NOTE: VEHICLES EQUIPPED WITH ALL-WHEEL DRIVE MANUAL TRANSMISSION.
UNDER COLD AND HUMID CONDITIONS, FROST MAY FORM AT THE TRANSMISSION OIL LEVEL GAUGE (DIPSTICK) WHERE THE BREATHING MECHANISM IS INCORPORATED. THIS COULD CAUSE PRESSURE TO BUILD INSIDE THE TRANSMISSION CASE WHICH IN TURN COULD PUSH OUT THE OIL SEAL. SUBSEQUENT OIL LEAKAGE COULD RESULT IN BURNING OF TRANSMISSION COMPONENTS AND POSSIBLE LOSS OF CONTROL DUE TO WHEEL LOCK-UP.
Safety Risk
No risk description available.
Remedy
ON VEHICLES WITH AN ALL METAL TYPE DIPSTICK, THE OIL LEVEL
THE UPPER TRANSAXLE OIL COOLER HOSE COULD PULL OUT OF THE CRIMPED COUPLING AT THE TRANSAXLE END OF THE LINE ASSEMBLY. IF THIS COUPLING WERE TO SEPARATE, TRANSAXLE OIL WOULD SPILL INTO THE ENGINE COMPARTMENT AND, IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.
Safety Risk
No risk description available.
Remedy
DEALERS WILL INSTALL A NEW UPPER TRANSAXLE OIL COOLER LINE ON ALL INVOLVED VEHICLES.
THE ENGINE SPROCKET NUT LOCKWASHER MAY NOT PROPERLY LOCK THE NUT IN PLACE. IF THE NUT WERE TO LOOSEN AND ALLOW THE SPROCKET TO COME OFF, THE CHAIN COULD LOCK THE REAR WHEEL, POSSIBLY CAUSING A CRASH.
Safety Risk
No risk description available.
Remedy
ENGINE SPROCKET NUT LOCKWASHER WILL BE REPLACED ON AFFECTED VEHICLES.
NOTE: R/V SUBURBAN TRUCKS - 2 WHEEL AND 4 WHEEL DRIVE VEHICLES WITH AUTOMATIC TRANSMISSIONS.
VEHICLES MAY DEVELOP AN ABNORMAL PRESSURE BUILD-UP IN THE TRANSMISSION WITH THE POSSIBILITY OF TRANSMISSION FLUID COMING OUT OF THE FILLER TUBE ONTO HOT ENGINE PARTS RESULTING IN A POSSIBLE VEHICLE FIRE.
Safety Risk
No risk description available.
Remedy
OWNERS WILL BE PROVIDED WITH A NEW DIPSTICK WITH A LOCK-SEAL TOP, NEW OWNER MANUAL INSTRUCTIONS, GRAPHICS FOR CHECKING THE AUTOMATIC TRANSMISSION FLUID LEVEL AND UPDATED INFORMATION ON TOWING WITH AN OVERDRIVE EQUIPPED AUTOMATIC TRANSMISSION.
NOTE: VEHICLES EQUIPPED WITH V6 ENGINE AND AUTOMATIC TRANSMISSION.
THE AUTOMATIC TRANSMISSION DIPSTICK MUST BE PROPERLY REINSTALLED AFTER CHECKING THE FLUID LEVEL. IF THE DIPSTICK IS NOT LOCKED, LEAKING AUTOMATIC TRANSMISSION FLUID MAY CONTACT THE EXHAUST MANIFOLD AND RESULT IN AN ENGINE COMPARTMENT FIRE.
Safety Risk
No risk description available.
Remedy
A WARNING TAG WILL BE INSTALLED TO THE DIPSTICK CAP TO SERVE AS A REMINDER TO ALWAYS LOCK THE DIPSTICK AFTER CHECKING THE FLUID LEVEL AND NOT TO OVERFILL WITH AUTOMATIC TRANSMISSION FLUID.
On certain K1500 vehicles, the one-piece prop shaft may have tube to yoke welds off location. This could result in separation of the tube from the yoke. If the prop shaft were to separate from the vehicle it could create a road hazard.
NOTE: RT TURBO MODELS.
THESE VEHICLES MAY HAVE BEEN BUILT WITH A TRANSFER CASE THAT COULD LEAK OIL. EXCESSIVE OIL LOSS MAY CAUSE BEARING FAILURE WHICH COULD CAUSE THE TRANSFER CASE TO LOCK-UP, RESULTING IN POSSIBLE LOSS OF VEHICLE CONTROL AND AN ACCIDENT.
Safety Risk
No risk description available.
Remedy
VEHICLES WILL BE INSPECTED AND EITHER AN IMPROVED CASE SEAL (O-RING) WILL BE INSTALLED, OR THE TRANSFER CASE WILL BE REPLACED.
NOTE: 4X4 VEHICLES ONLY.
VEHICLES WITH THE TOUCH DRIVE ELECTRIC SHIFT TRANSFER CASE EQUIPPED WITH PRIOR LEVEL ELECTRIC SHIFT MOTORS MAY SLIP OUT OF THE 4X4 HIGH-GEAR POSITION DURING COASTING IN FORWARD GEARS OR WITH POWER APPLIED IN REVERSE GEAR. THIS COULD CAUSE THE VEHICLE TO ROLL FREELY AS IF IN THE NEUTRAL POSITION REGARDLESS OF THE TRANSMISSION GEAR SELECTOR POSITION AND COULD RESULT IN DIMINISHED VEHICLE CONTROL.
Safety Risk
No risk description available.
Remedy
VEHICLES WILL BE INSPECTED AND TRANSFER CASE REPLACED IF NECESSARY.
