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fsa01m05fuelcrossflow.jpg FSA 01M05 Fuel Cross-Flow
Check [url=http://owner.ford.com/servlet/ContentServer?pagename=Owner/Page/RecallsPage]the Ford website[/url] &/or [url=http://www.nhtsa.gov/Vehicle Safety/Recalls & Defects]the NHTSA[/url] to see if your VIN is affected.

[url=http://www.supermotors.net/registry/media/879227][img]http://www.supermotors.net/getfile/879227/thumbnail/fdmvalve.jpg[/img][/url] . [url=http://www.supermotors.net/registry/media/863556][img]http://www.supermotors.net/getfile/863556/thumbnail/fuelcheckvalve.jpg[/img][/url] . [url=http://www.supermotors.net/registry/media/283459][img]http://www.supermotors.net/getfile/283459/thumbnail/fdm.jpg[/img][/url] . [url=http://www.supermotors.net/registry/media/825934][img]http://www.supermotors.net/getfile/825934/thumbnail/fuelpressuregauge.jpg[/img][/url]

ATTACHMENT III: Technical Information
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FUEL CROSS FLOW WARRANTY EXTENSION  AFFECTED VEHICLES: ALL 1990, 1991, 1992 AND 1993 MODEL YEAR F-SERIES VEHICLES EQUIPPED WITH 4.9, 5.0, 5.8 OR 7.5 LITER ENGINES AND DUAL FUEL TANKS 

NOTE: Check OASIS to see if either Safety Recall 00S57 or 93S68 is open. If either recall is open, do not continue with this procedure. Instead, perform the appropriate safety recall and return vehicle to the owner. 

SERVICE PROCEDURE:
1. Attach an EFI/CFI fuel pressure gauge to the Schrader valve on the engine fuel rail. 
WARNING: FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE, EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 
2. Start the engine and record the fuel pressure reading. Turn the ignition key to the OFF position. Then relieve the fuel system pressure by slowly opening the manual valve on the fuel pressure gauge. Remove the gauge from the fuel rail.


ALL EXCEPT CHASSIS CAB 

6-CYLINDER ENGINES
- If the fuel pressure is 55 PSI or less, perform all of the following: 
* External Check Valve Installation And Return Line Inspection â%uFFFD%uFFFD Rear Tank. 
* External Check Valve Installation And Return Line Inspection â%uFFFD%uFFFD Front Tank. 
- If the fuel pressure exceeds 55 PSI, perform all of the following: 
* Fuel Pressure Regulator Replacement. 
* External Check Valve Installation And Return Line Inspection â%uFFFD%uFFFD Rear Tank. 
* External Check Valve Installation And Return Line Inspection â%uFFFD%uFFFD Front Tank.

8-CYLINDER ENGINES
- If the fuel pressure is 39 PSI or less, perform all of the following: 
* External Check Valve Installation And Return Line Inspection â%uFFFD%uFFFD Rear Tank. 
* External Check Valve Installation And Return Line Inspection â%uFFFD%uFFFD Front Tank. 
- If the fuel pressure exceeds 39 PSI, perform all of the following: 
* Fuel Pressure Regulator Replacement. 
* External Check Valve Installation And Return Line Inspection â%uFFFD%uFFFD Rear Tank. 
* External Check Valve Installation And Return Line Inspection â%uFFFD%uFFFD Front Tank.


CHASSIS CAB 

6-CYLINDER ENGINES
- If the fuel pressure is 55 PSI or less, perform all of the following: 
* Fuel Delivery Module Installation And Return Line Inspection â%uFFFD%uFFFD Rear Tank. 
* External Check Valve Installation And Return Line Inspection â%uFFFD%uFFFD Front Tank. 
- If the fuel pressure exceeds 55 PSI, perform all of the following: 
* Fuel Pressure Regulator Replacement. 
* Fuel Delivery Module Installation And Return Line Inspection â%uFFFD%uFFFD Rear Tank. 
* External Check Valve Installation And Return Line Inspection â%uFFFD%uFFFD Front Tank.

8-CYLINDER ENGINES
- If the fuel pressure is 39 PSI or less, perform all of the following: 
* Fuel Delivery Module Installation And Return Line Inspection â%uFFFD%uFFFD Rear Tank. 
* External Check Valve Installation And Return Line Inspection â%uFFFD%uFFFD Front Tank. 
- If the fuel pressure exceeds 39 PSI, perform all of the following: 
* Fuel Pressure Regulator Replacement. 
* Fuel Delivery Module Installation And Return Line Inspection â%uFFFD%uFFFD Rear Tank. 
* External Check Valve Installation And Return Line Inspection â%uFFFD%uFFFD Front Tank.

FUEL PRESSURE REGULATOR REPLACEMENT 
NOTE: Perform only if fuel pressure exceeds levels specified earlier in this procedure.

1. Install a memory saver, then disconnect the battery negative cable. 
2. Disconnect the vacuum line from the fuel pressure regulator, which is located on the fuel rail. 
3. Remove the retaining screws from the fuel pressure regulator. 
4. Remove and discard the fuel pressure regulator, gasket and O-ring seal from the fuel rail manifold. 
5. Lubricate the new fuel pressure regulator O-ring with light oil (10W30 oil WSE-M2C903-A2 or equivalent). Install the new O-ring and the new gasket on the new regulator. 
6. Position the new fuel pressure regulator with O-ring and gasket onto the fuel rail and install the retaining screws. Tighten the screws to 4 Nm (35 lb-in). 
7. Connect the vacuum line to the new fuel pressure regulator.

EXTERNAL CHECK VALVE INSTALLATION AND RETURN LINE INSPECTION â%uFFFD%uFFFD REAR TANK (NON-CHASSIS CAB VEHICLES) 

1. Install a memory saver, then disconnect the battery negative cable. 
2. Drain the rear fuel tank, using Rotunda Fuel Storage Tanker 034-00002, 034-00014 or equivalent. 
3. Raise the vehicle on a hoist. 
4. Position the spare tire out of the way. 
5. Loosen the hose clamp at the fuel filler hose connection to the rear fuel tank. 
6. Position a safety stand under the rear fuel tank. 
7. Remove the fuel tank support straps. 
8. Access the fuel delivery module (FDM) at the top of the tank by lowering the tank while guiding the fuel filler hose from the tank. 
9.  NOTE: For vehicles equipped with stainless steel braided flex lines, proceed to the next step. Inspect the nylon fuel return lines for kinking.
- If the nylon fuel return line is not kinked or the vehicle is equipped with stainless steel braided flex lines, proceed to the next step.
- If the nylon return line is kinked, repair the line as necessary using Rotunda Tool 134-000001 (Plastic Fuel Line Fitting Connector Tool), before continuing this procedure. 
10. NOTE: Remove and discard the black hairpin clip on 1990 and 1991 model year vehicles. A new clip will be used when reconnecting the fuel supply line.  Disconnect the fuel supply line at the FDM.
11. If equipped, remove and discard the old external check valve. 
12. Install the external check valve to the supply tube of the FDM. Install the fuel line clip onto the external check valve.
13. Connect the fuel supply line to the external check valve. Install a new black hairpin clip on 1990 and 1991 model year vehicles.
14. Raise the rear fuel tank back into position while guiding the fuel filler hose onto the fuel tank. 
15. Install the fuel tank straps. Tighten bolts to 38 Nm (28 lb-ft). 
16. Tighten the fuel filler hose clamp to 4 Nm (35 lb-in). 
17. Remove the safety stand. 
18. Reposition the spare tire. 
19. Lower the vehicle. 

