14B07 – Transmission Inspection and Repair – 2013-2014 Ford C-Max & Fusion Hybrid

SEOCONTENT-START

Ó Copyright 2015 Ford Motor Company
Michael A. Berardi Ford Motor Company
Director P. O. Box 1904
Service Engineering Operations Dearborn, Michigan 48121
Ford Customer Service Division
November 9, 2015
TO: All U.S. Ford and Lincoln Dealers
SUBJECT: Customer Satisfaction Program 14B07
Certain 2013 through 2014 Model Year C-Max Hybrid and Fusion Hybrid Vehicles
Transmission Inspection and Repair
REF :
TSB 14-0214 – HF35 Transmission – Thumping/Rubbing Or Grinding Noise
Dated November 13, 2014
PROGRAM TERMS
This program will be in effect through May 31, 2016. There is no mileage limit for this program.
URGENCY / EXPIRATION DATE
This Customer Satisfaction Program has an expiration date of May 31, 2016 to encourage dealers
and customers to have this service performed as soon as possible.
We recommend dealers utilize their FSA VIN Lists name and address (available on December 4,
2015) to contact customers with affected vehicles. This will help minimize the number of vehicles that
may exhibit transfer shaft gear assembly-to-damper housing contact, which requires a more extensive
repair.
AFFECTED VEHICLES
Vehicle Model Year Assembly Plant Build Dates
Fusion Hybrid 2013-2014 Hermosillo November 30, 2012 through January 21, 2014
C-Max Hybrid 2013-2014 Michigan August 8, 2012 through June 17, 2014
Affected vehicles are identified in OASIS and FSA VIN Lists.
REASON FOR THIS PROGRAM
Under certain driving conditions, the transfer shaft gear assembly bearing may fail prematurely. This
can result in thumping, rubbing, or grinding noises from the transmission, and may be accompanied
by the illumination of the powertrain fault indicator (wrench light) in the instrument cluster.
SERVICE ACTION
Dealers are to disassemble and inspect the transmission for damage or excessive wear, then either
repair or replace the transmission as needed. This service must be performed on all affected vehicles
at no charge to the vehicle owner.
NOTE: Technical Assistance Center prior approval is not required if the transmission requires
replacement under this program.
OWNER NOTIFICATION MAILING SCHEDULE
Owner Letters are expected to be mailed the week of November 16, 2015. Dealers should repair any
affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.
Ó Copyright 2015 Ford Motor Company
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
Ó Copyright 2015 Ford Motor Company
ATTACHMENT I
Page 1 of 2
Customer Satisfaction Program 14B07
Certain 2013 through 2014 Model Year C-Max Hybrid and Fusion Hybrid Vehicles
Transmission Inspection and Repair
OASIS ACTIVATION
OASIS will be activated on November 9, 2015.
FSA VIN LISTS ACTIVATION
FSA VIN Lists will be available through https://web.fsavinlists.dealerconnection.com on November 9,
2015. Owner names and addresses will be available by December 4, 2015.
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 program 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 service
action.
STOCK VEHICLES
Use OASIS to identify any affected vehicles in your used vehicle inventory.
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.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this service action.
ADDITIONAL LABOR TIME AND/OR PARTS
Submit a request to the SSSC Web Contact Site prior to the repair if you have any of the following:
• Damage that you believe was caused by the covered condition.
• A condition that requires additional labor and/or parts to complete the repair.
• Aftermarket equipment or non-Ford modifications to the vehicle which might prevent the repair
of the covered condition.
Requests for approval after completion of the repair may not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not had
this recall performed on a timely basis. Additional related damage parts are subject to random
selection for return to the Ford Warranty Parts Analysis Center (WPAC).
Ó Copyright 2015 Ford Motor Company
ATTACHMENT I
Page 2 of 2
Customer Satisfaction Program 14B07
Certain 2013 through 2014 Model Year C-Max Hybrid and Fusion Hybrid Vehicles
Transmission Inspection and Repair
OWNER REFUNDS
• Ford Motor Company is offering a refund for owner-paid repairs covered by this program if the
repair was performed before the date of the Owner Notification Letter. This refund offer
expires January 31, 2016.
