Ford Motor Company: Safety Recalls in 1978

THE STEERING GEARS ON THE INVOLVED VEHICLES MAY HAVE BEEN BUILT WITH IMPROPERLY MANUFACTURED SECTOR SHAFTS FROM WHICH THE THREADED PORTIONS OF THE SHAFTS MAY FRACTURE AND SEPARATE. SHOULD THE SECTOR SHAFT FRACTURE, THE PITMAN ARM MAY DISENGAGE FROM THE SPLINED PORTION OF THE SECTOR SHAFT.

THE FLUID RETURN HOSE INSTALLED BETWEEN THE POWER STEERING RESERVOIR AND PUMP IS SUSCEPTIBLE TO DETERIORATION AND "KINKING". DETERIORATION OF THE HOSE PERMITS PARTICLES TO ENTER THE POWER STEERING FLUID SYSTEM RESTRICTING FLOW. BOTH HOSE DETERIORATION AND KINKING MAY RESULT IN LOSS OF POWER STEERING ASSIST AND INCREASED MANUAL STEERING EFFORTS.

THE INVOLVED VEHICLES WERE EQUIPPED WITH AUTOMATIC TRANSMISSIONS IN WHICH THE PARKING PAWL WAS NOT HEAT-TREATED. DURING NORMAL VEHICLE OPERATION, A PARKING PAWL THAT HAS NOT BEEN HEAT-TREATED COULD BECOME DEFORMED OR WORN TO THE POINT THAT THE TRANSMISSION WILL NOT LOCK IN "PARK". AS A RESULT, THE VEHICLE COULD ROLL FREE IF THE DRIVER DOES NOT SET THE PARKING BRAKE WHEN PARKING OR LEAVING VEHICLE UNATTENDED.

DUE TO AN ERROR IN THE VEHICLE ASSEMBLY COMPUTER BROADCAST PROGRAM, THE INVOLVED VEHICLES WERE EQUIPPED WITH 14X5.5 INCH WHEEL RIMS WHICH WERE INTENDED FOR USE ON PASSENGER CARS. THE TIRES WERE NOT MARKED WITH THE INFORMATION SPECIFIED BY FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS". AS A RESULT, A NON-COMPLIANCE EXISTS TO THIS STANDARD.

THE ENGINE COOLING FAN BLADES MAY CRACK UNDER HIGH SPEED OPERATING CONDITIONS. FRAGMENTS MAY SEPARATE AND DAMAGE THE ENGINE COMPONENTS, AND IF THE HOOD IS OPEN AND THE ENGINE IS RUNNING, BLADE FRAGMENTS COULD FLY OUT FROM THE VEHICLE AND INJURE NEARBY PERSONS.

THE INVOLVED WHEELS CONTAIN MISLOCATED STEM HOLES. THIS MAY ALLOW AIR LEAKAGE AT THE TIRE VALVE STEM, UNDER HIGH SPEED DRIVING CONDITIONS.

ON THE INVOLVED VEHICLES, THE POTENTIAL EXISTS FOR THE OUTBOARD SEAT BELTS TO BECOME TRAPPED IN THE SEAT-BED PIVOTING MECHANISM. SHOULD THE BELT BECOME TRAPPED IN THE MECHANISM WHEN THE SEAT IS CONVERTED TO A BED, THE BELT MAY BECOME CUT OR FRAYED.

ONE OR MORE OF THE FIVE COOLING FAN BLADES MAY HAVE BEEN IMPROPERLY RIVETED TO THE FAN SPIDER. THIS COULD ALLOW THE BLADES TO SEPARATE FROM THE FAN DURING ENGINE OPERATION.

THE LOWER STEERING SHAFT ASSEMBLIES CONTAIN COUPLING RIVET PINS WHICH WERE NOT RIVETED SECURELY ENOUGH DURING MANUFACTURE. CONSEQUENTLY ONE OR BOTH OF THE PINS COULD LOOSEN FROM THE FLANGE OF THE FLEXIBLE COUPLING DURING VEHICLE OPERATION. IF ONE PIN IS LOOSE, FREE PLAY WOULD RESULT. IF BOTH PINS WORK LOOSE, LOSS OF STEERING CONTROL WOULD OCCUR. ALSO, THE SHAFT ASSEMBLY MAY NOT CONTAIN A METAL REINFORCEMENT BETWEEN ONE OR BOTH OF THE RIVET PINS AND THE RUBBER FLEXIBLE COUPLING. AS A RESULT, THE RUBBER FLEXIBLE COUPLING COULD TEAR AND PRODUCE A NOISE OR LOOSE FEELING IN THE STEERING SYSTEM.

