Customer Satisfaction Program 02B02 - Installation Of Optional Police Interceptor Package Upgrade Kit (02B02)

SUBJECT

Police Package Upgrade Kit Program 02B02-S2 Update:  Certain 1992 through 2003 Model Year Crown Victoria Police Interceptor (CVPI) Vehicles Currently in Law Enforcement Duty - EXPIRATION DATE REMOVED 

REF

Upgrade Program 02B02: Certain 1992 through 2003 Model Year Crown Victoria Police Interceptor (CVPI) Vehicles Currently in Law Enforcement Duty - Installation of Optional Police Interceptor Package Upgrade Kit - Communications Dated October, 2002 and April, 2003

PROGRAM EXPIRATION DATE REMOVED

Effective immediately, the November 30, 2003 expiration date for the Police Package Upgrade Kit installation has been removed  . The no-charge Police Package Upgrade Kit will continue to be available for certain 1992 - 2003 model year CVPI vehicles in law enforcement duty until further notice.

Eligible VINs will continue to be identified in OASIS until further notice.

OWNER LETTER

Follow-up letters will be mailed to those owners who have not fully completed installation of the Police Package Upgrade Kit on their vehicles.

QUESTIONS

Dealer questions can be directed to the Special Service Support Center at 1-800-325-5621.

ATTACHMENT

Owner Letter Sample

SUBJECT

Optional Upgrade Program 02B02-S1: Certain 1998 through 2003 Model Year Crown Victoria Police Interceptor (CVPI) Vehicles Currently in Law Enforcement Duty - Inspection of Optional Police Interceptor Package Upgrade Kit Installation 

REF

Optional Upgrade Program 02B02: TECHNICAL INSTRUCTIONS REINFORCEMENT (dated March 2003)

REF

Optional Upgrade Program 02B02: Certain 1992 through 2003 Model Year Crown Victoria Police Interceptor (CVPI) Vehicles Currently in Law Enforcement Duty - Installation of Optional Police Interceptor Package Upgrade Kit

OASIS: Yes

OWNER LIST: No

PROGRAM TERMS: This inspection program will be in effect until November 30, 2003, regardless of mileage.

PURPOSE OF THIS SUPPLEMENT AND INSPECTION PROGRAM

Based upon vehicle inspections and a vehicle survey, Ford has found that some technicians are not removing the bolts and J-nuts affixing the evaporative emissions canister to the underbody of the trunk as instructed. Steps 8 through 15 of the 02B02 Technical Instructions must be completed properly to provide the full benefit of the optional Upgrade Kit.  The bolts and J-nuts must be removed and replaced with three (3) rivets for the evaporative emissions canister to be correctly mounted in the modification.

Ford will contact owners of certain 1998 through 2003 model year vehicles who, according to our records, had the 02B02 Upgrade Kit installed and ask them to return their vehicle(s) to their servicing dealer for inspection.

Ford is authorizing a labor operation to pay for inspection of these vehicles. However, should inspection determine an improper or incomplete Upgrade Kit installation, dealers inspecting their own previous Upgrade Kit installations are responsible for, and liable for, correcting any improper installations  (Reference Attachment II: Labor Allowances and Parts Ordering Information).

VEHICLES AFFECTED BY THIS INSPECTION

Certain 1998 through 2003 Model Year Crown Victoria Police Interceptor (CVPI) vehicles currently in law enforcement duty built at the St. Thomas Assembly Plant from Job #1, 1998 through October 21, 2002 that, based upon claims submitted to Ford, had the Upgrade Kit installed.

SERVICE ACTION

This procedure involves inspecting for modifications to the evaporative emissions canister mounting to determine if any corrections are necessary. The inspection procedure follows in order of the original 02B02 Attachment III Technical Instructions.

When you have completed the Technical Instructions, you will have:

1. Removed and discarded  the two (2) canister bolts  and two (2) J-nuts  from the evaporative emissions canister flange (from the front edge along the Z-bracket). Do not leave canister bolts and J-nuts in place. 
2. Installed the three (3)  rivets.
3. Re-tightened the two (2) canister retaining nuts  (located along the back edge of the evaporative emissions canister) to 6 Nm (53 lb-in).