• Dealers are also pre-approved to refund owner-paid emergency repairs that were performed
away from an authorized servicing dealer after the date of the Owner Notification Letter.
There is no expiration date for emergency repair refunds. Non-covered repairs, or those
judged by Ford to be excessive, will not be reimbursed.
• Refunds will only be provided for the cost associated with transmission replacement caused by
transfer shaft gear assembly bearing failure.
RENTAL VEHICLES
If you have a unique circumstance which may require a rental vehicle, please contact the SSSC via
the SSSC Web Contact Site.
CLAIMS PREPARATION AND SUBMISSION
• Enter claims using Direct Warranty Entry (DWE) or One Warranty Solution (OWS).
o DWE: refer to ACESII manual for claims preparation and submission information.
o OWS: when entering claims in DMS software, select claim type 31: Field Service Action.
The FSA number (14B07) is the sub code.
• Additional labor and/or parts must be claimed as related damage on a separate repair line
from which the FSA is claimed. Additional labor and/or parts require prior approval from the
SSSC via the SSSC Web Contact Site.
• Submit refunds on a separate repair line.
– Program Code: 14B07 – Misc. Expense: ADMIN
– Misc. Expense: REFUND – Misc. Expense: 0.2 Hrs.
• Multiple refunds should be submitted on one repair line and the invoice details for each repair
should be detailed in the comments section of the claim.
• For rental vehicle claiming, follow Extended Service Plan (ESP) guidelines for dollar amounts.
Enter the total amount of the rental expense under Miscellaneous Expense code “Rental”.
• PROGRAM TERMS: This program will be in effect through May 31, 2016. There is no
mileage limit for this program.
Ó Copyright 2015 Ford Motor Company
ATTACHMENT II
Page 1 of 4
Customer Satisfaction Program 14B07
Certain 2013 through 2014 Model Year C-Max Hybrid and Fusion Hybrid Vehicles
Transmission Inspection and Repair
LABOR ALLOWANCES
Description Vehicle Type Labor Operation Labor Time
Inspect and repair transmission (passes
inspection)
C-Max Hybrid
14B07B
11.6 Hours
Fusion Hybrid 9.9 Hours
Inspect and replace transmission (fails
inspection)
C-Max Hybrid
14B07C
10.0 Hours
Fusion Hybrid 8.3 Hours
Set front end toe – vehicles without Lane
Departure Warning System (use with
either 14B07B or 14B07C)
Fusion Hybrid 14B07D 0.6 Hours
Set front end toe – vehicles with Lane
Departure Warning System (use with
either 14B07B or 14B07C)
Fusion Hybrid 14B07F 0.8 Hours
PARTS REQUIREMENTS / ORDERING INFORMATION
For simplicity, parts requirements for Fusion Hybrid vehicles and C-Max Hybrid vehicles have been
separated into different tables. Each table contains three sections as follows:
• Parts that are common to both repair options (transmission repair and transmission
replacement)
• Additional parts that are to be used only for transmission repair (transmission passed
inspection)
• Additional parts that are to be used only for transmission replacement (transmission failed
inspection)
See Page 2 for Fusion Hybrid parts and Page 3 for C-Max Hybrid parts.
