Emissions Recall 04E08 - Powertrain Control Module Replacement (04E08)

SUBJECT

STOP SALE/DELIVERY HOLD:  Emissions Recall 04E08:

Certain In-Stock 2004 Model Year Expedition and Navigator Vehicles Equipped with 4.6L or 5.4L Engines and Non-California Emissions, Delivered to Dealers in New York and Vermont

Powertrain Control Module Replacement

REF

• Advance Notification Bulletin - Emission Recall 04E08 dated February 13, 2004
• Emission Certification - Related Sales Restrictions - 2004 Passenger Car and Truck Letter Dated April 10, 2003

AFFECTED VEHICLES

Certain in-stock 2004 model year Expedition and Navigator vehicles equipped with 4.6L or 5.4L engines, built at the Michigan Truck Assembly Plant from Job # 1 through January 22, 2004. The affected vehicles were produced with non-California emissions certification and delivered to dealers in New York and Vermont. Affected vehicles are identified in OASIS.

In addition, visit https://web.fsavinlists.dealerconnection.com  for a list of vehicles assigned to your dealership.

REASON FOR THIS STOP SALE/DELIVERY HOLD/EMISSIONS RECALL

Vehicles intended for sale and registration in the states of New York, Vermont, California, Maine, or Massachusetts require California emissions. Some dealers in New York and Vermont incorrectly ordered the affected vehicles (approximately 237 in dealer stock) without making an entry in column 42 of the Vehicle Order. If column 42 on the Vehicle Order was left blank, the affected vehicles were calibrated with non-California emissions.

SERVICE ACTION

Dealers are required to clarify their original ordering intention for all of their affected in-stock vehicles by utilizing the appropriate repair information contained in Attachment II. Vehicles intended for sale and registration in New York, Vermont, California, Maine, or Massachusetts require the replacement of the Powertrain Control Module (PCM), the VECI Label, Monroney Window Label, and Vehicle Content Label.

PLEASE NOTE:  Sale of uncorrected vehicles for registration in New York, Vermont, California, Maine, or Massachusetts could result in the imposition of civil penalties. Please reference the Emissions Certification Related Sales Restrictions for 2004 Passenger Car and Truck for further information, which is posted with this bulletin.

ATTACHMENTS

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

QUESTIONS?

1. Claims Information: ............................................................ 1-800-423-8851
2. Special Service Support Center (Dealer Only) Questions: .......... 1-800-325-5621

OASIS ACTIVATED?

Yes

FSA VIN LIST ACTIVATED?

Yes

Available through FMCDealer.com or at https://web.fsavinlists.dealerconnection.com  .

IN-STOCK VEHICLES

Correct all affected in-stock vehicles before delivery, if the vehicle will be registered in New York, Vermont, California, Maine, or Massachusetts.

RELATED DAMAGE

Related damage claims are not approved for this program.

ADDITIONAL LABOR TIME

This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement.

OWNER REFUNDS

Refunds are not authorized for this program.

RENTAL VEHICLES

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

CLAIMS PREPARATION AND SUBMISSION

• Enter claims using Direct Warranty Entry (DWE).
• Refer to ACESII manual for claims preparation and submission information.

LABOR ALLOWANCES

* Dealers must determine and designate their sales intentions for each of their affected in-stock vehicles by selecting one of the labor operations above. 

PARTS REQUIREMENTS / ORDERING INFORMATION

Dealers must determine the ordering intentions for all of their affected in-stock vehicles. For those vehicles that are intended for sale and registration in New York, Vermont, California, Maine, or Massachusetts, contact the Special Service Support Center at 1-800-325-5621 to order parts, labels, and documents. When calling this number, identify Emissions Recall 04E08, have the VIN of the dealer in-stock vehicle to be serviced, the VECI label 3-character suffix, PCM catchword and PCM part number (refer to Attachment III, steps 1 thru 4). The Special Service Support Center will place an order for your PCM requirements and ship a package containing the necessary labels and documents to your dealership.

For vehicles intended to be sold and registered outside of New York, Vermont, California, Maine, or Massachusetts, no service action is required.

POWERTRAIN CONTROL MODULES

OVERVIEW

The affected vehicles were built with non-California emissions certification. This service must be performed if the vehicle will be sold and registered in New York, Vermont, California, Maine or Massachusetts. This program involves replacing the PCM, the VECI label, vehicle description (Monroney) label and the content label. After the PCM is replaced, the PCM must be programmed with certain vehicle information.

SERVICE PROCEDURE

1. Open the hood.
2. NOTE: The tear tag is located on the dash panel near the PCM and is approximately 1 inch wide and 1/2 inch high.

   Locate tear tag and record the 4-character catchword. See Figure 1.

3. NOTE: The VECI label is located on the radiator sight shield.

   Record the VECI label 3-character suffix.