EXTERNAL CHECK VALVE INSTALLATION AND RETURN LINE INSPECTION â%uFFFD%uFFFD FRONT TANK (ALL VEHICLES) 

1. Drain the front fuel tank, using Rotunda Fuel Storage Tanker 034-00002, 034-00014 or equivalent. 
2. Raise the vehicle on a hoist. 
3. Remove the skid plate if equipped. 
4. Loosen the hose clamp at the fuel filler hose connection to the front tank. 
5. Position a safety stand under the fuel tank. 
6. Remove the fuel tank support strap bolts. 
7. Access the FDM at the top of the tank by lowering the tank while guiding the fuel filler hose from the tank.
8. NOTE: For vehicles equipped with stainless steel braided flex lines, proceed to the next step.  Inspect the nylon fuel return line for kinking. 
- If the nylon fuel return line is not kinked or the vehicle is equipped with stainless steel braided flex lines, proceed to the next step. 
- If the nylon return line is kinked, repair the line as necessary using Rotunda Tool 134-000001 (Plastic Fuel Line Fitting Connector Tool), before continuing this procedure. 
9. NOTE: Remove and discard the black hairpin clip on 1990 and 1991 model year vehicles. A new clip will be used when reconnecting the fuel supply line.  Disconnect the fuel supply line at the fuel delivery module. 
10. If equipped, remove and discard the old external check valve. 
11. Install the external check valve to the supply tube of the fuel delivery module. Install the fuel line clip onto the external check valve.
12. Connect the fuel supply line to the external check valve. Install a new black hairpin clip on 1990 and 1991 model year vehicles. 
13. Reinstall the skid plate if removed. 
14. Lower the vehicle. 
15. Fill the fuel tanks. 
16. Connect the battery negative cable, then remove the memory saver. 
17. Without starting the engine, turn the ignition key on and off several times to pressurize the fuel system and check for leaks.

FUEL DELIVERY MODULE REPLACEMENT AND RETURN LINE INSPECTION â%uFFFD%uFFFD REAR TANK (CHASSIS CAB VEHICLES) 

1. Install a memory saver, then disconnect the battery negative cable. 
2. Drain the rear fuel tank, using Rotunda Fuel Storage Tanker 034-00002, 034-00014 or equivalent. 
3. Raise the vehicle on a hoist. 
4. Position the spare tire out of the way. 
5. Loosen the hose clamp at the fuel filler hose connection to the rear fuel tank. 
6. Position a safety stand under the rear fuel tank. 
7. Remove the fuel tank support skid plate bolts. 
8. Access the fuel delivery module (FDM) at the top of the tank by lowering the tank while guiding the fuel filler hose from the tank. 
9. NOTE: Remove and discard the black hairpin clip. A new clip will be used when reconnecting the fuel supply line.
Disconnect the fuel supply line, fuel return line and the electrical connector (not shown) from the FDM. 10. Disconnect the vapor line from the fuel tank.
11. Lower the fuel tank while guiding the fuel filler hose out of the tank.
12. NOTE: For vehicles equipped with stainless steel braided flex lines, proceed to the next step. Inspect the nylon fuel return line for kinking. 
- If the nylon fuel return line is not kinked or the vehicle is equipped with stainless steel braided flex lines, proceed to the next step. 
- If the nylon return line is kinked, repair the line as necessary, using Rotunda Tool 134-000001 (Plastic Fuel Line Fitting Connector Tool) before continuing this procedure. 
13. Clean any dirt from the top of the tank around the FDM. 
14. Remove the locking ring from the FDM. 
15. Remove the FDM, then remove and discard the gasket. 
16. Clean the FDM mounting flange on the fuel tank, then install a new gasket onto the flange. 
17. Install the new FDM, then install the locking ring. Tighten the locking ring to 62 Nm (46 lb-ft). 
18. Raise the tank up into the vehicle, leaving enough room to make the connections on the top of the tank. 
19. Connect the vapor line to the fuel tank. 
20. Connect the fuel supply, fuel return and electrical connector to the FDM. Install a new black hairpin clip on the fuel supply line connection. 
21. Raise the rear fuel tank into position while guiding the fuel filler hose into the tank. 
22. Install the fuel tank support skid plate bolts. Tighten bolts 44 Nm (32 lb-ft). 
23. Tighten the fuel filler hose clamp to 4 Nm (35 lb-in). 
24. Remove the safety stand. 
25. Reposition the spare tire. 
26. Lower the vehicle.

ATTACHMENT II: Labor & Parts Information
--------------------------------------------------------------------------------
Labor Allowances 

Check fuel pressure and inspect for kinked fuel lines. Install two check valves (or install one check valve and one FDM on Chassis Cab vehicles)
Description  Labor Operation  Labor Time* 
1990/91 4.9L, 5.0L, 5.8L, and 7.5L Engine (Except Chassis Cab)  01M05B  1.5 Hour
1992/93 4.9L Engine  01M05C  1.9 Hour
1992/93 5.0L, 5.8L, and 7.5L Engine  01M05D  1.8 Hour
1990/91 Chassis Cab 4.9L Engine  01M05E  2.4 Hour
1990/91 Chassis Cab 5.0L, 5.8L, and 7.5L 01M05F  2.3 Hour

Check fuel pressure and inspect for kinked fuel lines. Install new fuel pressure regulator and two check valves (or fuel pressure regulator, one check valve, and one FDM on Chassis Cab vehicles)
Description  Labor Operation  Labor Time*
1990/91 4.9L, 5.0L, 5.8L, and 7.5L Engine (Except Chassis Cab)  01M05G  1.6 Hour
1992/93 4.9L Engine  01M05H  2.0 Hour
1992/93 5.0L, 5.8L, and 7.5L Engine  01M05J  1.9 Hour
1990/91 Chassis Cab 4.9L Engine  01M05M  2.5 Hour 
1990/91 Chassis Cab 5.0L, 5.8L, and 7.5L Engine  01M05N  2.4 Hour