Ó Copyright 2015 Ford Motor Company
ATTACHMENT II
Page 2 of 4
Customer Satisfaction Program 14B07
Certain 2013 through 2014 Model Year C-Max Hybrid and Fusion Hybrid Vehicles
Transmission Inspection and Repair
Part Number Description – Fusion Vehicles Only
Order
Quantity
Use the parts below for both transmission repair and transmission replacement
W714878-S439 Steering shaft bolt (4/package, 1 needed) 1
W520215-S440 Outer tie rod end nut (4/package, 2 needed) 1
W705606-S440 Lower stabilizer bar link nut (2/package, 2 needed) 1
W500545-S439 Lower ball joint bolt (4/package, 2 needed) 1
W520214-S442 Lower ball joint nut (1/package, 2 needed) 2
W716457-S439 Subframe bolts (4/package, 4 needed) 1
BB5Z-4B422-B LH halfshaft circlip 1
W520102-S442 RH halfshaft bearing support nuts (4/package, 2 needed) 1
Use the additional parts below for transmission repair only (passed inspection)
FG9Z-7H348-B Transmission end cover service kit 1
DG9Z-7048-A Input shaft seal 1
BB5Z-1S177-C RH output seal 1
9L8Z-1177-G LH output seal 1
ZC-30-A Motorcraft silicone gasket remover 1
TA-29 Motorcraft ultra silicone sealant 1
ZC-31-B Motorcraft metal surface prep wipes (25 per package, 2 needed) 1
XT-10-QLVC
Motorcraft automatic transmission fluid (1 quart bottles – 6 quarts
needed for flushing the transmission cooler and lines and 5 quarts
needed for refilling the transmission after repairs)
11
Use the additional parts below for transmission replacement only (failed inspection)
DM5Z-7000-K Automatic transmission assembly 1
XT-10-QLVC
Motorcraft automatic transmission fluid (1 quart bottles – 6 quarts
needed for flushing the transmission cooler, 3 quarts allowed for
topping off the transmission)
9
Ó Copyright 2015 Ford Motor Company
ATTACHMENT II
Page 3 of 4
Customer Satisfaction Program 14B07
Certain 2013 through 2014 Model Year C-Max Hybrid and Fusion Hybrid Vehicles
Transmission Inspection and Repair
Part Number Description – C-Max Vehicles Only
Order
Quantity
Use the parts below for both transmission repair and transmission replacement
CV6Z-9448-A Exhaust manifold gasket 1
W704474-S437 Exhaust manifold stud (4/package, 7 needed) 2
W713095-S437 Exhaust manifold nut (4/package, 7 needed) 2
CV6Z-9450-B Exhaust flange gasket 1
W520103-S442 Exhaust flange nuts (4/package, 2 needed) 1
DS7Z-19B596-A Refrigerant hose seal kit 1
AE5Z-4B422-A LH halfshaft circlip 1
CV6Z-3B477-A Halfshaft nut and washer (1/package, 2 needed) 2
W520102-S442 RH halfshaft bearing support nuts (4/package, 2 needed) 1
W715491-S442 Lower ball joint bolt (4/package, 2 needed) 1
W520415-S442 Lower ball joint nut (4/package, 2 needed) 1
VC-3DIL-B Motorcraft® orange antifreeze/coolant (1 gallon pre-diluted) 2
Use the additional parts below for transmission repair only (passed inspection)
FG9Z-7H348-B Transmission end cover service kit 1
DG9Z-7048-A Input shaft seal 1
BB5Z-1S177-C RH output seal 1
9L8Z-1177-G LH output seal 1
ZC-30-A Motorcraft silicone gasket remover 1
TA-29 Motorcraft ultra silicone sealant 1
ZC-31-B Motorcraft metal surface prep wipes (25 per package, 2 needed) 1
XT-10-QLVC
Motorcraft automatic transmission fluid (1 quart bottles – 6 quarts
needed for flushing the transmission cooler and lines and 5 quarts
needed for refilling the transmission after repairs)
11
Use the additional parts below for transmission replacement only (failed inspection)
DM5Z-7000-K Automatic transmission assembly 1
XT-10-QLVC
Motorcraft automatic transmission fluid (1 quart bottles – 6 quarts
needed for flushing the transmission cooler, 3 quarts allowed for
topping off the transmission)
9
Ó Copyright 2015 Ford Motor Company
ATTACHMENT II
Page 4 of 4
Customer Satisfaction Program 14B07
Certain 2013 through 2014 Model Year C-Max Hybrid and Fusion Hybrid Vehicles
Transmission Inspection and Repair
PARTS REQUIREMENTS / ORDERING INFORMATION, Continued
The DOR/COR number for this program is 51012.
Order your parts requirements through normal order processing channels.
For questions regarding parts, contact SSSC via the SSSC Web Contact Site.
DEALER PRICE
For latest prices, refer to DOES II.
HANDLING ALLOWANCE
An allowance of $330 per repair is being provided in lieu of part mark-up for transmission assemblies
if the transmission fails the inspection and must be replaced.
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.

