Safety Recall 17S42 – Supplement #4 – Driver and Passenger Airbag Inflator Replacement – 2004-2006 Ford Ranger – Ford & Lincoln

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NHTSA Campaign Number: 17V787
Manufacturer Ford Motor Company
Components AIR BAGS
Potential Number of Units Affected 328,213

Driver Side Air Bag Inflator May Rupture

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.

Summary

Ford Motor Company (Ford) is superseding a previous recall for certain 2004-2006 Ford Ranger trucks to implement a final repair. Upon deployment of the driver side frontal air bag, excessive internal pressure may cause the inflator to rupture.

Remedy

Ford will notify owners, and dealers will replace the driver’s frontal air bag inflator with an alternate inflator, free of charge. The recall is expected to begin December 26, 2017, and will be launched in phases through the end of March 2018. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 17S42. Note: This recall supersedes recall 16V-036 which was an interim repair. Vehicles that received a replacement air bag inflator under the previous campaign need to return to a dealer to have an alternate inflator installed.

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

NHTSA Campaign Number: 17V788
Manufacturer Ford Motor Company
Components AIR BAGS
Potential Number of Units Affected 328,213

Passenger Frontal Air Bag Inflator May Rupture

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

Summary

Ford Motor Company (Ford) is superseding a previous recall for certain 2004-2006 Ford Ranger trucks to implement a final repair. Upon deployment of the passenger side frontal air bag, excessive internal pressure may cause the inflator to rupture.

Remedy

Ford will notify owners, and dealers will replace the passenger’s frontal air bag inflator with an alternate inflator, free of charge. The recall began on December 22, 2017, and will be launched in phases through the end of March 2018. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 17S42. Note: This recall supersedes recall 15V322 which was an interim repair. Vehicles that received a replacement air bag inflator under the previous campaign need to return to a dealer to have an alternate inflator installed. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 17S42.

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

June 14, 2018

TO: All U.S. Ford and Lincoln Dealers

SUBJECT: Safety Recall 17S42 – Supplement #4
All 2004-2006 Model Year Ranger Vehicles
Driver and Passenger Airbag Inflator Replacement

New! REASON FOR THIS SUPPLEMENT

The rental vehicle reimbursement process and daily rate limits have changed. See attachment VIII Takata Airbag Recall Rental Vehicle Reimbursement Process for details.
Dealers with Quick Lanes may now use Quick Lane service bays and Quick Lane technicians to perform Takata Airbag Recalls. Reference the Quick Lane Repairs section for further details.
A dealer Q&A has been added to answer frequently asked questions.

AFFECTED VEHICLES

Vehicle	Model Year	Assembly Plant	Build Dates
Ranger	2004	Edison	Job 1 through Job Last
Ranger	2004 – 2006	Twin Cities	Job 1 through Job Last

Affected vehicles are identified in OASIS and FSA VIN Lists.

REASON FOR THIS SAFETY RECALL

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.

SERVICE ACTION

Dealers are to replace the driver and passenger airbag inflators. This service must be performed on all affected vehicles at no charge to the vehicle owner.

NOTE: This is a final / permanent repair. All vehicles that were previously serviced under Safety Recall 14B04, 15S22 and/or 16S03 must have this repair performed.

OWNER NOTIFICATION MAILING SCHEDULE

All original owner letter mailings have been completed. To encourage customers to have this important safety recall completed, follow up owner letter mailings are currently being sent on a regular cadence to customers that have not yet had this recall completed.

Dealers should repair any 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.

New! 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
Attachment V: Dealer Q&A (NEW!)
Attachment VI: Takata Airbag Recall Rental Vehicle Reimbursement Process (NEW!)
Attachment VII: Restricted Vehicle Use Agreement (NEW!)
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

Safety Recall 17S42 – Supplement #4
All 2004-2006 Model Year Ranger Vehicles
Driver and Passenger Airbag Inflator Replacement

OASIS ACTIVATION

OASIS was activated on December 13, 2017.

FSA VIN LISTS ACTIVATION

FSA VIN Lists were available through https://web.fsavinlists.dealerconnection.com on December 13, 2017. Owner names and addresses will be available by April 6, 2018.

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.