THE INVOLVED VEHICLES ARE EQUIPPED WITH FLEXIBLE COOLING FAN BLADES THAT MAY CRACK WHEN SUBJECTED TO HIGH ENGINE SPEED OPERATING CONDITIONS. FAN BLADE CRACKING CAN LEAD TO FRAGMENTS SEPARATING FROM THE FAN.

THE FULL SIZE SEDANS WERE EQUIPPED WITH INCORRECT TAIL LAMP SOCKETS AND THE FULL SIZE STATION WAGONS WERE INSTALLED WITH INCORRECT TAIL LAMP AND BACK UP LAMP SOCKETS. THEREFORE THESE VEHICLES FAIL TO COMPLY WITH THE PHOTOMETRIC REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES AND ASSOCIATED EQUIPMENT".

THE INVOLVED VEHICLES CONTAIN EMISSION CONTROL SYSTEMS THAT UTILIZE A PULSE AIR REED VALVE TO PERMIT AIR FLOW FROM THE AIR CLEANER TO THE EXHAUST MANIFOLD ON NEGATIVE PRESSURE PULSATIONS. THESE REED VALVES MAY FAIL UNDER COLD WEATHER CONDITIONS, CAUSING A BACKFLOW OF EXHAUST GAS INTO THE AIR CLEANER AND FUEL INDUCTION SYSTEM ON POSITIVE EXHAUST PULSES. THIS CAUSES AN OVERLY RICH AIR/FUEL MIXTURE, REDUCED FUEL ECONOMY AND REDUCED ENGINE PERFORMANCE. CONTINUED VEHICLE OPERATION MAY RESULT IN ENGINE STALLING OR OVERHEATING OF THE EXHAUST SYSTEM.

THESE TRANSMISSIONS MAY CONTAIN IMPROPERLY MANUFACTURED PARKING PAWL ACTUATING RODS. CONSEQUENTLY, THE UNHARDENED CAM SURFACE OF THESE RODS CAN ALLOW THE ROD TO DEFORM DURING USE WITH RESULTANT INCREASE IN SHIFT EFFORTS AND DIFFICULTY IN RELEASING THE PARKING PAWL AND ENGAGING THE PARKING GEAR.

THE WINDSHIELD WIPER AND WASHER SYSTEM CONTAINS AN INCORRECT 6 AMP CIRCUIT BREAKER INSTEAD OF THE 8.25 AMP CIRCUIT BREAKER. IF THE SYSTEM IS HEAVILY LOADED, AS IN THE CASE OF A PARTIALLY DRY WINDSHIELD, THE MOTOR CURRENT MAY EXCEED THE 6 AMP BREAKER"S CAPACITY. THIS WOULD CAUSE THE BREAKER TO OPEN, WHICH WOULD RESULT IN WIPER/WASHER FAILURE.

THE INVOLVED VEHICLES DO NOT CONTAIN A FUEL TANK SHIELD AT THE FRONT RIGHT CORNER OF THE MID-SHIP FUEL TANK. IN THE EVENT OF A FRONTAL IMPACT, EXCESSIVE FUEL SPILLAGE FROM THE FUEL TANK MAY OCCUR. THIS FAILS TO COMPLY WITH FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 301, "FUEL SYSTEM INTEGRITY".

THE TILT STEERING COLUMNS ON THE INVOLVED VEHICLES CONTAIN IN-PROCESS TEMPORARY ALIGNMENT PINS RATHER THAN THE PERMANENT PRESS-FIT PIVOT PINS. THE TEMPORARY PINS ARE SLIGHTLY UNDERSIZED AND COULD SEPARATE FROM THE STEERING COLUMN DURING VEHICLE OPERATION. THIS CAN CAUSE STEERING WHEEL LOCKUP.

THE WIPER ARMS COULD SEPARATE FROM THE PIVOT SHAFTS, RENDERING THE WIPERS INOPERATIVE.

