2006 Ford Ranger

Safety Recall 23S08 Passenger Airbag Inflator Inspection – 2004-2006 Ford Ranger

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February 24, 2023 NHTSA CAMPAIGN NUMBER: 23V125000

Replacement Air Bag Inflator Incorrectly Installed

An incorrectly installed inflator may not properly inflate the passenger air bag, increasing the risk of injury during a crash.

 

NHTSA Campaign Number: 23V125

Manufacturer FordeBay logo Motor Company

Components AIR BAGS

Potential Number of Units Affected 98,550

 

Summary

FordeBay logo Motor Company (FordeBay logo) is recalling certain 2004-2006 Ranger vehicles that received replacement front passenger air bag inflators under a previous recall. The replacement frontal passenger air bag inflators may have been installed incorrectly.

 

Remedy

Dealers will inspect and reinstall the front passenger air bag inflator, as necessary, free of charge. Owner notification letters were mailed April 5, 2023. Owners may contact FordeBay logo customer service at 1-866-436-7332. FordeBay logo’s number for this recall is 23S08.

 

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.nhtsa.gov.

 

Check if your Vehicle has a Recall

 

February 15, 2024

NEW VEHICLE DEMONSTRATION / DELIVERY HOLD –
Safety Recall 23S08 – Supplement #3
Certain 2004-2006 Model Year Ranger Vehicles
Passenger Airbag Inflator Inspection 

 

REASON FOR THIS SUPPLEMENT

  • Affected Vehicles: Additional vehicles from other markets have been added to the vehicle population. Model years and build dates have not changed.

 

AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
Ranger2004Edison19-May-2003 through 02-March-2004
Ranger2004-2006Twin Cities12-May-2003 through 02-May-2006

US population of affected vehicles: 229,010. Affected vehicles are identified in OASIS and FSA VIN Lists.

 

REASON FOR THIS SAFETY RECALL

In some of the affected vehicles, the replacement frontal passenger airbag inflator may have been installed in the incorrect orientation during a previously executed repair for Field Service Action (FSA) 17S42 or 18S02. If a previously remedied vehicle has a passenger airbag inflator that was misinstalled and is in a crash event necessitating deployment of the passenger airbag, the airbag may not deploy as intended, increasing the risk of injury.

 

SERVICE ACTION

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to inspect the passenger air bag inflator for correct installation and correct any installation errors if present. Dealers will submit photos of the air bag inflator installed correctly. This service must be performed on all affected vehicles at no charge to the vehicle owner.

 

OWNER NOTIFICATION AND MAILING SCHEDULE

Owner letters for the original population were mailed the week of April 3, 2023. Updated Owner letters for the additional population will be mailed the week of March 4, 2024. Dealers should repair any affected vehicles that arrive at their dealerships, 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 $26,315 per vehicle. Correct all vehicles in your new vehicle inventory before delivery.

 

MOBILE REPAIR RECOMMENDATIONS

  • Confirm with the customer a mobile repair is feasible.
  • Check OASIS before going to the customer’s home or business to confirm if any other outstanding FSA needs to be completed.
  • Transportation – due to the simplicity of this repair, a specialty vehicle is not required.

 

MOBILE REPAIR ADDITIONAL INFORMATION

Please ensure the technician brings the following to the mobile repair destination:

  • Printed Technical Instructions.
  • Printed Repair/Work Order or any other necessary documentation as customer copy(s) o Documents could also be emailed to the customer.
  • Shirt/uniform and vehicle graphic with the dealership or FordeBay logo logos are recommended.
  • Recommended tools and cleaning supplies: Standard hand tools.

 

MOBILE REPAIR QUESTIONS AND ASSISTANCE

  • Refer to Electronic Field Communication – EFC12071 2023 Remote Experience Program.
  • For questions and assistance, contact the Special Service Support Center (SSSC) via the SSSC Web Contact Site. Work with Dealership warranty administrator to create a SSSC contact ID#.
  • Once an SSSC agent responds to the new contact ID#, you may opt to call the SSSC hotline: (800) 325-5621.

 

MOBILE SERVICE REPAIR ASSESSMENT LEVEL

  • All repairs in this program have the following assessment level. – Light Mobile Service

 

SOLD VEHICLES

  • FordeBay logo has not issued instructions to stop selling/delivering or driving used vehicles under this safety recall. Owners should contact their dealers for an appointment to have their vehicles remedied as soon as practicable.
  • 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 new and used vehicle inventory.

 

STOCK VEHICLES

  • Correct all affected units in your new vehicle inventory before delivery.
  • Use OASIS to identify any affected vehicles in your used vehicle inventory.

 

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.

