Section 501-20B.
Package the replaced inflator in the new part box and provide to the appropriate dealership personnel
for part returns.

ATTACHMENT V

CERTAIN 2007-2009 RANGER VEHICLES — PASSENGER AIRBAG INFLATOR REPLACEMENT

OVERVIEW

SERVICE PROCEDURE

Recommended Tools:

1/4″ Drive Deep Socket – 7mm

1/4″ Drive Ratchet

1/4″ Drive Extension – 6″ (152mm)

1/4″ Drive Shallow Socket – 8mm

1/4″ Drive Impact Driver

1/4″ Drive Torque Wrench

AIRBAG INFLATOR REPLACEMENT

NOTE: The following repair instructions only apply to 2007-2009 Ranger vehicles. Repair instructions will be published in separate attachments for the other vehicle lines included in this recall as parts become available for those vehicles.

NOTE: The parts used in this safety recall may physically appear to be identical, but they have differing operating characteristics. It is crucial that parts are not interchanged or substituted.

WARNING: Failure to follow the instructions and warnings in the Workshop Manual (WSM) may result in injury.

NOTE: The ignition must remain OFF until this service procedure is completed.

Remove the passenger airbag from the vehicle. Please follow the WSM procedures in Section 501-20B.
Set the airbag face down onto a surface that will not scratch or damage the airbag face.
Remove the wiring harness connector retainer from the passenger airbag assembly.
See Figure 1.

FIGURE 1

NOTE: Carry out this step on the shorter wire on the end opposite of the airbag inflator retaining bracket. See Figure 2.

Remove the conduit from the passenger airbag assembly wire harness in the area shown. See Figure 2.

FIGURE 2

Position the shorting clip onto the harness wires, and crimp the shorting clip together one side at a time using pliers. See Figure 3.
Cut the harness wires between the shorting clip and the harness connector. See Figure 3.

FIGURE 3

Remove and discard the four passenger airbag inflator retaining bracket nuts and the retaining bracket. See Figure 4.

FIGURE 4

WARNING: Do not allow any debris on or around the airbag once the inflator is removed.

With an assistant holding the passenger airbag assembly, remove the inflator from the assembly by pushing outward on the inflator. Set the airbag inflator aside for return shipping. See Figure 5.
- If required, use of a brass punch is permitted (only at the location shown) to free the inflator from its mounted position.

FIGURE 5

NOTE: The serial number of the new airbag inflator must be provided to Ford for the warranty claim to be processed.

Record the 11 character serial number of the new airbag inflator on the repair order. See Figure 6.

FIGURE 6

NOTE: Both new inflator end caps are specific to their respective end of the inflator and must be
fully seated.

Install both new inflator end caps making sure the alignment feature on the cap nearest the inflator retaining bracket is properly oriented. See Figure 7.

FIGURE 7

Install the inflator into the passenger airbag assembly with the orange connector end facing out. Align the three tabs on the cap nearest the inflator retaining bracket with the airbag module lower channel (facing down). See Figure 8.

FIGURE 8

NOTE: If the inflator retaining bracket is unable to be installed, ensure the inflator tail end cap is fully seated.

Install the new passenger airbag inflator retaining bracket and new nuts. See Figure 9.
- Torque the new retaining nuts in the sequence shown below. Tighten to 4 Nm (35 lb in).

FIGURE 9

Align the T-shape index on both the wiring harness electrical connector and the airbag inflator. Install the new wiring harness onto the passenger airbag module and connect to both sides of the inflator and fully seat the tabs. See Figure 10.

NOTE: Pull gently on the wiring harness to ensure it is properly seated.

FIGURE 10

Install the new tape to the wiring harness and airbag assembly, do not cover the airbag warning label with the new tape. For correct placement See Figure 11.

FIGURE 11

Re-install the passenger airbag. Please follow WSM procedures in Section 501-20B.
Package the replaced inflator in the new part box and provide to the appropriate dealership personnel
for part returns.

ATTACHMENT VI

CERTAIN 2006-2009 MKZ/ZEPHYR VEHICLES – PASSENGER AIRBAG MODULE REPLACEMENT

OVERVIEW

Dealers are to replace the passenger airbag module. The serial number from the new airbag module must be recorded on the repair order. Place the replaced airbag module into the packaging from the new part and provide to the appropriate dealership personnel for part returns.

SERVICE PROCEDURE

NOTE: The following repair instructions only apply to 2006-2009 MKZ/Zephyr vehicles. Repair instructions will be published in separate attachments for other vehicle lines included in this recall as parts become available for those vehicles.

NOTE: The parts used in this safety recall may physically appear to be identical, but they have differing operating characteristics. It is crucial that parts are not interchanged or substituted.

WARNING: Failure to follow the instructions and warnings in the Workshop Manual (WSM) may result in injury.

NOTE: The ignition must remain OFF until this service procedure is completed.

Record the 13 character serial number of the new airbag module on the repair order. See Figure 1.
Replace the passenger airbag module. Refer to section 501-20B of the Workshop Manual.

NOTE: Use caution when removing the 5 instrument panel trim panel fasteners or the studs may strip out. Submit a contact to the SSSC if damage to the trim panel does occur.

Package the replaced airbag module in the new part box and provide to the appropriate dealership personnel for part returns.

FIGURE 1

ATTACHMENT VII

CERTAIN 2006-2009 FUSION AND MILAN VEHICLES – PASSENGER AIRBAG MODULE REPLACEMENT

OVERVIEW

SERVICE PROCEDURE

NOTE: The following repair instructions only apply to 2006-2009 Fusion and Milan vehicles. Repair instructions will be published in separate attachments for other vehicle lines included in this recall as parts become available for those vehicles.