4. Refer to the following chart. Locate the recorded catchword and VECI label suffix in the "ORIGINAL EQUIPMENT" rows. The "REPLACEMENT" rows provide the new  part information. To order replacement parts and documents, call the Special Service Support Center at 1-800-325-5621.
   NOTE: Along with the replacement PCM, a new  VECI label, Vehicle Description (Monroney) label, Content Label and invoice will be supplied. BE SURE TO PROVIDE THE INVOICE TO THE NEW CAR SALES MANAGER  .
   EQUIPMENT INFORMATION
   
   

   EXPEDITION	PCM	CATCHWORD	VECI LABEL
   Original Equipment	-	JFP0	4W7E-9C485-LUX
   Replacement	4L1Z-12A650-KA	KAM0	4W7E-9C485-LDP
   Original Equipment	-	NBS0	4W7E-9C485-LUX
   Replacement	4L1Z-12A650-MA	MPX0	4W7E-9C485-LDP
   Original Equipment	-	SEV0	4W7E-9C485-LUX
   Replacement	4L1Z-12A650-TA	TDK0	4W7E-9C485-LDP
   Original Equipment	-	RPM1	4W7E-9C485-LTP
   Replacement	4L1Z-12A650-PB	PGT1	4W7E-9C485-LKF

   EQUIPMENT INFORMATION
   
   

   NAVIGATOR	PCM	CATCHWORD	VECI LABEL
   Original Equipment	-	END0	4W7E-9C485-LTP
   Replacement	4L7Z-12A650-DA	DJN0	4W7E-9C485-LKF

5. Remove the original tear tag and replace it with the one supplied with the PCM.
6. Record the radio stations and disconnect the battery ground cable.
7. Disconnect the PCM connectors.
8. Remove the PCM retaining bolts and remove the PCM from the vehicle.
9. Install the new  PCM and tighten the retaining bolts to 7 Nm (62 lb-in).
10. Connect the PCM connectors.
11. Connect the battery ground cable.
12. Remove the original VECI label from the radiator sight shield. Clean the surface, then install the new  VECI label in its place.
13. Using WDS and the proper PCM part number and/or catchword information provided in the previous chart, program the PCM to the new  California emissions standards.
14. Reset the recorded radio stations.
15. Replace the vehicle description (Monroney) label and the content label (located on the door window glass) with the labels supplied. The Authorized Modifications label is not required.

Purpose

This section is designed to provide dealers with updated information on sales restrictions relating to various federal and state emissions-related requirements.

Differences in emissions-related regulations between various areas often prevent compliance with all requirements with a single version of a vehicle. The principal geographic compliance categories covered by this section are shown below:

• Federal 
• California Emissions States  (See table below)
• Cross-Border States  (See table below)

What's Changed from 2003 Model Year?

Beginning with 2004 model year, New York (NY) and Vermont (VT) have adopted California emission standards for vehicles ≥6,000-Lbs. GVWR and ≤14,000-Lbs. GVWR. As a result, as shown in the chart above, compliance categories have been simplified into two, versus three, last year.

Dealer Responsibilities

Dealers are responsible for the screening of customers and vehicle specifications to ensure that customers receive properly certified vehicles, as detailed below. While the distribution edit system contains a variety of controls to prevent several types of ordering errors that could create a sale that does not comply with applicable emissions regulations, many unique circumstances cannot be centrally anticipated or controlled. Drop ship situations, vehicle diversions, customer's area of principal use and eligibility for certain exemptions are examples of situations that require careful dealers attention to regulatory requirements.

Penalties

A vehicle sale that does not comply with one of the geographic or customer-related restrictions can result in the imposition of civil penalties of up to $31,500 per unit. Because the Company must rely on the dealer's representation as to the intended principal use of any unit in many cases, the Company may have no choice but to seek legal recourse against the dealer if action is taken against the Company as the result of a sale that is not in compliance with regulations. We are confident that dealers will avoid any such occurrence by continuing to provide the same level of management attention and care to these requirements as they have to similar requirements in the past.

Federal Requirements

Aside from the allowance for states contiguous to California Emission States to sell California vehicles, detailed later in this section, there are no unusual emissions compliance concerns for U.S. dealers outside of the California Emission States. Vehicles for sale and registration in areas outside of California Emission States (or border states, where applicable) will be labeled with federal certification statements.

Dealers selling vehicles to customers for registration in California Emission States must order the appropriate California vehicles (see table on page 1 for state and vehicle applicability).