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ATTACHMENT III
PAGE 1 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
CERTAIN 2013 – 2014 MODEL YEAR C-MAX HYBRID AND FUSION HYBRID
VEHICLES — TRANSMISSION INSPECTION AND REPAIR
OVERVIEW
Under certain driving conditions, the transfer shaft gear assembly bearing may fail prematurely. This
can result in thumping, rubbing, or grinding noises from the transmission, and may be accompanied by
the illumination of the powertrain fault indicator (wrench light) in the instrument cluster. Dealers are to
disassemble and inspect the transmission for damage or excessive wear, then either repair or replace the
transmission as needed.
SERVICE PROCEDURE
1. Remove the transmission assembly. Please follow the Workshop Manual (WSM) procedures in
Section 307-01.
2. Flush transmission fluid cooling system. Please follow the WSM procedures in Section 307-02.
3. Follow the Transmission – Disassembly and Inspection Procedure starting on Page 2.
– Is contact or wear present on damper housing or any of the gears or bearings?
– No – Proceed to Transmission – Repair and Assembly Procedure starting on Page 4.
– Yes – Install a new transmission assembly. Please follow the WSM procedures in
Section 307-01.
ATTACHMENT III
PAGE 2 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
E151264
FIGURE 1
Transmission – Disassembly and Inspection Procedure
1. Remove the bolts and the damper housing. See Figure 1.
2. Remove the transfer shaft gear assembly, traction motor drive gear assembly, final drive input gear
assembly, and the differential carrier gear assembly. See Figure 2.
1452A
FIGURE 2
ATTACHMENT III
PAGE 3 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
1452B
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
PASS INSPECTION
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
FAIL INSPECTION PASS INSPECTION
FIGURE 3
3. Inspect the damper housing for contact or wear from the transfer shaft gear assembly. See Figure 3.
Also inspect all gears and bearings (removed in Step 2) for damage or excessive wear. Are any
concerns present?
– No – Proceed to Transmission – Repair and Assembly Procedure starting on Page 4.
– Yes – Install a new transmission assembly. Please follow the WSM procedures in Section 307-01.
ATTACHMENT III
PAGE 4 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
Transmission – Repair and Assembly Procedure
204-029
Drawbar
205-153 (T80T-4000-W)
Handle
307-541
Installer, Transfer Gear Bearing
TKIT-2005D1-F
307-576
Installer, Bearing Cup
TKIT-2006UF-FLM
TKIT-2006UF-ROW
307-591
Shim Gauge, Dierential/Transfer Gear Bearing
TKIT-2006UF-FLM
TKIT-2006UF-ROW
307-626
Installer, Dierential Seal
TKIT-2008ET-FLM
TKIT-2008ET-ROW
307-672
Installer, Input Guide and Seal
TKIT-2010D-FLM
TKIT-2010D-ROW
307-692
Tool, Transfer Gear Preload
TKIT-2012C-FL
TKIT-2012C-ROW
TKIT-2012C-ROW2
307-693
Installer, Transfer Gear Bearing Cup
TKIT-2012C-FL
TKIT-2012C-ROW
TKIT-2012C-ROW2
Feeler Gauge
Hydraulic Press
Special Tool(s) / General Equipment
307-163 (T86P-70043-A)
Remover, Stator Case Bearing
TKIT-1986-F
TKIT-1986-LM
307-586
Remover, Dierential Bearing Cup
TKIT-2006UF-FLM
TKIT-2006UF-ROW
308-001 (T58L-101-B)
Remover, Pilot Bearing
Hydraulic Press
Puller
Punch
Disassembly Assembly
Differential – Disassembly and Assembly
204-069 (T81P-1104-C)
Remover/Installer, Front Wheel Hub
307-587
Installer and Guide, Dierential Bearing
TKIT-2006UF-FLM
TKIT-2006UF-ROW
Hydraulic Press
Puller
ATTACHMENT III
PAGE 5 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
E153250
307-163
308-001
FIGURE 4
1. Using the special tools, remove and discard the transmission side transfer gear bearing cup.
See Figure 4.
• Use Special Service Tools: 308-001 Remover, Pilot Bearing and 307-163 Remover, Stator Case
Bearing.