THE WINDSHIELD WIPER DRIVE LINKAGE ON THE AFFECTED VEHICLES MAY FRACTURE DUE TO METAL FATIGUE AS A RESULT OF REPEATED FLEXING OF THE DRIVE ARM ACROSS A STRESS SENSITIVE AREA. THIS CONDITION WILL RENDER THE WINDSHIELD WIPER SYSTEM INOPERATIVE.

THE DRIVER"S SIDE SHOULDER BELT RETRACTOR MOUNTING BRACKET ASSEMBLY CONTAINS A WELD NUT WHICH WAS IMPROPERLY ATTACHED TO THE BRACKET. THIS FAILS TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 210, "SEAT BELT ASSEMBLY ANCHORAGES".

THE INVOLVED VEHICLES WERE ASSEMBLED WITHOUT THE INTENDED WINDSHIELD WEATHERSTRIP LOWER RETAINER. THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 219, "WINDSHIELD ZONE INTRUSION".

THE ENGINE COOLING FAN BLADES MAY CRACK AND CHIP DUE TO HIGH STRESSES CAUSED BY VIBRATIONS. THE CHIPPED PIECES OF THE BLADE COULD FLY INTO THE UNDERHOOD COMPONENTS. ALSO, THESE PIECES COULD FLY OUT FROM THE VEHICLE IF THE HOOD IS OPEN AND THE ENGINE IS RUNNING.

AN IMPROPER TRANSMISSION SHIFT BRACKET WAS INSTALLED WHICH, BECAUSE OF ITS DESIGN, COULD CONTACT AND ABRADE THE FUEL HOSE. FUEL LEAKAGE AND POSSIBLE ACCUMULATION OF FUEL ON A SURFACE BENEATH A PARKED VEHICLE COULD RESULT.

IN THE EVENT THE VEHICLE IS STRUCK FROM THE REAR, THE FUEL FILLER PIPE COULD DISCONNECT FROM THE TANK OR THE TANK COULD BE PUNCTURED IN THE FORWARD FACE. THIS WOULD RESULT IN FUEL LEAKAGE.

TRANSMISSION SHIFT CONTROL RODS WERE INSTALLED THAT WERE INTENDED FOR USE WITH THE STEERING COLUMNS OF A PRIOR DESIGN LEVEL. ATTACHMENT OF THE SHIFT CONTROL ROD WITH THE STEERING COLUMN SHIFT LEVER GROMMET WILL ALLOW RELATIVE MOVEMENT BETWEEN THESE PARTS. CONTINUED USAGE COULD RESULT IN GROMMET WEAR AND DETERIORATION OF THE SHIFT CONTROL FUNCTION, WITH THE POTENTIAL FOR STARTING IN GEAR OR AN INABILITY TO ENGAGE THE PARKING GEAR.

THE INVOLVED VEHICLES ARE EQUIPPED WITH SHOULDER HARNESS RETRACTORS THAT MAY NOT LOCK. SHOULD THE VEHICLE EXPERIENCE A SUDDEN DECELERATION OR IMPACT, THE FRONT SEAT OCCUPANT MAY NOT BE RESTRAINED BY THE SHOULDER HARNESS PORTION OF THE THREE-POINT SEAT BELT SYSTEM. FURTHERMORE, THE SHOULDER HARNESS RETRACTORS MAY NOT ALLOW EXTRACTION OF THE SHOULDER BELT WEBBING DUE TO A PRE-LOCKED CONDITION. THIS IS A NON-COMPLIANCE TO THE EMERGENCY LOCKING RETRACTOR PERFORMANCE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 209, "SEAT BELT ASSEMBLIES".

THESE VEHICLES MAY BE EQUIPPED WITH STEERING LINKAGES ON WHICH COTTER PINS MAY NOT HAVE BEEN INSTALLED ON CASTELLATED NUTS TO SECURE THE STEERING DRAG LINK AND TIE-ROD CONNECTIONS. ALSO, THESE ATTACHING NUTS MAY NOT HAVE BEEN TIGHTENED TO SPECIFICATIONS. THIS COULD ALLOW LINKAGE SEPARATION.