California State Requirements

Aside from exemptions noted later in this section, all vehicles destined for registration in California (including those >14,000-Lbs. GVWR) and all vehicles less than or equal to 14,000-Lbs GVWR destined for sale in Maine, Massachusetts, New York and Vermont must conform to all applicable California regulations  , including emissions standards and emissions warranties. California-certified vehicles approved for sale in California/Maine/Massachusetts/New York/Vermont will be labeled with a California certification statement as shown on the underhood Vehicle Emissions Control Information (VECI) or Important Vehicles Information (IVI) Decal. Vehicles certified for "50-State Emissions" meet the California Certification requirement (see section below)

• A California Emission State dealer may sell federal vehicle (either from stock or on a drop ship basis) to customers for registration in non-California Emission State areas and those vehicles must comply with federal regulations covered herein.
• New California Emission State-only vehicles may not be sold by dealers outside California Emission States and their cross-border states unless the purchaser intends to title or register the vehicle in a California Emission State.
• While EPA technically allows California Emission states and their border states to sell California-certified vehicles (at the appropriate weight class, see the table on page 1) for registration to any other state in the country, this is discouraged both by EPA and by Ford Motor Company, in part because of potential individual state registration issues. Based on state-specific policies, California-certified products may not be permissible for registration in some non-California Emission, non-border states.

50-State Emissions

Certain vehicle configurations may be emissions-certified for all 50 states. These "50-State Emissions" vehicles may be sold and registered in any of the 50 states. For example, "50-State Emissions" is standard on many E-Series powertrain configurations. Consult your order guides for details.

Emergency and Public Service Vehicle Exception to California Emission Requirements

The State of California exempts certain Emergency and Public Service vehicles from California Emission requirements. This exemption also applies for Maine, Massachusetts, New York and Vermont. Cross-border state dealers may also order public service emergency vehicles without California emissions. This permits the availability of passenger cars and trucks certified as meeting the federal emissions standards (but not California's) for sale in California, Maine, Massachusetts, New York and Vermont to authorized governmental units and privately owned ambulance companies. Federal, state and local government activities and privately owned ambulance operations covered by this exemption are shown in Exhibit II.

Vehicles may be ordered for eligible customers/applications (as identified in Exhibit II) using normal ordering procedures by entering the option codes shown below:

Note that both option codes are required for vehicles ordered under this procedure - code 423 used alone is intended for vehicles to be delivered outside of California Emission States. Codes should be placed in the Additions  section of the vehicle order form.

Dealers are responsible for screening of purchasers to ensure compliance with eligibility guidelines, and should consult with local counsel, should eligibility questions arise. It is recommended that when this procedure is used to order vehicles without the California Emissions system but intended for principal use in California Emission States, you obtain a written statement of eligibility and intended use from the purchaser.

California Assembly Bill 965 (Young Bill)

The Young Bill permits manufacturers to sell a limited number of federal-certified passenger cars and light trucks (under 6,000-Lbs. GVWR) that would not otherwise be available for sale in California/Maine/Massachusetts/New York/Vermont, based on a complex emissions averaging formula.

This provision permits only those federal models specifically included in a plan submitted by the company and approved by the Air Resources Board  to be sold in California/Maine/Massachusetts/New York/Vermont.

Vehicles made available by the Company for sale in California/Maine/Massachusetts/New York/Vermont under the provisions of the Young Bill may be ordered in the same manner as other California/Maine/Massachusetts/New York/Vermont vehicles - no special handling is required.

Sale of non-eligible federal vehicles for registration in California/Maine/Massachusetts/New York/Vermont may result is state civil penalties of up to $31,500 per vehicle.

"New" Motor Vehicles

Federal vehicles are considered "new" and subject to the above restrictions until the title passes for the first time to an "ultimate purchaser" (e.g., retail or fleet customer). This means that vehicles and trucks purchased by dealers from Ford Motor Company as used employee lease vehicles, sales vehicles, pool vehicles, etc. are  treated as new motor vehicles, even through they may have accumulated several thousand miles while in Company service before being sold.

A California Emission States-only vehicle formerly used as a Ford Motor Company pool vehicle, for example, could be purchased by a California Emission or contiguous state dealer for resale in that state. The same vehicle could not be purchased by a dealer outside California Emission or the contiguous states for resale unless the purchaser intends to title or register the vehicle in California Emission States or the primary use of the vehicle will take place in California Emissions States.

California/Maine/Massachusetts/New York/Vermont consider every vehicle with 7,500 miles or less on the odometer a "new" vehicle. This means that any federal vehicle including one owned and driven by a retail customer that has not been certified for California sale, cannot be sold to a customer who plans to register it in California/Maine/Massachusetts/New York/Vermont if it has 7,500 miles or less on the odometer. Further, New York regulations require that both new and used 1993 and later model year vehicles be California-certified, regardless of mileage.

Exception

A California/Maine/Massachusetts/New York/Vermont resident traveling outside their state of residence may legally purchase and register a new (7,500 miles or less on the odometer) non-California-certified vehicle under the following circumstances:

• If the new vehicle replaces a vehicle which was damaged or became inoperative beyond reasonable repair while outside the state of residence or
• If it replaces a vehicle that was stolen while outside the state of residence.

The California Department of Motor Vehicles requires proof of loss through a police report or repair invoice in order to qualify the resident for exemption under the state code. Maine/Massachusetts/New York/Vermont may require similar proof of loss in order to qualify for exemption. Consumers should contact the DMV in their state of residence to determine exemption of requirements.