16S39 - Fuel Conditioning Module Bottom Cover Replacement

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NHTSA Campaign Number: 16V778
Manufacturer Ford Motor Company
Components FUEL SYSTEM, DIESEL
Potential Number of Units Affected 170

Drain Valve Opening May Cause Fuel Leak

If the shield becomes dislodged, the drain valve may open resulting in a fuel leak. A fuel leak, in the presence of an ignition source, increases the risk of a fire. Under certain conditions, significant liquid fuel on the road surface may cause a slip hazard, increasing the risk of a crash.

Summary

Ford Motor Company (Ford) is recalling certain model year 2017 Ford F-250 SD, F-350 SD, F-450 SD, and F-550 SD trucks manufactured March 21, 2016, to August 28, 2016.

The protective shield on the fuel conditioning module may have inadequate adhesion, allowing the shield to become dislodged.

Remedy

Ford will notify owners, and dealers will replace the protective shield, free of charge.

The recall began November 11, 2016.

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

Ford’s number for this recall is 16S39.

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

October 25, 2016

TO: All U.S. Ford and Lincoln Dealers

SUBJECT: NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 16S39
Certain 2017 Model Year F-Super Duty Chassis Cab Vehicles Equipped with a 6.7L Diesel Engine and Midship Fuel Tank
Fuel Conditioning Module Bottom Cover Replacement

AFFECTED VEHICLES

Vehicle	Model Year	Assembly Plant	Build Dates
F-Super Duty	2017	Kentucky Truck	March 21, 2016 through August 28, 2016

Affected vehicles are identified in OASIS and FSA VIN Lists.

REASON FOR THIS SAFETY RECALL

In all of the affected vehicles, the fuel conditioning module protective foam shield may be dislodged by water spray, leaving the fuel drain plug unprotected and susceptible to unintended opening. This could lead to air ingress into the fuel system or a fuel leak. Air ingress through the fuel drain plug into the fuel system may cause the engine to stumble and possibly stall, with or without restart capability. A significant diesel fuel leak onto the road surface may increase the risk of a slip hazard and decrease the stability of vehicles on the road. A fuel leak in the presence of an ignition source may increase the risk of fire.

SERVICE ACTION

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to replace the fuel conditioning module bottom cover which will include a protective metal shield around the fuel drain plug. This service must be performed on all affected vehicles at no charge to the vehicle owner.

OWNER NOTIFICATION MAILING SCHEDULE

Owner letters are expected to be mailed the week of November 7, 2016. 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 $21,000 per vehicle. Correct all vehicles in your new vehicle inventory before delivery.

ATTACHMENTS

Attachment I: Administrative Information
Attachment II: Labor Allowances and Parts Ordering Information
Attachment III: Technical Information
Owner Notification Letter

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,

Michael A. Berardi

ATTACHMENT I

NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 16S39
Certain 2017 Model Year F-Super Duty Chassis Cab Vehicles
Equipped with a 6.7L Diesel Engine and Midship Fuel Tank
Fuel Conditioning Module Bottom Cover Replacement

OASIS ACTIVATION

OASIS will be activated on October 25, 2016.

FSA VIN LISTS ACTIVATION

FSA VIN Lists will be available through https://web.fsavinlists.dealerconnection.com on October 25, 2016. Owner names and addresses will be available by November 18, 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.

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 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

A new law prohibits a Rental Company from selling, renting or leasing vehicles subject to a safety or compliance recall. This could impact dealer-operated rental fleets of 35 vehicles or more, including FRAC, LRAC, and DDR vehicles. Please see EFC04833 for details and consult your legal counsel for legal advice.

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 within new vehicle bumper-to-bumper warranty coverage, follow existing warranty and policy guidelines for related damage claims. No SSSC approval is required for these vehicles:
- Ford vehicles – 3 years or 36,000 miles
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 (16S39) is the sub code.
Additional labor and/or parts must be claimed as related damage on a separate repair line from the FSA.

ATTACHMENT II

LABOR ALLOWANCES

Description		Labor Operation	Labor Time
Replace the fuel conditioning module bottom cover		16S39B	0.6 Hours

PARTS REQUIREMENTS / ORDERING INFORMATION

Part Number	Description	Order Quantity
HC3Z-9G270-B	Fuel conditioning module bottom cover	1

The DOR/COR number for this recall is 51064.

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

DEALER PRICE

For latest prices, refer to DOES II.

