Safety Recall 21S05 Certain 2005-2014 Mustang, 2005-2006 Ford GT, 2004-2011 Ranger, 2006-2012 Fusion and MKZ/Zephyr, 2006-2011 Milan, and 2007-2010 Edge and MKX Vehicles Airbag Module Inspection and Replacement

February 17, 2021

TO: All U.S. Ford and Lincoln Dealers

SUBJECT: Safety Recall 21S05
Certain 2005-2014 Mustang, 2005-2006 Ford GT, 2004-2011 Ranger, 2006-2012 Fusion and MKZ/Zephyr, 2006-2011 Milan, and 2007-2010 Edge and MKX Vehicles
Airbag Module Inspection and Replacement

 

AFFECTED VEHICLES

Certain vehicles listed below that were serviced with a suspect airbag module in, or prior to, March 2019 and after having the airbag module or inflator replaced in accordance with safety recall 15S21, 16S26, 17S01, 17S42, 18S01, 18S02, and/or 19S01. Fewer than 2,000 vehicles are expected to be affected.

Vehicle	Model Year	Assembly Plant
Mustang	2005-2014	Flat Rock
Ford GT	2005-2006	Wixom
Ranger	2004	Edison
	2004-2011	Twin Cities
Fusion	2006-2012	Hermosillo
MKZ/Zephyr	2006-2012	Hermosillo
Milan	2006-2011	Hermosillo
Edge	2007-2010	Oakville
MKX	2007-2010	Oakville

 

Known affected vehicles are identified in OASIS and FSA VIN Lists.

 

REASON FOR THIS SAFETY RECALL

In some of the affected vehicles, the driver and/or passenger airbag module may have been serviced with an airbag module that contained a recalled Takata airbag inflator. NHTSA and Takata have determined that the propellant in certain Takata airbag inflators can experience an alteration over time with exposure to certain climate conditions. A combination of time, high temperature fluctuations, and humidity contribute to the degradation of the propellant in the inflators. This degradation can cause the propellant to burn too quickly, creating high pressure inside the inflator, and in extreme cases causing the inflator to rupture in the event of a crash necessitating airbag deployment. A ruptured inflator can send inflator parts toward vehicle occupants resulting in serious injury or death. Additional information regarding Takata recalls can be found at www.nhtsa.gov and www.safercar.gov.

 

SERVICE ACTION

For known affected vehicles, dealers are to inspect, and if necessary, replace the driver and/or passenger airbag inflators per the technical instructions.

Additionally, dealers are to review the part numbers in Attachment XIV: Recall Notice and identify any related part sales records. Contact any customers to whom a suspect airbag module was sold, provide them with a copy of the Recall Notice (Attachment XIV), and schedule a service date for an inspection and repairs as needed.

For any vehicle that is not identified in OASIS or FSA VIN Lists that is suspected to have an affected airbag module installed, please contact the Special Service Support Center (SSSC) via the Web Contact Site to request adding an affected VIN to this equipment recall prior to performing this service action. Use a VIN specific Non-Involved Vehicle Request.

This service must be performed on all vehicles at no charge to the vehicle owner.

Dealers must also return any remaining in-stock parts listed in Attachment XIV: Recall Notice.

 

OWNER NOTIFICATION AND MAILING SCHEDULE

Owner letters are expected to be mailed the week of March 8, 2021. 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 – 2005-2014 Mustang
Attachment IV: Technical Information – 2005-2006 Ford GT
Attachment V: Technical Information – 2004-2006 Ranger
Attachment VI: Technical Information – 2007-2011 Ranger
Attachment VII: Technical Information – 2006-2009 Fusion and Milan
Attachment VIII: Technical Information – 2010-2012 Fusion and 2010-2011 Milan
Attachment IX: Technical Information – 2006-2009 MKZ/Zephyr
Attachment X: Technical Information – 2010-2012 MKZ
Attachment XI: Technical Information – 2007-2010 Edge
Attachment XII: Technical Information – 2007-2010 MKX
Attachment XIII: Airbag Inflator Core Return
Attachment XIV: Recall Notice
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

 

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ATTACHMENT I

Safety Recall 21S05
Certain 2005-2014 Mustang, 2005-2006 Ford GT, 2004-2011 Ranger, 2006-2012 Fusion and
MKZ/Zephyr, 2006-2011 Milan, and 2007-2010 Edge and MKX Vehicles
Airbag Module Inspection and Replacement

 

OASIS ACTIVATION

OASIS will be activated on February 17, 2021.

 

FSA VIN LISTS ACTIVATION

FSA VIN Lists will be available through https://web.fsavinlists.dealerconnection.com by February 19, 2021. Owner names and addresses will be available by March 19, 2021.

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

• Ford has not issued instructions to stop selling/delivering or driving used vehicles under this safety recall. Owners should contact their dealer for an appointment to have their vehicles remedied as soon as practicable. Owners can continue to safely drive their vehicles.
• 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

• Use OASIS to identify any affected vehicles in your used vehicle inventory.

 

DEALER-OPERATED RENTAL VEHICLES

The Fixing America’s Surface Transportation (FAST) Act law effective June 2016 prohibits a rental company from selling, renting or leasing vehicles subject to a safety or compliance recall. Please consult your legal counsel for legal advice.

 

TITLE BRANDED / SALVAGED VEHICLES

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

 

OWNER REFUNDS  

Refunds are not approved for this program.

 

RENTAL VEHICLES

With proper parts ordering and service appointment scheduling, rental vehicles should not be required. However, if a customer requests a rental vehicle while their vehicle is being repaired, dealers are preapproved for up to 4 days of rental reimbursement (no approval code required). See below for approved dollar amounts.

If more than 4 rental days are required, dealers must request prior-approval from the SSSC for any additional days before the initial 4 days expire. Submit an SSSC web contact for all required rental days and provide details outlining why the additional days are required.

If a customer requests a rental vehicle, dealers must retain the customer’s vehicle until the recall repair is completed and the rental vehicle is returned. Dealers must also notify the customer promptly once the recall repair is completed. Rentals exceeding 7 days from the date the customer is notified that their vehicle is repaired, will not be reimbursed.

Alternative Transportation: If a customer is unable or does not wish to use a rental vehicle, the rental reimbursement allowance can be used for alternative transportation if necessary. The maximum reimbursement amounts listed below apply. Examples of alternative transportation includes taxis, public transportation (subway, train, bus, etc.), or ridesharing services (Uber, Lyft, etc.).

Make of Recalled Vehicle	Maximum Reimbursement per Day (including tax)
Ford	$44
Mercury	$44
Lincoln	$55

 

If a customer has paid for a rental vehicle or alternative transportation for the purpose of this recall, they are eligible for reimbursement within the guidelines outlined above. Dealers must follow the same process for claiming rental vehicle reimbursement and then refund the customer.

 

ADDITIONAL REPAIR (LABOR TIME AND/OR PARTS)
Additional repairs identified as necessary to complete the FSA should be managed as follows:

• For related damage and access time requirements, refer to the Warranty and Policy Manual / Section 6 – Ford & Lincoln Program Policies / General Information & Special Circumstances for FSA’s / Related Damage.
• For vehicles within new vehicle bumper-to-bumper warranty coverage, no SSSC approval is required, although related damage must be on a separate repair line with the “Related Damage” radio button checked.
  • Ford vehicles – 3 years or 36,000 miles o Lincoln vehicles – 4 years or 50,000 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.

