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Dealer Letter
Owner Letter
Attachment I - Administrative Information
OASIS ACTIVATED? Yes. OASIS was activated by November 9, 2005
FSA VIN LIST ACTIVATED? Yes
Available through the website as of November 11, 2005. Owner names and addresses were made available November 28, 2005.
NOTE:
Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action.
STOCK VEHICLES
Correct all affected units in your new vehicle inventory before delivery.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs
^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
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
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.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ For Labor Operation 05S40C, claim grease as miscellaneous expense code "OTHER" - for the amount of $0.10 per vehicle.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES (REMINDER: Only one labor operation will be accepted for each VIN.)
*NOTE: Wiper Motor Gear Covers on Taurus/Escape/Escape Hybrid/Mariner/Mariner Hybrid/Ranger are sealed with RTV. These vehicles will require a replacement wiper motor cover if the cover was removed for inspection.
[New!]
[New!]
**PLEASE NOTE: if the wiper motor has failed and the wiper motor is NOT within the date codes, OR the wiper motor has failed and grease IS present, motor replacement is NOT covered under this program. In this situation, follow the guidelines in the Warranty and Policy Manual.
[NEW!] PARTS REQUIREMENTS / ORDERING INFORMATION
The DOR/COR for this program is 50361. This number identifies parts ordered for this recall through the Parts Support Center.
DEALER PRICE
For latest prices, refer to DOES II.
[NEW!] PARTS RETENTION AND RETURN
Affected Wiper Motors that were replaced are subject to random return to the Ford Warranty Parts Analysis Center (WPAC) for supplier analysis. Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. 2006 Ford Truck Escape 2WD L4-2.3L VIN H Hybrid Copyright © 2009, ALLDATA 9.90 Page 6
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000.
DEALER SORT/INSPECTION OF PARTS INVENTORY
Dealers must inspect all wiper motor inventories with part numbers shown below. Wiper motors with a package label date of 8/26/05 through 10/21/05 should be returned to Ford. Those with an earlier or later packaging date are okay for use. For those found within the suspect date range, file a DOES II defective parts claim and include the information shown below.
^ Shipper Number: FSA 05S40
^ Comments: Wiper Motor Return
^ Return Reason Code: CD
Attachment III - Technical Information
OVERVIEW
This program involves inspecting the wiper motor manufacture code, then it necessary, inspecting for the presence of grease under the gear cover. Based on your inspection,
^ the vehicle may be reassembled and released, or
^ the wiper motor assembly will be replaced, or
^ [NEW] grease will be applied to the metal worm and plastic ring gears.
INSPECTION
The manufacture code is laser etched onto the cylindrical wiper motor housing. The code consists of two (2) lines of numbers. One line shows the wiper motor assembly engineering part number. The other line shows the date and time of manufacture, the assembly line it was built on (N for north or S for south) then the voltage of the motor.
The wiper motor assemblies that require additional inspection for the presence of grease on the gears were built from 8-26-05 through 10-10-05 on the south assembly line. Any motor built before or after these dates, or built on the north assembly line, requires no additional inspection and the vehicle can be immediately released. See Figure 1.
In some instances, the laser etching will be difficult to read. For these instances, the wiper motor gear cover must be removed to inspect for the presence of grease on the gear assemblies. The amount of grease will vary from motor to motor. If ANY grease is present on the worm or ring gear teeth, that wiper motor assembly requires no further service and the vehicle can be reassembled.
In most cases, the etching can be viewed with minimal removal of parts. Generally, the left wiper arm and left cowl panel grille have to be removed to view the motor and manufacture code.
Refer to the appropriate disassembly procedure for the vehicle being inspected. Then after accessing the manufacture code, refer to Inspection Results in this Attachment III.
ESCAPE, MARINER, ESCAPE HYBRID, MARINER HYBRID
NOTE:
All Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles have wiper motor assemblies that were built on the south assembly line. Therefore, it is only necessary to inspect the manufacture date code.