*NOTE: When additional time is required due to the conditions described below, this must be claimed as actual time. Use "MT01M05" as the labor operation for the additional time.
Trucks equipped with fuel tank skid plates 
Trucks over 8,500 lbs. GVW and equipped with a 5.8L engine

Parts Ordering Information
Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels as noted below:

Stock Orders  Effective immediately  Normal order process
Interim Orders  Effective immediately  Normal order process
Emergency Orders  First 30 days after launch  Call 1-800-325-5621
Emergency Orders  31 days after launch  Normal order process

Dealers will need to call 1-800-325-5621 for emergency orders for 60 days after campaign launch.
NOTE: ONLY A VERY SMALL PERCENTAGE OF VEHICLES WILL NEED THIS REPAIR BECAUSE IT IS ONLY FOR VEHICLES THAT HAVE HAD THE ORIGINAL RECALL (93S68 OR 00S57) COMPLETED AND HAVE HAD A SUBSEQUENT CROSS FLOW CONDITION.

Parts Requirements
Part Number  Description  Quantity 
 
1L3Z-9J274-BA Check Valve for 1990/91 4.9L/5.0L/5.8L/7.5L Engines (Also used for Chassis Cab Vehicles) - 1 package per vehicle (2 per pkg.) 
 
1L3Z-9J274-AA Check Valve for 1992/93 4.9L/5.0L/5.8L/7.5L Engines - 1 package per vehicle (2 per pkg.)

The following part is used only for 90-91 vehicles requiring repairs. See Attachment III. 
(Owner Letters for this vehicle population will be mailed sometime in late July 2001).

N806190-S1901 Black Hairpin Clip (Retainer-Push Connect) 90-91 vehicles only - 2 per vehicle (4 per pkg.) 

FOR CHASSIS CAB vehicles with 137" WB or 161" WB , ALSO ORDER THE PART BELOW. (only one check valve must be installed on the forward/mid-ship tank; the check valve will not fit on the rear tank) Dealers MUST install a fuel delivery module on the rear tank. 

F6TZ-9A407-EA  Fuel Delivery Module (rear plastic tank for Chassis Cab only) MUST CALL 1-800-325-5621 FOR ALL ORDER TYPES  1 per vehicle (ONLY FOR CHASSIS CAB VEHICLES) 


DOR/COR NUMBER 
DOR/COR for this program is 50243. This number identifies parts ordered for this campaign through the Special Service Support Center (1-800-325-5621). 

DEALER PRICE 
For latest prices, check or call your: 
DOES II 
Updated Price Book 
EXCESS STOCK RETURN 

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

ATTACHMENT I: Owner Letter
-----------------------------------------------------------------------------------
At Ford Motor Company, we are constantly working to improve our products. The reason for this letter is to tell you about a no charge coverage program (Extended Coverage Program 01M05).

What is the no charge coverage program?  Your vehicle may experience a fuel cross-flow condition if the check valve in the fuel pump/sender assembly becomes damaged. If this check valve becomes damaged, fuel may be supplied from one tank and some or all of the unused fuel may be returned to the other tank. Should this occur, the capacity of the receiving tank may be exceeded and fuel may overflow from the filler cap.Note: Your vehicle was covered under Safety Recall 93S68 which was initiated in late 1993 to address fuel cross-flow. If Safety Recall 93S68 has never been performed on your vehicle, we encourage you to have it performed. If Safety Recall 93S68 was performed and you are still experiencing fuel cross-flow, then the cost to repair the cross-flow condition will be covered under this extended coverage program, number 01M05.

Note: Your vehicle was covered under Safety Recall 93S68 which was initiated in late 1993 to address fuel cross-flow. If Safety Recall 93S68 has never been performed on your vehicle, we encourage you to have it performed. If Safety Recall 93S68 was performed and you are still experiencing fuel cross-flow, then the cost to repair the cross-flow condition will be covered under this extended coverage program, number 01M05.

What does Extended Coverage Program 01M05 cover?...  This program extends the coverage for the cross-flow condition to 12 years or 150,000 miles from your vehicle's warranty start date, whichever occurs first. This coverage will automatically transfer to subsequent owners. If the vehicle already has more than 150,000 miles, this coverage will last until December 31, 2001.

If your vehicle should experience a fuel cross-flow condition, your dealership will repair the condition free of charge (parts and labor).

Refunds ...  If your vehicle had a fuel cross-flow condition which was the cause of a repair which occurred before the date of this letter, Ford is offering a full refund. For the refund, please give your paid original receipt to your Ford or Lincoln Mercury dealer. To avoid delays, do not send receipts to Ford Motor Company.

If you've changed address or sold the vehicle...  Please fill out the enclosed prepaid postcard and mail it to us if you have changed address or sold the vehicle.

Quality Care is the commitment of Ford Motor Company and its dealerships to provide you with a superior service and ownership experience. We stand committed with our dealers to assist you with all of your automotive service needs. With our nationwide dealer network, we're here to ensure you receive Quality Care service so that your vehicle maintains peak performance throughout your ownership experience.

We hope this no charge coverage confirms our commitment to your satisfaction. We pride ourselves on becoming the world's leading consumer company for automotive products and services.
------------------------------------------------------------------------------
Safety Recall 93S68 - All 1990, 1991, 1992 and certain 1993 Model Year F-Series Vehicles equipped with 4.9, 5.0, 5.8 or 7.5 Liter Engines and Dual Fuel Tanks 

Affected Vehicles 
All 1990, 1991, 1992 and certain 1993 model F-Series vehicles equipped with 4.9, 5.0, 5.8 or 7.5 Liter engines and dual fuel tanks. 

Reasons For Recall 
Some of the affected vehicles may experience a cross tank fuel flow condition due to the damaged check valve in the fuel pump/sender assembly. Fuel may be supplied from one tank and some or all of the unused fuel may be returned to the other tank. Should this occur, the capacity of the receiving tank may be exceeded and fuel may overflow from the filler cap. Fuel spillage in the presence of an ignition source could potentially result in a fire. 

To correct this condition, the fuel pressure regulator will be replaced and a check valve will be installed between each fuel supply line and fuel tank. 

Free Fuel Line Removal Tool 
Standard fuel line removal tools can be used to disconnect fuel lines. However, because of the number of vehicles to be serviced, two free tools (#T93T-9550-AH) will be provided to each Ford dealer. These tools will be in your next Dealer Mail System (DMS) shipment (DMS packing slip #930902). 

Parts Kit Codes 
The required parts kit code for each vehicle will be shown on the attached VIN listing and will be printed at the top of each Owner Letter. Ask owners for the kit code shown on their letter when the owner calls for a service appointment.