On certain vehicles equipped with automatic transmission, the gear selector may indicate that the vehicle is in PARK or NEUTRAL, even though it could be in REVERSE or DRIVE. If this happens, the vehicle could start in REVERSE or DRIVE, or might move unexpectedly.
On certain vehicles, the transmission fluid may be forced out of the vent tube due to heat generation in the transmission caused by trailering heavy loads at high speeds or high-load/off road use. If the vented transmission fluid comes in contact with the catalytic converter, the fluid could ignite resulting in a vehicle fire.
Safety Risk
No risk description available.
Remedy
Dealers will install a longer transmission vent hose routed to the left side of the vehicle.
ON VEHICLES WITH AUTOMATIC TRANSMISSION, A LOW OIL LEVEL IN THE DIFFERENTIAL COULD CAUSE PREMATURE BEARING AND GEAR WEAR AND EVENTUAL FAILURE OF THE DIFFERENTIAL. THIS COULD RESULT IN POSSIBLE DRIVE WHEEL LOCK-UP AND LOSS OF VEHICLE CONTROL.
Safety Risk
No risk description available.
Remedy
DIFFERENTIAL WILL BE DRAINED AND OIL WILL BE REPLACED WITH AN ADVANCED DESIGN HIGH PERFORMANCE GEAR OIL. OWNERS WILL BE PROVIDED WITH A REVISED MAINTENANCE SCHEDULE.
NOTE: VEHICLES EQUIPPED WITH 4L60 AUTOMATIC TRANSMISSIONS.
THE SHIFT CONTROL CABLE CONDUIT MAY SEPARATE AND PREVENT THE TRANSMISSION FROM BEING SHIFTED INTO THE PROPER POSITION, FOR EXAMPLE, THE TRANSMISSION SHIFT LEVER MAY BE IN THE PARK POSITION WHEN THE TRANSMISSION IS ACTUALLY IN DRIVE OR REVERSE. THIS CONDITION MAY CAUSE UNEXPECTED VEHICLE MOVEMENT AND COULD RESULT IN A VEHICLE CRASH WITHOUT PRIOR WARNING.
Safety Risk
No risk description available.
Remedy
A REVISED SHIFT CONTROL LEVER WILL BE INSTALLED ON AFFECTED VEHICLES.
A FILLER PIECE WITH INSUFFIENT SUPPORT WAS INSTALLED IN THE AUTOMATIC TRANSMISSION. THIS PIECE CAN MOVE AND INHIBIT THE KICKDOWN FUNCTION. THIS COULD RESULT IN AN ACCIDENT DURING OVERTAKING.
Certain vehicles may develop an abnormal pressure build-up in the transmission with the possibility of transmission fluid coming out of the filler tube onto hot engine parts resulting in a possible vehicle fire.
Safety Risk
No risk description available.
Remedy
Owners will be provided with a new dipstick with a lock-seal top and new owner manual instructions and graphics for checking the automatic transmission fluid level.
Certain vehicles may develop an abnormal pressure build-up in the transmission with the possibility of transmission fluid coming out of the filler tube onto hot engine parts resulting in a possible vehicle fire.
Safety Risk
No risk description available.
Remedy
Owners will be provided with a new dipstick with a lock-seal top and new owner manual instructions and graphics for checking the automatic transmission fluid level.
On certain vehicles, the transmission may remain in reverse when the shift indicator shows neutral gear position. This could result in unexpected rearward movement and a crash without prior warning.
Safety Risk
No risk description available.
Remedy
Vehicles will be inspected and tested and transaxle replaced if necessary.
On certain vehicles with console shift, the transaxle shift control cable may disengage from the shift control cable bracket resulting in loss of gear indicator reference and shift selector operation. Under certain conditions this could result in unexpected vehicle movement and an accident without prior warning.
Safety Risk
No risk description available.
Remedy
Dealers will install a transaxle shift control cable retaining clip on suspect vehicles.
THE PARK MECHANISM OF THE A4LD AUTOMATIC TRANSMISSION MAY NOT ENGAGE WHEN THE SELECTOR LEVER IS PLACED IN THE "PARK" POSITION. IF PARKED ON AN INCLINE, THE VEHICLE MAY ROLL AS IF IN NEUTRAL IF THE PARKING BRAKE IS NOT SET. THIS COULD RESULT IN A VEHICLE ACCIDENT OR PERSONAL INJURY.
Safety Risk
No risk description available.
Remedy
OWNERS WILL BE NOTIFIED OF CONDITION AND ADVISED TO SET THE PARKING BRAKE EACH TIME THEY PARK THEIR VEHICLE. OWNERS WILL ALSO BE ADVISED WHEN DEALERS RECEIVE PARTS AND REPAIR INSTRUCTIONS AFTER FURTHER INVESTIGATION BY FORD.
ON SE MODELS WITH CONSOLE SHIFT, THE TRANSAXLE SHIFT CONTROL CABLE MAY DISENGAGE RESULTING IN LOSS OF GEAR INDICATOR REFERENCE. PLACING THE GEAR SELECTOR IN "PARK", COULD RESULT IN THE TRANSAXLE NOT BEING IN PARK POSITION AND ON AN INCLINED SURFACE THE VEHICLE MAY MOVE. ALSO WITH THE GEAR SELECTOR IN "DRIVE" OR "REVERSE", THE TRANSAXLE MAY NOT BE IN THE INDICATED GEAR POSITION AND THE VEHICLE COULD MOVE IN THE OPPOSITE DIRECTION: THESE CONDITIONS COULD RESULT IN AN ACCIDENT.
Safety Risk
No risk description available.
Remedy
A TRANSAXLE SHIFT CONTROL CABLE RETAINING CLIP WILL BE INSTALLED.