1. Remove the left cowl panel grille plastic pin-type retainers from along the front of the panel.
2. Carefully lift the left cowl panel to enable viewing of the wiper motor assembly and note the manufacture DATE code on the motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
3. Proceed to Inspection Results in this Attachment III.
E-SERIES
1. Remove the left wiper arm by lifting the arm slightly and releasing the lock tab, then removing the arm off of the shaft.
2. Remove the left cowl grille panel retainer screws, then remove the panel.
3. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
4. Proceed to Inspection Results in this Attachment III.
EXPEDITION, NAVIGATOR
1. Park the wipers in the highest position on the glass.
2. Lift the wiper arm nut cover. Remove the retaining nut and lift the arm off of the shaft.
3. Position aside the cowl grille panel seal.
4. Remove the pin-type retainer from the far left end of the panel, then lift the panel, disconnect the washer hose and remove the panel from the vehicle.
5. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
6. Proceed to Inspection Results in this Attachment III.
EXPLORER, MOUNTAINEER
1. Remove both wiper arms by lifting the arms slightly and releasing the lock tabs, then remove the arms off of the shafts.
2. Remove the passenger side, then the driver side cowl grille panels.
3. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
4. Proceed to Inspection Results in this Attachment III.
F-150, MARK LT
1. Remove the wiper arms by releasing the lock tabs and lifting the arms off of the shafts.
2. Remove the cowl grille panel plastic pin-type retainers (one per panel located near the fenders).
3. CAUTION: To avoid breaking the retainer hooks on the cowl grille panel, do not pull on the rear of the panel.
A) Remove the left (driver side) cowl grille panel, then the right (passenger side) panel.
B) Release the FRONT EDGE of the panel as follows:
^ Starting at the center of the vehicle, depress the forward tab and press upward on the forward edge of the panel to release it from the cowl.
^ Continuing outward from the center of the vehicle, depress the remaining forward tabs and release the rest of the panel from the cowl.
C) Release the REAR EDGE of the panel as follows:
^ Starting at the left fender, press down on the rear edge of the panel to release the retaining hook, then lightly pull the front edge of the panel forward.
^ Continuing toward the center of the vehicle, release the remaining hooks by pressing the panel down while gently pulling the panel forward.
D) Disconnect the windshield washer hose and remove the cowl grille panel from the vehicle.
4. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
5. Proceed to Inspection Results in this Attachment III.
RANGER
1. Open the hood and locate the wiper motor.
2. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
3. Proceed to Inspection Results in this Attachment III.
TAURUS
1. Park the wipers in the highest position on the glass.
2. Remove the wiper arm nut covers.
3. Remove the nuts then pull the wiper arms up off of the shafts.
4. Remove the cowl grille panel clips.
5. Remove the passenger side cowl grille panel, then the driver side panel.
6. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
7. Proceed to Inspection Results in this Attachment III.
INSPECTION RESULTS
1. If the manufacture code cannot be read (even after removing the label), refer to Gear Cover Removal and Inspection in this Attachment III.
2. The wiper motor assembly does not require additional inspection if it was built:
a) anytime on the north assembly line, or
b) before 8-26-05 or after 10-10-05 on the south assembly line. Reassemble and release the vehicle.
3. The wiper motor assembly should be inspected further only if it was built:
a) from 8-26-05 through 10-10-05 on the south assembly line.
Refer to Gear Cover Removal and Inspection in this Attachment III.
GEAR COVER REMOVAL AND INSPECTION
1. CAUTION: Use extreme care when bending the locking tabs back to remove the gear cover from the wiper motor. The cover is constructed with a glass reinforced resin which makes the tabs less flexible. Bend the tabs only far enough to release them from the lugs. Bending the tabs an excessive amount could cause them to break.
Using a small pocket screwdriver placed under the lock tab, rotate the screwdriver to disengage the tab from the lug on the motor housing. Disengage all five (5) tabs in the order indicated in Figure 2.
2. CAUTION: On Taurus, Escape Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles, the gear cover perimeter is sealed with silicone. Pry up around the perimeter of the gear cover to break the sealant from the cover.
CAUTION:
The gear cover must be squarely lifted oft of the motor housing. Any rocking or sideways motion may bend the three (3) internal electrical connector clips.