E151693
FIGURE 5
2. Remove and discard the LH halfshaft seal. See Figure 5.
• Use the General Equipment: Punch.
ATTACHMENT III
PAGE 6 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
E151698
x2
FIGURE 6
3. Remove the retainers and the transmission fluid oil sump baffle. See Figure 6.
E151718
FIGURE 7
4. Remove and discard the RH halfshaft seal. See Figure 7.
• Use the General Equipment: Punch.
E151719
FIGURE 8
5. Remove and discard the input shaft oil seal. See Figure 8.
• Use the General Equipment: Punch.
ATTACHMENT III
PAGE 7 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
E151843
308-001
307-163
FIGURE 9
6. Remove and discard the damper housing side transfer gear bearing cup. See Figure 9.
• Use Special Service Tool: 308-001 Remover, Pilot Bearing and 307-163 Remover, Stator Case
Bearing.
E151885
FIGURE 10
7. Remove and discard the transfer shaft preload shim. See Figure 10.
ATTACHMENT III
PAGE 8 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
E151846
307-586
1 2
3
FIGURE 11
8. Install 307-586 Remover, Differential Bearing Cup onto the damper housing bearing cup.
See Figure 11.
1. Position the 307-586 Remover, Differential Bearing Cup in the damper housing with the tabs on
the 307-586 Remover, Differential Bearing Cup aligned with the slots in the damper housing.
• Use Special Service Tool: 307-586 Remover, Differential Bearing Cup.
2. Expand the 307-586 Remover, Differential Bearing Cup by hand.
3. While holding the 307-586 Remover, Differential Bearing Cup in the expanded position with the
tabs in the slots of the damper housing, tighten the nut.
E151856
FIGURE 12
9. Remove and discard the damper housing side differential bearing cup. See Figure 12.
• Use Special Service Tool: 307-586 Remover, Differential Bearing Cup.
• Use the General Equipment: Hydraulic Press.
ATTACHMENT III
PAGE 9 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
E151884
FIGURE 13
10. Remove and discard the differential preload shim. See Figure 13.
E150580
204-069
FIGURE 14
11. Remove and discard the upper differential bearing using a Bearing Puller and Step Plate.
See Figure 14.
• Use Special Service Tool: 204-069 Remover/Installer, Front Wheel Hub.
• Use the General Equipment: Puller.
ATTACHMENT III
PAGE 10 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
307-587/1
307-587/2
E150586 FIGURE 15
12. Install the new upper differential bearing. See Figure 15.
• Use Special Service Tool: 307-587 Installer and Guide, Differential Bearing.
• Use the General Equipment: Hydraulic Press.
E152114
FIGURE 16
13. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive
means to clean sealing surfaces. These tools cause scratches and gouges which
make leak paths.
Make sure that the transmission mating faces are clean and free of foreign material. Please follow
RTV Sealing Surface Cleaning and Preparation in WSM Section 303-00 – Engine System – General
Information, General Procedures. See Figures 16 and 17.
NOTE: Do not apply metal surface prep at this time. This should be applied just before the silicone
sealant is applied, during assembly.
ATTACHMENT III
PAGE 11 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
E152113
FIGURE 17
E153252
307-693
205-153
FIGURE 18
14. Install the new transmission case side transfer shaft bearing cup. See Figure 18.
• Use Special Service Tool: 205-153 Handle and 307-693 Installer, Transfer Gear Bearing Cup.
ATTACHMENT III
PAGE 12 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
E152160
FIGURE 19
15. Install the new transfer shaft gear assembly and the differential carrier gear assembly. See Figure 19.
E151960
FIGURE 20
16. Place the new differential bearing cup and the new transfer shaft bearing cup on the bearings.
See Figure 20.
ATTACHMENT III
PAGE 13 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
E151968
307-591/1 307-692
FIGURE 21
17. Install the special tools on top of the bearing cups. See Figure 21.
• Use Special Service Tool: 307-591 Shim Gauge, Differential/Transfer Gear Bearing and 307-692
Tool, Transfer Gear Preload.