 

CLAIMS PREPARATION AND SUBMISSION

• Claim Entry: 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 21S05 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.
• Related Damage/Additional labor and/or parts: Must be claimed as Related Damage on a separate repair line from the FSA with same claim type and sub code as described in Claim Entry above.

IMPORTANT: Click the Related Damage Indicator radio button.

• Rentals: Dealers are pre-approved for up to 4 days of rental vehicle reimbursement with the following maximum rates:

Make of Recalled Vehicle	Maximum Reimbursement per Day (including tax)
Ford	$44
Mercury	$44
Lincoln	$55

 

• • If the rental period does NOT exceed 4 days, submit the rental expense on the same claim and RO line as the repair. Use Misc. Expense Code “RENTAL”. No approval code is needed. o If the rental period exceeds 4 days, a web contact must be submitted to the Special Service Support Center (SSSC) before the initial 4 days expire to request approval. Include details outlining why additional rental days are required.
    • The SSSC web contact must include all rental expenses, parts costs, and labor costs. All of these amounts are required so the approval code will cover the entire RO line amount.
    • Submit the rental expenses on the same claim and RO line as the repair. Use Misc. Expense Code “RENTAL”.

 

LABOR ALLOWANCES

2005-2014 Mustang

Description	Labor Operation	Labor Time
Inspect driver and passenger airbag modules – PASS	21S05B	0.4 Hour
Replace driver airbag inflator or module only (includes inspection)	21S05C	0.4 Hour
Replace passenger airbag inflator only (includes inspection)	21S05D	0.5 Hour
Replace driver and passenger airbag inflator or module (includes inspection)	21S05E	0.7 Hour

 

2005-2006 Ford GT

Description	Labor Operation	Labor Time
Inspect driver and passenger airbag modules – PASS	21S05F	0.5 Hour
Replace driver airbag inflator or module only (includes inspection)	21S05G	0.4 Hour
Replace passenger airbag inflator only (includes inspection)	21S05H	0.7 Hour
Replace driver and passenger airbag inflator or module (includes inspection)	21S05J	0.9 Hour

 

2004-2006 Ranger

Description	Labor Operation	Labor Time
Inspect driver and passenger airbag modules – PASS	21S05K	0.4 Hour
Replace driver airbag inflator only (includes inspection)	21S05L	0.4 Hour
Replace passenger airbag inflator only (includes inspection)	21S05M	0.5 Hour
Replace driver and passenger airbag inflator or module (includes inspection)	21S05N	0.7 Hour

 

2007-2011 Ranger

Description	Labor Operation	Labor Time
Inspect passenger airbag module – PASS	21S05P	0.3 Hour
Replace passenger airbag inflator (includes inspection)	21S05Q	0.5 Hour

 

LABOR ALLOWANCES (continued)

2006-2009 Fusion and Milan

Description	Labor Operation	Labor Time
Replace passenger airbag module	21S05R	0.4 Hour

 

2010-2012 Fusion and 2010-2011 Milan

Description	Labor Operation	Labor Time
Inspect passenger airbag module – PASS	21S05P	0.3 Hour
Replace passenger airbag module (includes inspection)	21S05S	2.8 Hours

 

2006-2009 MKZ/Zephyr

Description	Labor Operation	Labor Time
Replace passenger airbag module	21S05T	0.5 Hour

 

2010-2012 MKZ

Description	Labor Operation	Labor Time
Inspect passenger airbag module – PASS	21S05P	0.3 Hour
Replace passenger airbag module (includes inspection)	21S05U	2.9 Hours

 

2007-2010 Edge

Description	Labor Operation	Labor Time
Replace passenger airbag module	21S05V	0.4 Hour

 

2007-2010 MKX

Description	Labor Operation	Labor Time
Inspect passenger airbag module – PASS	21S05P	0.3 Hour
Replace passenger airbag module (includes inspection)	21S05W	0.7 Hour

 

PARTS REQUIREMENTS / ORDERING INFORMATION

Order your parts through normal order processing channels.

IMPORTANT: The parts used in this safety recall may physically appear to be identical, but they have differing operating characteristics. It is crucial that parts are NOT interchanged or substituted. Do not disassemble, modify, or alter the parts or repair procedure in any way. Doing so may prevent the airbag from operating properly during a deployment.

 

Driver Airbag Inflators and Modules

Vehicle	Description	Order Quantity	Claim Quantity	Part Number
2005-2006 Ford GT	Driver Airbag Inflator	1	1	5R3Z-63043B13-C
2005-2012 Mustang
2013-2014 Mustang (non-Shelby GT500)	Driver Airbag Module	1	1	CR3Z-63043B13-AD
2013-2014 Mustang (Shelby GT500 only)	Driver Airbag Module	1	1	DR3Z-63043B13-AD
2004-2006 Ranger	Driver Airbag Inflator	1	1	4L5Z-10043B13-D

 

Passenger Airbag Inflators and Modules

Vehicle	Description	Order Quantity	Claim Quantity	Part Number
2005-2009 Mustang	Passenger Airbag Inflator	1	1	5R3Z-63044A74-B
2010-2014 Mustang	Passenger Airbag Inflator	1	1	6G7Z-63044A74-A
2005-2006 Ford GT
2004-2006 Ranger	Passenger Airbag Inflator	1	1	8L5Z-10044A74-D
2007-2011 Ranger	Passenger Airbag Inflator	1	1	8L5Z-10044A74-E
2006-2009 Fusion and Milan	Passenger Airbag Module Interior color: Camel Part color: Dark Stone	1	1	8E5Z-54044A74-AC
	Passenger Airbag Module Interior colors: Black, Light Stone, Grey Part color: Black			8E5Z-54044A74-AD
2010-2012 Fusion and 2010-2011 Milan	Passenger Airbag Module	1	1	AE5Z-54044A74-D
	A-Pillar Trim Clip	1	2	W711044-S403
	Steering Column Shaft-toSteering Gear Bolt	1	1	W712961-S439
	Airbag Cushion Sheet	Only if required		AE5Z-7804500-A

 

PARTS REQUIREMENTS ARE CONTINUED ON THE FOLLOWING PAGE

 

PARTS REQUIREMENTS / ORDERING INFORMATION (continued)

Passenger Airbag Inflators and Modules (continued)

Vehicle	Description	Order Quantity	Claim Quantity	Part Number
2006-2009 MKZ/Zephyr	Passenger Airbag Module Interior color: Light Stone Part color: Light Stone	1	1	7H6Z-54044A74-AD
	Passenger Airbag Module Interior color: Black Part color: Black			7H6Z-54044A74-AE
	Passenger Airbag Module Interior color: Sand Part color: Sand			7H6Z-54044A74-AF
2010-2012 MKZ	Passenger Airbag Module	1	1	AH6Z-54044A74-D
	A-Pillar Trim Clip	1	2	W711044-S403
	Steering Column Shaft-to Steering Gear Bolt	1	1	W712961-S439
2007 Edge Only	Passenger Airbag Module Interior color: Light Stone Part color: Light Stone	1	1	9T4Z-78044A74-AC
2007 Edge Only	Passenger Airbag Module Interior color: Med. Camel Part color: Med. Camel			9T4Z-78044A74-AD
2007-2010 Edge Only	Passenger Airbag Module Interior color: Black, Camel Part color: Black			9T4Z-78044A74-AA
2008-2010 Edge Only	Passenger Airbag Module Interior color: Light Stone Part color: Greystone			9T4Z-78044A74-AB
2007-2010 MKX	Passenger Airbag Module	1	1	9A1Z-78044A74-A

 

 

             
PARTS RETENTION AND RETURN

It is critical that all original airbag inflators removed from vehicles are returned to ensure that they are not allowed back into the market. 