New! 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

If the customer requests a rental vehicle while waiting for parts to become available, refer to the Takata Airbag Recall Rental Vehicle Reimbursement Process (Attachment VIII) for rental reimbursement guidelines and the process for requesting rental vehicle reimbursement.

New! 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.

New! 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 (17S42) 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.
Part numbers (8L5Z-10044A74-A and 4L5Z-63043B13-A) used under 14B04, 15S22 and/or 16S03 must no longer to 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 (17S42).

NOTE: The serial numbers of the new driver and passenger airbag inflators must be provided to Ford for the claim to be processed. The Technical Information in this bulletin advises technicians to document the serial numbers from the new airbag inflators on the repair order. The driver airbag inflator serial number is 12 characters, and the passenger airbag inflator serial number is 14 characters. Enter the serial numbers of the new airbag inflators 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 one serial number per CODE field.
  - Driver airbag inflator serial number is 12 characters
  - Passenger airbag inflator serial number is 14 characters
- The serial number must entered without spaces or dashes.

Example:

86 17 157 04 59907 – incorrect
86171570459907 – CORRECT

New! CLAIMS PREPARATION AND SUBMISSION (continued)

Rental Vehicle Reimbursement:
- Claim should be submitted under long-term rental program 18A04.
- 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 14, 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 long-term 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.
- Reference the Takata Airbag Recall Rental Vehicle Reimbursement Process (Attachment VIII) for further detail on rental vehicle reimbursement.

ATTACHMENT II

Safety Recall 17S42 – Supplement #4
All 2004-2006 Model Year Ranger Vehicles
Driver and Passenger Airbag Inflator Replacement

LABOR ALLOWANCES

Description	Labor Operation	Labor Time
Replace Driver and Passenger Airbag Inflator	17S42B	0.7 Hours

Performing the supplemental restraint depower procedure and clearing DTCs was included in previous airbag inflator recalls 14B04, 15S22 and/or 16S03, but is no longer required.

PARTS REQUIREMENTS / ORDERING INFORMATION

To ensure a sufficient supply of parts are available to repair all higher risk vehicles in safety recall 18S02, the parts ordering status has changed from open ordering to restricted ordering.
To order parts for this recall dealers should submit a VIN specific part order request to the Special Service Support Center (SSSC).

Part Number	Description	Order Quantity
4L5Z-10043B13-D	Driver Airbag Inflator Kit	1
8L5Z-10044A74-D	Passenger Airbag Inflator Kit	1

IMPORTANT: Part numbers 8L5Z-10044A74-A and 4L5Z-63043B13-A used under field service action 14B04, 15S22 and/or 16S03 must no longer be installed in vehicles.

PARTS RETURN FOR INFLATORS REMOVED FROM VEHICLES

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

NOTE: RCRC will only pick-up parts that have a corresponding FCS-700 Tag.

Part return instructions:
- Dealers must monitor their OWS parts status report. A FCS-700 tag will be generated for each driver and passenger airbag inflator. Parts will be picked up by the RCRCs.
- The RCRC will not pick up parts that are not properly packaged in the new part box.
- Refer to Attachment IV for specific part return instructions and documentation.
- Disregard prepaid FedEx shipping instructions that may be included in new part boxes.
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.”

IMPORTANT: If a FCS-700 Tag is not issued, or the OWS parts status report directs to “Scrap” a part replaced under this safety recall, please submit a General Request to the SSSC Web Contact Site stating that you were directed to scrap a part.

PARTS RETURN FOR 8L5Z-10044A74-A and 4L5Z-63043B13-A IN DEALER STOCK

Dealer stock of part numbers 8L5Z-10044A74-A and 4L5Z-63043B13-A must no longer to be installed in vehicles and may be returned via the FSA parts return process. Please use “CG” as the claim code so they will be flagged as “defective” and note in the shipper field the FSA bulletin number (17S42).

NOTE: Ship dealer stock parts via contract carriage. Do not attempt to return parts using the shipping labels in the FCS-12637 return kit.

EXCESS STOCK RETURN

Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000.

DEALER PRICE

For latest prices, refer to DOES II.

ATTACHMENT III

CERTAIN 2004-2006 RANGER VEHICLES — DRIVER AND PASSENGER AIRBAG INFLATOR REPLACEMENT

OVERVIEW

Dealers are to replace the driver and passenger airbag inflators. The serial number from both new airbag inflators must be recorded on the repair order. Place the replaced inflators 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

DRIVER AIRBAG INFLATOR REPLACEMENT

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.