A check sheet is provided as part of the Technical Instructions for this supplement. Use this check sheet to inspect for proper modification of evaporative emissions canister mounting. The check sheet will help ensure steps 8 through 15 of the original 02B02 upgrade have been followed. Check off each item as you inspect it. After each set of checks, please answer whether the original modification was done properly. If any corrections were required, list them in the space provided. At the end of the entire procedure, sign and date the last page certifying the validity of the installation. Retain the check sheet in your dealership service records. 

FIRST-TIME 02B02 UPGRADE KIT INSTALLATION

For first-time installation of Optional Upgrade Program 02B02, consult the original 02B02 bulletin and Technical Instructions. Be mindful of the need to completely follow all steps of the Upgrade Kit installation exactly as written in the 02B02 Technical Instructions and as reinforced in this supplement. 

ATTACHMENTS

1. Attachment I: Administrative Information
2. Attachment II: Labor Allowances and Parts Ordering Information
3. Attachment III: Technical Information
4. Sample Customer Letter(s)

QUESTIONS?

1. Claims Information:.........................................1-800-423-8851
2. FSA VIN Lists Support:....................................1-800-555-9601
3. Other Program Questions:................................1-800-325-5621

OASIS

When a customer requests inspection of an Upgrade Kit installation, use OASIS to determine eligibility for this inspection program. Only vehicles having previously had the Upgrade Kit installed are eligible for this inspection program. 

PLEASE NOTE

Inspect, before delivery, all upgraded  vehicles in stock with build dates on or before October 21, 2002.

CLAIMS PREPARATION AND SUBMISSION

• Enter claims using DWE.
• Refer to ACESII manual for claims preparation and submission information.
• A part quantity of three (3) [rivets] should be entered on the ACES II claim.

OWNER REFUNDS

Owner refunds are not applicable for this inspection.

RENTAL VEHICLES

The use of rental vehicles is not authorized for this inspection.

LABOR ALLOWANCES FOR 02B02 INSPECTION

Reference the original 02B02 dealer bulletin for first-time Upgrade Kit installation labor times and technical instructions. Inspections do not apply to vehicles that have not had 02B02 performed previously. 

PARTS REQUIREMENTS / ORDERING INFORMATION

Parts will not be direct shipped for this program. Order your parts requirement through normal order processing channels. Effective immediately, follow the normal order process for Stock Orders and Interim Orders. For Emergency Orders for the first 30 days following launch, call 1-800-325-5621. After 30 days, follow the normal order process for Emergency Orders.

ORDER INFORMATION

The DOR/COR for this program is 50287  . This number identifies parts ordered for this Customer Satisfaction Program through the Special Service Support Center (1-800-325-5621).

DEALER PRICE

For latest prices, check DOES II or updated price book.

PARTS RETENTION

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.

INSPECTION

1. Evaporative Emissions Canister Inspection
   WARNING: DO NOT LEAVE BOLTS AND J-NUTS IN PLACE.  THE RIVETS ARE INTENDED TO REPLACE CANISTER BOLTS AND J-NUTS. THEY ARE NOT UTILIZED TO STRENGTHEN THE MECHANICAL CONNECTION BETWEEN THE Z-BRACKET AND THE EVAPORATIVE EMISSIONS CANISTER MOUNTING FLANGE. USING RIVETS OTHER THAN THE SUPPLIED HIGH CLAMP-LOAD RIVETS CAN JEOPARDIZE THE REPAIR.
   NOTE: Field audits have revealed portions of this repair are not being performed properly. Listed here are examples of what was found:
   

   • Bolts and J-nuts still installed - rivets installed (correctly or incorrectly)
   • Bolts and J-nuts still installed - rivets NOT installed
   • Only J-nuts still installed - rivets installed
   • Wrong number of rivets installed
   • Rivets not properly spaced along Z-bracket
   • Rivets installed on wrong Z-bracket flange (securing Z-bracket to floor instead of Z-bracket to EVAP canister)

   
   If the bolts and/or J-nuts are still installed, they must be removed. If the rivets are installed, they will need to be drilled out to allow removal of the J-nuts. Once they are removed, NEW high clamp-load rivets must be installed as outlined in 02B02 Attachment III.

