To: All Ford and Lincoln - Mercury Dealers

SAFETY RECALL
98S36 / Certain 1986 - 1995 Taurus and Sable and 1988 - 1994 Continental Vehicles - Sub-Frame Rear Plate Nut Replacement

December, 1998

To:
All Ford and Lincoln - Mercury Dealers

Subject:
Safety Recall 98S36 - Certain 1986 - 1995 Taurus and Sable and 1988 - 1994 Continental Vehicles - Sub-Frame Rear Plate Nut Replacement

AFFECTED VEHICLES

Certain 1986-1995 Taurus and Sable and 1988-1994 Continental vehicles that were originally sold or are currently registered in the following U.S. states and Canadian Provinces:

U.S. States:
Connecticut / Delaware / District of Columbia / Illinois / Indiana
Iowa / Kansas / Kentucky / Maine / Maryland
Massachusetts / Michigan / Minnesota / Missouri / Nebraska
New Hampshire / New Jersey / New York / Ohio / Pennsylvania
Rhode Island / Vermont / Virginia / West Virginia / Wisconsin
Canadian Provinces:
Manitoba / New Brunswick / Newfoundland / Nova Scotia
Ontario / Prince Edward Island / Quebec

REASONS FOR RECALL

The body mounts on the rear corners of the sub-frame that support the engine and transmission may separate. This can occur if the lower retainer plate of the mount or the retaining plate nut becomes severely corroded from long term exposure to road salts and retention of moisture in the mounts. This corrosion can weaken the retainer plate of the mount or the retaining plate nut severely enough to allow the bolt head to pull through the washer or out of the nut. Should both rear mounts separate, the rear of the sub-frame will drop and steering may suddenly become difficult. This could result in an accident.

SERVICE ACTION

To correct this condition, dealers will replace the attaching bolts, plate nuts and the reinforcement plates on the bottom of the sub-frame rear body mounts, on all affected vehicles.

SERVICE TRACKING

To monitor the effectiveness of regional programs, it is important that:

any vehicle with the same concern or operated in the same conditions as the affected vehicles be identified and
any affected vehicle listed in OASIS, presented for service to a dealer outside the geographic area covered by the Safety Program, be serviced under the terms of the program.

If a vehicle, not listed in OASIS, with the same concern or operated in the same conditions as affected vehicles listed in OASIS is presented for service, it is important that dealers obtain as much information about the vehicle as possible. Dealers are to call 1-800-325-5621 and provide Ford Motor Company with a description of the concern, VIN, model year and mileage. In appropriate situations, where the customer is willing to cooperate with the dealer in providing the required information and has agreed to provide the affected parts for possible inspection by the Company, the dealer will receive approval and will be reimbursed for performing the repair upon submission of the claim.

If an affected vehicle is presented to a dealer outside the geographic area covered by the program and if the vehicle is listed in OASIS, the dealer should perform the repair and submit the claim for reimbursement as prescribed in the program bulletin.

REPAIR APPROVAL/CLAIMS

In order to claim repairs on vehicles not included in the Notification Program, the dealer must call 1-800-325-5621, provide the information described above and obtain approval. Then, submit the claim under the Notification Program according to the directions on page 3-63 of the ACES II manual. Include the following information if the vehicle in question has the same concern or operated in the same conditions as those described in the Notification Program:

a description of the concern on the customer's vehicle
the VIN, model year and mileage of the vehicle
customer agreement to provide the affected parts for possible inspection by the Company,

QUESTIONS?

Claims Information 1-800-423-8851
Other Recall Questions 1-800-325-5621

Attachments

Attachment I
Administrative Information
Attachment II
Labor Allowances
Parts Requirements
Attachment III
Technical Information

ATTACHMENT I
Safety Recall 98S36

Certain 1986 - 1995 Taurus and Sable and 1988 - 1994 Continental Vehicles
Sub-Frame Rear Plate Nut Replacement

OASIS

You must use OASIS to determine if a vehicle is eligible for this recall. OASIS will be activated in phases beginning December 23, 1998 and will be completed by close of business on December 24, 1998.

If an owner whose vehicle is not listed in OASIS believes his/her vehicle should have been included, or this condition is observed in a vehicle not covered by this action, dealers are to call 1-800-325-5621 to obtain approval in order to obtain reimbursement. (See Dealer Letter for more details.)

PLEASE NOTE

Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle.

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 the owner a copy of the Owner Letter and schedule a service date.

REGIONAL CONTACT

Advise regional office if an owner:

cannot be contacted.
does not make a service date.

CLAIMS SUBMISSION

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

REFUNDS

See Section 3 of the ACESII Manual.

