Ford F250 recalls

FUEL SYSTEM, GASOLINE

THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. VEHICLE DESCRIPTION: 1990-1993 FORD F-SERIES VEHICLES EQUIPPED WITH DUAL FUEL TANKS AND 4.9, 5.0,5.8, OR 7.5 LITER GASOLINE FUELED ENGINES. SOME VEHICLES CAN EXPERIENCE A CROSS TANK FUEL FLOW CONDITION DUE TO A 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.

Risk: SHOULD THIS OCCUR, THE CAPACITY OF THE RECEIVING TANK MAY BE EXCEEDED AND FUEL MAY OVERFLOW FROM THE FILLER CAP.

Remedy: FORD IS EXTENDING THE WARRANTY FOR POTENTIAL FUEL CROSS-FLOW TO 12 YEARS OF SERVICE OR 150,000 MILES FROM THE VEHICLE'S WARRANTY START DATE, WHICHEVER OCCURS FIRST. THIS COVER WILL AUTOMATICALLY TRANSFER TO SUBSEQUENT OWNERS AT NO CHARGE. IF A VEHICLE ALREADY HAS MORE THAN 150,000 MILES, THIS OVERAGE WILL LAST UNTIL DECEMBER 31, 2001. IF THE VEHICLE IS EXPERIENCING A FUEL CROSS-FLOW CONDITION, DEALERS WILL REPAIR THE CONDITION FREE OF CHARGE.

ELECTRICAL SYSTEM:IGNITION

THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.

Risk: THIS CONDITION COULD CAUSE OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN AREA OF THE VEHICLE.

Remedy: DEALERS WILL REPLACE THE IGNITION SWITCH.

ELECTRICAL SYSTEM:IGNITION

THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.

Risk: THIS CONDITION COULD CAUSE OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN AREA OF THE VEHICLE.

Remedy: DEALERS WILL REPLACE THE IGNITION SWITCH.

ELECTRICAL SYSTEM:IGNITION

THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.

Risk: THIS CONDITION COULD CAUSE OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN AREA OF THE VEHICLE.

Remedy: DEALERS WILL REPLACE THE IGNITION SWITCH.

FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS

THE STEEL FUEL RETURN TUBES THAT CONNECT THE FRAME FUEL RETURN LINES WITH THE ENGINE FUEL RAIL CAN CONTACT THE PINCH WELD FLANGE CONNECTING THE DASH PANEL TO THE FLOOR PAN. CONTINUED CONTACT LEADS TO ABRASION OF THE STEEL FUEL RETURN TUBE AND EVENTUALLY RESULTS IN A FUEL LEAK.

Risk: ABRASION OF THE STEEL TUBE WALL THAT EVENTUALLY CAUSES A FUEL LEAK MAY RESULT IN A FIRE, IF A SOURCE OF IGNITION IS PRESENT.

Remedy: FORD DEALERS WILL REPLACE THE FUEL RETURN TUBES WITH FLEXIBLE STAINLESS STEEL BRAIDED/TEFLON TUBES. DEALERS WILL ALSO INSPECT THE FUEL SUPPLY TUBES.

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

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.

Risk: 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.

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DRUM:SHOES/LININGS

A REVISED BRAKE LINING NOISE INSULATOR RESULTED IN A DECREASE IN THE THERMAL INSULATION BETWEEN THE BRAKE LINING AND THE FRONT BRAKE CALIPER PISTON. THIS CAUSED GREATER HEAT TRANSFER TO THE CALIPER PISTONS WITH THE POTENTIAL TO OVERHEAT THE BRAKE FLUID AND DIMINISH BRAKE EFFECTIVENESS DURING SEVERE BRAKING CONDITIONS.

Risk: INCREASED STOPPING DISTANCES AND INABLILITY TO HOLDVEHICLES ON A STEEP GRADE RESULTS IN INCREASED RISK OF ACCIDENT IN THE EVENT OFA SUDDEN STOP OR WHEN CONSTANT BRAKING IS NEEDED TO MANEUVER THROUGH AREAS WITHSTEEP GRADES.

Remedy: ADD SNAP-IN INSULATORS THAT ATTACH TO EACH OF THE FRONT BRAKE CALIPER PISTONS. IN ADDITION, VEHICLES WITH 7.5 L ENGINES WILL HAVE INSULATION ADDED TO THE ENGINE COMPARTMENT BRAKE LINES.

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DRUM:SHOES/LININGS

A REVISED BRAKE LINING NOISE INSULATOR RESULTED IN A DECREASE IN THE THERMAL INSULATION BETWEEN THE BRAKE LINING AND THE FRONT BRAKE CALIPER PISTON. THIS CAUSED GREATER HEAT TRANSFER TO THE CALIPER PISTONS WITH THE POTENTIAL TO OVERHEAT THE BRAKE FLUID AND DIMINISH BRAKE EFFECTIVENESS DURING SEVERE BRAKING CONDITIONS.