   With the exception of corrosion, note any physical damage to the vehicle in the area of the evaporative emissions canister that would interfere with the service required (removal of bolts/J-nuts, installation of rivets). List the damage here. Any damage to this area must be corrected prior to completing inspection and any necessary repairs. Repair of physically damaged evaporative emissions canister components is customer pay and cannot be charged to this program or the original Optional Upgrade Program 02B02.

See Figure 1.

1. [ ] Verify the original attaching hardware (bolts and J-clips) has been removed and discarded from the front edge of the canister along the Z-bracket.
2. [ ] Verify the three (3) rivets have been installed equal distances apart from each other (about 2 inches) on the front edge of the of the canister along the Z-bracket.
3. [ ] Verify the canister retainer nuts, located at the rear corners of the canister assembly, are tightened to specification (6 Nm [53 lb-in]).

Was the Evaporative Emissions Canister service performed properly? YES  [ ]NO  [ ]

If NO  , describe correction(s) completed.

SUBJECT

Optional Upgrade Program 02B02: TECHNICAL INSTRUCTIONS REINFORCEMENT 

REF

Optional Upgrade Program 02B02: Certain 1992 through 2003 Model Year Crown Victoria Police Interceptor (CVPI) Vehicles Currently in Law Enforcement Duty - Installation of Optional Police Interceptor Package Upgrade Kit

It has come to Ford Motor Company's attention that some dealerships may not have properly completed all steps when installing 02B02 upgrade kit on 1998 through 2003 model year vehicles. Specifically, Steps 8 through 15 of the Technical Instructions cannot be skipped and must be completed properly to provide the full benefit of the optional upgrade.

Please read this important notice and share it with technicians who may install the 02B02 kit. 

If you have any questions, please call the Special Service Support Center at 1-800-325-5621.

• Refer to 02B02 Dealer Bulletin using the FSAs (Recalls), TSBs & EDSRs link from the www.FMCDealer.com  homepage for full Technical Instructions.
• It is critical that all steps in the Technical Instructions be followed and completed when performing Optional Upgrade Program 02B02. 
• For '98 - '03 model year vehicles, pay particular attention to Steps 8 through 15 - replacement of evaporative emissions canister retainer bolts and J-clips (located along the front edge of the canister) with three (3) rivets. When you have completed this portion of the Technical Instructions, you should have:
  1. Removed and discarded  the two (2) canister bolts  and two (2) J-nuts  from the evaporative emissions canister flange (from the front edge along the Z-bracket).
  2. Installed the three (3) rivets.
  3. Re-tightened the two (2) canister retaining nuts  (located along the back edge of the evaporative emissions canister) to 6 Nm (53 lb-in).
• Be sure to watch the video footage accompanying key steps in the Technical Instructions.

This communication confirms the Technical Instructions for Optional Upgrade Program 02B02.

SUBJECT

RETAIL CUSTOMER PURCHASE OF KITS USED IN  Optional Upgrade Program 02B02

REF

PARTS UPDATE - Kits used in Optional Upgrade Program 02B02

RETAIL PURCHASE AND INSTALLATION OF OPTIONAL UPGRADE KIT

The October 2002 Dealer Bulletin for 02B02 indicated that kits would be available for retail purchase and installation once supply exceeded registered law enforcement demand.

Restrictions against retail sale were removed beginning January 2003. 

Anticipated retail demand is limited.

• There are no restrictions against retail sale  (vehicle not currently in law enforcement duty) if a customer wishes to purchase the kit.
• Kit purchase and installation for retail is at owner expense and is a transaction between the dealer and customer.
• Refer to 02B02 Dealer Bulletin and Parts Update at www.FMCDealer.com  for kit ordering information. For latest dealer prices, check DOES II or updated price book.

SUBJECT

Optional Upgrade Program 02B02: PARTS UPDATE

REF

Optional Upgrade Program 02B02: Certain 1992 through 2003 Model Year Crown Victoria Police Interceptor (CVPI) Vehicles Currently in Law Enforcement Duty - Installation of Optional Police Interceptor Package Upgrade Kit

PARTS FOR 02B02 AVAILABLE THROUGH THE NORMAL ORDER PROCESS

• Effective immediately, dealers may order parts for 02B02 through the normal order process. 
• Reimbursement for this kit and installation remains limited to CVPI vehicles currently in Law Enforcement Duty. Refer to dealer bulletin for program details. 
• Law enforcement fleets are no longer required to register via the web (www.cvpi.com)  .
• A fleet-supplied Authorization Number is no longer needed for a dealer to order parts.
• Dealers are no longer required to contact the Special Service Support Center to place parts orders.
• If a customer wishes to purchase the kit, there are no restrictions against retail sale  .

