16S03 - Driver Airbag Inflator Replacement

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SUMMARY:

Ford Motor Company (Ford) is recalling certain model year 2004-2006 Ranger vehicles manufactured March 24, 2003, to May 4, 2006.

Upon deployment of the driver side frontal air bag, excessive internal pressure may cause the inflator to rupture.

CONSEQUENCE:

In the event of a crash necessitating deployment of the driver’s frontal air bag, the inflator could rupture with metal fragments striking the vehicle occupants potentially resulting in serious injury or death.

REMEDY:

Ford will notify owners, and dealers will replace the air bag inflators, free of charge.

The recall began February 26, 2016.

Owners may contact Ford customer service at 1-866-436-7332.

Ford’s number for this recall is 16S03.

Note: This recall supersedes 14V-343 and only applies to Rangers manufactured in North America.

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

May 3, 2016

TO: All U.S. Ford and Lincoln Dealers

SUBJECT: Safety Recall 16S03 – Supplement #1
All 2004-2006 Model Year Ranger Vehicles
Driver Airbag Inflator Replacement

REF: Safety Recall 15S22
Certain 2004-2006 Ford Ranger Vehicles
Passenger Airbag Inflator Replacement

REASON FOR THIS SUPPLEMENT

The process for returning replaced airbag inflators has changed. All claims paid beginning May 10, 2016 will be issued FCS-700 tags, and airbag inflators must be returned through the Regional Core Recovery Centers (RCRCs). RCRCs will only pick-up airbag inflators that have a corresponding FCS-700 Tag. Airbag inflators replaced under claims paid prior to May 10, 2016 must be returned using the previous shipping process.
To comply with NHTSA’s directive to have traceability of airbag inflator installations in vehicles, dealers are required to document the new airbag inflator serial number and provide to Ford during submission of the warranty claim.

AFFECTED VEHICLES

Vehicle	Model Year	Assembly Plant	Build Dates
Ranger	2004	Edison	April 7, 2003 through March 2, 2004
Ranger	2004 – 2006	Twin Cities	March 24, 2003 through May 4, 2006

Affected vehicles are identified in OASIS and FSA VIN Lists.

REASON FOR THIS SAFETY RECALL

SERVICE ACTION

Dealers are to replace the driver airbag inflator in vehicles ever registered in Alabama, American Samoa, Florida, Georgia, Guam, Louisiana, Hawaii, Mississippi, Puerto Rico, Saipan, Texas, or the U.S. Virgin Islands. These states and territories are identified as High Absolute Humidity (HAH) areas. Provide the customer with the Customer Information Sheet regarding the interim repair and the requirement to return at a future date for a permanent repair. This service should be performed on vehicles in the HAH area at no charge to the vehicle owner.

NOTE: This is an interim repair. The interim repair should only be performed one time per vehicle and will not close this safety recall. Repairs completed previously under 14B04 are equivalent to the interim repair under 16S03 and should not be performed again. This bulletin will be updated in late 2016 when it is expected that a permanent repair will be available.

For all vehicles outside of the HAH area, the interim repair should only be performed at customer request.

OWNER NOTIFICATION MAILING SCHEDULE

Owner Letters are expected to be mailed the week of February 22, 2016. Customers identified as having a vehicle ever registered in the HAH area that have not had repairs completed previously under 14B04 will be directed to dealers to have the interim repair under 16S03 completed. All other customers will be notified that parts are not currently available.

ATTACHMENTS

Attachment I: Administrative Information
Attachment II: Labor Allowances and Parts Ordering Information
Attachment III: Technical Information
Attachment IV: Regional Core Recovery Center Airbag Inflator Return Process
Customer Information Sheet – Interim Repair
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.

ATTACHMENT I

Safety Recall 16S03 – Supplement #1
All 2004-2006 Model Year Ranger Vehicles
Driver Airbag Inflator Replacement

OASIS ACTIVATION

OASIS was activated on January 25, 2016.

FSA VIN LISTS ACTIVATION

FSA VIN Lists were available through https://web.fsavinlists.dealerconnection.com on January 25, 2016. Owner names and addresses will be available by March 4, 2016.