ATTACHMENT II
Safety Recall 98S36

Certain 1986-1995 Taurus and Sable and 1988-1994 Continental Vehicles
Sub-Frame Rear Plate Nut Replacement

LABOR ALLOWANCES

Operation Description / Labor Allowances / Labor Operation
- Install Sub-Frame Reinforcement Kit (No inspection necessary) / 0.6 Hours / 98S36B
- Miscellaneous Expense Code / 0.1 Hours / "ADMIN"

PARTS REQUIREMENTS

Parts Ordering Information

Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channel as noted below:

Stock Orders / Effective Immediately / Normal Order Process
Interim Orders / Effective Immediately / Normal Order Process
Emergency Orders / 31 Days After Launch / Normal Order Process
Emergency Orders / First 30 Days After Launch / Call 1-800-325-5621
Part Number / Description / Quantity
XF1Z-5A364-AA / Sub-Frame Reinforcement Kit / 1

TOOL ALLOWANCE

Part Number / Description / Dealer Price
OSP / Allowance for unusual Hole Saw Wear/Fatigue (Per Vehicle) / $1.00

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.

ATTACHMENT III
Safety Recall 98S36

SUB-FRAME REAR PLATE NUT REPLACEMENT

AFFECTED VEHICLES: CONTINENTAL, TAURUS AND SABLE

SERVICE PROCEDURES

The following Service Procedure will replace both sub-frame rear retaining bolts, plate nuts and add or replace reinforcement plates under the mounts.

Remove the front floor mat.
Remove the push pin under the accelerator pedal which retains the carpet, if so equipped.
Pull back the front carpet to expose the front dash absorber.
On Continental models, proceed to Step 5. On Taurus/Sable models, proceed as follows:
Remove the push pin which holds the cowl side absorber in place.
Pull back dash absorber to expose the floor plan.
Locate the cowl side absorber push pin stud in the floor pan. Refer to Figure 1.
From the push pin stud, measure directly over 2 inches. Place a temporary mark at this location. Refer to Figure 1.
From the temporary mark, measure directly down 1 inch. See Figure 1. Center punch this new location.

Figure 1

Using a 2 1/2-inch hole saw, cut a hole in the floor pan at the center punched location. Do this same operation on the passenger side floor pan.
Proceed to Step 6.

On Taurus/Sable models, go back to Step 4. On Continental models, proceed as follows:
NOTE:
Cut out front dash absorber in one piece. The cut out section will be reinstalled during assembly.
Cut out front dash absorber in location and size shown in Figure 2. This will expose a circular stamped recess in the upper floor.
Measure 1 1/4 inches directly down from the lowest point of the circular stamped recess in the upper floor. See Figure 2. Center punch this new location.

Figure 2

NOTE: Continentals have a double layer of sheet metal in the floor pan at this location. Using a 2 1/2-inch hole saw, cut a hole in the floor pan at the center punched location. Do this same operation on the passenger side floor pan. Refer to Figure 2.
Proceed to Step 6.

Look through the 2 1/2-inch hole. The sub-frame rear retaining bolt and plate nut should be easy to see. See Figure 3.

Figure 3

Spray rust penetrating lubricant on the sub-frame rear retaining bolt and plate nut. Do this on both sides.

CAUTION
Front arms of hoist must be positioned as shown in illustration or possible vehicle damage could occur.

Raise and support the vehicle. Position the front arms of hoist on the sub-frame as shown in Figure 4.

Figure 4

Remove both of the sub-frame rear retaining bolts. Refer to Figure 4.

CAUTION
Do not completely lower the vehicle as the sub-frame is being supported by the front arms of the hoist.

Partially lower the vehicle. Keep the weight of the vehicle on the hoist.
Using the 2 1/2-inch cut holes to gain access, straighten the plate nut retaining tabs and remove both plate nuts. See Figure 5.

Figure 5

Install new plate nuts. Bend the retaining tabs to secure the plate nuts in place.
Raise the vehicle.
Using hand tools, install the reinforcement plate and the new sub-frame rear retaining bolts as shown in Figure 6. Tighten the retaining bolts to 88-118 Nm (65-87 lb-ft).

Figure 6

Lower the vehicle.
Apply Super Seal or equivalent to the exposed metal of the access holes in the floor pan.
Install the supplied grommet to cover the access holes. See Figure 7.

Figure 7

Reposition the front dash absorber
Install the front dash absorber push pins.
Reposition the front carpet.
Reinstall the push pin under the accelerator pedal which retains the carpet, if so equipped.
Install both of the floor mats.

