Dealer Letter:

January, 1999

To:

All Ford and Lincoln-Mercury Dealers

Subject:

Owner Notification Program 98B32 - Certain 1999 Model Year F250 through F550 Series 4x4 Trucks For Installation of Rear Brake Shield(s)

OASIS -

Yes

OWNER LIST -

Yes

PARTS RETURN -

No

PROGRAM TERMS -

July 31, 1999, Regardless of Mileage

AFFECTED VEHICLES

Certain 1999 model year F250/350/450/550 4X4 series trucks built from November 24, 1997 through November 11, 1998 at Kentucky Truck Plant.

REASON FOR THIS PROGRAM

The left rear caliper and fitting on affected vehicles operated on coarse gravel roads at highway speeds have been struck by stones causing loosening or damage to the brake line and fitting. Loss of brake fluid may occur leading to a soft pedal and eventually, a warning light, reduced brake effectiveness and extended stopping distances.

SERVICE ACTION

To correct this condition, a shield will be installed and the brake tube replaced on the left side of F250/350/450/550. Brake shields and brake tubes will be installed on both rear sides on F550 series trucks built on or after June 15, 1998.

NOTE:

Some F-350 DRW 4x4 vehicles may have been modified by TSB 98-17-2 (Lowering Rear Suspension - 5th Wheel and Goose Neck Applications). A modified rear brake shield will be available late January, 1999.

REFUNDS

Only for owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer).

QUESTIONS?

Claims Information 1-800-423-8851

Other Recall Questions 1-800-325-5621

ATTACHMENT I

Owner Notification Program 98B32 - B Program

OASIS

You must use OASIS to determine if a vehicle is eligible for this program.

PLEASE NOTE

Correct all vehicles in stock before delivery.

PROMPTLY CORRECT

-- Affected vehicles on the enclosed list.

-- Other eligible vehicles which are brought to your dealership.

DEALER-OWNER CONTACT

Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date.

CLAIMS

Enter claims using DWE. See ACESII Manual, Sections 5 & 6.

OWNER REFUNDS

See ACESII Manual, Section 3-59 for submission procedures.

For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE:

l           Program Code - 98B32

l           Misc. Expense - REFUND

l           Misc. Expense - ADMIN.

l           Misc. Expense - 0.2 Hr.

ATTACHMENT II

Owner Notification Program 98B32 - B Program

Certain 1999 Model Year F250 through F550 4X4 Series Trucks

 Installation of a Rear Brake Shields and Brake Lines

LABOR ALLOWANCES

Operation Description --   Install left rear brake shield and brake line on F250/350 Series             0.7 Hrs

Labor Operation Allowances --  B32B

Operation Description -- Install left rear brake shield and brake line on F450 and F550 series (built prior to June 15 1998) 

Labor--  0.9 Hrs  

Labor Operation Allowances --   B32C 

Operation Description --  Install both rear brake shields and brake lines on F550 Series (built on/after June 15, 1998

Labor--   1.3 Hrs               

Labor Operation Allowances --  B32D         

PARTS REQUIREMENTS

Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels.

PART NUMBER:  F81Z-2A753-AA

KIT CODE: AA

DESCRIPTION:   F250 - F350 SRW with 137", 142", 156", 158" & 172" wheel base

PART NUMBER:  F81Z-2A753-BA                

KIT CODE:  BA  

DESCRIPTION:  F250 - F350 Series   SRW/DRW with 141", 162", 165" & 176" wheel base  

PART NUMBER:  F81Z-2A753-CA   

KIT CODE:  CA

DESCRIPTION:  F450 Series        

PART NUMBER:  F81Z-2A753-DA   

KIT CODE:  DA

DESCRIPTION:  F550 Series vehicles left side built prior to 6/15/98      

PART NUMBER:  F81Z-2A753-EA   

KIT CODE:  EA

DESCRIPTION:  F550 Series vehicles right side built on after 6/15/98    

SRW - Denotes Single Rear Wheels

DRW - Denotes Dual Rear Wheels

DEALER PRICE

For latest prices, check or call your:

--         Order Processing Center

--         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.

CLAIMS PREPARATION

-- Enter using DWE.

-- Use code information shown below:

Program Code - 98B32

Labor Operation - See Above

See Sections 5 & 6 of the ACESII manual for detailed instructions.

ATTACHMENT III

Owner Notification Program 98B32

REAR DISC BRAKE MODIFICATION

AFFECTED VEHICLES:

CERTAIN 1999 SUPER DUTY MODELS EQUIPPED WITH REAR DISC BRAKES PRODUCED AT KENTUCKY TRUCK PLANT FROM NOVEMBER 24, 1997 THROUGH NOVEMBER 10, 1998

SERVICE PROCEDURE -- F250/F350

WARNING

BRAKE FLUID CONTAINS POLYGLYCOLETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS THE EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING.GET MEDICAL ATTENTION IMMEDIATELY.

CAUTION

Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

1.         Raise and support vehicle.

2.         Remove left rear tire and wheel assembly.

3.         Remove retaining bolt from left rear brake hose wire retainer. Refer to Figure 1.

4.         Disconnect left rear brake tube from junction block. Refer to Figure 1.

5.         Disconnect left rear brake hose from rear disc brake caliper. Refer to Figure 1. Discard banjo bolt and copper washers.