Squarely lift the gear cover off of the motor housing. Discard the covers only on Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. Retain the cover for reinstallation on all other affected models. If in the rare event a tab breaks off on of these covers, are a placement cover, part number 2L2Z-17C476-A, must be ordered.*
[NEW]* Only order a new cover if grease is found and wiper motor assembly replacement is NOT required. (See Step 3)
[NEW] 3. NOTE: QFP Grease can no longer be ordered. Dealers are to use their supply of grease on wiper motors which require it. Once the supply of grease is exhausted, wiper motors are to be replaced when no grease is found during wiper motor inspection.
Inspect the worm and ring gears for presence of grease. Any amount of grease is acceptable as long as there is some grease present on the worm and ring gears. See Figure 3.
^ If grease is present, no further service is required. Refer to Gear Cover Installation for specific cover installation procedures.
^ If no grease is present, apply a bead of grease, part number QFP, approximately 2-3 mm (1/8 in) wide and 20 mm (3/4 in) long, to the worm and ring gear mating area, beginning where the worm gear exits the motor. See Figure 3. The first tube will be shipped to dealers free of charge. DO NOT USE ANY OTHER GREASE. Then, refer to Gear Cover Installation for detailed gear cover installation procedures.
^ Refer to Attachment V for OFP Grease MSDS.
^ If grease is unavailable, replace the wiper motor assembly following the procedures in Section 501-16 of the appropriate workshop manual.
GEAR COVER INSTALLATION
NOTE:
A new gear cover, part number 1F2Z-17D532-CA, must be installed on Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. On all others, reinstall the original cover unless the locking tabs have been broken, bent or otherwise damaged, in which case, a new cover, part number 2L2Z-17C476-A, must be installed.
1. Inspect the three (3) internal electrical connector clips. All three (3) clips MUST be aligned against the plastic terminal holder. If any of the clips are misaligned or touching the motor housing, they must be straightened and positioned as shown in the illustration. See Figure 4.
2. NOTE: This step applies only to Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. For all others, proceed to Step 3.
CAUTION:
Do not use solvents or compressed air to remove the sealant from the motor gear housing. Any solvent entering the gear cavity may damage the motor. Also, remove all large pieces of sealant that enter the gear housing cavity during cleaning. Small particles of sealant left in the cavity are acceptable.
NOTE:
It is not necessary to remove the existing sealant attached to the vertical surfaces inside the gear housing.
Remove the existing sealant from the top surface of the gear housing and around each of the five (5) mounting lug areas. To avoid damaging the motor, extra care must be taken when removing sealant from the area around the internal electrical connector clips. See Figure 5.
3. Verity that the three (3) electrical spade terminals are not bent. It necessary, straighten them so that they are perpendicular to the cover as illustrated in Figure 6.
4. Make sure that the foam gasket is properly seated in the new cover as shown in Figure 6.
5. NOTE: This step applies only to Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. For all others, proceed to Step 6.
Make sure that the white cam follower arm is positioned as shown in Figure 6.
6. IMPORTANT: Position the cover on the gear housing so that each plastic locking tab is outside of the gear housing cavity and is resting over the mounting lugs. Ensure that the electrical spade terminals are lined up with the connector clips. See Figure 7.
7. Using two (2) hands, push the gear cover downward onto the gear housing uniformly, to ensure that the electrical terminals remain in alignment. Push down firmly until all five (5) locking tabs are latched correctly. See Figure 8.
8. CAUTION: If any of the locking tabs cannot be correctly latched as shown in Figure 9, contact the Special Service Support Center for further instructions. DO NOT attempt to remove the cover and reinstall it.
9. Reassemble the vehicle following the disassembly procedures in reverse order. On Taurus and Expedition/Navigator vehicles, tighten the wiper arm attaching nuts to 40 Nm (30 lb-ft).
10. IMPORTANT: Check for proper wiper motor operation in all speeds, intermittent and wash, then release the vehicle.
Questions and Answers
Q1: Why are so many different vehicle lines affected?