January, 1999

Serial Number: 12345678901234567 98S36

Mr. John Sample
123 Main Street
Anywhere, USA 12345

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Ford Motor Company has decided that a defect which relates to motor vehicle safety exists in certain 1986-1995 Taurus and Sable and 1988-1994 Continental vehicles.

SAFETY DEFECT

REPAIRS

At no charge to you, your dealer will replace the attaching bolts, plate nuts and the reinforcement plates on the bottom of the sub-frame rear body mounts, on your vehicle.

HOW LONG WILL IT TAKE?

The time needed for this service is less than one-half day. However, due to service scheduling times, your dealer may need your vehicle for a longer period. Please call your dealer for a service date.

CALL YOUR DEALER

Call your dealer without delay. Ask for a service date and whether parts are in stock for Safety Recall 98S36.

If the 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 vehicle in, show the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge.

REFUNDS

If you have paid to have this service done before the date of this letter, Ford is offering a full refund. For the refund, please show your paid original receipt to your Ford and Lincoln-Mercury dealer. To avoid delays, do not send receipts to Ford Motor Company.

CHANGED ADDRESS OR SOLD THE VEHICLE?

Please fill out the enclosed prepaid postcard and mail it to us if you have changed your address or sold the vehicle.

If the dealer doesn't make the repair promptly and without charge, you may contact the FordCustomerAssistanceCenter, 16800 Executive Plaza Drive, P. O. Box 6248, Dearborn, MI48121. You also may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S. W., Washington, D. C. 20590 or call the toll free Auto Safety Hotline 1-800-424-9393 (Washington, D. C. area residents may call 366-0123).

We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction.

SAFETY RECALL
98S36

SAFETY RECALL
98S36
Information - January 12, 1999 / Certain 1986-1995 Taurus & Sable and 1988 - 1994 Continental Vehicles - Sub-Frame Rear Plate Nut Replacement

January 12, 1999

To:
All Ford And Lincoln-Mercury Dealers

Subject:
Safety Recall 98S36: Certain 1986-1995 Taurus & Sable and 1988-1994 Continental Vehicles - Sub-Frame Rear Plate Nut Replacement

FROM:

FORD CUSTOMER SERVICE DIVISION VEHICLE SERVICE AND PROGRAMS

Recall Broadcast on FordStar - Safety Recall 98S36

Safety Recall 98S36 will be broadcast on the FordStar Dealer Communications Network from January 11 through January 22, 1999.
Recall 98S36 will be aired along with "Tech Time". Beginning next week, tune in to any of the "Tech Time" programs to view 98S36 Service Procedures.
Consult the January '99 StarGuide for "Tech Time" broadcast times.

Recall 98S36 Supersedes 92S61

All vehicles originally covered by 92S61 are now covered by 98S36.
Vehicles with 92S61 and 98S36 both showing open on OASIS will be corrected to show only 98S36.

98S36 Labor Time Concerns

The labor time of 0.6 hours established for 98S36 is correct. Labor time has been verified in dealerships with dealership technicians.
Comparison of this labor time to earlier Recall 92S61 is misleading because:
- The fix is similar, however the procedures are different (fewer hoisting operations, able to work on both sides simultaneously, bolt cutting is not required, etc.)
- Use of power tools are now permitted for disassembly. Power tools were not used in the development of Recall 92S61.
Service Managers should verify that technicians are following the technical procedure identified in Attachment III of Recall 98S36.

SAFETY RECALL
98S36
Supplement #1 - February, 1999 / Sub-Frame Rear Plate Nut Replacement, Dated December, 1998

February, 1999

To:
All Ford And Lincoln-Mercury Dealers

Subject:
Safety Recall 98S36 - Sub-Frame Rear Plate Nut Replacement, Dated December, 1998

From:

FORD CUSTOMER SERVICE DIVISION VEHICLE SERVICE AND PROGRAMS

98S36-S1 Tool Allowance Adjustment

The tool allowance for Safety Recall 98S36 has been reevaluated. Reevaluation was done in response to inquires and input from both Dealers and the Parts and Service Manager's Advisory Council (PSMAC).
Effective immediately, Ford will increase the tool allowance for this recall from $1.00 per vehicle to $2.00 per vehicle.

In order to extend hole saw life, drill head speed is critical. High RPMs, common when using a 3/8" drill (air powered), cause damage and accelerated wear on hole saw blades. When using a hole saw, a ½" variable speed electric drill is recommended. Electric drills provide greater control and allow the hole saw to cool properly while cutting. Always follow the hole saw manufacturer's recommendation on saw speed. Other factors which accelerate blade wear are improper drill angle and excessive pressure.

Hole-saw tests have demonstrated it is possible to cut up to 60 holes per saw, when the above recommendations have been followed.