SOME OF THESE VEHICLES MAY BE EQUIPPED WITH AUTOMATIC TRANSMISSIONS THAT WERE ASSEMBLED WITH IMPROPERLY MANUFACTURED CAST IRON EXTENSION HOUSINGS. THE HOUSINGS HAVE MISLOCATED CAST CAM PLATE STOPS. A MISLOCATED STOP MAY PREVENT THE TRANSMISSION FROM LOCKING IN THE PARK POSITION WHEN THE GEAR SHIFT SELECTOR LEVER IS PLACED IN THE "P" (PARK) POSITION. IF THIS OCCURS A DRIVER MAY RELY UPON THE READING ON THE GEARSHIFT SELECTOR LEVER INDICATOR AND MAY ASSUME THAT THE TRANSMISSION PARKING GEAR IS ENGAGED.

IN THE EVENT OF A FRONTAL IMPACT, FUEL LEAKAGE MAY OCCUR AT THE FUEL LINE TO FUEL PUMP CONNECTION IN THE ENGINE COMPARTMENT. THESE VEHICLES FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 301, "FUEL SYSTEM INTEGRITY".

THE AUTOMATIC LOCKING REAR SEAT BELT RETRACTORS ON CERTAIN VEHICLES MAY FAIL TO LOCK DUE TO BINDING OF THE LOCKING PAWL AGAINST THE RETRACTOR HOUSING. THIS BINDING IS CAUSED BY RETRACTOR HOUSING DEFORMATION WHICH OCCURRED DURING ASSEMBLY. AS A RESULT THE PASSENGERS WOULD BE RESTRAINED ONLY BY THE FULLY EXTENDED BELT. THIS FAILS TO COMPLY WITH FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 208, "OCCUPANT CRASH PROTECTION".

SOME OF THE INVOLVED VEHICLES MAY HAVE BEEN EQUIPPED WITH LR78-15 "C" LOAD RANGE TRUCK TIRES INSTEAD OF LR78-15 "B" LOAD RANGE PASSENGER CAR TIRES. THE WHEELS PRESENTLY ON THE INVOLVED VEHICLES ARE INTENDED FOR USE WITH PASSENGER VEHICLE TIRES AND WERE NOT RATED FOR THE HIGHER MAXIMUM AIR PRESSURE AND LOAD RATINGS MOLDED INTO THE SIDEWALL OF THE LR78-15 "C" LOAD RANGE TRUCK TIRES.

THE SHIFT SELECTOR REACTION SPRINGS MAY BE DEFORMED AS A RESULT OF IMPROPER INSTALLATION OF SELECTOR LEVERS DURING COLUMN BUILDUP. THUS THE LEVER MAY NOT BE ABLE TO BE MOVED INTO THE INSERT DETENTS LOCATED IN THE STEERING COLUMN ASSEMBLY. THIS COULD PREVENT THE "PARK" GEAR FROM BEING ENGAGED.

THE WHEEL RIM DIAMETERS ON THESE VEHICLES MAY EXCEED DIMENSIONAL SPECIFICATIONS. THIS MAY CAUSE THE TIRES AND TUBES TO BE OVERSTRESSED DURING MOUNTING OR IMPROPERLY MOUNTED.

SOME OF THE STEEL WHEELS ON THE INVOLVED VEHICLES MAY HAVE BEEN IMPROPERLY MANUFACTURED. THESE WHEELS, OVER A PERIOD OF TIME, COULD CRACK IN THE WHEEL RIM AREA THROUGH NORMAL OPERATION, WITHOUT PRIOR WARNING.

ON SOME OF THE INVOLVED VEHICLES THE STEERING COUPLING FLANGE MAY HAVE BEEN IMPROPERLY ASSEMBLED AND COULD LOOSEN DURING NORMAL VEHICLE OPERATION.

THE ENGINE COOLING FAN BLADES MAY CRACK FROM VIBRATIONAL MOTION. BLADE FRAGMENTS MAY SEPARATE WITHOUT PRIOR WARNING FROM A CRACKED BLADE WHILE THE VEHICLE IS IN OPERATION.

BECAUSE OF ITS POSITION, THE WIRING ASSEMBLY MAY CHAFE AGAINST THE COWL-TO-BRAKE PEDAL SUPPORT BRACE WHICH IS LOCATED UNDER THE INSTRUMENT PANEL.