NOTE: The parts used in this safety recall may physically appear to be identical, but they have differing operating characteristics. It is crucial that parts are not interchanged or substituted.

WARNING: Failure to follow the instructions and warnings in the Workshop Manual (WSM) may result in injury.

NOTE: The ignition must remain OFF until this service procedure is completed.

Record the 13 character serial number of the new airbag module on the repair order. See Figure 1.
Replace the passenger airbag module. Refer to section 501-20B of the workshop manual.
Package the replaced airbag module in the new part box and provide to the appropriate dealership personnel for part returns.

FIGURE 1

ATTACHMENT VIII

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Model of Recalled Vehicle	Rental Vehicle Reimbursement Cost Per Day Limit	Rental Vehicle Reimbursement Cost Per Month Limit
Ford	$44	$1,320
Mercury	$44	$1,320
Lincoln	$55	$1,650

Model of Recalled Vehicle	Enterprise Per Day Rate	Enterprise Per Month Rate
Ford	$40 plus tax	$1,200 plus tax
Mercury	$40 plus tax	$1,200 plus tax
Lincoln	$49 plus tax	$1,470 plus tax

¿Cuál es el problema?	El inflador de la bolsa de aire del pasajero de su vehículo podría detonar en caso de choque y causar el despliegue de la bolsa de aire del pasajero. Si detona un inflador, se podrían desprender fragmentos de metal puntiagudos y golpear al conductor o a otros ocupantes y provocarles lesiones graves o incluso la muerte.
¿Qué medidas adoptarán Ford y su distribuidor?	En este momento las piezas para reparar su vehículo se encuentran disponibles. Ford Motor Company ha autorizado a su distribuidor a reemplazar el inflador de la bolsa de aire del pasajero sin costo alguno (piezas y mano de obra).
¿Cuánto tiempo tomará?	El tiempo necesario para esta reparación será de menos de medio día. Sin embargo, debido a los requisitos de planificación de servicio, es posible que su distribuidor tarde un poco más.
¿Qué debe hacer?	Llame de inmediato a su distribuidor y solicite una cita de servicio para llevar a cabo esta reparación gratuita conforme a la campaña 17S01. Proporcione el VIN a su distribuidor, el cual está impreso debajo de sus datos al comienzo de esta carta. Si aún no tiene un distribuidor para realizar el servicio, puede acceder a www.Fordowner.com para conocer las direcciones de los distribuidores, ver mapas y obtener las instrucciones para llegar. Ford Motor Company le recomienda realizar esta campaña de seguridad gratuita en su vehículo. El propietario del vehículo es responsable de realizar los arreglos necesarios para llevar a cabo el trabajo. Tenga presente que: la ley federal exige que los arrendadores de vehículos que reciban este aviso de campaña envíen una copia del mismo al arrendatario en un plazo de diez días.
¿Qué pasa si usted ya no es el propietario del vehículo?	Si usted ya no es el propietario del vehículo y tiene la dirección del propietario actual, le solicitamos que le reenvíe esta carta. Usted recibió este aviso porque las regulaciones del gobierno exigen el envío de notificaciones al propietario conocido más reciente del registro. Nuestros registros se basan principalmente en datos estatales y de propiedad, que indican que usted es el propietario actual del vehículo.
¿Podemos hacer algo más por usted?	Si tiene problemas para reparar de inmediato su vehículo y sin costo alguno, comuníquese con el Gerente de Servicio de su distribuidor para solicitar ayuda. PROPIETARIOS MINORISTAS: Si tiene dudas o preguntas, comuníquese con nuestro Centro de Relación con Clientes Ford al 1-866-436-7332 y uno de nuestros representantes con gusto lo atenderán. Si desea comunicarse con nosotros a través de Internet, nuestra dirección es: www.Fordowner.com. Las personas con problemas de audición pueden llamar al 1-800-232-5952 (TDD). Los representantes están disponibles de lunes a viernes: 8:00 am a 8:00 pm (hora del Este). PROPIETARIOS DE FLOTAS: Si tiene dudas o preguntas, comuníquese con nuestro Centro de Información a Clientes de flotas al 1-800-34FLEET, elija la opción n.° 3 y uno de nuestros representantes con gusto lo atenderá. Si desea comunicarse con nosotros a través de Internet, nuestra dirección es: www.fleet.ford.com. Los representantes están disponibles de lunes a viernes: 8:00 am a 8:00 pm(hora del Este). Si aun así tiene problemas para reparar su vehículo en un periodo de tiempo razonable o sin costo alguno, puede escribir al Administrador en el National Highway Traffic Safety Administration, 1200 New Jersey Ave. S.E., Washington, D.C. 20590, llamar a la Línea directa de seguridad vehicular al 1-888-327-4236 (TTY: 1-800-424-9153) o bien visite www.safercar.gov. Mencione la Campaña de seguridad 17V-024 de la NHTSA.

Summary

Remedy

Notes

SERVICE PROCEDURE

SERVICE PROCEDURE

SERVICE PROCEDURE

Takata Airbag Recall Rental Vehicle Reimbursement Process

* * * IMPORTANT SAFETY RECALL * * *

A REPAIR IS AVAILABLE FOR YOUR VEHICLE

* * * CAMPAÑA DE SEGURIDAD IMPORTANTE * * *

* * * IMPORTANT SAFETY RECALL * * *

A REPAIR IS AVAILABLE FOR YOUR VEHICLE

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