Ford F SUPER DUTY recalls by model year

Reported: 1993-08-02 (August 2, 1993) · Model years: 1991, 1992, 1993

A MALFUNCTIONING CHECK VALVE WITHIN THE FUEL PUMP ASSEMBLY CAUSES A PORTION OF THE UNUSED FUEL FROM ONE TANK TO BE RETURNED TO THE SECOND TANK. WHEN THIS OCCURS, THE CAPACITY OF THE SECOND TANK CAN BE EXCEEDED, CAUSING FUEL SPILLAGE.

Consequence: SPILLED FUEL CAN RESULT IN A FIRE WHEN EXPOSED TO ASOURCE OF IGNITION.

Remedy: REPLACEMENT OF THE FUEL PRESSURE REGULATOR AND INSTALLATION OF REDUNDANT CHECK VALVES.

Reported: 1997-11-13 (November 13, 1997) · Model years: 1993, 1994, 1995, 1996, 1997

VEHICLE DESCRIPTION: MOTOR HOME CHASSIS. HOT EXHAUST GASSES CAN LEAK FROM THE EXHAUST GAS RETURN (EGR) TUBE ON THE ENGINE. A HOLE CAN DEVELOP IN THE FLEXIBLE SECTION OF THE TUBE. HEAT DAMAGE TO THE PASSENGER COMPARTMENT FLOOR AND FLOOR COVERING CAN OCCUR.

Consequence: DEPENDING ON THE MATERIALS USED IN THE CONSTRUCTION OF THE COMPLETED VEHICLE, IGNITION OF THESE MATERIALS COULD OCCUR RESULTING IN A VEHICLE FIRE.

Remedy: DEALERS WILL REPLACE THE EGR TUBE.

Reported: 1994-01-02 (January 2, 1994) · Model years: 1994

THE U-CLIP STYLE NUTS THAT RETAIN THE FRONT BUMPERS TO THE FRONT BUMPER INNER ARMS CAN FRACTURE.

Consequence: IF ONE OF THE U-CLIP NUTS FRACTURES, THE BUMPER WILL LOOSEN AND RATTLE CAUSING FRACTURE OF THE REMAINING U-CLIP NUTS, RESULTING IN SEPARATION OF THE BUMPER FROM THE VEHICLE. IF THE BUMPER WERE TO DETACH FROM THE VEHICLE WHILE IT IS BEING DRIVEN, A VEHICLE COLLISION COULD RESULT.

Remedy: INSPECTION AND REPLACEMENT OF THE FOUR U-CLIP NUTS AND THE ASSOCIATED BOLTS.

Reported: 1996-08-01 (August 1, 1996) · Model years: 1996

THE CROSSMEMBER FRAME GUSSETS WERE INSTALLED WITH UNDERSIZED THREADED FASTENERS FOLLOWING A BREAKDOWN OF THE PRODUCTION RIVET GUN THAT IS GENERALLY USED. THIS GUSSET IS THE ATTACHMENT POINT FOR THE REAR STRAP OF THE MID-SHIP FUEL TANK.

Consequence: THE SUBJECT FASTENERS CAN SEPARATE CAUSING IN THE REAR STRAP OF THE AFFECTED FUEL TANK TO BECOME DISCONNECTED. A LOOSE OR DISCONNECTED REAR STRAP ALLOWS THE FUEL TANK TO POSSIBLY CONTACT THE ROAD SURFACE INCREASING THE RISK OF A VEHICLE FIRE.

Remedy: DEALERS WILL REPLACE THE CROSSMEMBER GUSSET FASTENERS WITH THE SPECIFIED ALTERNATIVE FASTENERS (BOLTS).

Reported: 1996-09-18 (September 18, 1996) · Model years: 1997

A PLASTIC COATED STEEL SUPPORT STRAP FOR THE BATTERY CABLE WAS DAMAGED WHEN IT WAS CRIMPED ONTO THE CABLE.

Consequence: THIS DAMAGE CAN RESULT IN THE BATTERY CABLE DEVELOPING A SHORT TO GROUND. A SHORTED BATTERY CABLE CAN RESULT IN A VEHICLE FIRE.

Remedy: DEALERS WILL INSPECT THE CABLE INSULATION AND REPLACE THE SUPPORT STRAP WITH A REVISED, UNCRIMPED STRAP ATTACHED WITH TAPE. IN ADDITION, CONVOLUTE WILL BE ADDED BETWEEN THE CABLE AND THE SUPPORT STRAP. DAMAGED BATTERY CABLES WILL BE REPLACED.

Reported: 1997-10-29 (October 29, 1997) · Model years: 1997

VEHICLE DESCRIPTION: LIGHT DUTY PICKUP TRUCKS AND CHASSIS. THE TIRES ON THESE VEHICLES WERE DAMAGED DURING MOUNTING ONTO THE WHEELS. ONLY TRUCKS PRODUCED AT THE CUAUTITLAN, MEXICO PLANT BETWEEN SEPTEMBER 1, 1996, AND JULY 17, 1997, WERE AFFECTED BY THE DEFECT.

Consequence: THE BEAD AREA OF THE TIRE WAS CUT WHICH COULD RESULT IN AIR LOSS. SUDDEN AIR LOSS COULD OCCUR RESULTING IN A LOSS OF VEHICLE CONTROL.

Remedy: DUE TO THE AGE OF THE VEHICLES AND THIS RECALL AFFECTING ORIGINAL EQUIPMENT TIRES ONLY, FORD WILL NO LONGER ACCEPT CLAIMS FOR THIS CAMPAIGN.