The return mechanism for airbag inflators under this safety recall varies based on the part number of the new airbag module or inflator. Parts will either have a $100 core charge or will be issued an FCS-700 tag.

Review Attachment XIII: Airbag Inflator Core Return in full for the appropriate part return instructions.

 

EXCESS STOCK RETURN

To support NHTSA-assigned completion mandates for the Takata airbag recalls, and the numerous Ford and Lincoln vehicles that require repairs under the Takata airbag recalls, excess stock returns will not be accepted for unused new recall remedy parts until 85% of all affected vehicles have been repaired. Dealers should utilize their FSA VIN Lists and DMS information to contact their affected customers and repair all vehicles that are brought to your dealership with an open Takata airbag recall (FSAs 15S21, 17S42, 18S02, and 19S01).

NOTE: Because returns are not currently being accepted, the normal deadlines for returning excess stock parts are suspended for Takata airbag recall parts. Once part returns are authorized (upon 85% repair completion) dealers will be notified and a new deadline for returning excess stock parts will be communicated.

.

 

 

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ATTACHMENT III

NOTE:  The following repair instructions only apply to 2005-2014 Model Year (MY) Mustang vehicles.           Repair instructions are published in separate attachments for the other vehicle lines included in this recall.

IMPORTANT:  The parts used in this safety recall may physically appear to be identical, but they have differing operating characteristics.  It is crucial that parts are NOT interchanged or substituted.  Do not disassemble, modify, or alter the parts or repair procedure in any way.  Doing so may prevent the airbag from operating properly during a deployment.

 

SERVICE PROCEDURE

2005-2014 MY DRIVER AIRBAG INFLATOR INSPECTION

WARNING: Failure to follow the instructions and warnings in the Workshop Manual 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 when performing this service procedure. Turn the ignition to OFF and wait 1 minute, then it is safe to proceed with airbag inflator or airbag module replacement.

 

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

 

1. Remove the driver airbag module. Please follow the Workshop Manual (WSM) procedures in Section 501-20.

 

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

 

3. Inspect the label on the Driver Airbag inflator as shown in Figure 1. Is the label white in color?

 

Yes – PASS – Reinstall the Driver Airbag. Please follow the WSM procedures in Section 501-20.

– Proceed to the Passenger Airbag Inflator Inspection on Page 6.

No – DOES NOT PASS – Proceed to Driver Airbag Module or Inflator Replacement per MY below.

 

• 2013-2014 MY Vehicles – Proceed to Replace Driver Airbag Module on Page 3.
• 2005-2012 MY Vehicles – Proceed to Replace Driver Airbag Inflator on Page 4.

 

NOTE: If the label cannot be read or is missing entirely, perform the Driver Airbag Module or Inflator Replacement per MY above.

 

 

2013-2014 MY Vehicles – Replace Driver Airbag Module

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

 

1. Record the 13 character serial number of the new airbag inflator on the repair The inflator is pre-installed in the new airbag module. See Figure 2.

 

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 when performing this service procedure. Turn the ignition to OFF and wait 1 minute, then it is safe to proceed with airbag module replacement.

 

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

 

2. Install the new driver airbag module. Please follow the Workshop Manual (WSM) procedures in Section 501-20.

 

NOTE: Confirm that the Airbag Readiness light still indicates no SRS faults are present.

 

3. Package the replaced airbag module in the new part box and provide to the appropriate dealership personnel for part returns.

 

4. Proceed to the Passenger Airbag Inflator Inspection on Page 6.

 

 

2005-2012 MY Vehicles – Replace Driver Airbag Inflator

 

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 when performing this service procedure. Turn the ignition to OFF and wait 1 minute, then it is safe to proceed with airbag module replacement.

 

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

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

1. Remove and discard the four airbag inflator retaining nuts from the driver side See Figure 3.

 

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 3.

 

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

 

3. Record the 13 character serial number of the new airbag inflator on the repair order. See Figure 2.

 

4. Align the key on the driver airbag with the slot on the new Install the new inflator into the driver airbag. See Figure 4.

 

5. Install four new airbag inflator nuts onto the driver See Figure 4.

 

• Tighten to 6.5 Nm (57 lb-in).

 

6. Re-install the driver Please follow the WSM procedures in Section 501-20.

 

NOTE: Confirm that the Airbag Readiness light still indicates no SRS faults are present.

 

7. Package the replaced inflator in the new part box and provide to the appropriate dealership personnel for part returns.

 

8. Proceed to the Passenger Airbag Inflator Inspection on Page 6.

 

 

2005-2014 MY PASSENGER AIRBAG INFLATOR INSPECTION

 

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

 

NOTE: If the Airbag Readiness light indicates no Supplemental Restraint System (SRS) faults are present, it is not necessary to follow the WSM SRS Depowering and Repowering steps. Turn the ignition to OFF and wait 1 minute, then it is safe to proceed with airbag inflator replacement.

 

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

 

NOTE: To view a video demonstration of this repair procedure, click the video icon.

 

NOTE: For Mustang vehicles equipped with SYNC, it is not necessary to remove the Accessory Protocol Interface Module (APIM) retainers to access the passenger airbag module. Unclip the APIM mounting bracket and position the APIM aside.

 

1. Remove the passenger airbag from the vehicle. Please follow the WSM procedures in Section 501-20.

 

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

 

3. Inspect the passenger airbag inflator end for the presence of a plastic end cap as shown in Figure Is the plastic end cap present on the airbag inflator?

 

Yes – PASS – Inspection Complete. Install the Passenger Airbag. Please follow the WSM procedures in Section 501-20.

No – DOES NOT PASS – Proceed to the Passenger Airbag Inflator Replacement on Page 7.

 

NOTE: 2008 MY passenger airbag module shown, all passenger airbag modules similar.

 

 

2005-2014 MY PASSENGER AIRBAG INFLATOR REPLACEMENT

 

1. Remove the wiring harness connector retainer from the passenger airbag See Figure 6.

 

NOTE: Carry out this Step on the longer wire on the end opposite of the airbag inflator retaining bracket. See Figure 7.

 

2. Remove approximately 100 mm (3.93 in) of the conduit from the passenger airbag assembly wire harness. See Figure 7.

 

3. Position the shorting clip onto the harness wires, and crimp the shorting clip together one side at a time using pliers. See Figure 8.