Affected Vehicles: 1990 - 1992 and certain 1993 Model Year F-Series vehicles with 4.9, 5.0, 5.8 or 7.5 Liter Engines and Dual Fuel Tanks 

WARNING: DO NOT SMOKE, CARRY LIGHTED TOBACCO OR ANY OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. 

WARNING: FUEL SUPPLY LINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVE BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN. 

CAUTION: Each kit and instruction sheet is unique. Be sure to use the kit and instruction sheet that matches the vehicle to be serviced. Detailed instructions are not reproduced here but are included in each kit. 


Follow all instructions in each kit carefully. In particular, note the following items: 
* Be sure to leak test each truck before returning it to the customer. 
* Be careful not to kink fuel lines when reinstalling fuel tanks. 
* Do not mix parts. Some parts look similar. For example, some kits contain short check valve connectors (orange tag with part number imprinted); other kits contain long check valve connectors (white tag with part number imprinted). 
(See detailed instructions included in each kit) 

Kit AA: 
(I.S. 8115) 1990/91 F-Series with Dual Fuel Tanks and 4.9L Engine (except 137" and 161" WB). 

Kit BB: 
(I.S. 8116) 1990/91 F-Series with Dual Fuel Tanks and 5.0L/5.8L/7.5L Engine (except 137" and 161" WB). 

Kit CC: 
(I.S. 8117) 1992/93 F-Series with Dual Fuel Tanks and 4.9L Engine (except 137" and 161" WB). 

Kit DD: 
(I.S. 8118 ) 1992/93 F-Series with Dual Fuel Tanks and 5.0L/5.8L/7.5L Engine (except 137" and 161" WB). 

Kit EE: (Chassis Cab) 
(I.S. 8122) 1990/91 F-Series Chassis Cab 137" WB with Dual Fuel Tanks and 4.9L Engine. 

Kit FF: (Chassis Cab) 
(I.S. 8123) 1990/91 F-Series Chassis Cab 137" WB with Dual Fuel Tanks and 5.0L/5.8L/7.5L Engine. 

Kit GG: (Chassis Cab) 
(I.S. 8124) 1990/91 F-Series Chassis Cab 161" WB with Dual Fuel Tanks and 4.9L Engine. 

Kit HH: (Chassis Cab) 
(I.S. 8125) 1990/91 F-Series Chassis Cab 161" WB with Dual Fuel Tanks and 5.0L/5.8L/7.5L Engine.

Labor Allowances
Install new fuel pressure regulator and check valves (or new fuel lines with built-in check valves):

APPLICATION  PARTS KIT  TIME  LABOR CODE  
1990/91 4.9L Engine  AA  1.6 Hrs.  Insert in Box "B" on Form 1864  
1990/91 5.0L/5.8L/7.5L Engine  BB  1.5 hrs.  Insert in Box "B" on Form 1864  
1992/93 4.9L Engine  CC  1.9 hrs.  Insert in Box "B" on Form 1864  
1992/93 5.0L/5.8L/7.5L Engine  DD  1.8 Hrs.  Insert in Box "C" on Form 1864  
1990/91 Chassis Cab 4.9L Engine  EE, GG  2.5 Hrs.  Insert in Box "C" on Form 1864  
1990/91 Chassis Cab 5.0L/5.8L/7.5L  FF, HH  2.4 Hrs.  Insert in Box "C" on Form 1864  


NOTE: 
Add 0.1 hour Administrative Allowance to the total repair time. 

Add additional 0.3 hour if truck is equipped with fuel tank skid plates. 

Add additional 0.1 hour if truck is over 8,500 lbs. and equipped with a 5.8L engine. 

Parts Requirements 

Parts will not be direct shipped for this recall. 

For Kits AA, BB, CC, and DD, order your parts requirements through normal order processing channels. 

For Kits EE, FF, GG, and HH, order your parts by calling Renkim Corporation at 1-800-325-5621. When calling, be prepared to announce Recall 93S68, give your name, dealer name, P & A code, the VIN number of the vehicle to be serviced, and the kit part number required (do not order Kits AA, BB, CC or DD by calling this number.).

PART NUMBER  DESCRIPTION  CLASS  DEALER PRICE  
F4PZ-9155-A  Kit AA - 1990/91 4.9L (all wheel bases except 137" WB and 161" WB)  AG  $25.00  
F4PZ-9155-B  Kit BB - 1990/91 5.0L/5.8L/7.5L (all wheel bases except 137" WB and 161" WB)  AG  $25.00  
F4PZ-9155-C  Kit CC - 1992/93 4.9L Engines  AG  $25.00  
F4PZ-9155-D  Kit DD - 1992/93 4.9L Engines  AG  $25.00  
F4PZ-9155-E *  Kit EE - 1990/91 4.9L Chassis Cab 137" WB  AG  $50.00  
F4PZ-9155-F 1  Kit FF - 1990/91 4.9L Chassis Cab 161" WB  AG  $50.00  
F4PZ-9155-G 1  Kit GG - 1990/91 4.9L Chassis Cab 161" WB  AG  $50.00  
F4PZ-9155-H 1  Kit HH - 1990/91 5.0L/5.8L/7.5L Chassis Cab 161" WB  AG  $50.00  

* Must be ordered by calling 1-800-325-5621 - see instructions above..
------------------------------------------------------------------------------
Safety Recall 00S57 - Certain 1993 Model Year F-Series Vehicles Equipped with Dual Fuel Tanks and 4.9, 5.0, 5.8 or 7.5 Liter Engines - Fuel Pressure Regulator  

AFFECTED VEHICLES 

The following 1993 model year Ford F-Series Trucks equipped with dual fuel tanks and 4.9, 5.0, 5.8 or 7.5 Liter engines produced at the following assembly plants: 

Kansas City Assembly Plant from November 13, 1992 through August 21, 1993 
Michigan Truck plant from November 23, 1992 through August 13, 1993 
Norfolk Assembly Plant from November 12, 1992 through August 2, 1993 
Chassis Cab vehicles built at Ontario Assembly Plant from November 11, 1992 through August 24, 1993 
SAFETY CONCERN 

The affected vehicles have a carbon steel fuel pressure regulator in the fuel system that may wear out during the life of the vehicle. If this should occur, the vehicle may experience a cross tank fuel flow condition. Fuel may be supplied from one tank and some or all of the unused fuel may be returned to the other tank. Should this occur, the capacity of the receiving tank may be exceeded and fuel may overflow from the filler cap. Fuel spillage in the presence of an ignition source could potentially result in a fire. 

SERVICE ACTION 

To correct this condition, the fuel pressure regulator will be replaced on all affected vehicles. 