There are no other changes to Optional Upgrade Program 02B02.

SUBJECT

Optional Upgrade Program 02B02: Certain 1992 through 2003 Model Year Crown Victoria Police Interceptor (CVPI) Vehicles Currently in Law Enforcement Duty - Installation of Optional Police Interceptor Package Upgrade Kit

OASIS : Yes - Activated October 22, 2002

1. Only CVPI vehicles built in the affected time period currently in law enforcement duty are eligible for this program. Ford has used motor vehicle and U.S. postal records to purge vehicles known to no longer be in law enforcement duty.
2. If you encounter a vehicle currently in law enforcement duty that is not listed in OASIS, see ATTACHMENT I.
3. See "FINAL ELIGIBILITY CHECK" on ATTACHMENT I.

OWNER LIST: No

PROGRAM TERMS: This program will be in effect until November 30, 2003, regardless of mileage.

AFFECTED VEHICLES

Certain 1992 through 2003 Model Year Crown Victoria Police Interceptor (CVPI) vehicles currently in law enforcement duty built at the St. Thomas Assembly Plant from Job #1, 1992 through October 21, 2002.

REASON FOR PROGRAM

The CVPI is a safe and effective vehicle for police work. On October 3, 2002, the National Highway Traffic Safety Administration (NHTSA) closed its investigation into high-speed rear impacts involving Crown Victoria vehicles without finding a defect. Ford accepted the challenge to look for additional opportunities to make the vehicle (and the police-working environment) even safer in high-risk situations.

Because law enforcement vehicles are frequently exposed to high-speed traffic situations, Ford is making available to law enforcement fleets optional upgrades that will reduce the risk that high-speed rear impacts will cause fuel tank punctures.

SERVICE ACTION

The dealer will install an optional, upgrade kit at no-charge for CVPI vehicles currently in law enforcement duty. The upgrades are:

• Axle-mounted shields
• Fuel tank strap shields
• A differential shield
• Revised mounting of the evaporative emissions canister ('98 - '03 MY only)

SPECIAL PARTS ORDERING PROCEDURE

Beginning October 22, 2002, law enforcement fleets using CVPI vehicles currently in law enforcement duty will be asked to register using their Fleet Identification Number (FIN) on www.cvpi.com  to allow priority parts ordering. Fleets without web access or FIN codes may register at the Police Interceptor Registration Center via telephone at 1-800-490-4288. Eligible fleets may establish a FIN code by calling the Fleet Customer Information Center at 1-800-34-FLEET.

Once on the cvpi.com website, the fleet representative will input fleet name, contact and vehicle information. The fleet representative must also indicate he/she agrees to review information on the cvpi.com website. Fleets without web access will be sent information contained on the website. Once the required information is provided, an Authorization Number will be generated by the website. The fleet will provide their dealer(s) of choice the Authorization Number, which will allow priority ordering of parts.

Dealers will then contact the Low Volume Coordination Center at 1-800-248-0186 and provide the fleet's Authorization Number to order parts (up to the authorized quantity). A verification of the Authorization Number will be performed and the parts will be ordered for you by the Program Coordination Center.

Fleets who do not register may still order parts through their servicing dealer(s); however, priority fulfillment of parts orders will be given to registered fleets.

Depending upon law enforcement fleet registrations, upgrade kits should arrive at your dealership after October 28, 2002. It is estimated that 10% of total kits required to upgrade CVPI vehicles will be available by October 31, 2002.  No kits will be available for law enforcement fleets that choose not to register or for retail purchase and installation until supply exceeds registered law enforcement demand. It is anticipated that parts ordering restrictions will be removed beginning January 2, 2003.

ATTACHMENTS

1. Attachment I: Administrative Information
2. Attachment II: Labor Allowances and Parts Ordering Information
3. Attachment III: Technical Information
4. Customer Letter

QUESTIONS?