PARTS RETENTION AND RETURN

Follow the provisions of the Warranty and Policy Manual, Section 1 – WARRANTY PARTS RETENTION AND RETURN POLICIES.

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 2017 MODEL YEAR F-SUPER DUTY CHASSIS CAB VEHICLES EQUIPPED WITH A 6.7L DIESEL ENGINE AND MIDSHIP FUEL TANK — FUEL CONDITIONING MODULE BOTTOM COVER REPLACEMENT

OVERVIEW

SERVICE PROCEDURE

With the vehicle in NEUTRAL, position it on a hoist. Please follow the Workshop Manual (WSM) procedures in Section 100-02.
Disconnect the primary and secondary battery ground cables. Please follow the WSM procedures in Section 414-01.
Release the fuel system pressure by waiting two minutes after pump has shut off for the low-pressure system to bleed off pressure.
Disconnect the water-in-fuel (WIF) sensor electrical connector. See Figure 1.

FIGURE 1

Disconnect the return fuel line quick connect coupling from the fuel conditioning module or from the fuel pump and sender unit. See Figure 2. Please follow the WSM procedures in Section 310-00 for quick release coupling (Type 3) information.
- Failure to fully disconnect the return fuel line could siphon excess fuel from the fuel tank when the fuel conditioning module is drained in the next step.

FIGURE 2

Loosen the fuel drain plug. See Figure 3.
- Tighten by hand once the fuel has drained.

FIGURE 3

Loosen the bolts and remove the fuel conditioning module bottom cover. See Figure 4.
- Tighten to 44 lb.in (5 Nm).

FIGURE 4

NOTE: During installation, make sure the fuel conditioning module bottom cover O-ring is clean and not damaged.

Slide the fuel filter element to unlock it from the fuel conditioning module bottom cover. Remove the fuel filter element. See Figure 5.

FIGURE 5

Rotate the WIF sensor counter clockwise and remove the sensor. See Figure 6.

FIGURE 6

Reverse the removal procedures using the new fuel conditioning module bottom cover.
After installing the new fuel conditioning module bottom cover, bleed the fuel system. Please follow the WSM procedures in Section 310-00.

November, 2016

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

Safety Recall Notice 16S39 / NHTSA Recall 16V-778
Aviso de Revisión de Seguridad 16S39

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?	On your vehicle, the fuel conditioning module protective shield may be dislodged by road debris or water spray, leaving the fuel drain plug unprotected and susceptible to unintended opening. This could lead to air ingress into the fuel system or a substantial fuel leak. Air ingress through the fuel drain plug into the fuel system may cause engine stumble or other driveability symptoms. A fuel leak in the presence of an ignition source may increase the risk of fire. In addition, under certain conditions, significant liquid fuel on the road surface may cause a slip hazard, increasing the risk of a crash.
What will Ford and your dealer do?	Ford Motor Company has authorized your dealer to replace the fuel conditioning module bottom cover which will include a protective metal shield around the fuel drain plug free of charge (parts and labor).
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 for Recall 16S39. 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 recall completed on your vehicle. The vehicle owner is responsible for making arrangements to have the work completed. 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. Your vehicle may be equipped with a diagnostic feature called the Vehicle Health Report which can inform you about all available recalls, as well as other key vehicle health information. Please see https://owner.ford.com/vehicle-health for more information.
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 have questions or concerns, please contact our Ford Customer Relationship Center at 1-866-436-7332 and one of our representatives will be happy to assist you. If you wish to contact us through the Internet, our address is: www.Fordowner.com. For the hearing impaired call 1-800-232-5952 (TDD). Representatives are available Monday through Friday: 8:00AM – 8:00PM(Eastern Time). FLEET OWNERS: If you have questions or concerns, please contact our Fleet Customer Information Center at 1-800-34-FLEET, choose Option #3, and one of our representatives will be happy to assist you. If you wish to contact us through the Internet, our address is: www.fleet.ford.com. Representatives are available Monday through Friday: 8:00AM – 8:00PM(Eastern Time). MOTORHOME OWNERS: If you have questions or concerns, please contact our Motorhome Customer Assistance Center toll free at 1-866-906-9811. Representatives are available 24 hours a day. 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: 1-800-424-9153) or go to www.safercar.gov. Reference NHTSA Safety Recall 16V-778.
Para asistencia en Español	Visite nuestro sitio web para ver este anuncio en Español al siguiente dirección: https://es.owner.ford.com/recall. 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.