This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Check the Ford website &/or the NHTSA to see if your VIN is affected.

Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1992-1994 Model Year Bronco, F-150-350 Series Trucks and 1993-1994 Model Year Explorer/Ranger vehicles.

Safety Defect
During rapid pedal application of the parking brake, the pedal may go to the floor with little or no effort. Should this occur, the parking brake system may not achieve full tension, potentially resulting in parking brake ineffectiveness, or diminished effectiveness.

Repairs
At no charge to you, your dealer will install a parking brake lock-in wedge. This wedge retains the adjustment pawl in mesh with the ratchet. Dealers currently have instructions and parts ordering information.

WARNING: DO NOT PARK THE VEHICLE IN NEUTRAL. USE FIRST (1) GEAR AND SET THE PARKING BRAKE FULLY.

NOTE: When the transfer case is in the N (Neutral) Position, the engine and transmission are disconnected from the rest of the driveline. Therefore, the vehicle is free to roll even if the manual transmission is in gear. Do not leave the vehicle unattended with the transfer case in N (Neutral).

NOTE: Always set the parking brake fully and turn off the ignition when leaving the vehicle. Make sure that the gearshift is securely positioned in First (1) gear.

How Long Will It Take?
The time needed for this service is about one-half hour. However, due to service scheduling times, your dealer may need your vehicle for one full working day.

Call your dealer without delay. Ask for a service date and whether parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week.

When you bring your truck in, show the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge.

AFFECTED VEHICLES:
CERTAIN 1992-1994 BRONCO, F-150/350 SERIES TRUCKS AND CERTAIN 1993-1994 EXPLORER/RANGER VEHICLES EQUIPPED WITH MANUAL TRANSMISSIONS

OVERVIEW
The parking brake procedures described in this attachment supersede all previous parking brake procedures.

The following instructions have been revised to make them easier to follow. Special emphasis is placed on the installation of the lock-in wedge and verifying that the wedge is properly installed. When installed properly, the wedge WILL NOT fall out.

Except where noted, the illustrations included here are of the Bronco/F-Series. The Explorer/Ranger are similar. PLEASE FOLLOW THESE INSTRUCTIONS CAREFULLY.

NOTE: This recall applies to PARKING BRAKES ONLY. The service brake system is not affected by this recall.

PRELIMINARY CHECKS

1. Park the vehicle on a flat surface. Turn the ignition OFF. Do not apply the parking brake.

2. Check the parking brake control assembly to see if it is a â%uFFFD%uFFFDCam-In-Postâ%uFFFD%uFFFD design. The â%uFFFD%uFFFDCam-In-Postâ%uFFFD%uFFFD design control assembly does not require installation of the lock-in wedge. If the vehicle has a â%uFFFD%uFFFDCam-In-Postâ%uFFFD%uFFFD design control assembly, return the vehicle to the owner.

3. NOTE: This step is not necessary for Explorer/Ranger vehicles. Check the release rod and spring for proper position. The release rod must be fully inserted into the slot in the bracket, and the spring must be located behind the slot in the bracket.

1. Without moving the parking brake pedal, inspect the parking brake control assembly to determine if the lock-in wedge has been previously installed.

A. If the lock-in wedge has not been previously installed or has fallen out, proceed to Lock-In Wedge Service Procedure (Next Image).

B. If the lock-in wedge has been previously installed, it must be inspected for proper installation. Inspect to make sure the flange of the lock-in wedge is flush with the edge of the pawl. Place a small screwdriver between the lock-in wedge and the sector gear. Apply a firm, up and down prying force to the wedge. The wedge should feel very stiff, with no movement between the sector gear, wedge and pawl.
-- If no movement is noted, the wedge has been properly installed. Return the vehicle to the owner.
-- If movement is noted, proceed to Lock-In Wedge Service Procedure (Next Image).

LOCK-IN WEDGE SERVICE PROCEDURE

NOTE: This procedure should only be performed if the lock-in wedge was never installed, or the original wedge is loose or missing.