1. Claims Information:.........................................1-800-423-8851
2. Other Program Questions:................................1-800-325-5621

OASIS

You must use OASIS to determine if a vehicle is eligible for this program. Not all CVPI vehicles built in the affected time period are eligible for this program because many are no longer in law enforcement duty. Ford has used motor vehicle and U.S. postal records to purge vehicles known to no longer be currently in law enforcement duty. If you encounter a vehicle currently in law enforcement duty that is not listed in OASIS, see below. Also, see "FINAL ELIGIBILITY CHECK" below for additional restrictions.

VIN ADDITION OF NON-P71 VEHICLES CURRENTLY IN LAW ENFORCEMENT DUTY

Non-Police Interceptor package Crown Victoria vehicles (P70, P72, P73, P74) currently in law enforcement duty & subjected to risk of high-speed, high-energy rear impact collisions may have 02B02 performed at no-charge at the request of a law enforcement official. Documentation of law enforcement use, such as a letter on department letterhead with VIN, is required. Please call 1-800-325-5621 to request the addition to OASIS of a non-P71 Crown Victoria vehicle currently in law enforcement duty.

FINAL ELIGIBILITY CHECK AND REMOVAL OF INELIGIBLE VEHICLES FROM OASIS

In addition to preliminary eligibility verification through OASIS, please verify by visual inspection the vehicle is currently in law enforcement duty.

Under 02B02, all CVPI vehicles currently in law enforcement duty can be upgraded at no-charge. Many CVPI vehicles are sold to the secondary market (taxi, private use) after retirement from law enforcement duty. Based on vehicle registration data available to Ford, some of these secondary market vehicles may inadvertently receive an owner letter. Therefore, possession of a letter from Ford does not, in itself, indicate eligibility for 02B02. CVPI vehicles in the secondary market are not eligible for no-charge upgrades under the terms of program 02B02. If the CVPI is no longer currently used in law enforcement duty, and the VIN is active in OASIS, submit a claim for VIN closure (see ATTACHMENT II).

PLEASE NOTE

If requested by your law enforcement fleet customer, correct in-stock vehicles before delivery.

You must contact the Low Volume Coordination Center at 1-800-248-0186 to arrange for parts if you have an involved vehicle in stock. When calling this number, identify Optional Upgrade Program 02B02 and have the VIN of the dealer stock vehicle to be serviced.

DEALER-OWNER CONTACT

An Online Involved Unit Listing will not be available for this program. Not all CVPI vehicles built in the affected time period are eligible for this program. Ford has used motor vehicle and U.S. postal records to purge vehicles known to no longer be currently in law enforcement duty.

CLAIMS PREPARATION AND SUBMISSION

• Enter claims using DWE.
• Refer to ACESII manual for claims preparation and submission information.

STATUS OF TECHNICAL SERVICE BULLETIN (TSB) 01-21-14

Optional Upgrade Program 02B02 eliminates the need for TSB 01-21-14 . Warranty claims submitted for performing TSB 01-21-14 on or after September 27, 2002 will not be processed.

OWNER REFUNDS FOR TSB 01-21-14

Ford Motor Company will only refund owner-paid repairs for TSB 01-21-14 made before September 27, 2002 on CVPI vehicles currently in law enforcement duty. No other requests for refunds, including repairs not endorsed by Ford Motor Company, will be accepted. Refer to ACESII manual for refund information.

1. Program Code: 02B02
2. Misc. Expense: REFUND
3. Misc. Expense: ADMIN
4. Misc. Expense: 0.2 Hr.

RENTAL CARS

The use of rental vehicles is not authorized for this program.

LABOR ALLOWANCES

PARTS ORDERING INFORMATION

LAW ENFORCEMENT VEHICLES:

Beginning October 22, 2002, law enforcement fleets using CVPI vehicles currently in law enforcement duty will be asked to register using their Fleet Identification Number (FIN) on www.cvpi.com  to allow priority parts ordering. Fleets without web access or FIN codes may register at the Police Interceptor Registration Center via telephone at 1-800-490-4288. Eligible fleets may establish a FIN code by calling the Fleet Customer Information Center at 1-800-34-FLEET.