A1: Our supplier produces different wiper motor assemblies for many vehicles. Several of these different assemblies were produced during the time period when the grease was not being dispensed as intended.
Q2: Do all of the affected vehicles have wiper motors without grease?
A2: No. Only a portion of the motors with date codes ranging from 8/26/05 to 10/10/05 may have been built without grease. All wiper motors with date codes outside of the affected range can be immediately released.
Q3: What do I do when I find a motor without grease?
A3: Apply only the 05S40 Wiper Motor Grease provided specifically for this recall. Do not use any other grease. In the unlikely case where you encounter a motor in a customer vehicle that you suspect has been damaged, call the Special Service Support Center at 1-800-325-5621 for instructions.
Q4: Why do some motors get replacement covers installed?
A4: When you encounter a motor built with the suspect date codes, it needs to be opened to see if grease is present. The covers on motors used on Taurus, Ranger, Escape, Escape Hybrid, Mariner and Mariner Hybrid are sealed with RTV sealant. Once these covers are removed for the grease inspection, the RTV sealant is destroyed and the cover must be replaced to obtain a proper seal. Covers on all other vehicles contain a reusable gasket instead of the RTV sealant so the cover can be reused.
Q5: How much grease needs to be on the worm gear and ring gear?
A5: Only a very small amount is needed. If you can feel grease, then enough is present.
Q6: Can I "over-grease"?
A6: No, but a large amount is unnecessary and wasteful. One 3-ounce tube should be sufficient to grease 30 to 35 motors built without grease. And, remember, many vehicles will not need grease at all. Motors built outside of the affected date codes, and those found to have grease after inspection will not need more grease. If applied as instructed, most dealers will only need one tube of grease to service their affected population.
Wiper Grease Material Safety Sheet
Dealer Letter
Owner Letter
Attachment I - Administrative Information
OASIS ACTIVATED? Yes. OASIS was activated by November 9, 2005
FSA VIN LIST ACTIVATED? Yes
Available through the website as of November 11, 2005. Owner names and addresses were made available November 28, 2005.
NOTE:
Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action.
STOCK VEHICLES
Correct all affected units in your new vehicle inventory before delivery.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs
^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
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
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.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ For Labor Operation 05S40C, claim grease as miscellaneous expense code "OTHER" - for the amount of $0.10 per vehicle.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES (REMINDER: Only one labor operation will be accepted for each VIN.)
| INSPECT WIPER MOTOR BUILD DATE CODE ONLY (WIPER MOTOR NOT AFFECTED) | Labor Operation | Labor Time |
| Lincoln Mark LT and F-150 | 05S40A | 0.3 Hours |
| Expedition, Navigator | 05S40A | 0.4 Hours |
| Explorer, Mountaineer | 05S40A | 0.3 Hours |
| Escape, Escape Hybrid, Mariner, and Mariner Hybrid | 05S40A | 0.3 Hours |
| Ranger | 05S40A | 0.2 Hours |
| E-Series | 05S40A | 0.3 Hours |
| Taurus | 05S40A | 0.3 Hours |
| INSPECT WIPER MOTOR BUILD DATE CODE, REMOVE COVER, CHECK FOR GREASE (GREASE PRESENT) | Labor Operation | Labor Time |
| Lincoln Mark LT and F-150 | 05S40B | 0.5 Hours |
| Expedition, Navigator | 05S40B | 0.6 Hours |
| Explorer, Mountaineer | 05S40B | 0.5 Hours |
| Escape*, Escape Hybrid*, Mariner*, and Mariner Hybrid* | 05S40B | 0.6 Hours |
| Ranger* | 05S40B | 0.5 Hours |
| E-Series | 05S40B | 0.6 Hours |
| Taurus* | 05S40B | 0.6 Hours |
| INSPECT WIPER MOTOR BUILD DATE CODE, REMOVE COVER, CHECK FOR GREASE, AND APPLY GREASE (IF AVAILABLE) | Labor Operation | Labor Time |
| Lincoln Mark LT and F-150 | 05S40C | 0.5 Hours |
| Expedition, Navigator | 05S40C | 0.6 Hours |
| Explorer, Mountaineer | 05S40C | 0.5 Hours |
| Escape*, Escape Hybrid*, Mariner*, and Mariner Hybrid* | 05S40C | 0.6 Hours |
| Ranger* | 05S40C | 0.5 Hours |
| E-Series | 05S40C | 0.6 Hours |
| Taurus* | 05S40C | 0.6 Hours |
[New!]