OTHER COVERAGE 

All of the vehicles affected by Safety Recall 00S57 (Fuel Pressure Regulator Replacement) are also affected by Owner Notification Program 01M05 (extended coverage for the cross-flow condition). For this reason, 00S57 is being launched concurrently with Owner Notification Program 01M05. If an affected customer reports fuel cross-flow, always complete Safety Recall 00S57 first and release the vehicle. Program 01M05 only applies if the customer reports fuel cross-flow after Safety Recall 00S57 has been completed.

Technical Information 
For replacement of the Fuel Pressure Regulator, please follow the procedures in the appropriate Workshop Manual.

Labor Allowances 
Description  Labor Operation  Labor Time  
Replace Fuel Pressure Regulator  00S57B  0.5 Hour  
Administrative Allowance  Misc. Expense 
Code "ADMIN"  0.1 Hour
fsa01m05fuelcrossflow.jpg | Hits: 21354 | Posted on: 6/17/09 | View original size (145.64 KB)

FSA 01M05 Fuel Cross-Flow
Check the Ford website &/or the NHTSA to see if your VIN is affected.

. . .

ATTACHMENT III: Technical Information
--------------------------------------------------------------------------------
FUEL CROSS FLOW WARRANTY EXTENSION AFFECTED VEHICLES: ALL 1990, 1991, 1992 AND 1993 MODEL YEAR F-SERIES VEHICLES EQUIPPED WITH 4.9, 5.0, 5.8 OR 7.5 LITER ENGINES AND DUAL FUEL TANKS

NOTE: Check OASIS to see if either Safety Recall 00S57 or 93S68 is open. If either recall is open, do not continue with this procedure. Instead, perform the appropriate safety recall and return vehicle to the owner.

SERVICE PROCEDURE:
1. Attach an EFI/CFI fuel pressure gauge to the Schrader valve on the engine fuel rail.
WARNING: FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE, EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD.
2. Start the engine and record the fuel pressure reading. Turn the ignition key to the OFF position. Then relieve the fuel system pressure by slowly opening the manual valve on the fuel pressure gauge. Remove the gauge from the fuel rail.


ALL EXCEPT CHASSIS CAB

6-CYLINDER ENGINES
- If the fuel pressure is 55 PSI or less, perform all of the following:
* External Check Valve Installation And Return Line Inspection %uFFFD%uFFFD Rear Tank.
* External Check Valve Installation And Return Line Inspection %uFFFD%uFFFD Front Tank.
- If the fuel pressure exceeds 55 PSI, perform all of the following:
* Fuel Pressure Regulator Replacement.
* External Check Valve Installation And Return Line Inspection %uFFFD%uFFFD Rear Tank.
* External Check Valve Installation And Return Line Inspection %uFFFD%uFFFD Front Tank.

8-CYLINDER ENGINES
- If the fuel pressure is 39 PSI or less, perform all of the following:
* External Check Valve Installation And Return Line Inspection %uFFFD%uFFFD Rear Tank.
* External Check Valve Installation And Return Line Inspection %uFFFD%uFFFD Front Tank.
- If the fuel pressure exceeds 39 PSI, perform all of the following:
* Fuel Pressure Regulator Replacement.
* External Check Valve Installation And Return Line Inspection %uFFFD%uFFFD Rear Tank.
* External Check Valve Installation And Return Line Inspection %uFFFD%uFFFD Front Tank.


CHASSIS CAB

6-CYLINDER ENGINES
- If the fuel pressure is 55 PSI or less, perform all of the following:
* Fuel Delivery Module Installation And Return Line Inspection %uFFFD%uFFFD Rear Tank.
* External Check Valve Installation And Return Line Inspection %uFFFD%uFFFD Front Tank.
- If the fuel pressure exceeds 55 PSI, perform all of the following:
* Fuel Pressure Regulator Replacement.
* Fuel Delivery Module Installation And Return Line Inspection %uFFFD%uFFFD Rear Tank.
* External Check Valve Installation And Return Line Inspection %uFFFD%uFFFD Front Tank.

8-CYLINDER ENGINES
- If the fuel pressure is 39 PSI or less, perform all of the following:
* Fuel Delivery Module Installation And Return Line Inspection %uFFFD%uFFFD Rear Tank.
* External Check Valve Installation And Return Line Inspection %uFFFD%uFFFD Front Tank.
- If the fuel pressure exceeds 39 PSI, perform all of the following:
* Fuel Pressure Regulator Replacement.
* Fuel Delivery Module Installation And Return Line Inspection %uFFFD%uFFFD Rear Tank.
* External Check Valve Installation And Return Line Inspection %uFFFD%uFFFD Front Tank.

FUEL PRESSURE REGULATOR REPLACEMENT
NOTE: Perform only if fuel pressure exceeds levels specified earlier in this procedure.

1. Install a memory saver, then disconnect the battery negative cable.
2. Disconnect the vacuum line from the fuel pressure regulator, which is located on the fuel rail.
3. Remove the retaining screws from the fuel pressure regulator.
4. Remove and discard the fuel pressure regulator, gasket and O-ring seal from the fuel rail manifold.
5. Lubricate the new fuel pressure regulator O-ring with light oil (10W30 oil WSE-M2C903-A2 or equivalent). Install the new O-ring and the new gasket on the new regulator.
6. Position the new fuel pressure regulator with O-ring and gasket onto the fuel rail and install the retaining screws. Tighten the screws to 4 Nm (35 lb-in).
7. Connect the vacuum line to the new fuel pressure regulator.

EXTERNAL CHECK VALVE INSTALLATION AND RETURN LINE INSPECTION %uFFFD%uFFFD REAR TANK (NON-CHASSIS CAB VEHICLES)

1. Install a memory saver, then disconnect the battery negative cable.
2. Drain the rear fuel tank, using Rotunda Fuel Storage Tanker 034-00002, 034-00014 or equivalent.
3. Raise the vehicle on a hoist.
4. Position the spare tire out of the way.
5. Loosen the hose clamp at the fuel filler hose connection to the rear fuel tank.
6. Position a safety stand under the rear fuel tank.
7. Remove the fuel tank support straps.
8. Access the fuel delivery module (FDM) at the top of the tank by lowering the tank while guiding the fuel filler hose from the tank.
9. NOTE: For vehicles equipped with stainless steel braided flex lines, proceed to the next step. Inspect the nylon fuel return lines for kinking.
- If the nylon fuel return line is not kinked or the vehicle is equipped with stainless steel braided flex lines, proceed to the next step.
- If the nylon return line is kinked, repair the line as necessary using Rotunda Tool 134-000001 (Plastic Fuel Line Fitting Connector Tool), before continuing this procedure.
10. NOTE: Remove and discard the black hairpin clip on 1990 and 1991 model year vehicles. A new clip will be used when reconnecting the fuel supply line. Disconnect the fuel supply line at the FDM.
11. If equipped, remove and discard the old external check valve.
12. Install the external check valve to the supply tube of the FDM. Install the fuel line clip onto the external check valve.
13. Connect the fuel supply line to the external check valve. Install a new black hairpin clip on 1990 and 1991 model year vehicles.
14. Raise the rear fuel tank back into position while guiding the fuel filler hose onto the fuel tank.
15. Install the fuel tank straps. Tighten bolts to 38 Nm (28 lb-ft).
16. Tighten the fuel filler hose clamp to 4 Nm (35 lb-in).
17. Remove the safety stand.
18. Reposition the spare tire.
19. Lower the vehicle.