Risk: INCREASED STOPPING DISTANCES AND INABLILITY TO HOLDVEHICLES ON A STEEP GRADE RESULTS IN INCREASED RISK OF ACCIDENT IN THE EVENT OFA SUDDEN STOP OR WHEN CONSTANT BRAKING IS NEEDED TO MANEUVER THROUGH AREAS WITHSTEEP GRADES.

Remedy: ADD SNAP-IN INSULATORS THAT ATTACH TO EACH OF THE FRONT BRAKE CALIPER PISTONS. IN ADDITION, VEHICLES WITH 7.5 L ENGINES WILL HAVE INSULATION ADDED TO THE ENGINE COMPARTMENT BRAKE LINES.

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DRUM:SHOES/LININGS

A REVISED BRAKE LINING NOISE INSULATOR RESULTED IN A DECREASE IN THE THERMAL INSULATION BETWEEN THE BRAKE LINING AND THE FRONT BRAKE CALIPER PISTON. THIS CAUSED GREATER HEAT TRANSFER TO THE CALIPER PISTONS WITH THE POTENTIAL TO OVERHEAT THE BRAKE FLUID AND DIMINISH BRAKE EFFECTIVENESS DURING SEVERE BRAKING CONDITIONS.

Risk: INCREASED STOPPING DISTANCES AND INABLILITY TO HOLDVEHICLES ON A STEEP GRADE RESULTS IN INCREASED RISK OF ACCIDENT IN THE EVENT OFA SUDDEN STOP OR WHEN CONSTANT BRAKING IS NEEDED TO MANEUVER THROUGH AREAS WITHSTEEP GRADES.

Remedy: ADD SNAP-IN INSULATORS THAT ATTACH TO EACH OF THE FRONT BRAKE CALIPER PISTONS. IN ADDITION, VEHICLES WITH 7.5 L ENGINES WILL HAVE INSULATION ADDED TO THE ENGINE COMPARTMENT BRAKE LINES.

FUEL SYSTEM, GASOLINE:STORAGE:AUXILLARY TANK:SELECTOR DEVICES

THE DUAL FUEL TANK SELECTOR VALVE MAY MALFUNCTION AND CAUSE AN OVERFILL CONDITION IN ONE OF THE FUEL TANKS, RESULTING IN AN OVERFLOW OF FUEL PAST THE FILLER CAP.

Risk: THE OVERFLOW OF FUEL PAST THE FILLER CAP CAUSES A FUELLEAKAGE, WHICH CAN RESULT IN A FIRE WHEN EXPOSED TO A SOURCE OF IGNITION.

Remedy: REPLACE THE DUAL FUEL TANK SELECTOR VALVE.

POWER TRAIN:AUTOMATIC TRANSMISSION:GEAR POSITION INDICATION (PRNDL)

UNDER CERTAIN CONDITIONS, THE SNAP RING THAT LOCATES THE PARK GEAR ON THE OUTPUT SHAFT OF THE TRANSMISSION MAY FRACTURE.

Risk: WHEN THE GEAR IS PLACED IN PARK, THE PARK GEAR WOULD NOTENGAGE, ALLOWING THE TRUCK TO ROLL FREELY IF THE PARKING BRAKE IS NOT PROPERLYSET. THIS COULD RESULT IN AN ACCIDENT.

Remedy: INSTALL IMPROVED SNAP RING AND REVISED TRANSMISSION EXTENSION HOUSING.

POWER TRAIN:AUTOMATIC TRANSMISSION:GEAR POSITION INDICATION (PRNDL)

UNDER CERTAIN CONDITIONS, THE SNAP RING THAT LOCATES THE PARK GEAR ON THE OUTPUT SHAFT OF THE TRANSMISSION MAY FRACTURE.

Risk: WHEN THE GEAR IS PLACED IN PARK, THE PARK GEAR WOULD NOTENGAGE, ALLOWING THE TRUCK TO ROLL FREELY IF THE PARKING BRAKE IS NOT PROPERLYSET. THIS COULD RESULT IN AN ACCIDENT.

Remedy: INSTALL IMPROVED SNAP RING AND REVISED TRANSMISSION EXTENSION HOUSING.

FUEL SYSTEM, GASOLINE:STORAGE:AUXILLARY TANK:SELECTOR DEVICES

INCORRECTLY INSTALLED FUEL LINE CONNECTORS HAVE FUEL SUPPLY AND RETURN LINES CROSSED.

Risk: FUEL COULD BE TRANSFERRED FROM ONE TANK TO THE OTHER,POSSIBLY RESULTING IN FUEL OVERFLOW AND SPILLAGE, IN PRESENCE OF AN IGNITIONSOURCE, A FIRE COULD OCCUR.

Remedy: REPLACE FUEL LINE ASSEMBLY.

FUEL SYSTEM, GASOLINE:STORAGE:AUXILLARY TANK

SHIELDS ON THE FRONTS OF THE MIDSHIP MOUNTED FUEL TANKS WERE OMITTED DURING ASSEMBLY.