| INSPECT WIPER MOTOR BUILD DATE CODE, REMOVE COVER, CHECK FOR GREASE, NO GREASE IN MOTOR AND GREASE NOT AVAILABLE - REPLACE WIPER MOTOR | Labor Operation | Labor Time |
| Lincoln Mark LT and F-150 | 05S40D** | 0.6 Hours |
| Expedition, Navigator | 05S40D** | 0.8 Hours |
| Explorer, Mountaineer | 05S40D** | 0.6 Hours |
| Escape*, Escape Hybrid*, Mariner*, Mariner Hybrid | 05S40D** | 0.7 Hours |
| Ranger* | 05S40D** | 0.6 Hours |
| E-Series | 05S40D** | 0.6 Hours |
| Taurus* | 05S40D** | 0.7 Hours |
| REPLACE WIPER MOTOR THAT HAS FAILED DUE TO A LACK OF GREASE | Labor Operation | Labor Time |
| Lincoln Mark LT and F-150 | 05S40E** | 0.6 Hours |
| Expedition, Navigator | 05S40E** | 0.8 Hours |
| Explorer, Mountaineer | 05S40E** | 0.6 Hours |
| Escape*, Escape Hybrid*, Mariner*, Mariner Hybrid | 05S40E** | 0.7 Hours |
| Ranger* | 05S40E** | 0.6 Hours |
| E-Series | 05S40E** | 0.6 Hours |
| Taurus* | 05S40E** | 0.7 Hours |
[NEW!] PARTS REQUIREMENTS / ORDERING INFORMATION
| Part Number | Description | Quantity |
| Refer to catalog for Wiper Motor (Base number is 17508.) | Wiper Motor assembly | 1 |
| 1F2Z-17D532-CA | Wiper Motor Gear Cover (RTV style) - for Taurus, Ranger and Escape/Mariner/Hybrid. Note: These vehicles will require a replacement wiper motor gear cover if the cover was removed for inspection. | 1 |
| 2L2Z-17C476-A** | Wiper Motor Gear Cover (tab style) - for Explorer/Mountaineer, Expedition/Navigator, E-Series, Lincoln Mark LT and F-150. Note: This cover should only be replaced in the rare case a locking tab is broken or damaged during removal. **Available through normal order processing channels. | As Required |
DEALER PRICE
For latest prices, refer to DOES II.
[NEW!] PARTS RETENTION AND RETURN
Affected Wiper Motors that were replaced are subject to random return to the Ford Warranty Parts Analysis Center (WPAC) for supplier analysis. Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. 2006 Ford Truck Escape 2WD L4-2.3L VIN H Hybrid Copyright © 2009, ALLDATA 9.90 Page 6
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000.
DEALER SORT/INSPECTION OF PARTS INVENTORY
Dealers must inspect all wiper motor inventories with part numbers shown below. Wiper motors with a package label date of 8/26/05 through 10/21/05 should be returned to Ford. Those with an earlier or later packaging date are okay for use. For those found within the suspect date range, file a DOES II defective parts claim and include the information shown below.