EXTERNAL CHECK VALVE INSTALLATION AND RETURN LINE INSPECTION %uFFFD%uFFFD FRONT TANK (ALL VEHICLES)

1. Drain the front fuel tank, using Rotunda Fuel Storage Tanker 034-00002, 034-00014 or equivalent.
2. Raise the vehicle on a hoist.
3. Remove the skid plate if equipped.
4. Loosen the hose clamp at the fuel filler hose connection to the front tank.
5. Position a safety stand under the fuel tank.
6. Remove the fuel tank support strap bolts.
7. Access the FDM at the top of the tank by lowering the tank while guiding the fuel filler hose from the tank.
8. NOTE: For vehicles equipped with stainless steel braided flex lines, proceed to the next step. Inspect the nylon fuel return line for kinking.
- If the nylon fuel return line is not kinked or the vehicle is equipped with stainless steel braided flex lines, proceed to the next step.
- If the nylon return line is kinked, repair the line as necessary using Rotunda Tool 134-000001 (Plastic Fuel Line Fitting Connector Tool), before continuing this procedure.
9. NOTE: Remove and discard the black hairpin clip on 1990 and 1991 model year vehicles. A new clip will be used when reconnecting the fuel supply line. Disconnect the fuel supply line at the fuel delivery module.
10. If equipped, remove and discard the old external check valve.
11. Install the external check valve to the supply tube of the fuel delivery module. Install the fuel line clip onto the external check valve.
12. Connect the fuel supply line to the external check valve. Install a new black hairpin clip on 1990 and 1991 model year vehicles.
13. Reinstall the skid plate if removed.
14. Lower the vehicle.
15. Fill the fuel tanks.
16. Connect the battery negative cable, then remove the memory saver.
17. Without starting the engine, turn the ignition key on and off several times to pressurize the fuel system and check for leaks.

FUEL DELIVERY MODULE REPLACEMENT AND RETURN LINE INSPECTION %uFFFD%uFFFD REAR TANK (CHASSIS CAB VEHICLES)

1. Install a memory saver, then disconnect the battery negative cable.
2. Drain the rear fuel tank, using Rotunda Fuel Storage Tanker 034-00002, 034-00014 or equivalent.
3. Raise the vehicle on a hoist.
4. Position the spare tire out of the way.
5. Loosen the hose clamp at the fuel filler hose connection to the rear fuel tank.
6. Position a safety stand under the rear fuel tank.
7. Remove the fuel tank support skid plate bolts.
8. Access the fuel delivery module (FDM) at the top of the tank by lowering the tank while guiding the fuel filler hose from the tank.
9. NOTE: Remove and discard the black hairpin clip. A new clip will be used when reconnecting the fuel supply line.
Disconnect the fuel supply line, fuel return line and the electrical connector (not shown) from the FDM. 10. Disconnect the vapor line from the fuel tank.
11. Lower the fuel tank while guiding the fuel filler hose out of the tank.
12. NOTE: For vehicles equipped with stainless steel braided flex lines, proceed to the next step. Inspect the nylon fuel return line for kinking.
- If the nylon fuel return line is not kinked or the vehicle is equipped with stainless steel braided flex lines, proceed to the next step.
- If the nylon return line is kinked, repair the line as necessary, using Rotunda Tool 134-000001 (Plastic Fuel Line Fitting Connector Tool) before continuing this procedure.
13. Clean any dirt from the top of the tank around the FDM.
14. Remove the locking ring from the FDM.
15. Remove the FDM, then remove and discard the gasket.
16. Clean the FDM mounting flange on the fuel tank, then install a new gasket onto the flange.
17. Install the new FDM, then install the locking ring. Tighten the locking ring to 62 Nm (46 lb-ft).
18. Raise the tank up into the vehicle, leaving enough room to make the connections on the top of the tank.
19. Connect the vapor line to the fuel tank.
20. Connect the fuel supply, fuel return and electrical connector to the FDM. Install a new black hairpin clip on the fuel supply line connection.
21. Raise the rear fuel tank into position while guiding the fuel filler hose into the tank.
22. Install the fuel tank support skid plate bolts. Tighten bolts 44 Nm (32 lb-ft).
23. Tighten the fuel filler hose clamp to 4 Nm (35 lb-in).
24. Remove the safety stand.
25. Reposition the spare tire.
26. Lower the vehicle.

ATTACHMENT II: Labor & Parts Information
--------------------------------------------------------------------------------
Labor Allowances

Check fuel pressure and inspect for kinked fuel lines. Install two check valves (or install one check valve and one FDM on Chassis Cab vehicles)
Description Labor Operation Labor Time*
1990/91 4.9L, 5.0L, 5.8L, and 7.5L Engine (Except Chassis Cab) 01M05B 1.5 Hour
1992/93 4.9L Engine 01M05C 1.9 Hour
1992/93 5.0L, 5.8L, and 7.5L Engine 01M05D 1.8 Hour
1990/91 Chassis Cab 4.9L Engine 01M05E 2.4 Hour
1990/91 Chassis Cab 5.0L, 5.8L, and 7.5L 01M05F 2.3 Hour

Check fuel pressure and inspect for kinked fuel lines. Install new fuel pressure regulator and two check valves (or fuel pressure regulator, one check valve, and one FDM on Chassis Cab vehicles)
Description Labor Operation Labor Time*
1990/91 4.9L, 5.0L, 5.8L, and 7.5L Engine (Except Chassis Cab) 01M05G 1.6 Hour
1992/93 4.9L Engine 01M05H 2.0 Hour
1992/93 5.0L, 5.8L, and 7.5L Engine 01M05J 1.9 Hour
1990/91 Chassis Cab 4.9L Engine 01M05M 2.5 Hour
1990/91 Chassis Cab 5.0L, 5.8L, and 7.5L Engine 01M05N 2.4 Hour

*NOTE: When additional time is required due to the conditions described below, this must be claimed as actual time. Use "MT01M05" as the labor operation for the additional time.
Trucks equipped with fuel tank skid plates
Trucks over 8,500 lbs. GVW and equipped with a 5.8L engine

Parts Ordering Information
Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels as noted below:

Stock Orders Effective immediately Normal order process
Interim Orders Effective immediately Normal order process
Emergency Orders First 30 days after launch Call 1-800-325-5621
Emergency Orders 31 days after launch Normal order process

Dealers will need to call 1-800-325-5621 for emergency orders for 60 days after campaign launch.
NOTE: ONLY A VERY SMALL PERCENTAGE OF VEHICLES WILL NEED THIS REPAIR BECAUSE IT IS ONLY FOR VEHICLES THAT HAVE HAD THE ORIGINAL RECALL (93S68 OR 00S57) COMPLETED AND HAVE HAD A SUBSEQUENT CROSS FLOW CONDITION.

