Extended Coverage Program 06N06 - Extended Coverage For Forward Clutch Cylinder (06N06)

SUBJECT

Extended Coverage Program 06N06 - Supplement #4 

Certain 2005 and 2006 Crown Victoria Long Wheelbase Vehicles

Extended Coverage for Forward Clutch Cylinder

REF

Extended Coverage Program 06N06 Supplement #3 dated October 20, 2006

Extended Coverage Program 06N06 Supplement #2 dated June 23, 2006

Extended Coverage Program 06N06 Supplement #1 dated April 18, 2006

Extended Coverage Program 06N06 dated February 22, 2006

REASON FOR THIS SUPPLEMENT

A new remanufactured transmission is being introduced for the 2006 MY vehicles.

PROGRAM TERMS

This program extends the coverage of the forward clutch cylinder to 3 years of service or 150,000 miles from the warranty start date of the vehicle, whichever occurs first. This is a one-time replacement program. Coverage is automatically transferred to subsequent owners.

VEHICLES COVERED BY THIS PROGRAM

Certain 2005 and 2006 Crown Victoria long wheelbase vehicles built at the St. Thomas Assembly Plant from Job #1, 2005 through February 26, 2006. Affected vehicles are identified in OASIS.

REASON FOR PROVIDING ADDITIONAL COVERAGE

In some of the affected vehicles, the forward clutch cylinder in the transmission may crack at the snap ring groove location causing a loss of clutch capacity and the eventual loss of forward gears. This concern is caused by excessive 4-3 downshifts that may occur during certain city taxi driving conditions. To resolve this concern, the calibration was updated in vehicles repaired under Field Service Action 06B36 . The extra coverage provided by Extended Coverage Program 06N06 covers any forward clutch cylinder fracture that may occur as a result of vehicle operation with the old calibration.

SERVICE ACTION

If an affected vehicle experiences slipping in or loss of forward gears, follow the inspection instructions in Attachment III of this bulletin to determine if the forward clutch cylinder is cracked. If the inspection process determines that there is a forward clutch fracture, replace the transmission with a replacement unit as described in Attachment III. This service will be performed on affected vehicles at no charge to the vehicle owner, within the program time/mileage limits.

ATTACHMENTS

1. Attachment I: Administrative Information
2. Attachment II: Labor Allowances and Parts Ordering Information
3. Attachment III: Technical Information
4. Customer Notification Letter

QUESTIONS?

Special Service Support Center (Dealer Only) Questions: ... 1-800-325-5621

OASIS ACTIVATED?

Yes. OASIS was activated April 18, 2006.

FSA VIN LIST ACTIVATED?

No.

STOCK VEHICLES

Do not perform this program unless the affected vehicle exhibits the covered condition (fix only if broken).

SOLD VEHICLES

Only owners with affected vehicles that exhibit the covered condition will be directed to dealers for repairs.

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this Field Service Action.

RELATED DAMAGE

Related damage claims are not approved for this program.

ADDITIONAL LABOR TIME

• If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted.
• If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center.

OWNER REFUNDS

• The refund period for non-emergency repairs expired on May 22, 2006.
• Ford Motor Company will only refund emergency owner-paid repairs covered by this program. Refund claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement.
• Refund Claiming Information. (Submit on separate repair line.)
  1. - Program Code: 06N06
  2. - Misc. Expense: REFUND
  3. - Misc. Expense: ADMIN
  4. - Misc. Expense: 0.2 Hrs.

RENTAL VEHICLES

The use of rental vehicles is not authorized for this program.

CLAIMS PREPARATION AND SUBMISSION

• Enter claims using Direct Warranty Entry (DWE).
• Refunds for emergency owner-paid repairs must be claimed on a repair line that is separate from the repair line on which the FSA is claimed.
• "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires approval from Special Service Support Center.
• Refer to ACESII manual for claims preparation and submission information.

HANDLING ALLOWANCE

An allowance of $280.00 per repair is being provided in lieu of part mark-up for transmission assemblies. To claim the allowance, enter $280.00 as "HANDLG" in the "MISC EXPENSE" area of the claim form.