 

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.
  • FordeBay logo Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed before 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 FordeBay logo Motor Company at P.O. Box 6251, Dearborn, MI 481216251.
  • Dealers are also pre-approved 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 FordeBay logo to be excessive, will not be reimbursed.
  • Refunds will only be provided for the cost associated with the passenger air bag inflator.

 

RENTAL VEHICLES 

Rental vehicles are not approved for this program.

 

PICK-UP AND DELIVERY

All customers affected by this program have the option of complimentary Vehicle Pick-up & Delivery service (at participating dealers). Refer to EFC12071, 2023 Remote Experience Program, Pickup & Delivery (PDL) Offset section for additional details.

Dealers not participating in the 2023 Remote Experience Program for Pick-up & Delivery are authorized to claim unique services for completing this program:

  • Dealers are authorized to claim one-half labor hour per repair for vehicle pick-up & delivery services. Refer to Labor Allowances for details.
  • Dealers must retain a Vehicle Pick-up & Delivery Record with the repair order documentation.

 

PARTS REQUIREMENTS

Parts are not required to complete this repair.

 

CERTAIN 2004– 2006 RANGER VEHICLES – PASSENGER AIRBAG INFLATOR INSPECTION

 

PASSENGER AIRBAG INFLATOR INSPECTION

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 inspection.

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

1.  Remove the passenger airbag from the vehicle. Follow the WSM procedures in Section 501-20B.

2.  Set the airbag face down onto a surface that will not scratch or damage the airbag face.

3. Inspect the passenger airbag inflator to make sure that the plastic end caps are installed on correct ends of the inflator and the inflator is installed in the correct orientation as shown in Figure 1. Are the plastic end caps installed on the correct ends of the inflator and is the inflator installed correctly in the module?

Yes: Inspection PASS – NO REPAIR IS REQUIRED.

  • Capture a photo of the passenger airbag inflator as shown in Figure 1 and submit the photo via Concern Reports using the “Report a Vehicle Concern” process. Concern Reports may be submitted via Web Based PTS or through Mobile PTS using any mobile device (e.g., tablets, smart phones). Please see Page 10 for additional details.
  • Passenger airbag inflator inspection complete. Reinstall the Passenger Airbag. Follow the WSM procedures in Section 501-20B

No: Inspection DOES NOT PASS – REPAIR IS REQUIRED

  • Capture a photo of the passenger airbag inflator installed incorrectly. See Figures 1 and 2 for examples of incorrect inflator installation. This photo will be submitted along with a photo of the inflator installed correctly at a later step. Please see Page 10 for additional details. Proceed to step 4.

 

4. Disengage the orange tab and disconnect the wiring harness electrical connector. See Figure 3.

NOTE: Depending on how the inflator was previously installed, it is possible for the connector end of the inflator to be on either side of the airbag module. Figure 3 illustrates the connector on the inboard side of the module, but the process is the same if the connector end is on the outboard side of the module.

 

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

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

6. Remove the inflator from the airbag assembly by pushing outward on the inflator. See Figure 5.

 

7. Remove both end caps from the inflator by pulling them straight off. See Figure 6.

 

NOTE: Both inflator connector end caps must be installed with the tab features aligned and fully seated. Both end caps are specific to either end of the Inflator.

NOTE: The tail end cap does not have an alignment tab.

8. Align and install both inflator end caps. See Figures 7 and 8.

 

9. Install inflator into air bag assembly with connector end facing out, so that the alignment feature is aligned directly facing up. See Figure 9.

 

10. Align and Install the inflator retaining bracket. See Figure 10

 

11. Install the four nuts. Assure pop-up indicator on air bag assembly is present. See Figure 11.

  • Tighten to 3.9 Nm (35 lb-in) in the specified sequence.

 

12. Align the T-shape index on both the wiring harness electrical connector and the airbag inflator, connect the new airbag wiring harness to the inflator module and fully seat the orange tab. See Figure 12.

13. Ensure the connection between the wiring harness electrical connector and the airbag inflator by pulling gently on the connector to ensure it is properly seated. See Figure 12.

 

14. Install inflator harness connector to the air bag assembly bracket. See Figure 13.

 

15. Capture a photo of the passenger airbag inflater installed correctly and submit along with the photo of the incorrect installation taken in step 3. Submit the photos via Concern Reports using the “Report a Vehicle Concern” process. Concern Reports may be submitted via Web Based PTS or through Mobile PTS using any mobile device (e.g., tablets, smart phones). Please see Page 10 for additional details.