Once on the cvpi.com website, the fleet representative will input fleet name, contact and vehicle information. The fleet representative must also certify he/she agrees to review information on the cvpi.com website. Fleets without web access will be sent information contained on the website. Once the required information is provided, an Authorization Number will be generated by the website. The fleet will provide their dealer(s) of choice the Authorization Number, which will allow priority ordering of parts.

Dealers will then contact the Low Volume Coordination Center at 1-800-248-0186 and provide the fleet's Authorization Number to order parts (up to the authorized quantity). A verification of the Authorization Number will be performed and the parts will be ordered for you by the Program Coordination Center.

Fleets who do not register may still order parts through their servicing dealer(s); however, priority fulfillment of parts orders will be given to registered fleets.

Depending upon law enforcement fleet registrations, upgrade kits should arrive at your dealership after October 28, 2002. It is estimated that 10% of total kits required to upgrade CVPI vehicles will be available by October 31, 2002.  No kits will be available for law enforcement fleets that choose not to register or for retail purchase and installation until supply exceeds registered law enforcement demand. It is anticipated that parts ordering restrictions will be removed beginning January 2, 2003.

STOCK VEHICLES

If requested by your law enforcement fleet customer, upgrade before delivery in-stock vehicles listed in OASIS.

Contact the Low Volume Coordination Center at 1-800-248-0186 to arrange for parts. When calling this number, identify Customer Satisfaction Program 02B02 and have the VIN of the dealer stock vehicle to be serviced.

Parts ordering will be restricted to the process listed above through December 31, 2002. Beginning January 2, 2003, order your parts requirement through normal order processing channels.

PART REQUIREMENTS

Parts will not be direct shipped for this program. Parts will be available the week of October 28, 2002 at approximately 10% of total kits required to upgrade CVPI vehicles. Although at launch the upgrade kit inventory may not support completion of all orders, partial shipments will be made on a fair share basis from facing depots until order requirements are completed. Up through December 31, 2002,  order status by fleet and authorization number will be communicated via CUDL and DOES II.

All Orders Until December 31, 2002  Contact 1-800-248-0186 with Authorization Number

All Orders January 2, 2003 and after Normal Order Process

ORDER INFORMATION

The DOR/COR for this program is 50287. This number identifies parts ordered for this Optional Upgrade Program through the Low Volume Coordination Center (1-800-248-0186).

DEALER PRICE

For latest prices, check DOES II or updated price book.

PARTS RETENTION

Not applicable for this program.

EXCESS STOCK RETURN

Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000.

AFFECTED VEHICLES

CERTAIN 1992 THROUGH 2003 MODEL YEAR CROWN VICTORIA POLICE INTERCEPTOR (CVPI) VEHICLES CURRENTLY IN POLICE DUTY 

OVERVIEW

This procedure provides details for installation of the following:

For all affected vehicles

• Two (2) rear axle shields
• One (1) differential cover shield
• Two (2) fuel tank strap shields

Additional parts required for 1998 through 2003 model year vehicles

• Two (2) foam pads onto the evaporative emissions canister
• Replacement of evaporative emissions canister retainer bolts and J-clips (located along the front edge of the canister) with three (3) rivets

SERVICE PROCEDURE

1. Raise the vehicle on a hoist.
2. NOTE:  Shields are molded with "LH" and "RH" to ease identification.

   Install the left and right axle shields being sure to position them so there is clearance between the shield and the stabilizer bar as illustrated. On 1992 to 1997 model year vehicles, be sure the ABS circuit wiring harness is not pinched under the shield and the right side parking brake cable is positioned in the notch molded into the shield. Tighten the clamps to 6 Nm (53 lb-in). See Figures 1 and 2.

   In some cases, excess weld material on the coil spring seat or stabilizer bar bracket can interfere with clamp installation. If necessary, grind away only enough excess weld material to allow for correct seating of the shield and clamp onto the axle. DO NOT grind the parent metal.

3. CAUTION:  Tie straps, which are required for 1998 to 2002 model year vehicles only, have specific heat resistant properties. Use of a tie strap other than what is supplied in the kit can jeopardize the repair. Also, correct orientation of the tie strap is critical to the repair. The head of the tie strap must be positioned on the forward-facing side of the shock mount bracket.