 

4. Cut the harness wires between the shorting clip and the harness connector. See Figure 9.

 

5. Remove and discard the four passenger airbag inflator retaining bracket nuts and the retaining See Figure 10.

 

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

 

6. With an assistant holding the passenger airbag assembly, remove the inflator from the assembly by pushing outward on the inflator. Set the airbag inflator aside for return shipping. See Figure 11.

 

• If required, use of a brass punch is permitted (only at the location shown) to free the inflator from its mounted position.

 

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

 

7. Record the 11 character serial number of the new airbag inflator on the repair order. See Figure 12.

 

8. NOTE: Both new inflator end caps are specific to their respective end of the inflator and must be fully seated.

 

NOTE: The tail end cap does not have an alignment tab and may be installed in any orientation.

Make sure the tail end cap is fully seated or you will not be able to install the inflator retaining bracket.

 

Install both new inflator end caps making sure the alignment feature on the cap nearest the inflator retaining bracket is properly oriented. See Figure 13.

 

9. Install the inflator into the passenger airbag assembly with the orange connector end facing out. Align the three tabs on the cap nearest the inflator retaining bracket with the airbag module lower channel (facing down). See Figure 14.

 

NOTE: If the inflator retaining bracket is unable to be installed, ensure the inflator tail end cap is fully seated.

 

10. Install the new passenger airbag inflator retaining bracket and new See Figure 15.

 

• Torque the new retaining nuts in the sequence shown below to 4 Nm (35 in).

 

11. Align the T-shape index on both the wiring harness electrical connector and the airbag Install the new wiring harness onto the passenger airbag module and connect to both sides of the inflator. See Figure 16.

 

12. Insert the inflator wiring harness connector See Figure 17.

 

NOTE: Pull gently on the wiring harness to ensure it is properly seated.

 

13. Re-install the passenger Please follow WSM procedures in Section 501-20.

 

14. Package the replaced inflator in the new part box and provide to the appropriate dealership personnel for part returns.

.

 

 

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ATTACHMENT IV

CERTAIN 2005 AND 2006 MODEL YEAR FORD GT VEHICLES — DRIVER AND PASSENGER AIRBAG INFLATOR INSPECTION

 

NOTE: The following repair instructions only apply to 2005 and 2006 Model Year (MY) Ford GT vehicles. Repair instructions are published in separate attachments for the other vehicle lines included in this recall.

 

IMPORTANT: The parts used in this safety recall may physically appear to be identical, but they have differing operating characteristics. It is crucial that parts are NOT interchanged or substituted. Do not disassemble, modify, or alter the parts or repair procedure in any way. Doing so may prevent the airbag from operating properly during a deployment.

 

SERVICE PROCEDURE

 

DRIVER AIRBAG INFLATOR INSPECTION

WARNING: Failure to follow the instructions and warnings in the Workshop Manual 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 when performing this service procedure. Turn the ignition to OFF and wait 1 minute, then it is safe to proceed with airbag inflator or airbag module replacement.

 

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

 

1. Remove the driver airbag module. Please follow the Workshop Manual (WSM) procedures in Section 501-20.

 

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

 

3. Inspect the label on the Driver Airbag inflator as shown in Figure 1. Is the label white in color?

 

Yes – PASS – Reinstall the Driver Airbag. Please follow the WSM procedures in Section 501-20.

– Proceed to the Passenger Airbag Inflator Inspection on Page 6.

No – DOES NOT PASS – Proceed to Driver Airbag Inflator Replacement on Page 3.

 

NOTE: If the label cannot be read or is missing entirely, perform the Driver Airbag Inflator Replacement on Page 3.

 

Driver Airbag Inflator Replacement

 

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 when performing this service procedure. Turn the ignition to OFF and wait 1 minute, then it is safe to proceed with airbag module replacement.

 

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

 

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

1. Remove and discard the four airbag inflator retaining nuts from the driver side See Figure 2.

 

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 2.

 

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

 

3. Record the 13 character serial number of the new airbag inflator on the repair order. See Figure 3.

 

4. Align the key on the driver airbag with the slot on the new Install the new inflator into the driver airbag. See Figure 4.

 

5. Install four new airbag inflator nuts onto the driver See Figure 4.

 

• Tighten to 6.5 Nm (57 lb-in).

 

6. Re-install the driver Please follow the WSM procedures in Section 501-20.

 

NOTE: Confirm that the Airbag Readiness light still indicates no SRS faults are present.

 

7. Package the replaced inflator in the new part box and provide to the appropriate dealership personnel for part returns.

 

8. Proceed to the Passenger Airbag Inflator Inspection on Page 6.

 

 

PASSENGER AIRBAG INFLATOR INSPECTION

 

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

 

NOTE: If the Airbag Readiness light indicates no Supplemental Restraint System (SRS) faults are present, it is not necessary to follow the WSM SRS Depowering and Repowering steps. Turn the ignition to OFF and wait 1 minute, then it is safe to proceed with airbag inflator replacement.

 

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

 

NOTE: To view a video demonstration of this repair procedure, click the video icon.

 

NOTE: Mustang airbag shown in this procedure, Ford GT similar.

 

1. Remove the passenger airbag from the vehicle. Please follow the WSM procedures in Section 501-20.

 

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

 

3. Inspect the passenger airbag inflator end for the presence of a plastic end cap as shown in Figure Is the plastic end cap present on the airbag inflator?

 

Yes – PASS – Inspection Complete. Install the Passenger Airbag. Please follow the WSM procedures in Section 501-20.

No – DOES NOT PASS – Proceed to the Passenger Airbag Inflator Replacement on Page 7.

 

PASSENGER AIRBAG INFLATOR REPLACEMENT

 

1. Remove the wiring harness connector retainer from the passenger airbag See Figure 6.

 

NOTE: Carry out this Step on the longer wire on the end opposite of the airbag inflator retaining bracket.

See Figure 7.

 

2. Remove approximately 100 mm (3.93 in) of the conduit from the passenger airbag assembly wire See Figure 7.

 

3. Position the shorting clip onto the harness wires, and crimp the shorting clip together one side at a time using pliers. See Figure 8.

 

4. Cut the harness wires between the shorting clip and the harness connector. See Figure 9.

 

5. Remove and discard the four passenger airbag inflator retaining bracket nuts and the retaining See Figure 10.

 

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

 

6. With an assistant holding the passenger airbag assembly, remove the inflator from the assembly by pushing outward on the inflator. Set the airbag inflator aside for return shipping. See Figure 11.

 

• If required, use of a brass punch is permitted (only at the location shown) to free the inflator from its mounted position.

 

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

 

7. Record the 11 character serial number of the new airbag inflator on the repair order. See Figure 12.

 

8. NOTE: Both new inflator end caps are specific to their respective end of the inflator and must be fully seated.

 

NOTE: The tail end cap does not have an alignment tab and may be installed in any orientation.

 

Install both new inflator end caps making sure the alignment feature on the cap nearest the inflator retaining bracket is properly oriented. See Figure 13.

 

9. Install the inflator into the passenger airbag assembly with the orange connector end facing out. Align the three tabs on the cap nearest the inflator retaining bracket with the airbag module lower channel (facing down). See Figure 14.

 

NOTE: If the inflator retaining bracket is unable to be installed, ensure the inflator tail end cap is fully seated.