E151969
307-591/3
307-591/3
FIGURE 22
NOTE: Make sure that the silicone has been cleaned off the machined surface of the transmission case
and the damper housing before installing the 307-591/3 Shim Gauge, Differential/Transfer Gear
Bearing (4 spacers) or the preload measurement may be inaccurate.
18. Install the special tools, placing the spacers on the studs. See Figures 22 and 23.
• Use Special Service Tool: 307-591 Shim Gauge, Differential/Transfer Gear Bearing.
ATTACHMENT III
PAGE 14 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
E151974
307-591/3
307-591/3
FIGURE 23
E151975
FIGURE 24
19. Install the damper housing on the special tools. See Figure 24.
E152013
307-591/3
FIGURE 25
20. Install the nuts on the studs. See Figure 25.
• Use Special Service Tool: 307-591 Shim Gauge, Differential/Transfer Gear Bearing.
• Tighten to 18 lb.ft (24 Nm).
ATTACHMENT III
PAGE 15 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
E152023
FIGURE 26
21. Rotate the transfer shaft and the differential several times to seat the bearing cups. See Figure 26.
E152051
FIGURE 27
22. Using a feeler gauge, measure and record the smallest and largest preload gap on the 307-591/1
Shim Gauge, Differential/Transfer Gear Bearing. Average the two measurements to get the
measurement needed when referring to the shim chart for proper shim selection. See Figure 27.
– Refer to the WSM Specifications chart for proper shim selection/part number, (307-01 Automatic
Transmission – Automatic Transmission – HF35, Specifications).
NOTE: Measurements and shim thicknesses are not the same.
ATTACHMENT III
PAGE 16 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
E152053
FIGURE 28
23. Using a feeler gauge measure and record the smallest and largest preload gap on the 307-692 Tool,
Transfer Gear Preload. Average the two measurements to get the measurement needed when
referring to the shim chart for proper shim selection. See Figure 28.
– Refer to the WSM Specifications chart for proper shim selection/part number, (307-01 Automatic
Transmission – Automatic Transmission – HF35, Specifications).
NOTE: Measurements and shim thicknesses are not the same.
E151885
FIGURE 29
24. Install the new transfer shaft preload shim. See Figure 29.
ATTACHMENT III
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CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
E152054
307-693
205-153
FIGURE 30
25. Using the special tools, install the new damper housing side transfer gear bearing cup.
See Figure 30.
• Use Special Service Tool: 205-153 Handle and 307-693 Installer, Transfer Gear Bearing Cup.
E151884
FIGURE 31
26. Install the new differential preload shim. See Figure 31.
ATTACHMENT III
PAGE 18 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
E152055
204-029
307-576
204-029 307-541
FIGURE 32
27. Using the special tools, install the new damper housing side differential bearing cup. See Figure 32.
• Use Special Service Tool: 204-029 Drawbar, 307-541 Installer, Transfer Gear Bearing and
307-576 Installer, Bearing Cup.
ATTACHMENT III
PAGE 19 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
307-672/2
E187772
FIGURE 33
28. Using the special tool, install the new input shaft oil seal. See Figure 33.
• Use Special Service Tool: 307-672 Installer, Input Guide and Seal.
E152156
205-153
307-626
FIGURE 34
29. Using the special tool, install the new RH halfshaft seal. See Figure 34.
• Use Special Service Tool: 205-153 Handle and 307-626 Installer, Differential Seal.
ATTACHMENT III
PAGE 20 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
E151698
x2
FIGURE 35
30. Install the transmission fluid oil sump baffle and the retainers. See Figure 35.
• Tighten to 97 lb.in (11 Nm).
E152157
205-153
307-626
FIGURE 36
31. Using the special tool, install the new LH halfshaft seal. See Figure 36.
• Use Special Service Tool: 205-153 Handle and 307-626 Installer, Differential Seal.
ATTACHMENT III
PAGE 21 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
E151686
FIGURE 37
32. Install the differential carrier gear assembly. See Figure 37.
E151663
FIGURE 38
33. Install the final drive input gear assembly. See Figure 38.
E151631
FIGURE 39
34. Install the new transfer shaft gear assembly and the traction motor drive gear assembly.
See Figure 39.
