Ford Motor Company: Safety Recalls in 1977

THE INVOLVED VEHICLES MAY CONTAIN FRONT PARK/TURN SIGNAL LAMP ASSEMBLIES THAT MAY BE IN NON-COMPLIANCE TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES AND ASSOCIATED EQUIPMENT". THE NON-COMPLIANCE EXISTS BECAUSE OF A POSSIBLE SEPARATION BETWEEN THE LAMP LENS AND LAMP HOUSING DUE TO VIBRATION. THIS SEPARATION COULD ALLOW MOISTURE AND DIRT ACCUMULATION TO OCCUR INSIDE THE LAMP ASSEMBLY.

THE INVOLVED VEHICLES ARE EQUIPPED WITH AIR CONDITIONING UNITS WHICH CONTAIN BLOWER MOTOR RESISTOR WIRES WHICH ARE IMPROPERLY POSITIONED. AS A RESULT, UNDER CERTAIN CONDITIONS THE POLYPROPYLENE CASE MATERIAL COULD BECOME OVERHEATED AND EVENTUALLY IGNITE, ESPECIALLY IF THE BLOWER MOTOR SWITCH IS IN THE LOW OR MEDIUM POSITION.

THE INVOLVED VEHICLES MAY CONTAIN AIR CONDITIONERS WHICH HAVE BLOWER MOTOR RESISTOR WIRES WHICH WERE IMPROPERLY ROUTED TOO CLOSE TO THE BLOWER HOUSING WALL. AS A RESULT, THE BLOWER MOTOR COULD BECOME JAMMED AND, IF THE BLOWER SWITCH IS IN EITHER THE MEDIUM OR LOW POSITION, THE POLYPROPYLENE BLOWER HOUSING COULD IGNITE.

THE INVOLVED VEHICLES WERE BUILT WITH AFT-OF-AXLE FUEL TANKS WHICH WERE NOT AUTHORIZED BY LIGHT TRUCK ENGINEERING. AS A RESULT, THESE VEHICLES FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 301, "FUEL SYSTEM INTEGRITY", DUE TO POSSIBLE FUEL TANK LEAKAGE WHEN IMPACTED FROM THE REAR.

ON THE INVOLVED VEHICLES, THE MANUAL STEERING GEARS MAY CONTAIN STEERING GEAR RECIRCULATORY BALLS THAT COULD FRACTURE. THIS FRACTURING IS A RESULT OF IMPROPER HEAT-TREATMENT DURING MANUFACTURE AND CAN EVENTUALLY CAUSE INCREASED STEERING EFFORT.

THE ELECTRONIC ENGINE CONTROL (EEC) WIRING HARNESS MAY BE MISROUTED. THIS MISROUTING MAY CAUSE THE SPEED CONTROL SERVO ARM TO BE HELD OPEN DUE TO MECHANICAL INTERFERENCE WHEN THE SPEED CONTROL IS ENGAGED. THIS CAUSES A PARTIALLY OPEN THROTTLE CONDITION THAT CANNOT BE CANCELLED BY DRIVER ACTIONS NORMALLY USED TO SHUT OFF THE SPEED CONTROL SYSTEM.

ON THE INVOLVED VEHICLES, LEAKAGE MAY OCCUR AT THE THREADED CARBURETOR-TO-FUEL FILTER CONNECTION ON THE SUSPECT CARBURETORS. THIS IS DUE TO AN IMPROPERLY MACHINED CARBURETOR FUEL INLET CONNECTION.

THE INVOLVED VEHICLES MAY HAVE BEEN EQUIPPED WITH CAST ALUMINUM WHEELS WITH INADEQUATE LUG NUT COUNTERBORE DEPTHS. THIS CONDITION MAY NOT PROVIDE SUFFICIENT LUG NUT THREAD ENGAGEMENT. THE LUG NUTS MAY LOOSEN AND FALL OFF, ALLOWING THE WHEEL TO SEPARATE FROM THE VEHICLE.