^ Shipper Number: FSA 05S40
^ Comments: Wiper Motor Return
^ Return Reason Code: CD
| Service Number | Motorcraft |
| YL3Z-17508-AB | WM-558 |
| 2L1Z-17508-AB | WM-575 |
| 6F1Z-17508-A | WM-684 |
| 6L1Z-17508-AB | WM-629 |
| 6L3Z-17508-AA | WM-637 |
| 6L3Z-17508-AC | WM-639 |
| 6L8Z-17508-AA | WM-633 |
| 6R9Z-17508-AA | WM-665 |
| 6W1Z-17508-AA | WM-660 |
| 6W7Z-17508-BB | WM-658 |
| YL8Z-17508-AA | WM-557 |
| 5C2Z-17508-AA | WM-614 |
| 6F3Z-17508-AA | WM-648 |
| 6L2Z-17508-AA | WM-634 |
| 6L3Z-17508-AB | WM-638 |
| 6L5Z-17508-AA | WM-644 |
| 6R3Z-17508-AA | WM-649 |
| 6U7Z-17508-AA | WM-666 |
| 6W7Z-17508-AB | WM-657 |
OVERVIEW
This program involves inspecting the wiper motor manufacture code, then it necessary, inspecting for the presence of grease under the gear cover. Based on your inspection,
^ the vehicle may be reassembled and released, or
^ the wiper motor assembly will be replaced, or
^ [NEW] grease will be applied to the metal worm and plastic ring gears.
INSPECTION
The manufacture code is laser etched onto the cylindrical wiper motor housing. The code consists of two (2) lines of numbers. One line shows the wiper motor assembly engineering part number. The other line shows the date and time of manufacture, the assembly line it was built on (N for north or S for south) then the voltage of the motor.
The wiper motor assemblies that require additional inspection for the presence of grease on the gears were built from 8-26-05 through 10-10-05 on the south assembly line. Any motor built before or after these dates, or built on the north assembly line, requires no additional inspection and the vehicle can be immediately released. See Figure 1.
In some instances, the laser etching will be difficult to read. For these instances, the wiper motor gear cover must be removed to inspect for the presence of grease on the gear assemblies. The amount of grease will vary from motor to motor. If ANY grease is present on the worm or ring gear teeth, that wiper motor assembly requires no further service and the vehicle can be reassembled.
In most cases, the etching can be viewed with minimal removal of parts. Generally, the left wiper arm and left cowl panel grille have to be removed to view the motor and manufacture code.
Refer to the appropriate disassembly procedure for the vehicle being inspected. Then after accessing the manufacture code, refer to Inspection Results in this Attachment III.
ESCAPE, MARINER, ESCAPE HYBRID, MARINER HYBRID
NOTE:
All Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles have wiper motor assemblies that were built on the south assembly line. Therefore, it is only necessary to inspect the manufacture date code.
1. Remove the left cowl panel grille plastic pin-type retainers from along the front of the panel.
2. Carefully lift the left cowl panel to enable viewing of the wiper motor assembly and note the manufacture DATE code on the motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
3. Proceed to Inspection Results in this Attachment III.
E-SERIES
1. Remove the left wiper arm by lifting the arm slightly and releasing the lock tab, then removing the arm off of the shaft.
2. Remove the left cowl grille panel retainer screws, then remove the panel.
3. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
4. Proceed to Inspection Results in this Attachment III.
EXPEDITION, NAVIGATOR
1. Park the wipers in the highest position on the glass.
2. Lift the wiper arm nut cover. Remove the retaining nut and lift the arm off of the shaft.
3. Position aside the cowl grille panel seal.
4. Remove the pin-type retainer from the far left end of the panel, then lift the panel, disconnect the washer hose and remove the panel from the vehicle.
5. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
6. Proceed to Inspection Results in this Attachment III.
EXPLORER, MOUNTAINEER
1. Remove both wiper arms by lifting the arms slightly and releasing the lock tabs, then remove the arms off of the shafts.
2. Remove the passenger side, then the driver side cowl grille panels.
3. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
4. Proceed to Inspection Results in this Attachment III.
F-150, MARK LT
1. Remove the wiper arms by releasing the lock tabs and lifting the arms off of the shafts.
2. Remove the cowl grille panel plastic pin-type retainers (one per panel located near the fenders).
3. CAUTION: To avoid breaking the retainer hooks on the cowl grille panel, do not pull on the rear of the panel.
A) Remove the left (driver side) cowl grille panel, then the right (passenger side) panel.
B) Release the FRONT EDGE of the panel as follows:
^ Starting at the center of the vehicle, depress the forward tab and press upward on the forward edge of the panel to release it from the cowl.