   On 1998 to 2002 model year vehicles, install one (1) tie strap on each shield to secure it to the shock absorber lower mount bracket as illustrated. If necessary, use pliers and LIGHT  force to engage the locking feature of the tie strap. DO NOT STRETCH THE TIE STRAP UNNECESSARILY. See Figure 3.

4. On 1992 to 1997 model year vehicles, install the supplied convolute over the ABS circuit wiring leading to each rear wheel. Position the convolute so it is up against the grommet as shown in the illustration. Secure with vinyl tape. See Figure 4.
5. CAUTION:  Do not loosen or remove more than three (3) differential cover bolts at any one time or a leak may develop.
   NOTE: If the axle identification tag (all affected model year vehicles) and/or fluid identification tag (2002 to 2003 model year vehicles only) interferes with the installation of the differential cover shield, relocate the tag(s) as necessary to another bolt location on the cover. In some instances, the tag may simply need to be rotated to avoid interference with the shield installation.

   Reposition the axle and/or fluid identification tag as necessary. Hand-tighten the bolt(s) at this time. See Figure 5.

6. Remove and discard  the three (3) differential cover bolts located at the 4, 6 and 8 o'clock positions. Position the differential cover shield and press into place. The cover should fit snug over the existing bolts. Install the three (3) new  bolts. Tighten all loosened or removed bolts to 45 Nm (33 lb-ft). See Figure 5. Be sure to also tighten the axle tag bolt(s) to specification.
7. CAUTION:  The fuel tank strap shields are marked for right and left sides of the vehicle. Be sure to install them in the correct location and so that they are oriented from the outside toward the center of the vehicle.
   NOTE: Spray the area around the fuel tank and strap brackets with silicone lubricant to assist with shield installation. Use a rubber mallet to lightly tap the shields into position only if necessary.

   Install the left and right fuel tank strap shields as follows. See Figure 6.

   1. Insert the shield between the fuel tank and the strap from the outside, pushing it in toward the center of the vehicle.
   2. Position the long tab up into the strap bracket.
   3. Secure the push-pin retainers into the mating holes in the strap bracket to secure the shield.
   4. Visually check to make sure the shield is correctly positioned. Peel the backing off the adhesive strip and, while holding the upper portion against the fuel tank flange, secure the two halves firmly together.
   NOTE:

   • For 1992 to 1997 model year vehicles, the service procedure is complete. Lower the vehicle.
   • For 1998 to 2003 model year vehicles, continue with this procedure.
8. Remove the two (2) evaporative emissions canister retainer bolts from the front edge along the Z-bracket.
9. Using a straightedge, draw a line indicating the centerline connecting the (2) two bolt holes. Then, measuring from the edge of either of the two bolt holes, mark the centerline at 50 mm (2-in), 101 mm (4-in) and at 152 mm (6-in). See Figure 7.
10. CAUTION:  DO NOT drill through the trunk floor when drilling the rivet holes. Place a drill stop or an abundance of tape 12 mm (1/2-inch) from the tip of the drill bit.

    Reinstall one of the removed bolts to hold the canister securely, then drill the three, 5 mm (13/64-inch) rivet holes through the Z-bracket and the evaporative emissions canister mounting flange. See Figure 8.

11. Remove the one (1) bolt and the two (2) evaporative emissions canister retaining nuts and lower the canister off of the studs and disconnect the canister purge valve electrical connector. Discard  both removed canister bolts.
12. Remove and discard  the two (2) J-nuts from the evaporative emissions canister flange.
13. Using Motorcraft Brake Parts Cleaner or equivalent and a clean shop rag, clean the top surface of the canister. Affix the two (2) self-adhesive foam pads onto the canister in the position shown in the illustration. See Figure 9.
14. Reconnect the canister purge valve, then position the evaporative emissions canister and install the two (2) retaining nuts finger tight.
15. CAUTION:  The rivets supplied in the kit provide a high clamp-load and MUST be used. Using rivets other than what is supplied in the kit may jeopardize the repair.
    NOTE: The kit comes with a total of five (5) rivets. Only three (3) are required for this repair. These rivets are very sturdy and may be difficult to install with a small, hand-held pop rivet installer. The use of a large capacity or air/hydraulic rivet installer is recommended but is not necessary.

    Install the three (3) rivets, then tighten the two canister retaining nuts to 6 Nm (53 lb-in).

16. Lower the vehicle.