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 the airbag once the inflator is removed.

Release the retaining tab and slide the driver airbag inflator connector off of 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: 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 serial number of the new driver airbag inflator must be provided to Ford for the warranty claim to be processed.

Record the 12 character serial number of the new driver airbag inflator on the repair order.
See Figure 2.

FIGURE 2

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 driver airbag inflator and install four new nuts. See Figure 3.

Tighten to 6.5 Nm (57 lb-in) in the specified sequence.

FIGURE 3

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 4.
Ensure the connection between the wiring harness electrical connector and the airbag inflator by pulling gently on the wiring harness to ensure it is properly seated. See Figure 4.
Slide the airbag inflator connector onto the tang. See Figure 4.

FIGURE 4

Re-install the driver airbag. Please follow the WSM procedures in Section 501-20B.
Confirm that the airbag readiness light still indicates no SRS faults are present.
Package the replaced inflator in the new part box and provide to the appropriate dealership personnel for part returns.

PASSENGER AIRBAG INFLATOR REPLACEMENT

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.

NOTE: Care must be taken as to not pierce the inflator harness wiring.

Cut and peel back wiring sleeve to expose inflator wiring. See Figure 5.

FIGURE 5

Install a wiring shunt between the inflator wiring connector and the inflator body, this will cause the inflator to become inert. See Figure 6.

FIGURE 6

Cut the inflator wiring between connector and the shunt. See Figure 7.

FIGURE 7

Remove and discard the four airbag inflator retaining nuts and the bracket. See Figure 8.

FIGURE 8

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

With an assistant holding the airbag assembly, remove the inflator from the airbag assembly by
pushing outward on the inflator. See Figure 9.

FIGURE 9

Remove the airbag inflator harness electrical connector. See Figure 10.

FIGURE 10

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

Record the 14 character serial number of the new passenger airbag inflator on the repair order.
See Figure 11.

FIGURE 11

NOTE: Both new 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.

Align and install both new inflator end caps. See Figure 12 and 13.

FIGURE 12

Install inflator into air bag assembly with connector end facing out, so that the alignment feature is aligned directly facing up. See Figure 13.

FIGURE 13

Align and Install the new inflator retaining bracket . See Figure 14.

FIGURE 14

Install four new nuts. Assure pop-up indicator on air bag assembly is present. See Figure 15.
- Tighten to 3.9 Nm (35 lb-in) in the specified sequence.

FIGURE 15

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 16.
Ensure the connection between the wiring harness electrical connector and the airbag inflator by pulling gently on the wiring harness to ensure it is properly seated. See Figure 16.

FIGURE 16

Install inflator harness connector to the air bag assembly bracket. See Figure 17.

FIGURE 17

Re-install the passenger airbag. Please follow the WSM procedures in Section 501-20B.
Confirm that the airbag Readiness light still indicates no SRS faults are present.
Package the replaced inflator in the new part box and provide to the appropriate dealership personnel for part returns.

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¿Cuál es el problema?	Los infladores de la bolsa de aire del conductor y del pasajero en su vehículo podrían detonar en caso de choque y causar el despliegue de la bolsa de aire delantera. Si detona un inflador, se podrían desprender fragmentos de metal y golpear al conductor o a otros ocupantes y provocarles lesiones graves o incluso la muerte. Esta reparación es gratuita y es la reparación final para la bolsa de aire delantera tanto del conductor como del pasajero de su vehículo. IMPORTANTE: Los infladores de la bolsa de aire de su vehículo se deben reemplazar incluso si se reemplazaron anteriormente conforme a alguna otra campaña.
¿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 los infladores de la bolsa de aire del conductor y 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 17S42. Proporcione el VIN a su distribuidor, el cual está impreso debajo de sus datos al comienzo de esta carta.
¿Qué debe hacer? (continuación)	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 17V787 y 17V788 de la NHTSA
Para asistencia en español	Visite nuestro sitio web para ver este anuncio en español en la siguiente dirección: https://es.owner.ford.com/tools/account/maintenance/recalls.html 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.

Summary

Remedy

Notes

Summary

Remedy

Notes

SERVICE PROCEDURE

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