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.

STOCK VEHICLES

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

SOLD VEHICLES

Owners of vehicles ever registered in the HAH area that have not had repairs completed previously under 14B04 will be directed to dealers to have the interim repair under 16S03 completed.
For dealers in the HAH area, immediately contact any of your 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.

TITLE BRANDED / SALVAGED VEHICLES

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

ADDITIONAL REPAIR (LABOR TIME AND/OR PARTS)

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

For vehicles outside new vehicle bumper-to-bumper warranty coverage, submit an Approval Request to the SSSC Web Contact Site prior to completing the repair.

OWNER REFUNDS

Refunds are not approved for this program.

RENTAL VEHICLES

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

CLAIMS PREPARATION AND SUBMISSION

Enter claims using Direct Warranty Entry (DWE) or One Warranty Solution (OWS).
- DWE: refer to ACESII manual for claims preparation and submission information.
- OWS: when entering claims in DMS software, select claim type 31: Field Service Action. The FSA number (16S03) is the sub code.

NOTE: The serial number of the new airbag inflator must be provided to Ford for the claim to be processed. The Technical Information in this bulletin advises technicians to document the new airbag inflator serial number on the repair order.

Enter the 11 character serial number of the new airbag inflator in the claim as follows:
- For claims submitted using DMS or OWS on-line, enter the serial number in the Test Results Section.
  - Select DTC REQUIRED MEASUREMENT OR RESULTS from the drop down list. Enter the serial number in the CODE field.
- For claims submitted using ACESII on-line, enter the serial number on the ACESII DIAG CODE ENTRY screen.
  - MIL ON = N
  - Enter the serial number in the OTHER field.
- Additional labor and/or parts must be claimed as related damage on a separate repair line from the FSA.

NOTE: Maintain supporting documentation for all Miscellaneous Expenses according to procedure as identified in the Warranty and Policy Manual.

ATTACHMENT II

Safety Recall 16S03 – Supplement #1
All 2004-2006 Model Year Ranger Vehicles
Driver Airbag Inflator Rep

LABOR ALLOWANCES

Description		Labor Operation	Labor Time
Replace Driver Airbag Inflator – Interim Repair Only NOTE: Will not close 16S03		16S03JJ	0.6 Hours

PARTS REQUIREMENTS / ORDERING INFORMATION

Part Number	Description	Order Quantity
4L5Z-63043B13-A	Driver Airbag Inflator Kit	1

The DOR/COR number for this recall is 51024.

Order your parts through normal order processing channels. To guarantee the shortest delivery time, an emergency order for parts must be placed.

New! PART RETENTION AND RETURN

NOTE: All replaced airbag inflators must be returned in the new inflator box. If the new airbag inflator box is damaged or lost, contact Miguel Prigadaa at 210-250-5078 or SCTakataRestraints_International@xpo.com for a replacement box.

NOTE: RCRCs will only pick-up airbag inflators that have a corresponding FCS-700 Tag. Airbag inflators replaced under claims paid prior to May 10, 2016 must be returned using the previous shipping process.

Part return instructions for dealers in the lower 48 United States:
- Dealers must monitor their PEARS register. A FCS-700 tag will be generated for each airbag inflator on claims paid on or after May 10, 2016. Airbag inflators will be picked up by the RCRCs.
- The RCRC will not pick up airbag inflators that are not properly packaged in the new inflator box. o Refer to Attachment IV for specific airbag inflator return instructions and documentation.
- Disregard prepaid FedEx shipping instructions that may be included in new airbag inflator boxes. However, airbag inflators replaced under claims paid prior to May 10, 2016 must still be returned using the previous FedEx shipping process.
Part return instructions for dealers outside of the lower 48 United States:
- Continue to follow the previous FedEx airbag inflator return process of contacting Miguel Prigadaa at 210-250-5078 or Prigadaa@email.xpo.com.
Follow the provisions of the Warranty and Policy Manual, Section 1 “WARRANTY PARTS RETENTION AND RETURN POLICIES.”