A. Lock-In Wedge Removal (If Applicable)

1. Depress the parking brake pedal until a full travel position is achieved. The pedal will be in a vertical position.

WARNING: BE CAREFUL TO AVOID ACCIDENTALLY ACTIVATING THE RELEASE LEVER DURING ANY PART OF THE LOCK-IN WEDGE SERVICE PROCEDURE.

2. Using a pair of standard or needle nose pliers, grip the tab of the lock-in wedge. Pull the wedge out with a twisting motion.

3. Release the parking brake.

4. Inspect the wedge for damage. If any part of the wedge is broken or damaged, obtain a new wedge.

C. Parking Brake Adjustment

NOTE:
The installation of the lock-in wedge disables the self-adjusting feature of the parking brake system. Therefore, it is critical to adjust the parking brake system before installing the lock-in wedge.

1. Place the transmission in neutral, then raise the vehicle on a hoist until the rear wheels are off the ground.

NOTE: The vehicle must be supported by the rear axle to maintain curb height.

2. Position two (2) jack stands under the rear axle housing, then lower the hoist until the weight of the vehicle is supported by the rear axle.

3. Apply and release the parking brake three times allowing the pedal to return each time without any interference.

4. Firmly apply the parking brake.

5. Verify that the parking brake is applied by trying to rotate the rear wheels by hand.

6. Release the parking brake with your foot resting on the pedal, and allow the pedal to return slowly to the released position.

7. Verify that the parking brake is fully released. Check for brake drag by rotating the rear wheels by hand.

8. Raise the vehicle and remove the two (2) jack stands. Lower the vehicle.

9. Call 1-800-325-5621 for further instructions if any of the following conditions exist:
a. The rear wheels turn while the parking brake is applied.
b. Brake drag occurs when the parking brake is released.

C. Lock-In-Wedge Installation

NOTE: Do not proceed unless the parking brake system is working properly.
WARNING: BE VERY CAREFUL TO AVOID ACCIDENTALLY ACTIVATING THE RELEASE LEVER DURING ANY PART OF THE LOCK-IN WEDGE SERVICE PROCEDURE.

1. Depress the parking brake pedal so that the pedal travels 75 mm (3 inches) from the released position.

2. Visually inspect to make sure that the pawl is fully seated in the bottom of a sector gear tooth. If it is not, place a screwdriver between the sector gear and pawl, pry down on the pawl to force it into a sector gear tooth.

3. When the pawl and sector gear are fully engaged, depress the parking brake pedal until a full travel position is achieved. This will allow more working room and make the installation of the wedge easier.

NOTE: The Bronco/F-Series uses a white wedge and the Explorer/Ranger uses a black wedge. They are not interchangeable.

4. Obtain the proper lock-in wedge for the vehicle.

5. Grab the tab of the lock-in wedge with a pair of needle nose pliers and position the wedge so the teeth of the wedge are pointing up.

6. Using the needle nose pliers, insert the lock-in wedge between the pawl and the sector gear with the flange of the wedge behind the pawl and sector gear.

7. Position a punch on the drive area of the lock-in wedge.

7. (continued) Using a hammer, drive the lock-in wedge between the pawl and the sector gear, until the flange of the wedge is flush with the edge of the pawl. NOTE: The drive surface of the wedge is where the head of the punch must be placed during installation of the wedge.

8. Verify that the lock-in wedge is fully seated. Wedge teeth must be fully engaged with at least one of the sector teeth. Wedge flange must be flush with the edge of the pawl.

9. Apply and release the parking brake at least two times, allowing the pedal to return each time without any interference. This will cause the wedge to loosen or fall out if it is not installed properly.