THE DUST TUBE PORTION OF THE ACCELERATOR CABLE ASSEMBLY ON THE INVOLVED VEHICLES MAY BIND DUE TO IMPROPER CRIMPING OF THE CABLE ASSEMBLY DURING MANUFACTURE. AS A RESULT, THE RETURN RATE OF THE THROTTLE MAY BE SLOWED OR THE THROTTLE MAY BE PREVENTED FROM CLOSING PROPERLY. IN THIS CONDITION, A VEHICLE SPEED OF 30 T0 40 MPH COULD BE MAINTAINED WITHOUT DEPRESSING THE ACCELERATOR PEDAL.

ON THE INVOLVED VEHICLES, TEMPERED GLASS MAY HAVE BEEN INSTALLED IN THE REAR DOORS INSTEAD OF LAMINATED GLASS. THIS CONSTITUTES A NON-COMPLIANCE TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 217, "BUS WINDOW RETENTION AND RELEASE". ONE PURPOSE OF THE STANDARD IS TO MINIMIZE THE LIKELIHOOD OF OCCUPANTS BEING EJECTED FROM A BUS IN THE EVENT OF A COLLISION.

THE SEAT BELTS ON THE INVOLVED VEHICLES FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NOS. 208, "OCCUPANT CRASH PROTECTION", AND 209, "SEAT BELT ASSEMBLIES". THE NON-CONFORMITY EXISTS BECAUSE WHEN THE DRIVER"S SEAT IS ADJUSTED TO THE FULL FORWARD POSITION, THE SEAT CUSHION IS ADJUSTED TO MAXIMUM ELEVATION, AND THE SEAT BACK IS TILTED TO THE FULLY UPRIGHT POSITION, THE SEAT BELTS ARE NOT LONG ENOUGH TO ACCOMMODATE SOME DRIVERS.

THE INVOLVED VEHICLES ARE EQUIPPED WITH SAFETY COMPLIANCE CERTIFICATION LABELS AND INCOMPLETE VEHICLE DOCUMENTS THAT INDICATE THAT THE GROSS AXLE WEIGHT RATING (GAWR) IS APPROXIMATELY 0.6 TO 6.0 PERCENT GREATER THAN THE COMBINED LOAD CAPACITY OF THE TIRES AT THE SPECIFIED TIRE INFLATION PRESSURE. THIS FAILS TO COMPLY WITH FEDERAL MOTOR VEHICLE SAFETY STANDARD NOS. 120, "AIR BRAKE SYSTEMS", AND 119, "NEW PNEUMATIC TIRES FOR VEHICLES OTHER THAN PASSENGER CARS", OR 109, "NEW PNEUMATIC TIRES".

ON THE INVOLVED VEHICLES, THE PARK ACTUATION SUPPORT PLATES ARE DEFECTIVE DUE TO THEIR SUSCEPTIBILITY TO CRACKING DUE TO IMPROPER HEAT TREATMENT DURING MANUFACTURE. AS A RESULT, FRAGMENTS FROM A BROKEN PLATE CAN BECOME LODGED IN THE TRANSMISSION PARKING PAWL MECHANISM. THIS COULD PREVENT THE TRANSMISSION PARKING PAWL FROM ENGAGING WHEN THE SELECTOR LEVER IS PLACED IN THE "PARK" POSITION, OR PREVENT THE PAWL FROM BEING DISENGAGED FROM THE PARK GEAR.

ON THE INVOLVED VEHICLES, THE STEERING TIE ROD AND LINK ASSEMBLIES WITH ADJUSTING SLEEVE CLAMPS MAY HAVE BEEN IMPROPERLY MANUFACTURED. THE CLAMPS CONTAIN A SHARP DIE MARK WHICH COULD CAUSE THE CLAMP TO FRACTURE WHEN THE CLAMP BOLT IS TIGHTENED TO SPECIFICATIONS. THE CLAMP COULD BREAK AND CAUSE SEPARATION OF THE TIE ROD ADJUSTING SLEEVES.