Risk: TRUCKS WOULD NOT COMPLY WITH 30 MPH IMPACT TEST OFFMVSS NO. 301, FUEL SYSTEM INTEGRITY.

Remedy: INSTALL FUEL TANK SHIELDS.

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:MOUNTING

FUEL RESERVOIR SHIELDS, THAT PROTECT THE RESERVOIR FROM CONTACT BY THE TRANSFER CASE IN CERTAIN FRONTAL IMPACTS, WERE NOT INSTALLED.

Risk: FUEL SPILLAGE IN EXCESS OF THAT PERMITTED BY FMVSS 301COULD OCCUR.

Remedy: INSTALL FUEL RESERVOIR PROTECTIVE SHIELDS.

VISIBILITY:GLASS, SIDE/REAR

SLIDING REAR WINDOW MAY CONTAIN GLAZING PANELS WHICH DO NOT MEET REQUIREMENTS OF FMVSS 205.

Risk: A FRACTURED WINDOW MAY CONTAIN FRAGMENTS THAT ARE LARGERTHAN THE 425 GRAMS ALLOWED.

Remedy: REPLACE SUSPECT WINDOW PANELS.

WHEELS:LUGS/NUTS/BOLTS/STUDS

WHEEL LUG NUT CONE ANGLES DO NOT MATCH LUG NUT SEATING ANGLES.

Risk: NUTS COULD LOOSEN IN SERVICE CREATING POTENTIAL FORWHEELS TO SEPARATE FROM TRUCK.

Remedy: REPAIR TO PREVENT LOOSENING OF LUG NUTS.

FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS

SPRING LOCK FUEL LINE COUPLING MAY NOT BE PROPERLY ENGAGED.

Risk: COUPLING COULD DISENGAGE DUE TO FUEL PRESSURE,VIBRATION, AND ENGINE MOVEMENTS; THIS WOULD CAUSE LOSS OF FUEL WHICH, INPRESENCE OF AN IGNITION SOURCE, CREATES A FIRE RISK.

Remedy: INSTALL RETAINER CLIPS OVER THE COUPLINGS TO PREVENT COUPLING SEPARATION AND FUEL LEAKAGE.

FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS

SPRING LOCK FUEL LINE COUPLING MAY NOT BE PROPERLY ENGAGED.

Risk: COUPLING COULD DISENGAGE DUE TO FUEL PRESSURE,VIBRATION, AND ENGINE MOVEMENTS; THIS WOULD CAUSE LOSS OF FUEL WHICH, INPRESENCE OF AN IGNITION SOURCE, CREATES A FIRE RISK.

Remedy: INSTALL RETAINER CLIPS OVER THE COUPLINGS TO PREVENT COUPLING SEPARATION AND FUEL LEAKAGE.

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:MOUNTING

TRUCKS FAIL TO MEET REQUIREMENT OF FMVSS NO. 301, FUEL SYSTEM INTEGRITY, IN A 30 MPH FRONT ANGULAR BARRIER TEST IMPACT BECAUSE OF THE OMISSION OF THE NOSE SHIELD ON MIDSHIP FUEL TANK. CONSEQUENCE OF DEFECT: IN CASE OF AN ACCIDENT, FUEL SPILLAGE IN THE TRUCKS WHICH DO NOT MEET THE FMVSS INCREASES THE RISK OF A FIRE.

Remedy: INSTALL NOSE SHIELD ON THE MIDSHIP FUEL TANK. FUEL TANK.

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:MOUNTING

TRUCKS FAIL TO MEET REQUIREMENT OF FMVSS NO. 301, FUEL SYSTEM INTEGRITY, IN A 30 MPH FRONT ANGULAR BARRIER TEST IMPACT BECAUSE OF THE OMISSION OF THE NOSE SHIELD ON MIDSHIP FUEL TANK. CONSEQUENCE OF DEFECT: IN CASE OF AN ACCIDENT, FUEL SPILLAGE IN THE TRUCKS WHICH DO NOT MEET THE FMVSS INCREASES THE RISK OF A FIRE.

Remedy: INSTALL NOSE SHIELD ON THE MIDSHIP FUEL TANK. FUEL TANK.

FUEL SYSTEM, GASOLINE:FUEL INJECTION SYSTEM:FUEL RAIL

METAL BURRS AND SHARP EDGES ON FUEL RAILS MAY HAVE DAMAGED ADJACENT O-RING SEALS DURING ASSEMBLY. THE DEFECT COULD CAUSE FUEL LEAKAGE WHEN ENGINE IS OPERATING.

Remedy: FUEL RAILS WILL BE INSPECTED FOR LEAKS, WETNESS OR SEEPAGE OF FUEL AND, IF NECESSARY, FUEL RAILS AND RELATED COMPONENTS WILL BE REPLACED WITHOUT COST TO THE OWNER.