Parts Requirements
Part Number Description Quantity

1L3Z-9J274-BA Check Valve for 1990/91 4.9L/5.0L/5.8L/7.5L Engines (Also used for Chassis Cab Vehicles) - 1 package per vehicle (2 per pkg.)

1L3Z-9J274-AA Check Valve for 1992/93 4.9L/5.0L/5.8L/7.5L Engines - 1 package per vehicle (2 per pkg.)

The following part is used only for 90-91 vehicles requiring repairs. See Attachment III.
(Owner Letters for this vehicle population will be mailed sometime in late July 2001).

N806190-S1901 Black Hairpin Clip (Retainer-Push Connect) 90-91 vehicles only - 2 per vehicle (4 per pkg.)

FOR CHASSIS CAB vehicles with 137" WB or 161" WB , ALSO ORDER THE PART BELOW. (only one check valve must be installed on the forward/mid-ship tank; the check valve will not fit on the rear tank) Dealers MUST install a fuel delivery module on the rear tank.

F6TZ-9A407-EA Fuel Delivery Module (rear plastic tank for Chassis Cab only) MUST CALL 1-800-325-5621 FOR ALL ORDER TYPES 1 per vehicle (ONLY FOR CHASSIS CAB VEHICLES)


DOR/COR NUMBER
DOR/COR for this program is 50243. This number identifies parts ordered for this campaign through the Special Service Support Center (1-800-325-5621).

DEALER PRICE
For latest prices, check or call your:
DOES II
Updated Price Book
EXCESS STOCK RETURN

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

ATTACHMENT I: Owner Letter
-----------------------------------------------------------------------------------
At Ford Motor Company, we are constantly working to improve our products. The reason for this letter is to tell you about a no charge coverage program (Extended Coverage Program 01M05).

What is the no charge coverage program? Your vehicle may experience a fuel cross-flow condition if the check valve in the fuel pump/sender assembly becomes damaged. If this check valve becomes damaged, fuel may be supplied from one tank and some or all of the unused fuel may be returned to the other tank. Should this occur, the capacity of the receiving tank may be exceeded and fuel may overflow from the filler cap.Note: Your vehicle was covered under Safety Recall 93S68 which was initiated in late 1993 to address fuel cross-flow. If Safety Recall 93S68 has never been performed on your vehicle, we encourage you to have it performed. If Safety Recall 93S68 was performed and you are still experiencing fuel cross-flow, then the cost to repair the cross-flow condition will be covered under this extended coverage program, number 01M05.

Note: Your vehicle was covered under Safety Recall 93S68 which was initiated in late 1993 to address fuel cross-flow. If Safety Recall 93S68 has never been performed on your vehicle, we encourage you to have it performed. If Safety Recall 93S68 was performed and you are still experiencing fuel cross-flow, then the cost to repair the cross-flow condition will be covered under this extended coverage program, number 01M05.

What does Extended Coverage Program 01M05 cover?... This program extends the coverage for the cross-flow condition to 12 years or 150,000 miles from your vehicle's warranty start date, whichever occurs first. This coverage will automatically transfer to subsequent owners. If the vehicle already has more than 150,000 miles, this coverage will last until December 31, 2001.

If your vehicle should experience a fuel cross-flow condition, your dealership will repair the condition free of charge (parts and labor).

Refunds ... If your vehicle had a fuel cross-flow condition which was the cause of a repair which occurred before the date of this letter, Ford is offering a full refund. For the refund, please give your paid original receipt to your Ford or Lincoln Mercury dealer. To avoid delays, do not send receipts to Ford Motor Company.

If you've changed address or sold the vehicle... Please fill out the enclosed prepaid postcard and mail it to us if you have changed address or sold the vehicle.

Quality Care is the commitment of Ford Motor Company and its dealerships to provide you with a superior service and ownership experience. We stand committed with our dealers to assist you with all of your automotive service needs. With our nationwide dealer network, we're here to ensure you receive Quality Care service so that your vehicle maintains peak performance throughout your ownership experience.

We hope this no charge coverage confirms our commitment to your satisfaction. We pride ourselves on becoming the world's leading consumer company for automotive products and services.
------------------------------------------------------------------------------
Safety Recall 93S68 - All 1990, 1991, 1992 and certain 1993 Model Year F-Series Vehicles equipped with 4.9, 5.0, 5.8 or 7.5 Liter Engines and Dual Fuel Tanks

Affected Vehicles
All 1990, 1991, 1992 and certain 1993 model F-Series vehicles equipped with 4.9, 5.0, 5.8 or 7.5 Liter engines and dual fuel tanks.

Reasons For Recall
Some of the affected vehicles may experience a cross tank fuel flow condition due to the damaged check valve in the fuel pump/sender assembly. Fuel may be supplied from one tank and some or all of the unused fuel may be returned to the other tank. Should this occur, the capacity of the receiving tank may be exceeded and fuel may overflow from the filler cap. Fuel spillage in the presence of an ignition source could potentially result in a fire.

To correct this condition, the fuel pressure regulator will be replaced and a check valve will be installed between each fuel supply line and fuel tank.

Free Fuel Line Removal Tool
Standard fuel line removal tools can be used to disconnect fuel lines. However, because of the number of vehicles to be serviced, two free tools (#T93T-9550-AH) will be provided to each Ford dealer. These tools will be in your next Dealer Mail System (DMS) shipment (DMS packing slip #930902).

Parts Kit Codes
The required parts kit code for each vehicle will be shown on the attached VIN listing and will be printed at the top of each Owner Letter. Ask owners for the kit code shown on their letter when the owner calls for a service appointment.

Affected Vehicles: 1990 - 1992 and certain 1993 Model Year F-Series vehicles with 4.9, 5.0, 5.8 or 7.5 Liter Engines and Dual Fuel Tanks

WARNING: DO NOT SMOKE, CARRY LIGHTED TOBACCO OR ANY OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.

WARNING: FUEL SUPPLY LINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVE BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN.

CAUTION: Each kit and instruction sheet is unique. Be sure to use the kit and instruction sheet that matches the vehicle to be serviced. Detailed instructions are not reproduced here but are included in each kit.