Reported: 1998-04-01 (April 1, 1998) · Model years: 1999

VEHICLE DESCRIPTION: MOTOR HOME CHASSIS. THE ACCELERATOR CABLE IS SUSCEPTIBLE TO FREEZING. WATER CAN ACCUMULATE IN THE END FITTING AND AT TEMPERATURES OF 32 DEGREES FAHRENHEIT AND BELOW, CAN FREEZE. THE ICE COULD PREVENT THE ACCELERATOR FROM RETURN TO IDLE.

Consequence: INCREASED STOPPING DISTANCE WOULD BE REQUIRED, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL REPLACE THE ACCELERATOR CABLE WITH A REVISED ACCELERATOR CABLE.

Reported: 1998-12-02 (December 2, 1998) · Model years: 1999

VEHICLE DESCRIPTION: MOTOR HOME CHASSIS. THE ACCELERATOR CABLE IS SUSCEPTIBLE TO FREEZING. WATER CAN ACCUMULATE IN THE END FITTING AND CAN FREEZE AT TEMPERATURES OF 32 DEGREES FAHRENHEIT AND BELOW. THE ICE COULD PREVENT THE ACCELERATOR FROM RETURNING TO IDLE.

Consequence: INCREASED STOPPING DISTANCE WOULD BE REQUIRED, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL REPLACE THE ACCELERATOR CABLE WITH A REVISED ACCELERATOR CABLE.

Reported: 1999-09-20 (September 20, 1999) · Model years: 1999, 2000

VEHICLE DESCRIPTION: SUPER DUTY TRUCKS AND CHASSIS-CABS EQUIPPED WITH 5.4L MANUAL TRANSMISSION POWERTRAINS. THE ACCELERATOR CABLE CORE WIRE CAN WEAR THE CABLE CONDUIT END FITTING DUE TO A FIFTEEN DEGREE ANGLE IT MAKES WITH THE CONDUIT AT THE THROTTLE BODY END. THIS COULD ALSO LEAD TO WEAR OR SEPARATION OF STRANDS OF THE CORE WIRE, WHICH COULD PREVENT THE THROTTLE FROM RETURNING TO THE IDLE POSITION.

Consequence: A "STUCK" THROTTLE COULD ADVERSELY AFFECT VEHICLE CONTROL.

Remedy: DEALERS WILL REPLACE THE ACCELERATOR CABLE AND THROTTLE BODY.

Reported: 2000-06-19 (June 19, 2000) · Model years: 2000

VEHICLE DESCRIPTION: F-SUPER DUTY STRIPPED MOTOR HOME CHASSIS BECAUSE THEY MAY HAVE A MISSING OR PARTIALLY INSTALLED BRAKE PEDAL TO MASTER CYLINDER PUSHROD RETAINING CLIP.

Consequence: IF THE CLIP IS MISSING OR FALLS OUT, THE PUSHROD COULD DISCONNECT FROM THE BRAKE PEDAL, RESULTING IN THE OPERATOR BEING UNABLE TO APPLY THE BRAKES, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL INSPECT THE RETAINING CLIP INSTALLATION. MISSING OR PARTIALLY INSTALLED CLIPS WILL BE PROPERLY INSTALLED. IN ADDITION, DEALERS WILL ALSO INSPECT VEHICLES FOR LOWER THAN INTENDED WHEEL LUG NUT TORQUE; INCOMPLETE TRANSMISSION SHIFT CABLE INSTALLATION; STEERING COLUMN SHIFT LEVER BRACKET BOLT TORQUE LOWER THAN INTENDED; STEERING GEAR BRACKET FASTENER TORQUE LOWER THAN INTENDED; AND LOWER STEERING COLUMN YOKE BOLT TORQUE LOWER THAN INTENDED.

Reported: 2000-09-06 (September 6, 2000) · Model years: 2000

VEHICLE DESCRIPTION: MOTOR HOME CHASSIS. THESE VEHICLES MAY HAVE A MIS-ROUTED WIRE HARNESS THAT ATTACHES TO THE BRAKE PEDAL POSITION SWITCH. THE WIRE COULD RUB ON THE STEERING COLUMN, RESULTING IN A SHORT CIRCUIT AND A BLOWN FUSE, CAUSING A LOSS OF STOP LAMP FUNCTION.

Consequence: THIS WOULD FAIL TO WARN A FOLLOWING DRIVER THAT THE VEHICLE IS BRAKING AND COULD LEAD TO A CRASH.

Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, REPAIR THE WIRE HARNESS TO THE BRAKE PEDAL SWITCH. OWNER NOTIFICATION BEGAN SEPTEMBER 25, 2000. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673.

Reported: 2001-03-27 (March 27, 2001) · Model years: 2001

VEHICLE DESCRIPTION: F-SUPER DUTY CREW CAB PICKUP TRUCKS (F-350 SHORT WHEELBASE TRUCKS EQUIPPED WITH A 6 3/4' PICKUP BOX AND DUAL REAR WHEELS) WERE BUILT AFTER A CHANGE WAS IMPLEMENTED TO DELETE A CLAMP, AND LATER A BRACKET THAT PROVIDED A GROUND FOR THE FUEL FILLER PIPE. THE PICKUP BOX MAY NOT HAVE BEEN PROPERLY GROUNDED.

Consequence: WITHOUT PROPER GROUNDING, AN ELECTROSTATIC DISCHARGE COULD RESULT DURING FUEL FILL UP, POTENTIALLY LEADING TO A FIRE.

Remedy: DEALERS WILL INSTALL A FUEL FILLER PIPE GROUND. OWNER NOTIFICATION BEGAN MARCH 26, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673.