10. Place a small screwdriver between the lock-in wedge and the sector gear. Apply a firm, up and down prying force to the wedge. The wedge should feel very stiff, with no movement between the sector gear, wedge and pawl.
If no movement is noted, the wedge has been properly installed. Proceed to Parking Brake Functional Test.
If movement is noted, call 1-800-325-5621 for further instructions.
PARKING BRAKE FUNCTIONAL TEST

NOTE: The parking brake system has been adjusted, checked for proper operation, and a wedge installed. The following parking brake functional test must be performed to verify proper parking brake adjustment.

1. Place the transmission in neutral, then raise the vehicle on a hoist until the rear wheels are off the ground.

NOTE: The vehicle must be supported by the rear axle to maintain curb height.

2. Position two (2) jack stands under the rear axle housing, then lower the hoist until the weight of the vehicle is supported by the rear axle.

3. Firmly apply the parking brake.

4. Verify that the parking brake is applied by trying to rotate the rear wheels by hand.

5. Release the parking brake.

6. Verify that the parking brake is fully released. Check for brake drag by rotating the rear wheels by hand.

7. Raise the vehicle and remove the two (2) jack stands. Lower the vehicle.

8. Turn the ignition to the "RUN" position and verify that the dash brake light is not illuminated.

9. Call 1-800-325-5621 for further instructions if any of the following conditions exist:
a. The rear wheels turn while the parking brake is applied.
b. Brake drag occurs when the parking brake is released.
c. The dash board brake light is illuminated with the parking brake released.

NOTE: In the future, if the parking brakes require adjustment, the lock-in wedge must be removed. The parking brakes must be adjusted according to the procedure on page 5 of this attachment. The lock-in wedge must be reinstalled after the parking brakes have been adjusted.

TSB 00-01-03 PARKING BRAKE - PROCEDURE FOR SERVICING PARKING BRAKE - SERVICE TIP - BRONCO AND F-SERIES BUILT THROUGH 4/22/1994 AND EXPLORER/RANGER BUILT THROUGH 5/13/1994

Publication Date: DECEMBER 22, 1999

FORD: 1992-94 BRONCO, F-150-350 SERIES
1993-94 EXPLORER, RANGER

ISSUE: When servicing the parking brake or service brake systems where the lock-in wedge has been installed in the parking brake control, additional service procedures will be necessary.

ACTION: When a lock-in wedge part has been previously installed in the parking brake control assembly, it must be removed prior to conducting maintenance procedures from the appropriate Service Manual, Sections 06-04 (Rear Drum Brakes) and 06-05 (Parking Brake System). The wedge must be reinstalled after service is completed. Refer to Service Recall Bulletin 94S91-S3 for lock-in wedge part removal and installation detailed service procedures, part numbers, and diagrams. Be sure to inspect the wedge for damage. If any part of the wedge is broken or damaged, install a new wedge.

OTHER APPLICABLE ARTICLES: 94S91-S3
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SAFETY RECALL 94S91 Supplement 3
Certain 1992-1994 Bronco, F-150-350 Series Trucks and 1993-1994 Explorer/Ranger Vehicles Equipped with Manual Transmissions - Installation of a Parking Brake Lock-in Wedge
December, 1999

Subject: Enhanced Parking Brake Lock-In Wedge Inspection and Service Procedure (See Attachment III)

Reference: Certain 1992-1994 Model Year Bronco, F-150-350 Series Trucks and 1993-1994 Model Year Explored/Ranger Vehicles equipped with Manual Transmission - Installation of a Parking Brake Lock-in Wedge
This supplement (94S91-S3) only affects Technical Instructions (Attachment III) and Labor Allowances. These new technical instructions have enhanced inspection and service procedures. Effective immediately, all Technicians must use these procedures when servicing any vehicles affected by Safety Recall 94S91.
Please discard the original 94S91 bulletin, Supplements #1, and Supplement #2. This supplement (94S91-S3) combines the information from all previous supplements and the original bulletin.

REASON FOR THIS SUPPLEMENT
This supplement only affects the Technical Instructions (See Attachment III). These instructions provide an improved method for inspecting the parking brake lock-in wedge installation. In addition, the service procedures have been enhanced to make them easier to understand and follow.