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

ALL 2004-2006 MODEL YEAR RANGER VEHICLES — DRIVER AIRBAG INFLATOR REPLACEMENT

OVERVIEW

Takata has determined that the propellant in some driver side airbag inflators may degrade over several years in service and potentially cause the airbag inflator to rupture in the event of an airbag deployment resulting from a crash. A ruptured airbag inflator could lead to injury or death in the event of a deployment. Dealers are to remove the affected airbag module from the vehicle and replace only the inflator portion of the airbag. The serial number from the new airbag inflator must be recorded on the work order. The replaced inflator will be placed into the packaging from the new inflator to be returned to Takata.

SERVICE PROCEDURE

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

Remove the driver 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.

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

Release the retaining tab and slide the airbag inflator connector off the tang. See Figure 1.
Remove and discard the four airbag inflator retaining nuts from the driver side airbag. See Figure 1.

FIGURE 1

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 2.

FIGURE 2

NOTE: In order to verify the correct airbag inflator is installed, mark the old airbag inflator with a felt tip marker prior to removal.

Remove the airbag inflator and set aside for return shipping. See Figure 1.

NOTE: The new airbag inflator must be installed in the same orientation as the original part to ensure the inflator module and airbag harness electrical connector T-shape indexes are aligned properly. See Figures 1 and 3.

Install the new inflator into the driver airbag. See Figure 1.

NOTE: Line up the T-shape index on both the wiring harness electrical connector and the airbag inflator. Pull gently on the wiring harness to ensure it is properly seated. See Figure 3.

Install and connect the new airbag wiring harness to the inflator module.

FIGURE 3

Install four new airbag inflator nuts onto the driver airbag. See Figure 1.
- Tighten to 6.5 Nm (57 lb-in).
Slide the airbag inflator connector onto the tang. See Figure 1.
Re-install the driver airbag. Please follow the 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

REGIONAL CORE RECOVERY CENTER AIRBAG INFLATOR RETURN PROCESS

PART RETURN INSTRUCTIONS AND SHIPPING DOCUMENTATION

The Regional Core Recover Center (RCRC) will only pick up airbag inflators with a corresponding FCS-700 tag, and the replaced inflator must be packaged in the box from the new inflator. A FCS700 tag will be generated for each airbag inflator on claims paid on or after May 10, 2016.

NOTE: Airbag inflators that do not have FCS-700 tags must be returned utilizing the previous return process; RCRC’s will not accept any airbag inflators that do not have FCS-700 tags.

NOTE: If the new airbag inflator box is damaged or lost, contact Miguel Prigadaa at 210-250-5078 or SCTakataRestraints_International@xpo.com for a replacement box.

Print and provide both of the following completed documents to the RCRC driver:

Hazardous Materials Shipping Document (Page 2)
1. In the box titled Shipper, enter your dealership name and address.
2. In the box titled Receiver, enter the address of your Regional Core Recovery Center. NOTE: Page 4 contains a list of RCRC locations. If you are unsure of which RCRC location serves your dealership, consult the RCRC driver.
3. In the box titled Number/Type of Package, enter the number of boxed inflators.
4. In the box titled Weight, enter the total shipment weight of all boxed inflators.
5. At the bottom of the Hazardous Materials Shipping Document, complete the Shipper’s Certification
North American Emergency Response Guide 171 (Page 3)

HAZARDOUS MATERIALS SHIPPING DOCUMENT – GROUND TRANSPORTATION

SHIPPER		RECEIVER
Dealership Name:		Ford Motor Company
		Regional Core Recovery Center
Address:		Address:
.
.
Phone:		Phone:
24-HOUR EMERGENCY CONTACT: INFOTRAC 1-800-535-5053 (Domestic) 1-352-323-3500 (International)

General Instructions: Pursuant to 49 CFR each person who offers a hazardous material for transportation shall perform the following pre- transportation functions: (1) Determine the hazard class of the material (2) Select authorized hazmat packaging

(3)Fill hazmat packaging (4) Properly close hazmat packaging (5) Properly mark the package (6) Properly label the package (7) Prepare shipping document (8) Provide and maintain emergency response information (9) Review shipping paper to verify compliance to 49 CFR (10) Sign shipping document to certify shipment is in conformance to 49 CFR (11) Load hazardous material in transport vehicle (12) Segregate hazardous material from incompatible cargo (13) Select, provide or affix placards to transport vehicle to indicate that it holds hazardous materials.

Also, pursuant to 49 CFR an employer must ensure any employee performing any function affecting the transport of hazardous materials must be appropriately trained for the function the employee performs and must be retrained every thirty-six months.

DOT Shipping Description

Number/Type of Package	UN Number, Proper Shipping Name , Hazard Class, Packing Group	Weight
Box(es)	UN3268, Safety Devices, Class 9	Lbs.
.
.
.
.
.
.

Shipper’s Certification (49 CFR 172.204): This is to certify that the above named materials are properly classified, described, packaged, marked and labeled and are in proper condition for transportation according to the applicable regulations of the Department of Transportation.

NAME: ____________________________
SIGNATURE: ___________________________DATE:________

RCRC Locations

RCRC CODE	Address	City	State	Zip
00708	TRI COUNTY COMMERCE PARK, BLDG. 3/3A, 2511 LOVI ROAD	FREEDOM	PA	15042
01183	20501 PENNSYLVANIA ROAD STE 140	BROWNSTOWN Twp	MI	48192
01326	9040 BURROUGH DOVER LANE	PENNSAUKEN	NJ	08110
01728	3700 CLAYMOORE PK. DR., S. 160	HOUSTON	TX	77043
01729	5915 CORRIDOR PARKWAY	SCHERTZ	TX	78154
02276	4300 ROUND LAKE ROAD W. UNIT 200	ARDEN HILLS	MN	55112
02454	1605 SURVEYOR BLVD.	CARROLLTON	TX	75006
03001	8333 WASHINGTON PL NE Suite E	ALBUQUERQUE	NM	87113
03199	7103 E. 47TH AVE.	DENVER	CO	80216
04861	5503 F ST	OMAHA	NE	68117
05399	3421 W. WELDON.	PHOENIX	AZ	85017
05495	4161 DIXON AVE	DES MONIES	IA	50313
05514	3645 DEVELOPERS RD.	INDIANAPOLIS	IN	46227
06201	3737 S. CAPITOL AVE.	WHITTIER	CA	90601
06583	600 SOUTH THERESA AVE.	ST LOUIS	MO	63103
06586	4444 SOUTH BLVD.	CHARLOTTE	NC	28209
06615	8242 SANDY COURT	JESSUP	MD	20794
06952	7145 INDUSTRIAL	EL PASO	TX	79915
06953	550 GILLS DRIVE	ORLANDO	FL	32824
06954	5286 GEORRGIA HWY 85, SUITE 200	FOREST PARK	GA	30297
06955	545 FORD AVE	JACKSON	MS	39209
06959	900 W. MAIN	OKLAHOMA CITY	OK	73106
07089	4304 EUBANK ROAD	RICHMOND	VA	23231
08263	11 CHAPIN RD, UNIT A	PINE BROOK	NJ	07058
08453	18637 72nd AVE S	KENT	WA	98032
08454	5220 N. E. 152ND PLACE	PORTLAND	OR	97230
08587	2999 MILLER STREET	SAN LEANDRO	CA	94577
08731	8250 NE UUNDERGROUND DRIVE PILLAR 153	KANSAS CITY	MO	64161
08858	2333 S. 1800 WEST	WEST VALLEY CITY	UT	84119
09001	3311 CORPORATE DR	JOLIET	IL	60431
09121	444 WHITNEY ST	NORTHBOROUGH	MA	01532
09252	1901 LEMOYNE AVE.	SYRACUSE	NY	13208

ATTACHMENT IV

Safety Recall 16S03 Interim Repair
Customer Information Sheet

Takata, the manufacturer of the airbag in your vehicle, has determined that the propellant in some driver side airbag inflators may degrade over several years in service and potentially cause the airbag inflator to rupture in the event of a crash necessitating deployment of the driver side frontal airbag. A new driver airbag inflator with different propellant to perform a permanent repair is not currently available. Until permanent repair parts are available, Ford Motor Company is offering an interim repair to install a newer manufactured Takata driver airbag inflator in your vehicle.