6.         Remove left rear brake hose and tube assembly. See Figure 1.

            Figure 1

7.         Using new banjo bolt and copper washers, connect new left rear brake hose to rear disc brake caliper. See Figure 2. Route brake hose as shown in Figure 2. Tighten banjo bolt to 43-57 Nm (32-42 lb-ft).

            Figure 2

8.         Connect left rear brake tube to junction block. Route brake tube as shown in Figure 3. Tighten brake tube nut to 14-20 Nm (11-14 lb-ft).

            Figure 3

9.         NOTE: Some vehicles will have this hole already in the left rear spring seat. If hole is present, proceed to the next numbered step.

Drill hole in the left rear spring seat as follows:

l           Position brake tube wire retainer on rear face of left rear spring seat.Mark spring seat as shown in Figure 4.

            Figure 4

l           NOTE: Make sure the hole is deep enough to allow installation of the self tapping screw. Drill a 6.75 mm (17/64 in.) diameter hole at the mark on the rear face of the left rear spring seat.

10.       NOTE: Only use the supplied self-tapping screw if Step 9 was performed, otherwise use the screw removed in Step 3.

Using correct screw, install brake tube wire retainer to rear face of left rear spring seat. Tighten screw to 19-25 Nm (14-18 lb-ft).

11.       Bleed left rear brake assembly and refill master cylinder reservoir.

12.       NOTE: Replace the caliper anchor mounting bolts one at a time.This will prevent the caliper assembly from slipping out of place.

Replace the upper and then the lower caliper anchor mounting bolts with new caliper anchor mounting studs. See Figure 5.

            Figure 5

13.       On F250/F350 vehicles, tighten both anchor mounting studs to 149-201 Nm (110-148 lb-ft).

14.       Install brake tube protective shield on anchor mounting studs. See Figure 6. Tighten retaining nuts to 53-71 Nm ( 39-52 lb-ft).

            Figure 6

15.       Install left rear tire and wheel assembly.

16.       Lower vehicle.

SERVICE PROCEDURE -- F450/F550

WARNING

BRAKE FLUID CONTAINS POLYGLYCOLETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS THE EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING.GET MEDICAL ATTENTION IMMEDIATELY.

CAUTION

Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

1.         Raise and support vehicle, if necessary.

2.         Remove retaining bolt from left rear brake hose wire retainer. Refer to Figure 7.

3.         Disconnect left rear brake hose from rear disc brake caliper. See Figure 7. Discard banjo bolt and copper washers.

            Figure 7

4.         Disconnect left rear brake tube from junction block.

5.         Remove left rear brake hose and tube assembly.

6.         Install new left rear brake hose and tube assembly.

7.         Connect left rear brake tube to junction block. Route brake tube as shown in Figure 8. Tighten brake tube nut to 14-20 Nm (11-14 lb-ft).

            Figure 8

8.         Using original screw, install brake hose wire retainer to rear face of left rear spring seat. See Figure 9. Tighten screw to 19-25 Nm (14-18 lb-ft).

            Figure 9

9.         Using new banjo bolt and copper washers, connect new left rear brake hose to rear disc brake caliper. See Figure 10. Route brake hose as shown in Figure 10. Tighten banjo bolt to 43-57 Nm (32-42 lb-ft).

            Figure 10

10.       NOTE: On vehicles with dual forward-of-axle rear brake calipers, do not bleed brake system until right side rear brake assembly has been modified.

Bleed rear brake assembly and refill master cylinder reservoir.

11.       NOTE: Replace caliper anchor mounting bolts one at a time. This will prevent caliper assembly from slipping out of place.

Replace the upper and then the lower caliper anchor mounting bolts with new caliper anchor mounting studs. See Figure 11.

            Figure 11

12.       Tighten caliper anchor mounting studs as follows:

l           Tighten lower mounting stud to 360-440 Nm (266-324 lb-ft).

l           Tighten upper mounting stud to 136 Nm (100 lb-ft) using crowfoot type wrench. Place a mark on the caliper anchor bracket and the mounting stud.See Figure 12. Tighten mounting stud an additional 1/8-1/4 turn, using suitable box end wrench.

            Figure 12

13.       Install brake tube protective shield on anchor mounting studs. See Figure 13. Tighten retaining nuts to 53-71 Nm (39-52 lb-ft).

            Figure 13

14.       On vehicles with dual forward-of-axle rear brake calipers, repeat procedure on right side rear brake assembly.

15.       Lower vehicle.

---

Customer Letter:

January, 1999

Serial Number: 12345678901234567          98B32

Mr. John Sample

123 Main Street

Anywhere, USA 12345

Ford Motor Company is providing a no-charge Service Program, Number 98B32, to owners of certain 1999 model year F250 through F550 series 4x4 trucks.

REASON FOR THIS PROGRAM

The left rear caliper and fitting on affected vehicles operated on coarse gravel roads at highway speeds have been struck by stones causing loosening or damage to the line and fitting. Loss of brake fluid may occur leading to a soft pedal and eventually, a warning light, reduced brake effectiveness and extended stopping distances.

NO CHARGE SERVICE

At no charge to you, your dealer will install a revised brake line and a shield.

Your truck is eligible for this program through July 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 truck for one full working day. Please call your dealer for a service date.

CALL YOUR DEALER

Ask for a service date and if parts are in stock for Program Number 98B32.

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.

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 truck 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

98B32