ATTACHMENT III
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CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
E152154
FIGURE 40
NOTE: Before applying silicone sealant, finish cleaning the transmission case mating surfaces and apply
the metal surface prep. Follow the RTV Sealing Surface Cleaning and Preparation procedures in
WSM Section 303-00 – Engine System – General Information, General Procedures.
35. NOTE: Make sure silicone is applied to the shoulder on the inner bolt hole.
Apply Ultra Silicone Sealant / TA-29 to the transmission case assembly. See Figure 40.
E151264
FIGURE 41
36. NOTE: Tighten in a crisscross pattern.
Install the damper housing and the bolts. See Figure 41.
• Tighten to 18 lb.ft (25 Nm).
ATTACHMENT III
PAGE 23 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
1452C
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
PASS INSPECTION
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
TAPE COVERING HOLES
FIGURE 42
37. Place tape over transmission mount boss holes to prevent any debris lodged in the holes from falling
into transmission during removal. See Figure 42.
E152795
FIGURE 43
38. Remove the transmission case end cover bolts. Remove and discard the transmission case end
cover assembly. See Figure 43.
ATTACHMENT III
PAGE 24 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
39. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive
means to clean sealing surfaces. These tools cause scratches and gouges which
make leak paths.
Make sure that the transmission mating faces are clean and free of foreign material. Please follow
RTV Sealing Surface Cleaning and Preparation in WSM Section 303-00 – Engine System – General
Information, General Procedures. See Figure 44.
E152800
FIGURE 44
40. Apply Ultra Silicone Sealant / TA-29 to the transmission case assembly. See Figure 45.
E152801
FIGURE 45
ATTACHMENT III
PAGE 25 OF 25
CUSTOMER SATISFACTION PROGRAM 14B07
CPR © 2015 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2015
E152795
FIGURE 46
41. Install the new transmission case end cover assembly and the bolts. See Figure 46.
• Tighten to 18 lb.ft (25 Nm).

**************************************************************************************************************

Ó Copyright 2015 Ford Motor Company
Ford Motor Company
Ford Customer Service Division
P. O. Box 1904
Dearborn, Michigan 48121
November 2015
Customer Satisfaction Program 14B07
Programa de satisfacción del cliente 14B07
Mr. John Sample
123 Main Street
Anywhere, USA 12345
Your Vehicle Identification Number (VIN): 12345678901234567
At Ford Motor Company, we are committed not only to building high quality, dependable products, but
also to building a community of happy, satisfied customers. To demonstrate that commitment, we are
providing a no-charge Customer Satisfaction Program for your vehicle with the VIN shown above.
Why are you
receiving this
notice?
Under certain driving conditions, the transfer shaft gear assembly
bearing on your vehicle may fail prematurely. This can result in
thumping, rubbing, or grinding noises from the transmission, and
may be accompanied by the illumination of the powertrain fault indicator in the
instrument cluster (shown above to the right).
What will Ford and
your dealer do?
In the interest of customer satisfaction, Ford Motor Company has authorized
your dealer to inspect your vehicle’s transmission and either repair or replace
it free of charge (parts and labor) under the terms of this program.
This Customer Satisfaction Program will be in effect until May 31, 2016
regardless of mileage. Coverage is automatically transferred to subsequent
owners.
How long will it take? The time needed for this repair is less than two days. 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 Customer
Satisfaction Program 14B07. Provide the dealer with the VIN of your vehicle,
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 service action 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 service action performed
on a timely basis. Therefore, please have this service action performed as
soon as possible.
Ó Copyright 2015 Ford Motor Company
Have you previously
paid for this repair?
If you have previously paid for a repair that addresses the issue described in
this letter, you still need to have this service action performed to ensure the
correct parts and procedures were used.
If the previously paid for repair was performed before the date of this letter,
you may be eligible for a refund. Refunds will only be provided for service
related to transmission repairs related to transfer shaft gear assembly bearing
failure. To verify eligibility and expedite reimbursement, give your paid
original receipt to your dealer before January 31, 2016. To avoid delays, do
not send receipts to Ford Motor Company.
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 our records, which are based primarily on
state registration and title data, 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.
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.
Thank you for your attention to this important matter.
Ford Customer Service Division

SEOCONTENT-END