^ Continuing outward from the center of the vehicle, depress the remaining forward tabs and release the rest of the panel from the cowl.
C) Release the REAR EDGE of the panel as follows:
^ Starting at the left fender, press down on the rear edge of the panel to release the retaining hook, then lightly pull the front edge of the panel forward.
^ Continuing toward the center of the vehicle, release the remaining hooks by pressing the panel down while gently pulling the panel forward.
D) Disconnect the windshield washer hose and remove the cowl grille panel from the vehicle.
4. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
5. Proceed to Inspection Results in this Attachment III.
RANGER
1. Open the hood and locate the wiper motor.
2. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
3. Proceed to Inspection Results in this Attachment III.
TAURUS
1. Park the wipers in the highest position on the glass.
2. Remove the wiper arm nut covers.
3. Remove the nuts then pull the wiper arms up off of the shafts.
4. Remove the cowl grille panel clips.
5. Remove the passenger side cowl grille panel, then the driver side panel.
6. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label.
7. Proceed to Inspection Results in this Attachment III.
INSPECTION RESULTS
1. If the manufacture code cannot be read (even after removing the label), refer to Gear Cover Removal and Inspection in this Attachment III.
2. The wiper motor assembly does not require additional inspection if it was built:
a) anytime on the north assembly line, or
b) before 8-26-05 or after 10-10-05 on the south assembly line. Reassemble and release the vehicle.
3. The wiper motor assembly should be inspected further only if it was built:
a) from 8-26-05 through 10-10-05 on the south assembly line.
Refer to Gear Cover Removal and Inspection in this Attachment III.
GEAR COVER REMOVAL AND INSPECTION
1. CAUTION: Use extreme care when bending the locking tabs back to remove the gear cover from the wiper motor. The cover is constructed with a glass reinforced resin which makes the tabs less flexible. Bend the tabs only far enough to release them from the lugs. Bending the tabs an excessive amount could cause them to break.
Using a small pocket screwdriver placed under the lock tab, rotate the screwdriver to disengage the tab from the lug on the motor housing. Disengage all five (5) tabs in the order indicated in Figure 2.
2. CAUTION: On Taurus, Escape Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles, the gear cover perimeter is sealed with silicone. Pry up around the perimeter of the gear cover to break the sealant from the cover.
CAUTION:
The gear cover must be squarely lifted oft of the motor housing. Any rocking or sideways motion may bend the three (3) internal electrical connector clips.
Squarely lift the gear cover off of the motor housing. Discard the covers only on Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. Retain the cover for reinstallation on all other affected models. If in the rare event a tab breaks off on of these covers, are a placement cover, part number 2L2Z-17C476-A, must be ordered.*
[NEW]* Only order a new cover if grease is found and wiper motor assembly replacement is NOT required. (See Step 3)
[NEW] 3. NOTE: QFP Grease can no longer be ordered. Dealers are to use their supply of grease on wiper motors which require it. Once the supply of grease is exhausted, wiper motors are to be replaced when no grease is found during wiper motor inspection.
Inspect the worm and ring gears for presence of grease. Any amount of grease is acceptable as long as there is some grease present on the worm and ring gears. See Figure 3.
^ If grease is present, no further service is required. Refer to Gear Cover Installation for specific cover installation procedures.
^ If no grease is present, apply a bead of grease, part number QFP, approximately 2-3 mm (1/8 in) wide and 20 mm (3/4 in) long, to the worm and ring gear mating area, beginning where the worm gear exits the motor. See Figure 3. The first tube will be shipped to dealers free of charge. DO NOT USE ANY OTHER GREASE. Then, refer to Gear Cover Installation for detailed gear cover installation procedures.
^ Refer to Attachment V for OFP Grease MSDS.
^ If grease is unavailable, replace the wiper motor assembly following the procedures in Section 501-16 of the appropriate workshop manual.
GEAR COVER INSTALLATION
NOTE:
A new gear cover, part number 1F2Z-17D532-CA, must be installed on Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. On all others, reinstall the original cover unless the locking tabs have been broken, bent or otherwise damaged, in which case, a new cover, part number 2L2Z-17C476-A, must be installed.