 

10. Install the new passenger airbag inflator retaining bracket and new See Figure 15.

 

• Torque the new retaining nuts in the sequence shown below to 4 Nm (35 in).

 

11. Align the T-shape index on both the wiring harness electrical connector and the airbag Install the new wiring harness onto the passenger airbag module and connect to both sides of the inflator. See Figure 16.

 

12. Insert the inflator wiring harness connector See Figure 17.

 

NOTE: Pull gently on the wiring harness to ensure it is properly seated.

 

13. Re-install the passenger Please follow WSM procedures in Section 501-20.

 

14. Package the replaced inflator in the new part box and provide to the appropriate dealership personnel for part returns.

.

 

 

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ATTACHMENT V

CERTAIN 2004–2006 MODEL YEAR RANGER VEHICLES — DRIVER AND PASSENGER AIRBAG INFLATOR INSPECTION

 

NOTE: The following repair instructions only apply to 2004-2006 Model Year (MY) Ranger vehicles.

Repair instructions are published in separate attachments for the other vehicle lines included in this recall.

 

IMPORTANT: The parts used in this safety recall may physically appear to be identical, but they have differing operating characteristics. It is crucial that parts are NOT interchanged or substituted. Do not disassemble, modify, or alter the parts or repair procedure in any way. Doing so may prevent the airbag from operating properly during a deployment.

 

SERVICE PROCEDURE

 

DRIVER AIRBAG INFLATOR INSPECTION

 

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

 

NOTE: If the Airbag Readiness light indicates no Supplemental Restraint System (SRS) faults are present, it is not necessary to follow the WSM SRS Depowering and Repowering steps. Turn the ignition to OFF and wait 1 minute, then it is safe to proceed with airbag inflator replacement.

 

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

 

1. Remove the driver airbag from the Please follow the WSM procedures in Section 501-20.

 

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

 

3. Inspect the label on the Driver Airbag inflator as shown in Figure 1. Is the label white in color?

 

Yes – PASS – Reinstall the Driver Airbag. Please follow the WSM procedures in Section 501-20.

– Proceed to the Passenger Airbag Inflator Inspection on Page 5.

No – DOES NOT PASS – Proceed to Driver Airbag Inflator Replacement on Page 3 and then, proceed to the Passenger Airbag Inflator Inspection on Page 5.

 

NOTE: If the label cannot be read or is missing entirely, perform the Driver Airbag Inflator Replacement on Page 3, then proceed to the Passenger Airbag Inflator Inspection on Page 5.

 

 

DRIVER AIRBAG INFLATOR REPLACEMENT

 

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

1. Release the retaining tab and slide the driver airbag inflator connector off of the tang. See Figure 2.

 

2. Remove and discard the four airbag inflator retaining nuts from the driver side See Figure 2.

 

3. 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 2.

 

4. 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 3.

 

5. 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 See Figures 2 and 4.

 

Install the new driver airbag inflator and install four new nuts. See Figure 4.

 

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

 

6. 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 5.

 

7. 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 5.

 

8. Slide the airbag inflator connector onto the tang. See Figure 5.

 

9. Re-install the driver Please follow the WSM procedures in Section 501-20.

 

10. Confirm that the airbag readiness light still indicates no SRS faults are present.

 

11. Package the replaced inflator in the new part box and provide to the appropriate dealership personnel for part returns.

 

12. Proceed to Passenger Airbag Inflator Inspection on Page 5 (below).

 

 

PASSENGER AIRBAG INFLATOR INSPECTION

 

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

 

NOTE: If the Airbag Readiness light indicates no Supplemental Restraint System (SRS) faults are present, it is not necessary to follow the WSM SRS Depowering and Repowering steps. Turn the ignition to OFF and wait 1 minute, then it is safe to proceed with airbag inflator replacement.

 

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

 

1. Remove the passenger airbag from the Please follow the WSM procedures in Section 501-20.

 

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

 

3. Inspect the passenger airbag inflator end for the presence of a white plastic end cap as shown in Figure Is the white plastic end cap present on the airbag inflator?

 

Yes – PASS – Inspection Complete. Install the Passenger Airbag. Please follow the WSM procedures in Section 501-20.

No – DOES NOT PASS – Proceed to the Passenger Airbag Inflator Replacement on Page 6.

 

 

PASSENGER AIRBAG INFLATOR REPLACEMENT

 

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

 

1. Cut and peel back wiring sleeve to expose inflator See Figure 7.

 

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

 

3. Cut the inflator wiring between connector and the shunt. See Figure 9.

 

4. Remove and discard the four airbag inflator retaining nuts and the See Figure 10.

 

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

 

5. With an assistant holding the airbag assembly, remove the inflator from the airbag assembly by pushing outward on the inflator. See Figure 11.

 

6. Remove the airbag inflator harness electrical See Figure 12.

 

7. 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 13.

 

8. NOTE: Both new inflator connector end caps must be installed with the tab features aligned and fully 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 14 and 15.

 

9. Install inflator into air bag assembly with connector end facing out, so that the alignment feature is aligned directly facing up. See Figure 15.

 

10. Align and Install the new inflator retaining See Figure 16.

 

11. Install four new Assure pop-up indicator on air bag assembly is present. See Figure 17.

 

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

 

12. Align the T-shape index on both the wiring harness electrical connector and the airbag inflator, connect the new airbag wiring harness to the inflator module and fully seat the orange tab. See Figure 18.

 

13. 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 18.

 

14. Install inflator harness connector to the air bag assembly bracket. See Figure 19.

 

15. Re-install the passenger Please follow the WSM procedures in Section 501-20.

 

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

 

17. Package the replaced inflator in the new part box and provide to the appropriate dealership personnel for part returns.

.

 

 

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ATTACHMENT VI

CERTAIN 2007–2011 MODEL YEAR RANGER VEHICLES — PASSENGER AIRBAG INFLATOR INSPECTION

 

NOTE: The following repair instructions only apply to 2007-2011 Model Year (MY) Ranger vehicles.

Repair instructions are published in separate attachments for the other vehicle lines included in this recall.

 

IMPORTANT: The parts used in this safety recall may physically appear to be identical, but they have differing operating characteristics. It is crucial that parts are NOT interchanged or substituted. Do not disassemble, modify, or alter the parts or repair procedure in any way. Doing so may prevent the airbag from operating properly during a deployment.

 

 

SERVICE PROCEDURE

 

PASSENGER AIRBAG INFLATOR INSPECTION

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

 

NOTE: If the Airbag Readiness light indicates no Supplemental Restraint System (SRS) faults are present, it is not necessary to follow the WSM SRS Depowering and Repowering steps. Turn the ignition to OFF and wait 1 minute, then it is safe to proceed with airbag inflator replacement.

 

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

 

1. Remove the passenger airbag from the vehicle. Please follow the WSM procedures in Section 501-20.

 

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

 

3. Inspect the passenger airbag inflator end for the presence of a plastic end cap as shown in Figure 1. Is the plastic end cap present on the airbag inflator?

 

Yes – PASS – Inspection Complete. Install the Passenger Airbag. Please follow the WSM procedures in Section 501-20.

No – DOES NOT PASS – Proceed to the Passenger Airbag Inflator Replacement on Page 3.

