Customer Satisfaction Program 21B05 – High-Speed Cooling Fan Motor Relay – 2016-2018 Ford Police Interceptor Utility

NHTSA ID Number: 10201080

Manufacturer Communication Number: 21B05

 

Summary

After extended idling, the high-speed cooling fan relay may fail in some of the affected vehicles. A failure will cause the fan to either continuously run or never turn on. A continuously running fan will increase the temperature of the relayâ??s connections (terminals) to beyond their design maximum. This may eventually create an electrical arc which heats and damages the relay terminals. Customers may experience a drained battery and a non-functional or even a melted/burned high-speed cooling fan relay inside the battery junction box (BJB). A damaged non-functional relay causing the fan to never turn on, may lead to engine overheating at idle.

 

 


3 Affected Products

Vehicle

MAKEMODELYEAR
FORDeBay logoEXPLORER POLICE INTERCEPT2016-2018

 


PROGRAM TERMS 

This program will be in effect through August 31, 2022 There is no mileage limit for this program.

 

AFFECTED VEHICLES

VehicleModel YearAssembly PlantBuild Dates
Police Interceptor Utility2016-2018ChicagoOctober 1, 2014 through September 16, 2018

 

REASON FOR THIS PROGRAM

After extended idling, the high-speed cooling fan relay may fail in some of the affected vehicles. A failure will cause the fan to either continuously run or never turn on. A continuously running fan will increase the temperature of the relay’s connections (terminals) to beyond their design maximum. This may eventually create an electrical arc which heats and damages the relay terminals. Customers may experience a drained battery and a non-functional or even a melted/burned high-speed cooling fan relay inside the battery junction box (BJB). A damaged non-functional relay causing the fan to never turn on, may lead to engine overheating at idle.

 

SERVICE ACTION

Dealers are to replace (splice) the four affected high-speed cooling fan relay terminals in the BJB and reroute the new terminals to a new larger relay. This service must be performed on all affected vehicles at no charge to the vehicle owner.

 

OWNER NOTIFICATION AND MAILING SCHEDULE

Owner letters are expected to be mailed the week of September 06, 2021. Dealers should repair any affected vehicles that experience high-speed cooling fan relay issues that arrive at their dealerships, whether or not the customer has received a letter.

 

PARTS REQUIREMENTS

Part NumberDescriptionOrder QuantityClaim Quantity
JU2Z-14474-BAWire Circuit kit – Repair for Blue/Red and Green/Orange Wires with Terminals, Crimp Tubes, and Heat Shrink (5 sets per pkg, 2 req’d)

NOTE: Heat Shrink included may not fit over crimp tubes per this kit. See allowance below as needed.

12
KU2Z-14474-EAWire Circuit kit – Repair for Grey and Brown Wires with Terminals, Crimp Tubes, and Heat Shrink (5 sets per pkg, 2 req’d)12
F8OZ-14N089-AARelay – Full Iso, for High-Speed Cooling Fan11
Obtain Locally3/8 Inch Heat Shrink Tubing with Lined Adhesive

(Package expected to support multiple repairs)

As Needed Claim as MISC OTHER up to $2.00

 


CERTAIN 2016-2018 MODEL YEAR POLICE INTERCEPTOR UTILITY VEHICLES — HIGH SPEED COOLING FAN MOTOR RELAY

 

SERVICE PROCEDURE

NOTE: The high speed cooling fan relay (R11) will be relocated to the (R24) position in the Battery Junction Box (BJB) as shown in Figures 1 and 2.

 

1. Disconnect the positive and negative battery cables and position the cables and harness aside. Please follow the Workshop Manual (WSM) procedures in Section 414-01.

2. Remove the Battery Junction Box (BJB) cover. See Figure 3.

 

3. Remove the nuts and power feed cables from the BJB studs and position aside both power feed cables. See Figure 4.

 

4. Record the amperage and location of the fuses and location of the relay’s in the area shown in Figure 5.
Then, remove all of the fuses and relay’s within the red boxed area shown. See Figure 5.

NOTE: It is recommended to take a close up picture, of your particular vehicles BJB fuse and relay population, which will also aid in the reinstallation later in this procedure.

NOTE: The BJB has been removed in some of the following Figures for clarity.

 

5. Using a pair of needle nose pliers, pull straight up to remove the Terminal Position Assurance (TPA) plastic insert from the BJB as shown in Figure 6.

 

6. Using a pocket screwdriver, release the four (4) BJB tabs (two (2) on each side) and separate the upper half of the BJB from the lower half. See Figures 7 and 8.

 

7. Using a terminal removal tool, remove the wire terminal from the R11 relay cavity 11-3 (blue/red wire).
See Figure 9.

– From the top side of the BJB, insert the tip of the terminal removal tool into the terminal cavity until it stops.
– Holding the release tool in place, gently push the wire of the terminal to be removed toward the housing until it stops.
– Rotate the release tool toward the terminal to unlock the latch beam from the terminal. While holding the tool in position, gently pull the wire until the terminal is released, then pull it straight out from the bottom side of the BJB.

NOTE: Refer to the Workshop Manual (WSM) procedure in Section 100-00 – General Procedures for additional terminal removal information.

 

8. Using the terminal removal tool, remove the remaining three (3) wire terminals (noted below) from the R11 relay cavities, in the same manner as the previous Step, and position the wire terminals out from under the BJB. See Figure 10.

– Cavity 11-1 gray wire.
– Cavity 11-2 brown wire.
– Cavity 11-5 green/orange wire.

NOTE: Refer to the Workshop Manual (WSM) procedure in Section 100-00 – General Procedures for additional terminal removal information.