Ford is closely working with our suppliers to accelerate part availability and we apologize for any inconvenience. We expect to have permanent repair parts in late 2016 or early 2017. Ford will send a letter to inform you when parts are available, at which time you should return to a Ford dealer as soon as possible to have the permanent repair parts installed on your vehicle.

Again, we apologize for the inconvenience this situation causes and assure you that we are doing everything possible to expedite resolution.

Sincerely,

Ford Motor Company

Ford Customer Service Division

February 2016

* * * IMPORTANT SAFETY RECALL * * *
(PROGRAMA DE SEGURIDAD IMPORTANTE)

Safety Recall Notice 16S03 / NHTSA Recall 16V-036
Aviso de Revisión de Seguridad 16S03

Mr. John Sample
123 Main Street
Anywhere, USA 12345

Your Vehicle Identification Number (VIN): 12345678901234567

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.

Ford Motor Company has decided that a defect which relates to motor vehicle safety exists in your vehicle, with the VIN shown above.

We apologize for this situation and want to assure you that, with your assistance, we will correct this condition. Our commitment, together with your dealer, is to provide you with the highest level of service and support.

What is the issue?	The front driver side airbag inflator housing may rupture and deploy abnormally in the event of a crash necessitating deployment of the driver side frontal airbag. An inflator rupture could result in metal fragments striking the driver or other occupants resulting in serious injury or death.
What will Ford and your dealer do?	Ford Motor Company has authorized your dealer to replace the driver airbag inflator as an interim repair on your vehicle free of charge (parts and labor). Parts are not currently available to perform a permanent repair. Ford Motor Company will send a letter to inform you when parts are available.
How long will it take?	The time needed for this repair is less than one-half day. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.
What should you do?	Please call your dealer without delay and request a service date to perform the interim repair for Recall 16S03. Provide the dealer with your VIN, which is printed near your name at the beginning of this letter. If you do not already have a servicing dealer, you can access www.Fordowner.com for dealer addresses, maps, and driving instructions. Ford Motor Company wants you to have this safety completed on your vehicle. The vehicle owner is responsible for making arrangements to have the work completed. Ford Motor Company can deny coverage for any vehicle damage that may result from the failure to have this recall performed on a timely basis. Therefore, please have this recall performed as soon as possible. Please note: Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
What if you no longer own this vehicle?	If you no longer own this vehicle, and have an address for the current owner, please forward this letter to the new owner. You received this notice because government regulations require that notification be sent to the last known owner of record. Our records are based primarily on state registration and title data, which indicate that you are the current owner.
Can we assist you further?	If you have difficulties getting your vehicle repaired promptly and without charge, please contact your dealership’s Service Manager for assistance. RETAIL OWNERS: If you still have concerns, please contact the Ford Motor Company Customer Relationship Center at 1-866-436-7332 and one of our representatives will be happy to assist you. For the hearing impaired call 1-800-232-5952 (TDD). Representatives are available Monday through Friday: 8:00AM – 8:00PM (Eastern Time). If you wish to contact us through the Internet, our address is: www.Fordowner.com . Para asistencia en Español: Si necesita ayuda o tiene alguna pregunta, por favor llame al Centro de Relación con Clientes al 1-866-436-7332 y presione 2 para Español. FLEET OWNERS: If you still have concerns, please contact the Fleet Customer Information Center at 1-800-34-FLEET, Option #3 and one of our representatives will be happy to assist you. Representatives are available Monday through Friday: 8:00AM – 8:00PM (Eastern Time). Or you may contact us through the Internet at www.fleet.ford.com . If you are still having difficulty getting your vehicle repaired in a reasonable time or without charge, you may write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave. S.E., Washington, D.C. 20590 or call the toll free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1800-424-9153) or go to www.safercar.gov . Reference NHTSA Safety Recall 16V-036.