 

 

PASSENGER AIRBAG INFLATOR REPLACEMENT

 

1. Remove the wiring harness connector retainer from the passenger airbag See Figure 2.

 

NOTE: Carry out this Step on the shorter wire on the end opposite of the airbag inflator retaining bracket. See Figure 3.

 

2. Remove the conduit from the passenger airbag assembly wire harness in the area See Figure 3.

 

3. Position the shorting clip onto the harness wires, and crimp the shorting clip together one side at a time using pliers. See Figure 4.

 

4. Cut the harness wires between the shorting clip and the harness connector. See Figure 4.

 

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

 

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

 

6. With an assistant holding the passenger airbag assembly, remove the inflator from the assembly by pushing outward on the inflator. Set the airbag inflator aside for return See Figure 6.

 

• If required, use of a brass punch is permitted (only at the location shown) to free the inflator from its mounted position.

 

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

 

7. Record the 11 character serial number of the new airbag inflator on the repair order. See Figure 7.

 

8. NOTE: Both new inflator end caps are specific to their respective end of the inflator and must be fully seated.

 

NOTE: The tail end cap does not have an alignment tab and may be installed in any orientation.

Make sure the tail end cap is fully seated or you will not be able to install the inflator retaining bracket.

 

Install both new inflator end caps making sure the alignment feature on the cap nearest the inflator retaining bracket is properly oriented. See Figure 8.

 

9. Install the inflator into the passenger airbag assembly with the orange connector end facing out. Align the three tabs on the cap nearest the inflator retaining bracket with the airbag module lower channel (facing down). See Figure 9.

 

NOTE: If the inflator retaining bracket is unable to be installed, ensure the inflator tail end cap is fully seated.

 

10. Install the new passenger airbag inflator retaining bracket and new See Figure 10.

 

• Torque the new retaining nuts in the sequence shown Tighten to 4 Nm (35 lb in).

 

11. Align the T-shape index on both the wiring harness electrical connector and the airbag Install the new wiring harness onto the passenger airbag module and connect to both sides of the inflator and fully seat the black tabs. See Figure 11.

 

NOTE: Pull gently on the wiring harness to ensure it is properly seated.

 

12. Install the new tape to the wiring harness and airbag assembly, do not cover the airbag warning label with the new For correct placement See Figure 12.

 

13. Re-install the passenger Please follow WSM procedures in Section 501-20.

 

14. Package the replaced inflator in the new part box and provide to the appropriate dealership personnel for part returns.

.

 

 

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ATTACHMENT VII

CERTAIN 2006–2009 MODEL YEAR FUSION AND MILAN VEHICLES — PASSENGER AIRBAG MODULE REPLACEMENT

 

NOTE: The following repair instructions only apply to 2006-2009 Model Year (MY) Fusion and Milan vehicles. Repair instructions are published in separate attachments for the other vehicle lines included in this recall.

 

IMPORTANT: The parts used in this safety recall may physically appear to be identical, but they have differing operating characteristics. It is crucial that parts are NOT interchanged or substituted. Do not disassemble, modify, or alter the parts or repair procedure in any way. Doing so may prevent the airbag from operating properly during a deployment.

 

SERVICE PROCEDURE

 

PASSENGER AIRBAG MODULE 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.

 

1. Record the 13 character serial number of the new airbag module on the repair See Figure 1.

 

2. Replace the passenger airbag Please follow the Workshop Manual procedures in Section 501-20.

 

3. Package the replaced airbag module in the new part box and provide to the appropriate dealership personnel for part returns.

.

 

 

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ATTACHMENT VIII

CERTAIN 2010–2012 MODEL YEAR FUSION AND 2010–2011 MODEL YEAR MILAN VEHICLES — PASSENGER AIRBAG MODULE INSPECTION

 

NOTE: The following repair instructions only apply to 2010–2012 Model Year Fusion and 2010–2011 Model Year (MY) Milan vehicles. Repair instructions are published in separate attachments for the other vehicle lines included in this recall.

 

IMPORTANT: The parts used in this safety recall may physically appear to be identical, but they have differing operating characteristics. It is crucial that parts are NOT interchanged or substituted. Do not disassemble, modify, or alter the parts or repair procedure in any way. Doing so may prevent the airbag from operating properly during a deployment.

 

SERVICE PROCEDURE

 

PASSENGER AIRBAG INFLATOR INSPECTION

 

1. Fully lower the glove compartment door and look up at the passenger airbag module. Inspect the passenger airbag inflator end for the presence of a plastic end cap as shown in Figure 1. Is the plastic end cap present on the airbag inflator?

 

Yes – PASS – Inspection Complete. Raise and close the glove compartment door.

No – DOES NOT PASS – Proceed to the Passenger Airbag Inflator Replacement on Page 2.

 

PASSENGER 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.

 

1. Record the 13 character serial number of the new airbag module on the repair order. See Figure 2.

 

NOTE: Reduce the risk of damaging interior components by allowing the interior of the vehicle to reach a warm inside temperature.

 

2. Remove the left hand (LH) and right hand (RH) A-Pillar trim Reuse the LH and RH trim panels for this repair. See Figure 3.

 

• Grasp the trim panel approximately five (5) inches from the top and pull downward toward the door, then rotate the panel inward toward the windshield to slide it off of the A-pillar

 

NOTE: Do not bend or flex the trim panels during removal to avoid stress marks from occurring.

 

NOTE: To view a video demonstration of this repair procedure, click the video icon.

https://bcove.video/2NCVmtj

 

3. Remove and discard the top A-Pillar clip from the See Figure 4.

 

4. Remove the passenger airbag module. Please follow the Workshop Manual (WSM) procedures in Section 501-20.

 

NOTE: Remove the instrument panel with care, prevent damage by covering any interior components that may scrape or hit the instrument panel upon removal. Once removed gently place the instrument panel onto a clean surface.

 

• Remove the instrument panel crossmember-to-airbag module See Figure 5.

 

• Torque to 80 in (9 Nm).

 

5. Remove the six (6) nuts retaining the airbag module bracket to the instrument Remove the bracket from the instrument panel. See Figure 6.

 

• Torque to: 80 in (9 Nm).

 

6. Inspect the white airbag cushion sheets installed on the instrument panel. See Figure 7.

 

NOTE: If any damage is present on either of the airbag cushion sheets, the damaged sheet(s) must be replaced. Type of damage includes, but is not limited to, cuts, creases, folds or the perforations being broken.

 

NOTE: Sheets can be installed in any direction or orientation.

 

7. Replace sheet or sheets if damaged, clear both sheets of any dirt or debris and reinstall both sheets on the airbag mounting bracket studs. See Figure 8.

 

NOTE: The sheets will not lay perfectly flat when installed on the instrument panel.

 

IMPORTANT: Two airbag cushion sheets should be present on the instrument panel before proceeding.

 

8. Reinstall the airbag module bracket onto the instrument panel. See Figure

 

9. Install the new airbag module and instrument Please follow the WSM procedures in Section 501-20.

 

• Install the instrument panel crossmember-to-airbag module See Figure 5.

 

10. Install the new A-Pillar trim panel clip onto the trim panel. See Figure 9.

 

NOTE: If the new A-Pillar trim panel clips are not equipped with a screw installed, re-use the screw from the original clip from Step 3. Install the screw into the new clip by hand.

 

• Torque to: 9 in (1 Nm).

 

11. Install the LH and RH A-Pillar trim panels by aligning the attachment clips to the holes and snapping the new trim panel in place.

 

12. Package the replaced airbag module in the new part box and provide to the appropriate dealership personnel for part returns.

.

 

 

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ATTACHMENT IX

CERTAIN 2006-2009 MODEL YEAR MKZ AND ZEPHYR VEHICLES – PASSENGER AIRBAG MODULE REPLACEMENT

 

NOTE: The following repair instructions only apply to 2006-2009 (MY) MKZ and Zephyr vehicles. Repair instructions are published in separate attachments for the other vehicle lines included in this recall.

 

IMPORTANT: The parts used in this safety recall may physically appear to be identical, but they have differing operating characteristics. It is crucial that parts are NOT interchanged or substituted. Do not disassemble, modify, or alter the parts or repair procedure in any way. Doing so may prevent the airbag from operating properly during a deployment.

 

SERVICE PROCEDURE

 

PASSENGER AIRBAG MODULE 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.

 

1. Record the 13 character serial number of the new airbag module on the repair See Figure 1.

 

2. Replace the passenger airbag Please follow the Workshop Manual procedures in Section 501-20.

 

NOTE: Use caution when removing the 5 instrument panel trim panel fasteners or the studs may strip out. Submit a contact to the SSSC if damage to the trim panel does occur.

 

3. Package the replaced airbag module in the new part box and provide to the appropriate dealership personnel for part returns.

.

 

 

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ATTACHMENT X

CERTAIN 2010–2012 MODEL YEAR MKZ VEHICLES — PASSENGER AIRBAG MODULE INSPECTION

 

NOTE: The following repair instructions only apply to 2010–2012 Model Year (MY) MKZ vehicles. Repair instructions are published in separate attachments for the other vehicle lines included in this recall.

 

IMPORTANT: The parts used in this safety recall may physically appear to be identical, but they have differing operating characteristics. It is crucial that parts are NOT interchanged or substituted. Do not disassemble, modify, or alter the parts or repair procedure in any way. Doing so may prevent the airbag from operating properly during a deployment.

 

SERVICE PROCEDURE

 

PASSENGER AIRBAG INFLATOR INSPECTION

 

1. Fully lower the glove compartment door and look up at the passenger airbag module. Inspect the passenger airbag inflator end for the presence of a plastic end cap as shown in Figure 1. Is the plastic end cap present on the airbag inflator?

 

Yes – PASS – Inspection Complete. Raise and close the glove compartment door.

No – DOES NOT PASS – Proceed to the Passenger Airbag Inflator Replacement on Page 2.

 

PASSENGER 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.

 

1. Record the 13 character serial number of the new airbag module on the repair order. See Figure 2.

 

NOTE: Reduce the risk of damaging interior components by allowing the interior of the vehicle to reach a warm inside temperature.

 

2. Remove the left hand (LH) and right hand (RH) A-Pillar trim Reuse the LH and RH trim panels for this repair. See Figure 3.

 

• Grasp the trim panel approximately 5 inches from the top and pull downward toward the door, then rotate the panel inward toward the windshield to slide it off of the A-pillar

 

NOTE: Do not bend or flex the trim panels during removal to avoid stress marks from occurring.

 

NOTE: MKZ A-Pillar trim is wrapped in fabric, be sure to protect the fabric from stains when removing.

 

NOTE: To view a video demonstration of this repair procedure, click the video icon.

https://bcove.video/2NCVmtj

 

3. Remove and discard the top A-Pillar clip from the See Figure 4.

 

4. Remove the passenger airbag module. Please follow the Workshop Manual (WSM) procedures in Section 501-20.

 

NOTE: Remove the instrument panel with care, prevent damage by covering any interior components that may scrape or hit the instrument panel upon removal. Once removed gently place the instrument panel onto a clean surface.

 

• Remove the instrument panel crossmember-to-airbag module See Figure 5.

 

• Torque to 80 in (9 Nm).

 

5. Install the new airbag module and instrument panel. Please follow WSM procedures in Section 501-20.

 

• Install the instrument panel crossmember-to-airbag module See Figure 5.

 

6. Install the new A-Pillar trim panel clip onto the trim panel. See Figure 6.

 

NOTE: If the new A-Pillar trim panel clips are not equipped with a screw installed, re-use the screw from the original clip from Step 3. Install the screw into the new clip by hand.

 

• Torque to 9 in (1 Nm).

 

7. Install the LH and RH A-Pillar trim panels by aligning the attachment clips to the holes and snapping the new trim panel in place.

 

8. Package the replaced airbag module in the new part box and provide to the appropriate dealership personnel for part returns.

.

 

 

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ATTACHMENT XI

CERTAIN 2007 – 2010 EDGE VEHICLES — PASSENGER AIRBAG MODULE REPLACEMENT

 

NOTE: The following repair instructions only apply to 2007 – 2010 Model Year (MY) Edge vehicles.

Repair instructions are published in separate attachments for the other vehicle lines included in this recall.

 

IMPORTANT: The parts used in this safety recall may physically appear to be identical, but they have differing operating characteristics. It is crucial that parts are NOT interchanged or substituted. Do not disassemble, modify, or alter the parts or repair procedure in any way. Doing so may prevent the airbag from operating properly during a deployment.

 

SERVICE PROCEDURE

 

PASSENGER AIRBAG MODULE 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.

 

1. Record the 13 character serial number of the new airbag module on the repair See Figure 1.

 

2. Replace the passenger airbag Please follow the Workshop Manual (WSM) procedures in Section 501-20.

 

NOTE: Releasing the side tabs of the airbag trim cover first will aid in the removal process.

 

3. Package the replaced airbag module in the new part box and provide to the appropriate dealership personnel for part returns.

.

 

 

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ATTACHMENT XII

CERTAIN 2007 – 2010 MODEL YEAR MKX VEHICLES — PASSENGER AIRBAG INFLATOR INSPECTION

 

NOTE: The following repair instructions only apply to 2007 – 2010 Model Year (MY) MKX vehicles.

Repair instructions are published in separate attachments for the other vehicle lines included in this recall.

 

IMPORTANT: The parts used in this safety recall may physically appear to be identical, but they have differing operating characteristics. It is crucial that parts are NOT interchanged or substituted. Do not disassemble, modify, or alter the parts or repair procedure in any way. Doing so may prevent the airbag from operating properly during a deployment.

 

SERVICE PROCEDURE

 

PASSENGER AIRBAG INFLATOR INSPECTION

 

1. Fully lower the glove compartment door and look up at the passenger airbag module. Inspect the passenger airbag inflator end for the presence of a plastic end cap as shown in Figure 1. Is the plastic end cap present on the airbag inflator?

 

Yes – PASS – Inspection Complete. Raise and close the glove compartment door.

No – DOES NOT PASS – Proceed to the Passenger Airbag Module Replacement on Page 2.

 

PASSENGER AIRBAG MODULE 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.