 

9. Replace the terminal ends on the four (4) R11 wire terminals that were removed in Steps 7 and 8 using the directions below:

NOTE: The pigtail terminals supplied in the designated repair kits are of like wire gauge but are different colors and have larger terminals ends.

NOTE: There are two (2) different gauge wires for this repair. The two (2) smaller gauge wires will use the pigtail terminals supplied in the repair kit Part Number KU2Z-14474-EA. The two (2) larger gauge wires will use the pigtail terminals, supplied in the repair kit Part Number JU2Z-14474-BA.

a. Cut off and discard the four (4) wire terminal ends, terminals just removed from the R11 cavities, at the base of the terminal (where the wire meets the metal terminal end).

b. Size and cut the new wires to the length of approximately 6 in. (150 mm) including the female terminal end:

1. Two (2) of the new smaller gauge pigtail terminals (Part Number KU2Z-14474-EA).

2. Two (2) of the new larger gauge pigtail terminals (Part Number JU2Z-14474-BA).

c. Strip 0.38 in (9.53 mm) of the insulation from the two (2), in vehicle, smaller gauge wires of the terminals just removed (from the grey and the brown wires) and two (2) new smaller gauge wires that were just cut to length (Part Number KU2Z-14474-EA).

d. Strip 0.5 in (12.7 mm) of the insulation from the two (2), in vehicle, larger gauge wires of the terminals just removed (from the blue/red and the green/orange) and the two (2) new larger gauge wires that were just cut to length (Part Number JU2Z-14474-BA).

e. Install heat shrink with lined adhesive:

1. On the harness side, install a piece of two inch long, 0.38 in. (9.53 mm) diameter, heat shrink tubing over both larger 8 AWG wires.

2. Then, install a piece of heat shrink tubing, supplied with Part Number KU2Z-14474-EA, over both smaller 10-12 AWG wires.

3. Slide all four (4) heat shrink tubes away from the heat while soldering. See Figure 11.

f. Crimp – Blue/Red and Green/Orange Wires:

1. Make 4 crimps using the Rotunda/Motorcraft Wiring Pro – NAIAT-RACT-NI or equivalent to crimp the 8 AWG crimp tubes per the kit.

2. Crimp one (1) of the new 8 AWG 6 inch pigtail terminals with an 8 AWG crimp tube.

3. Then, crimp the other side to the Blue/Red wire where the terminal was removed from in the BJB.

4. Repeat this step for the Green/Orange wire. See Figure 12.

g. Crimp – Gray and Brown Wires:

1. Make 4 crimps using the Rotunda/Motorcraft Wiring Pro – NAIAT-RACT-NI or equivalent to crimp the 10-12 AWG crimp tubes per the kit.

2. Crimp one (1) of the new 10-12 AWG 6 inch pigtail terminals with an 10-12 AWG crimp tube.

3. Then, crimp the other side to the Gray wire where the terminal was removed from in the BJB.

4. Repeat this step for the Brown wire. See Figure 12.

h. NOTE: Use Rosin Mildly Activated (RMA) solder. Do Not use acid core solder.

• Using the solder hole in the center of the crimp, solder the wires together.

i. Slide the piece of heat shrink tubing evenly over the soldered repair on all four (4) repaired wires.

j. Use a suitable heat gun, such as Rotunda Shielded Flameless Heat Gun with Heat Deflector (NAIAT-R5902) that is equipped with a shrink tubing attachment, to heat the heat shrink tubing until the adhesive comes out of both ends on all four (4) repaired wires. See Figure 13.

 

10. Install the four (4) wires, removed from the original relay with new terminal ends, into the new relay R24 cavities as noted below. See Figures 14 and 15.

– Install what was the original gray wire into cavity 24-1.
– Install what was the original brown wire into cavity 24-2.
– Install what was the original blue/red wire into cavity 24-3.
– Install what was the original green/orange wire into cavity 24-5.

NOTE: When installing the terminal, gently insert the terminal end straight into the cavity until you hear, or feel, a click. When the terminal end is fully inserted, softly pull on the terminated lead to insure the terminal is locked into place.

 

11. Position all wiring into the lower BJB half. Then, align the upper BJB half with the lower BJB half.
Push straight down to seat the clips on the side. Audible clicks can be heard as the clips correctly seat.

12. Reinstall the TPA plastic lock by aligning all of the male terminals in the BJB with the TPA lock and gently push straight down. As the TPA is installed, it can be felt as it passes by the lobes and properly seats. See Figure 6.

– Inspect all four (4) corners of the TPA insert to ensure it is flush with the BJB housing.

13. Install the new larger high speed cooling fan relay into the new location, R24. See Figures 1 and 16.

14. Install the remaining fuses and relays with the exception of the original cooling fan relay R11 location, which should have been discarded. The original relay location (R11) will stay empty. See Figure 16.

 

15. Position back both of the BJB’s power feed cables and install the nuts. See Figure 17.

• Tighten to 80 lb in (9 Nm).

 

16. Install the BJB cover. See Figure 3.

17. Position back the battery cable harness and connect the positive and negitive battery cables. Please follow the WSM procedures in Section 414-01.

18. Ensure the high speed cooling fan motor is operational.

IMPORTANT NOTE: Federal law prohibits selling motor vehicle parts or components that are under safety, compliance, or emissions recall. Unless a part is requested to be returned to FordeBay logo, all parts replaced under this FSA must be scrapped in accordance with all applicable local, state and federal environmental protection and hazardous material regulations. Refer to the Parts Retention, Return, & Scrapping section of the FSA dealer bulletin for further information.

 

 


 


1 Associated Document

Manufacturer Communications

Customer Satisfaction Program 21B05
August 19, 2021

https://www.nhtsa.gov/recalls?nhtsaId=10201080

MC-10201080-0001.pdf 5901.078KB

 


 

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