THE PITMAN ARM TO STEERING GEAR ATTACHMENT NUTS MAY NOT HAVE BEEN PROPERLY TIGHTENED ON THE INVOLVED VEHICLES. THE NUT COULD COME OFF DURING VEHICLE OPERATION.

ON SOME OF THE INVOLVED VEHICLES, THE TRANSMISSION PARKING PAWL MAY NOT ENGAGE THE PARKING GEAR WHEN THE TRANSMISSION SELECTOR LEVER IS PLACED IN THE "PARK" POSITION. THIS CONDITION IS ATTRIBUTABLE TO EXCESSIVE FREE PLAY IN THE TRANSMISSION SHIFT LINKAGE ADJUSTMENT.

SOME OF THE INVOLVED VEHICLES MAY HAVE DEFECTIVE CARBURETORS IN WHICH, UNDER CERTAIN CIRCUMSTANCES, THE SECONDARY THROTTLE PLATES MAY STICK OPEN.

THE FRONT DISC BRAKE ROTORS INSTALLED ON THE INVOLVED VEHICLES MAY HAVE BEEN IMPROPERLY MANUFACTURED SO THAT THEY CONTAIN CRACKS. THESE CRACKED ROTORS COULD FRACTURE DURING VEHICLE BRAKING AND CAUSE BRAKE PULL AND AFFECT VEHICLE DIRECTIONAL CONTROL.

THE INVOLVED VEHICLES MAY BE IN NON-COMPLIANCE TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 105, "HYDRAULIC BRAKE SYSTEMS", DUE TO INSTALLATION OF INCORRECT REAR AXLE ASSEMBLIES. CONSEQUENTLY, EARLY REAR WHEEL LOCK-UP UNDER LIGHT LOADING CONDITIONS COULD RESULT CAUSING VEHICLE DIRECTIONAL INSTABILITY. REAR BRAKING EFFECTIVENESS WOULD ALSO BE REDUCED.

THE INVOLVED VEHICLES MAY HAVE BEEN INCORRECTLY EQUIPPED WITH MANUAL BRAKES INSTEAD OF POWER BRAKES. CONSEQUENTLY, A NON-COMPLIANCE TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 105, "HYDRAULIC BRAKE SYSTEMS", MAY EXIST.

THE FUEL FILLER CAPS ON THE INVOLVED VEHICLES MAY FAIL TO MEET THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 301, "FUEL SYSTEM INTEGRITY". IN THE EVENT OF A REAR-END COLLISION, FUEL LEAKAGE MAY OCCUR.

THE INVOLVED VEHICLES MAY EXPERIENCE FUEL LEAKAGE AT THE RUBBER HOSE CONNECTING THE FUEL INLET TUBE TO THE CARBURETOR FILTER. THIS LEAKAGE CONDITION IS DUE TO INSUFFICIENT INSERTION OF THE FUEL TUBE INTO THE HOSE OR IMPROPER POSITIONING OF THE HOSE CLAMP, CAUSING THE CLAMP TO BE CRIMPED DIRECTLY OVER THE FUEL TUBE BEAD.

THE INVOLVED VEHICLES WERE FITTED WITH TILT STEERING COLUMNS CONTAINING TRANSMISSION CONTROL INSERTS INTENDED FOR TRUCKS RATHER THAN PASSENGER VEHICLES. THIS MAY CAUSE THE TRANSMISSION SELECTOR POINTER TO BE MISALIGNED AND THE POSSIBILITY OF STARTING THE ENGINE WHEN THE SELECTOR IS BETWEEN THE NEUTRAL (N) AND DRIVE (D) DETENTS AND THE TRANSMISSION IS IN DRIVE.