 

1. Record the 13 character serial number of the new airbag module on the repair See Figure 2.

 

2. Replace the passenger airbag Please follow the WSM procedures in Section 501-20.

 

NOTE: When reinstalling the airbag module, hand-tighten the bolts and then torque to specification.

Overtightening the bolts may result in instrument panel damage.

 

3. Package the replaced airbag module in the new part box and provide to the appropriate dealership personnel for part returns.

.

 

 

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ATTACHMENT XIII

AIRBAG INFLATOR CORE RETURN PROCESS

Regional Core Recovery Centers (RCRCs) will pick up core parts associated with this safety recall, with some exceptions for dealerships outside the 48 contiguous United States.

Refer to the table below to determine the appropriate process for the part(s) in question, then:

• for the FCS-700 Tag return process, refer to page 2.
• for the Core Charge return process, refer to page 3.

 

IMPORTANT: If an FCS-700 tag is not issued as expected, 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. The SSSC will provide return instructions.

Part Number Installed	Vehicle Application	Part Description	Return Process
5R3Z-63043B13-C	2005-06 Ford GT	Driver Airbag Inflator	FCS-700 Tag – Go to Page 2
CR3Z-63043B13-AD	2013-2014 Mustang	Driver Airbag Module
DR3Z-63043B13-AD	2013-2014 Mustang	Driver Airbag Module
4L5Z-10043B13-D	2004-2006 Ranger	Driver Airbag Inflator
8L5Z-10044A74-D	2004-2006 Ranger	Passenger Airbag Inf lator
5R3Z-63044A74-B	2005-2009 Mustang	Passenger Airbag Inf lator	Core Charge – Go to Page 3
6G7Z-63044A74-A	2010-2014 Mustang	Passenger Airbag Inf lator
8L5Z-10044A74-E	2007-2011 Ranger	Passenger Airbag Inf lator
8E5Z-54044A74-AC	2006-2009 Fusion	Passenger Airbag Module
8E5Z-54044A74-AD	2006-2009 Fusion	Passenger Airbag Module
AE5Z-54044A74-D	2010-2012 Fusion and 2010-2011 Milan	Passenger Airbag Module
7H6Z-54044A74-AD	2006-2009 MKZ	Passenger Airbag Module
7H6Z-54044A74-AE	2006-2009 MKZ	Passenger Airbag Module
7H6Z-54044A74-AF	2006-2009 MKZ	Passenger Airbag Module
AH6Z-54044A74-D	2010-2012 MKZ	Passenger Airbag Module
9T4Z-78044A74-AC	2007 Edge	Passenger Airbag Module
9T4Z-78044A74-AD	2007 Edge	Passenger Airbag Module
9T4Z-78044A74-AA	2007-2010 Edge	Passenger Airbag Module
9T4Z-78044A74-AB	2008-2010 Edge	Passenger Airbag Module
9A1Z-78044A74-A	2007-2010 MKX	Passenger Airbag Module

 

RETURN PROCESS – PARTS WITH FCS-700 TAG

Dealers must monitor their OWS parts status report. An FCS-700 tag will be generated for each applicable airbag inflator. Parts will be picked up by the RCRCs, except for dealerships outside the 48 contiguous United States.

IMPORTANT: If an FCS-700 tag is not issued as expected, or the OWS parts status report directs to “scrap” a part replaced under this saf ety recall, please submit a General Request to the SSSC Web Contact Site stating that you were directed to scrap a part. The SSSC will provide return instructions.

 

Key Information:

• All replaced driver airbag inflators and modules must be returned in the new part box with original If the new part box is damaged or lost, contact XPO logistics at 210 -250-5079 or [email protected] for a replacement box.
  • Ensure that you have processes in place to safeguard the packaging.
  • The dealer-provided Haz-Mat Materials must also be returned in the The new replacement service part packaging is certified with the appropriate DOT marks and labels.
  • RCRCs will not accept any airbag inflators without correct packaging or Haz-Mat documentation.
  • Ensure that all marks and labels are present prior to tendering to the RCRC for core credit.
• Disregard prepaid FedEx shipping instructions that may be included in new part boxes.

 

Part Return Instructions – Dealers in the 48 Contiguous United States:

1. Package the airbag inflator or module in the new part box as outlined above.
2. Print and provide both of the following completed documents to the RCRC driver:
   • Hazardous Materials Shipping Document (Page 4)
     • In the box titled Shipper, enter your dealership name and address.
     • In the box titled Receiver, enter the address of your Regional Core Recovery Center. NOTE: Page 6 contains a list of RCRC locations. If you are unsure of which RCRC location services your dealership, consult the RCRC driver.
     • In the box titled Number/Type of Package, enter the number of boxed inflators.
     • In the box titled Weight, enter the total shipment weight of all boxed inflators.
     • At the bottom of the Hazardous Materials Shipping Document, complete the Shipper’s Certification
   • North American Emergency Response Guide 171 (Page 5)

 

Part Return Instructions – Dealers Outside of the 48 Contiguous United States:

1. Contact Miguel Prigadaa at 210-250-5078 or [email protected] for instructions on returning the airbag inflator(s) via FedEx.

 

 

RETURN PROCESS – PARTS WITH A CORE CHARGE

Parts subject to a core charge will be identified as such with the yellow core label on the packaging. The Regional Core Recover Center (RCRC) will pick up these airbag inflators along with other core returns during your normal core retrieval visit. This includes dealers in Alaska and Hawaii.

 

Key Information:

• All replaced driver airbag inflators and modules must be returned in the new part box with original If the new part box is damaged or lost, contact XPO logistics at 210 -250-5079 or [email protected] for a replacement box.
  • Ensure that you have processes in place to safeguard the packaging.
  • The dealer-provided Haz-Mat Materials must also be returned in the The new replacement service part packaging is certified with the appropriate DOT marks and labels.
  • RCRCs will not accept any airbag inflators without correct packaging or Haz-Mat documentation.
  • Ensure that all marks and labels are present prior to tendering to the RCRC for core credit.
• Disregard prepaid FedEx shipping instructions that may be included in new part boxes.

 

Part Return Instructions – All Dealers:

3. Package the airbag inflator or module in the new part box as outlined above.
4. Print and provide both of the following completed documents to the RCRC driver:
   • Hazardous Materials Shipping Document (Page 4)
     • In the box titled Shipper, enter your dealership name and address.
     • In the box titled Receiver, enter the address of your Regional Core Recovery Center. NOTE: Page 6 contains a list of RCRC locations. If you are unsure of which RCRC location services your dealership, consult the RCRC driver.
     • In the box titled Number/Type of Package, enter the number of boxed inflators.
     • In the box titled Weight, enter the total shipment weight of all boxed inflators.
     • At the bottom of the Hazardous Materials Shipping Document, complete the Shipper’s Certification
   • North American Emergency Response Guide 171 (Page 5)

 

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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re Safety Recall 21S05 Certain 2005-2014 Mustang, 2005-2006 Ford GT, 2004-2011 Ranger, 2006-2012 Fusion and MKZ/Zephyr, 2006-2011 Milan, and 2007-2010 Edge and MKX Vehicles Airbag Module Inspection and Replacement

RCMN-21V076-1868.pdf 10623.22KB

 

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Last update on 2026-05-30 / Affiliate links / Images from Amazon Product Advertising API

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