AFFECTED VEHICLES:
ASSEMBLY PLANT & PRODUCTION DATES - AFFECTED VEHICLES
Original Bulletin (Dated October 25, 1994): Norfolk Assembly Prior to 01/27/94, Michigan Truck Prior to 02/04/94, Ontario Truck Prior to 02/09/94, Kentucky Truck Prior to 02/16/94, Kansas City Assembly Prior to 04/22/94 - Certain 1992-1994 Model Year Bronco, F-150-350 Series Trucks with Manual Transmission
All 1993-1994 Model Year Ranger/Explorer vehicle with Manual Transmission produced prior to 05/01/94

Supplement Number 1 (Dated May 1995):
Edison Assembly 05/01/94 through 05/13/94 - 1994 MY Rangers with Manual Transmission, Louisville Assembly 05/01/94 through 05/12/94 - 1994 MY Rangers and Explorers with Manual Transmissions
Supplement Number 2 (Dated July 1995):
Twin Cities Assembly 05/01/94 through 05/13/94 - 1992 MY F-Series 150-350 trucks with Manual Transmissions

REASONS FOR RECALL: During rapid pedal application, the parking brake pedal, with little or no effort, may go to the floor and the parking brake may be ineffective in holding the vehicle stationary. Should this occur, the self-adjustment pawl may skip over one or more teeth on the ratchet. To correct this condition, a lock-in wedge will be installed in the parking brake assembly. This wedge locks out the self-adjustment mechanism and retains the adjustment pawl in mesh with the ratchet.

WARNING: DO NOT PARK THE VEHICLE IN NEUTRAL.USE FIRST (1) GEAR AND SET THE PARKING BRAKE FULLY. (NOTE: WHEN THE TRANSFER CASE IS IN THE N (NEUTRAL) POSITION, THE ENGINE AND TRANSMISSION ARE DISCONNECTED FROM THE REST OF THE DRIVELINE. THEREFORE, THE VEHICLE IS FREE TO ROLL EVEN IF THE MANUAL TRANSMISSION IS IN GEAR. DO NOT LEAVE THE VEHICLE UNATTENDED WITH THE TRANSFER CASE IN N (NEUTRAL)). ALWAYS SET THE PARKING BRAKE FULLY AND TURN OFF THE IGNITION WHEN LEAVING THE VEHICLE.

WARNING: MAKE SURE THAT THE GEARSHIFT IS SECURELY POSITIONED IN FIRST (1) GEAR. NOTE: IF THE PARKING BRAKE PEDAL MOVES TO THE FLOOR WITH LITTLE OR NO EFFORT WHEN APPLIED, RELEASE AND RESET THE PARKING BRAKE. NEVER LEAVE YOUR VEHICLE UNATTENDED WHILE IT IS RUNNING. IF YOU DO NOT TAKE THESE PRECAUTIONS, YOUR VEHICLE MAY MOVE UNEXPECTEDLY AND INJURE SOMEONE.

QUESTIONS? Claims Information 1-800-423-8851 - Other Recall Questions 1-800-325-5621

LABOR ALLOWANCES:
Operation Description Labor Allowances Labor Operation
Inspect vehicle for previous wedge installation or Cam-In Brake design and using a screwdriver, check wedge for looseness. 0.2 Hours 94S91A
Adjust parking brake, install parking brake wedge, and perform parking brake functional test (Includes Inspection) 0.7 Hours 94S91B
Administrative Allowance 0.1 Hour Misc. Expense Code "ADMIN"
NOTE: The Labor Operation Numbers and Time listed above supersede those listed in all previous supplements to this recall.

PARTS REQUIREMENTS
Part Number Description Quantity Per Vehicle
F4TZ-2L780-C Wedge - Explorer/Ranger (Large size, Black) 1
F4TZ-2L780-D Wedge - Bronco/F-Series (Small size, White) 1
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See also: