Additional Affected Units (Manual Transmission Equipped Vehicles) and Revised Program End Date

Dealer Letter:

May, 1999

To:

All Ford and Lincoln-Mercury Dealers

Subject:

Owner Notification Program 98B29, Additional Affected Units (Manual Transmission Equipped Vehicles) and Revised Program End Date

REF:

All Dealer Letter Dated January, 1999 - Certain 1999 Model Year F-250/350 Super Duty Series 4x4 Trucks - Gem Module Replacement

OASIS:

Yes

OWNER LIST:

Yes; Additional Affected Vehicles Equipped With Manual Transmissions Have Been Added To This Program

PARTS RETURN:

No

PROGRAM TERMS:

REVISED TO: Through December 31, 1999, regardless of mileage (After this program expires, the vehicle may still be eligible for this service under any remaining vehicle warranty coverage).

ADDITIONAL AFFECTED VEHICLES

Dealers are notified that an additional number of affected vehicles equipped with manual transmissions have been identified and are being added to the program.

l           A total of 2,899 affected vehicles have been added to the U.S. vehicle population

l           A total of 374 affected vehicles have been added to the Canadian vehicle population

Affected vehicle VIN lists will be mailed to dealers the week of May 24, 1999.

PROGRAM TERMS EXTENDED

The above referenced letter originally indicated that involved vehicles were eligible for this program through July 31, 1999, regardless of mileage (All Dealer Letter Dated January, 1999). The Expiration Date For This Program Has Been Extended Through December 31, 1999, Regardless Of Mileage.

ACTION TO NOTIFY OWNERS

Owners of additionally affected vehicles will be notified with the attached owner letter.

QUESTIONS?

Claims Information 1-800-423-8851

Other Recall Questions 1-800-325-5621

ATTACHMENT III

Owner Notification Program 98B29

GENERIC ELECTRONIC MODULE (GEM) REPLACEMENT

AFFECTED VEHICLES:

CERTAIN 1999 MODEL YEAR F-250/350 SUPER DUTY SERIES TRUCKS

SERVICE PROCEDURE

1.         Record radio stations, then disconnect battery negative cable.

2.         Remove steering column lower opening panel (knee bolster).

3.         Remove four (4) junction block assembly retaining bolts/nuts. See Figure 1.

            Figure 1

4.         Disconnect junction block electrical connectors.

5.         Disconnect GEM electrical connectors.

6.         Remove junction block assembly.

7.         Check engineering suffix of the GEM part number (-14B205-), shown in Figure 2.

Vehicles without Remote Keyless Entry (RKE) Replace GEM if the part number suffix is any designation other than "DJ"

Vehicles with Remote Keyless Entry (RKE) Replace GEM if the part number suffix is any designation other than "EL".

            Figure 2

8.         Remove GEM-to-junction block retaining screws. Refer to Figure 3.

9.         Using flat bladed screwdriver, separate GEM from junction block.See Figure 3. There will be some resistance when removing the GEM, due to an electrical connector between the two units.

            Figure 3

10.       Attach new GEM to junction block. Make sure electrical connector is fully seated. See Figure 4.

            Figure 4

11.       Install GEM-to-junction block retaining screws. Tighten screws to 2-3 Nm (18-26 lb-in).

12.       Position junction block assembly in vehicle.

13.       Connect two (2) GEM electrical connectors.

14.       Connect two (2) junction block electrical connectors. Tighten retaining screws to 5-6 Nm (44-53 lb-in).

15.       Install four (4) junction block assembly retaining bolts/nuts. Tighten retaining screws to 5-6 Nm (44-53 lb-in).

16.       Install steering column lower opening panel (knee bolster).

17.       Connect battery negative cable.

18.       On vehicles equipped with manual transmission, proceed as follows:

Reconfigure GEM for manual transmission as follows:

- Obtain Ford Service Function (FSF) Program card with software level of 4.0 or higher.

- Insert FSF Program Card into NGS.

- Connect NGS into the DLC.

- Turn ignition switch to Run position (engine off).

- Scroll highlighted bar to "SERVICE BAY FUNCTIONS," then press trigger button.

- Scroll highlighted bar to "GEM - GENERIC ELECTRONIC MODULE," then press trigger button.

- Scroll highlighted bar to "MANUFACTURE OPTIONS," then press trigger button.

l           If the NGS displays: "-COMMUNICATION LINK ESTABLISHED - YOU MUST MAKE SELECTION FOR THE FOLLOWING FIELD: VEHICLE," press trigger button.

- Scroll highlighted bar to "TRANSMISSION," then press trigger button.

- Turn dial to the right and "ENABLED" will change to "DISABLED." Press trigger button.

- Press DONE (numeric 8 button) and the GEM module will be programmed to a manual transmission equipped vehicle.

Disconnect NGS from DLC.

Remove FSF Program Card from NGS.

Insert Diagnostic Card into NGS.

Connect NGS to DLC.

Retrieve and clear all Diagnostic Trouble Codes (DTC).

Retrieve DTC's again.

If there are no DTC's, proceed to Step 19. If ABS codes B2141 and/or B2477 are present, reconfigure the ABS module for correct tire/axle ratio as follows:

- Disconnect NGS from DLC.

- Remove Diagnostic Card from NGS.

- Insert same Ford Service Function (FSF) Program card (software level of 4.0 or higher) into NGS.

- Connect NGS into the DLC.

- Turn ignition switch to Run position (engine off).

- Scroll highlighted bar to "SERVICE BAY FUNCTIONS," then press trigger button.

- Scroll highlighted bar to "ABS -ANTI LOCK BRAKE MODULE," then press trigger button.

- Scroll highlighted bar to "TIRE SIZE/AXLE RATIO CONFIGURE," then press trigger button.

l           If the NGS displays: "-COMMUNICATION LINK ESTABLISHED - YOU MUST MAKE SELECTION FOR THE FOLLOWING FIELD: VEHICLE," press trigger button.

Scroll highlighted bar to "TIRE SIZE," then press trigger button.

- Turn dial to the right until correct tire size is displayed, then press trigger button.

- If tire size is not listed, rotate dial until "-- REVS/MILE" is displayed, then press trigger button. Use the following formula to calculate revolutions per mile:

l           63360 divided by circumference of tire measured in inches. Add 2 zeros in front of the solution. Enter this number into the NGS, then press trigger button.

- Scroll highlighted bar to "TONE RING SIZE." Verify 10.50 IN/ 27CM (00120) is displayed.

- Scroll highlighted bar to "OPTION," then press trigger button.

- Turn dial to the right until "N/A" is displayed. Press trigger button.

- Scroll highlighted bar to "VEHICLE," then press trigger button.

- Turn dial to the right until "F250/F350" is displayed. Press trigger button.

- Press DONE (numeric 8 button) and the ABS module will be reconfigured.

- Remove NGS from DLC.

- Recheck speedometer accuracy.

19.       On vehicles equipped with keyless entry, reprogram remote transmitters as follows:

Turn the ignition from OFF to RUN five (5) times within ten (10) seconds, ending in RUN. If the GEM has successfully entered program mode, it will lock and unlock all the doors.

Press a button on remote transmitter, wait several seconds. The doors should lock and unlock. Repeat this step for all remote transmitters.

Turn the ignition switch to the OFF position. If the GEM has exited program mode, it will lock and unlock all the doors one last time.

20.       Program radio stations.

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Customer Letter:

 

 

May, 1999

Serial Number: 12345678901234567          98B23-S1

Mr. John Sample

123 Main Street

Anywhere, USA 12345

Ford Motor Company is providing a no-charge Service Program, Number 98B29, to owners of certain 1999 F-250/350 4x4 Super Duty series trucks.

REASON FOR THIS PROGRAM

The Electronic Shift On the Fly (ESOF) 4x4 system may become inoperable. In some cases it may also shift from 4x2 into 4x4 without input from the driver. This condition may be the result of GEM (Generic Electronic Module) system software concerns.

NO CHARGE SERVICE

At no charge to you, your dealer will replace the GEM module to correct these concerns.

Your vehicle is eligible for this program through December 31, 1999, regardless of mileage.

HOW LONG WILL IT TAKE?

The time needed for this service is one-half day. However, due to service scheduling times, your dealer may need your vehicle for one full working day.

CALL YOUR DEALER

Ask for a service date for Program Number 98B29. When you bring your truck in, show the dealer this letter. If you misplace this letter, your dealer will still perform the service, free of charge.

REFUNDS

If you paid to have this service done before the date of this letter, Ford is offering a full refund. For the refund, please give your paid original receipt to your Ford dealer. To avoid delays, do not send receipts to Ford Motor Company.

CHANGED ADDRESS OR SOLD THE TRUCK?

Please fill out the enclosed prepaid postcard and mail it to us if you have changed your address or sold the truck.

We are taking this action as part of our ongoing efforts to maintain owner confidence in our products. We hope this program will confirm your continued satisfaction in your Ford built truck.

OWNER NOTIFICATION PROGRAM

98B23-S1