Follow all instructions in each kit carefully. In particular, note the following items:
* Be sure to leak test each truck before returning it to the customer.
* Be careful not to kink fuel lines when reinstalling fuel tanks.
* Do not mix parts. Some parts look similar. For example, some kits contain short check valve connectors (orange tag with part number imprinted); other kits contain long check valve connectors (white tag with part number imprinted).
(See detailed instructions included in each kit)

Kit AA:
(I.S. 8115) 1990/91 F-Series with Dual Fuel Tanks and 4.9L Engine (except 137" and 161" WB).

Kit BB:
(I.S. 8116) 1990/91 F-Series with Dual Fuel Tanks and 5.0L/5.8L/7.5L Engine (except 137" and 161" WB).

Kit CC:
(I.S. 8117) 1992/93 F-Series with Dual Fuel Tanks and 4.9L Engine (except 137" and 161" WB).

Kit DD:
(I.S. 8118 ) 1992/93 F-Series with Dual Fuel Tanks and 5.0L/5.8L/7.5L Engine (except 137" and 161" WB).

Kit EE: (Chassis Cab)
(I.S. 8122) 1990/91 F-Series Chassis Cab 137" WB with Dual Fuel Tanks and 4.9L Engine.

Kit FF: (Chassis Cab)
(I.S. 8123) 1990/91 F-Series Chassis Cab 137" WB with Dual Fuel Tanks and 5.0L/5.8L/7.5L Engine.

Kit GG: (Chassis Cab)
(I.S. 8124) 1990/91 F-Series Chassis Cab 161" WB with Dual Fuel Tanks and 4.9L Engine.

Kit HH: (Chassis Cab)
(I.S. 8125) 1990/91 F-Series Chassis Cab 161" WB with Dual Fuel Tanks and 5.0L/5.8L/7.5L Engine.

Labor Allowances
Install new fuel pressure regulator and check valves (or new fuel lines with built-in check valves):

APPLICATION PARTS KIT TIME LABOR CODE
1990/91 4.9L Engine AA 1.6 Hrs. Insert in Box "B" on Form 1864
1990/91 5.0L/5.8L/7.5L Engine BB 1.5 hrs. Insert in Box "B" on Form 1864
1992/93 4.9L Engine CC 1.9 hrs. Insert in Box "B" on Form 1864
1992/93 5.0L/5.8L/7.5L Engine DD 1.8 Hrs. Insert in Box "C" on Form 1864
1990/91 Chassis Cab 4.9L Engine EE, GG 2.5 Hrs. Insert in Box "C" on Form 1864
1990/91 Chassis Cab 5.0L/5.8L/7.5L FF, HH 2.4 Hrs. Insert in Box "C" on Form 1864


NOTE:
Add 0.1 hour Administrative Allowance to the total repair time.

Add additional 0.3 hour if truck is equipped with fuel tank skid plates.

Add additional 0.1 hour if truck is over 8,500 lbs. and equipped with a 5.8L engine.

Parts Requirements

Parts will not be direct shipped for this recall.

For Kits AA, BB, CC, and DD, order your parts requirements through normal order processing channels.

For Kits EE, FF, GG, and HH, order your parts by calling Renkim Corporation at 1-800-325-5621. When calling, be prepared to announce Recall 93S68, give your name, dealer name, P & A code, the VIN number of the vehicle to be serviced, and the kit part number required (do not order Kits AA, BB, CC or DD by calling this number.).

PART NUMBER DESCRIPTION CLASS DEALER PRICE
F4PZ-9155-A Kit AA - 1990/91 4.9L (all wheel bases except 137" WB and 161" WB) AG $25.00
F4PZ-9155-B Kit BB - 1990/91 5.0L/5.8L/7.5L (all wheel bases except 137" WB and 161" WB) AG $25.00
F4PZ-9155-C Kit CC - 1992/93 4.9L Engines AG $25.00
F4PZ-9155-D Kit DD - 1992/93 4.9L Engines AG $25.00
F4PZ-9155-E * Kit EE - 1990/91 4.9L Chassis Cab 137" WB AG $50.00
F4PZ-9155-F 1 Kit FF - 1990/91 4.9L Chassis Cab 161" WB AG $50.00
F4PZ-9155-G 1 Kit GG - 1990/91 4.9L Chassis Cab 161" WB AG $50.00
F4PZ-9155-H 1 Kit HH - 1990/91 5.0L/5.8L/7.5L Chassis Cab 161" WB AG $50.00

* Must be ordered by calling 1-800-325-5621 - see instructions above..
------------------------------------------------------------------------------
Safety Recall 00S57 - Certain 1993 Model Year F-Series Vehicles Equipped with Dual Fuel Tanks and 4.9, 5.0, 5.8 or 7.5 Liter Engines - Fuel Pressure Regulator

AFFECTED VEHICLES

The following 1993 model year Ford F-Series Trucks equipped with dual fuel tanks and 4.9, 5.0, 5.8 or 7.5 Liter engines produced at the following assembly plants:

Kansas City Assembly Plant from November 13, 1992 through August 21, 1993
Michigan Truck plant from November 23, 1992 through August 13, 1993
Norfolk Assembly Plant from November 12, 1992 through August 2, 1993
Chassis Cab vehicles built at Ontario Assembly Plant from November 11, 1992 through August 24, 1993
SAFETY CONCERN

The affected vehicles have a carbon steel fuel pressure regulator in the fuel system that may wear out during the life of the vehicle. If this should occur, the vehicle may experience a cross tank fuel flow condition. Fuel may be supplied from one tank and some or all of the unused fuel may be returned to the other tank. Should this occur, the capacity of the receiving tank may be exceeded and fuel may overflow from the filler cap. Fuel spillage in the presence of an ignition source could potentially result in a fire.

SERVICE ACTION

To correct this condition, the fuel pressure regulator will be replaced on all affected vehicles.

OTHER COVERAGE

All of the vehicles affected by Safety Recall 00S57 (Fuel Pressure Regulator Replacement) are also affected by Owner Notification Program 01M05 (extended coverage for the cross-flow condition). For this reason, 00S57 is being launched concurrently with Owner Notification Program 01M05. If an affected customer reports fuel cross-flow, always complete Safety Recall 00S57 first and release the vehicle. Program 01M05 only applies if the customer reports fuel cross-flow after Safety Recall 00S57 has been completed.

Technical Information
For replacement of the Fuel Pressure Regulator, please follow the procedures in the appropriate Workshop Manual.

Labor Allowances
Description Labor Operation Labor Time
Replace Fuel Pressure Regulator 00S57B 0.5 Hour
Administrative Allowance Misc. Expense
Code "ADMIN" 0.1 Hour
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