16. Re-install the passenger airbag. Follow the WSM procedures in Section 501-20B.

17. Confirm that the airbag Readiness light still indicates no SRS faults are present.

 


⬇ Download PDF (2.6 MB)

 

Chronology of Defect Determination – 23S08

November – December 2022
On November 17, 2022, FordeBay logo’s Critical Concern Group (CCRG) initiated an investigation into reports of improperly installed frontal passenger airbag inflators in vehicles previously repaired as part of FordeBay logo Field Service Actions 17S42 and 18S02 (NHTSA Campaign Numbers 17V-788 and 18V-022). In order to conduct the recall repairs, dealers and a third-party mobile repair team replaced the frontal passenger airbag inflator. Detailed work instructions explained the service procedure; however, some previously executed Field Service Actions repairs resulted in the replacement inflators being installed in an incorrect orientation.

A third party mobile repair team first discovered an incorrectly installed airbag inflator while servicing a vehicle with an open recall VIN. In that vehicle, the third party mobile repair team reported that the frontal passenger airbag inflator had been replaced, but the new inflator was incorrectly installed.

Initial investigation steps included outreach to the third party mobile repair team to identify any vehicles they found with an incorrect inflator repair installation. In parallel, FordeBay logo searched inspection audits for airbag recall repairs and identified two examples of frontal passenger airbag inflator repairs that were found to be installed in an incorrect orientation.

January – February 2023
Analysis of the incorrect repairs indicated it is possible that the previous airbag recall repairs were performed incorrectly by a third party mobile repair team and by select dealerships that previously were subject to FordeBay logo’s recall repair audits. In January 2023, FordeBay logo consulted with technicians involved in the incorrect repairs. Technicians who mis-installed the inflator told FordeBay logo they did not review the instructions prior to installation.

FordeBay logo has developed enhanced dealer messaging and technical service notifications to reemphasize the importance of following service instructions and installing the airbag inflator correctly. Service kits will be reworked by the service packager to help ensure the replacement inflator can only be installed in the correct orientation. Additionally, an instruction sheet will be added to the service kit box that illustrates a correct and incorrect installation.

As of February 6, 2023, seven (7) total vehicles with incorrect inflator orientation have been identified from October 12, 2022, through January 24, 2023. Five (5) of those vehicles were identified by the third party mobile repair team, and two (2) other vehicles were discovered when conducting the review of select dealership repairs. These seven (7) vehicles have subsequently been re-repaired correctly.

On February 15, 2023, FordeBay logo had an information-sharing meeting with NHTSA ODI, and discussed the criteria for inclusion in this potential action.

FordeBay logo is not aware of any warranty or field reports related to this condition.

On February 17, 2023, FordeBay logo’s Field Review Committee reviewed the concern and approved a field action.

FordeBay logo is not aware of any reports of accident or injury related to this condition.

###

 

3 Affected Products

Vehicle

MAKEMODELYEAR
FORDeBay logoRANGER2004-2006

 

13 Associated Documents

Miscellaneous Document – Chronology of Defect Determination – 23S08

RMISC-23V125-8030.pdf 33.996KB


⬇ Download PDF (33.2 KB)

 

Defect Notice 573 Report

RCLRPT-23V125-5488.PDF 213.94KB

 

Manufacturer Notices(to Dealers,etc) – Advance Notice re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice – Safety Recall 23S08 Certain 2004-2006 Model Year Ranger Vehicles Passenger Airbag Inflator Inspection

RCMN-23V125-7591.pdf 43.853KB


⬇ Download PDF (42.83 KB)

 

Recall Acknowledgement

RCAK-23V125-6746.pdf 644.996KB

 

Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 23S08 Certain 2004-2006 Model Year Ranger Vehicles Passenger Airbag Inflator Inspection

RCMN-23V125-6333.pdf 10429.958KB


⬇ Download PDF (9.95 MB)

 

ISSUED Owner Notification Letter(Part 577)

RCONL-23V125-4965.pdf 49.851KB


⬇ Download PDF (48.68 KB)

 

Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 23S08 – Supplement #1 Certain 2004-2006 Model Year Ranger Vehicles Passenger Airbag Inflator Inspection

RCMN-23V125-5968.pdf 10247.089KB


⬇ Download PDF (9.77 MB)

 

Recall 573 Report – 4/28/23

RCLRPT-23V125-9984.PDF 214.024KB

 

Recall 573 Report – 4/28/23

RCLRPT-23V125-6170.PDF 214.024KB

 

Recall Quarterly Report #1, 2023-2

RCLQRT-23V125-5819.PDF 211.141KB

 

Recall Quarterly Report #2, 2023-3

RCLQRT-23V125-9802.PDF 211.374KB

 

Recall Quarterly Report #3, 2023-4

RCLQRT-23V125-0143.PDF 211.46KB

 

Manufacturer Notices(to Dealers,etc)

RCMN-23V125-5992.pdf 2724.374KB


⬇ Download PDF (2.6 MB)

 

Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V125&docType=RCL

 

 

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