1. Inspect the three (3) internal electrical connector clips. All three (3) clips MUST be aligned against the plastic terminal holder. If any of the clips are misaligned or touching the motor housing, they must be straightened and positioned as shown in the illustration. See Figure 4.
2. NOTE: This step applies only to Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. For all others, proceed to Step 3.
CAUTION:
Do not use solvents or compressed air to remove the sealant from the motor gear housing. Any solvent entering the gear cavity may damage the motor. Also, remove all large pieces of sealant that enter the gear housing cavity during cleaning. Small particles of sealant left in the cavity are acceptable.
NOTE:
It is not necessary to remove the existing sealant attached to the vertical surfaces inside the gear housing.
Remove the existing sealant from the top surface of the gear housing and around each of the five (5) mounting lug areas. To avoid damaging the motor, extra care must be taken when removing sealant from the area around the internal electrical connector clips. See Figure 5.
3. Verity that the three (3) electrical spade terminals are not bent. It necessary, straighten them so that they are perpendicular to the cover as illustrated in Figure 6.
4. Make sure that the foam gasket is properly seated in the new cover as shown in Figure 6.
5. NOTE: This step applies only to Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. For all others, proceed to Step 6.
Make sure that the white cam follower arm is positioned as shown in Figure 6.
6. IMPORTANT: Position the cover on the gear housing so that each plastic locking tab is outside of the gear housing cavity and is resting over the mounting lugs. Ensure that the electrical spade terminals are lined up with the connector clips. See Figure 7.
7. Using two (2) hands, push the gear cover downward onto the gear housing uniformly, to ensure that the electrical terminals remain in alignment. Push down firmly until all five (5) locking tabs are latched correctly. See Figure 8.
8. CAUTION: If any of the locking tabs cannot be correctly latched as shown in Figure 9, contact the Special Service Support Center for further instructions. DO NOT attempt to remove the cover and reinstall it.
9. Reassemble the vehicle following the disassembly procedures in reverse order. On Taurus and Expedition/Navigator vehicles, tighten the wiper arm attaching nuts to 40 Nm (30 lb-ft).
10. IMPORTANT: Check for proper wiper motor operation in all speeds, intermittent and wash, then release the vehicle.
Questions and Answers
Q1: Why are so many different vehicle lines affected?
A1: Our supplier produces different wiper motor assemblies for many vehicles. Several of these different assemblies were produced during the time period when the grease was not being dispensed as intended.
Q2: Do all of the affected vehicles have wiper motors without grease?
A2: No. Only a portion of the motors with date codes ranging from 8/26/05 to 10/10/05 may have been built without grease. All wiper motors with date codes outside of the affected range can be immediately released.
Q3: What do I do when I find a motor without grease?
A3: Apply only the 05S40 Wiper Motor Grease provided specifically for this recall. Do not use any other grease. In the unlikely case where you encounter a motor in a customer vehicle that you suspect has been damaged, call the Special Service Support Center at 1-800-325-5621 for instructions.
Q4: Why do some motors get replacement covers installed?
A4: When you encounter a motor built with the suspect date codes, it needs to be opened to see if grease is present. The covers on motors used on Taurus, Ranger, Escape, Escape Hybrid, Mariner and Mariner Hybrid are sealed with RTV sealant. Once these covers are removed for the grease inspection, the RTV sealant is destroyed and the cover must be replaced to obtain a proper seal. Covers on all other vehicles contain a reusable gasket instead of the RTV sealant so the cover can be reused.
Q5: How much grease needs to be on the worm gear and ring gear?
A5: Only a very small amount is needed. If you can feel grease, then enough is present.
Q6: Can I "over-grease"?
A6: No, but a large amount is unnecessary and wasteful. One 3-ounce tube should be sufficient to grease 30 to 35 motors built without grease. And, remember, many vehicles will not need grease at all. Motors built outside of the affected date codes, and those found to have grease after inspection will not need more grease. If applied as instructed, most dealers will only need one tube of grease to service their affected population.
Wiper Grease Material Safety Sheet