ON THE INVOLVED VEHICLES, BUILD-UP OF CARPET/MAT DEADENER AND INSULATION UNDER THE REAR SEAT FRAME AND SEAT BELT ANCHOR TABS MAY PREVENT THE OPTIONAL FOLDING REAR SEAT CUSHION FROM LATCHING PROPERLY. THE LATCH MAY BE ONLY PARTIALLY ENGAGED AND FAIL TO SUSTAIN THE SEAT BELT ANCHORAGE LOADING REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 210, "SEAT BELT ASSEMBLY AND ANCHORAGES".

THE ENGINE FAN BLADES ON THE INVOLVED VEHICLES MAY BE SUBJECT TO CRACKING DUE TO STRESSES GENERATED DURING NORMAL OPERATION. BLADES MAY FRACTURE AND FRAGMENTS WOULD BE PROPELLED FROM THE ROTATING FAN.

THE INVOLVED VEHICLES WERE ASSEMBLED WITH INCORRECT ATTACHING U-NUTS USED TO SECURE THE REAR BUMPER LEFT ISOLATOR AND BRACKET ASSEMBLY. IN THE EVENT OF A REAR-END COLLISION, THE U-NUTS COULD CONTACT AND CUT THE FUEL TANK, CAUSING FUEL LEAKAGE.

THE INSTRUMENT PANELS ON THE INVOLVED VEHICLES CAN BE BROKEN DURING OCCUPANT IMPACT.

SEVEN-BLADE COOLING FANS INSTALLED ON THE INVOLVED VEHICLES MAY BE SUBJECT TO FATIGUE CRACKING OF THE BLADES DUE TO STRESSES GENERATED DURING NORMAL VEHICLE OPERATION.

THE UPPER SUPPORT STRAP NUTS, ATTACHING THE FUEL TANK, WERE NOT TIGHTENED TO SPECIFICATIONS. THIS MAY ALLOW THE FUEL TANK TO DETACH AND FALL TO THE GROUND.

THE INVOLVED VEHICLES DO NOT CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS". THESE LIGHT TRUCKS WERE INCORRECTLY CLASSIFIED AS PASSENGER VEHICLES AND WERE EQUIPPED WITH LOAD RANGE "A" INSTEAD OF LOAD RANGE "B" TIRES. THIS COULD LEAD TO INADVERTENT VEHICLE OVERLOADING.

THESE VEHICLES WERE EQUIPPED WITH INCORRECT FUEL TUBES AND REAR FUEL HOSES. THIS MAY CAUSE THE FUEL HOSE TO CONTACT THE LEFT EXHAUST OUTLET PIPE. THE HEAT FROM THE EXHAUST PIPE WILL DETERIORATE THE HOSE AND CAUSE A FUEL LEAK TO DEVELOP.

THE INVOLVED VEHICLES MAY HAVE BEEN BUILT WITH LEFT DOOR LOCK ASSEMBLIES THAT CONTAIN PAWL SPRING RETAINERS THAT WERE NOT PRODUCED TO ENGINEERING SPECIFICATIONS. CONSEQUENTLY, THE SPRING COULD BREAK, CAUSING THE LATCH PAWL TO DISENGAGE FROM THE LATCH CAM.

THE SEAT BACK PIVOT PIN BRACKET ON THE INVOLVED VEHICLES MAY FAIL. CONSEQUENTLY, THE SEAT BACK WILL ROTATE REARWARD.

THE INVOLVED VEHICLES MAY HAVE BEEN ASSEMBLED WITH IMPROPERLY MANUFACTURED FRONT SPRING U-BOLTS USED TO SECURE THE FRONT AXLE ASSEMBLY TO THE SPRING. THE FOUR U-BOLTS MAY EXPERIENCE CRACKS AND COULD ULTIMATELY BREAK. SHOULD TWO U-BOLTS ON THE SAME SIDE OF THE VEHICLE BREAK, THE FRONT AXLE WOULD NOT BE RETAINED SECURELY.

THE FRONT WHEEL SPINDLE ON THE INVOLVED VEHICLES MAY CRACK IN SERVICE. SPINDLE STEM SEPARATION COULD OCCUR DUE TO FAILURE OF THE STEM AT THE INNER BEARING FILLET LOCATION.