LABOR ALLOWANCES

PARTS REQUIREMENTS / ORDERING INFORMATION

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

*Labels come in packages of 25 and are provided to dealers at no charge.

DEALER PRICE

For latest prices, refer to DOES II.

HANDLING ALLOWANCE

An allowance of $280.00 per repair is being provided in lieu of part mark-up for transmission assemblies. To claim the allowance, enter $280.00 as "HANDLG" in the "MISC EXPENSE" area of the claim form.

PARTS RETENTION AND RETURN

Affected transmissions are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions.

Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures."

OVERVIEW

This program involves vehicles which exhibit a slipping or loss of forward gear condition caused by a fractured forward clutch cylinder. Repair services include performing specified diagnostics, and if necessary, replacing the transmission with a replacement unit. Transmission disassembly and overhaul are not covered under this program.

Other service procedures that must be performed when replacing the transmission include replacement of the oil-to-air (OTA) cooler and flushing the transmission cooler lines. Please note that the 2005 Workshop Repair Manual refers to the OTA cooler as the Auxiliary Transmission Fluid Cooler, and that in the 2006 models, the OTA cooler is integral to the A/C condenser. On 2006 vehicles, the condenser must be replaced.

A Repair Flow Chart has been provided to make sure the repairs are performed in the proper order. Diagnostics are provided in this attachment III. Refer to the Crown Victoria Workshop Repair Manual found on the PTS website for removal and installation procedures.

REPAIR FLOW CHART

Fig 1: Repair Flow Chart

Fig 2: Repair Flow Chart (Continued)

PCM RECALIBRATION

1. Verify that the scan tool (WDS, VCM or equivalent scan tool) is updated to software version:
   • B41.8, B41.9, B42.1 or higher for 2005 vehicles.
   • B41.9, B42.1 or higher for 2006 vehicles.
   NOTE: The new calibration for these vehicles is not included in the B42 update CD. When you load the B42 CD, please download any available updates as well.
2. Recalibrate the PCM to the latest level using one of the following methods:
   1. Worldwide Diagnostic System (WDS),
   2. Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or
   3. equivalent scan tool.
      • If the calibration process was successful, proceed to Authorized Modification Label Installation instructions in this Attachment III.
      • If unable to calibrate the PCM:
        1. - module replacement will not be covered under this program, and
        2. - prior to disconnecting the scan tool and closing the session, call the Special Service Support Center at 1-800-325-5621 for further instructions.

AUTHORIZED MODIFICATIONS LABEL INSTALLATION

1. Obtain and prepare the Authorized Modifications Label. Describe the modification performed, and enter your P & A Code, date of repair and the program type and program number. See Fig 3.

Fig 3: Authorized Modifications Label

TRANSMISSION TESTING

NOTE 1:  Check forward clutch pressure.

1. Attach a 0-2068 kPa (0-300 psi) pressure gauge to the forward clutch pressure tap. See Fig 4.
2. Apply the brakes firmly.
3. Start the engine and move the transmission selector lever to any forward gear position.
4. Note the pressure reading on the gauge.
5. Remove the gauge and reinstall the plug. Tighten to 12 Nm (9 lb-ft).

Fig 4: Forward Clutch Pressure Tap Location

NOTE 2:  Perform stall speed test.

1. Firmly apply the brakes.
2. NOTE:  Do not use the instrument panel tachometer for this test. Connect a scan tool to monitor rpm pid.
3. NOTE:  If the rpm recorded by the scan tool exceeds the maximum limit of 2,424 rpm, release the accelerator pedal immediately because clutch or band slippage is indicated.

   With the transmission selector lever in any forward gear position, press the accelerator pedal to the floor and hold it just long enough to let the engine get to wide open throttle (WOT). While carrying out this test, do not hold the throttle open for more than five (5) seconds at a time.

4. Note the results. Engine maximum limit for the affected vehicles is 2,424 rpm.
5. After running the engine at WOT for this test, move the transmission selector lever to NEUTRAL and run the engine at 1,000 rpm for about 15 seconds to cool the torque converter.