Safety Recall 21S05 - Airbag Module Inspection And Replacement (21S05)

SUBJECT

Safety Recall 21S05 

Certain 2005-2014 Mustang, 2005-2006 Ford GT, 2004-2011 Ranger, 2006-2012 Fusion and MKZ/Zephyr, 2006-2011 Milan, and 2007-2010 Edge and MKX Vehicles

Airbag Module Inspection and Replacement

AFFECTED VEHICLES

Certain vehicles listed below that were serviced with a suspect airbag module in, or prior to, March 2019 and after having the airbag module or inflator replaced in accordance with safety recall 15S21 , 16S26 , 17S01 , 17S42 , 18S01 , 18S02 , and/or 19S01 . Fewer than 2,000 vehicles are expected to be affected. 

Known affected vehicles are identified in OASIS and FSA VIN Lists.

REASON FOR THIS SAFETY RECALL

In some of the affected vehicles, the driver and/or passenger airbag module may have been serviced with an airbag module that contained a recalled Takata airbag inflator. NHTSA and Takata have determined that the propellant in certain Takata airbag inflators can experience an alteration over time with exposure to certain climate conditions. A combination of time, high temperature fluctuations, and humidity contribute to the degradation of the propellant in the inflators. This degradation can cause the propellant to burn too quickly, creating high pressure inside the inflator, and in extreme cases causing the inflator to rupture in the event of a crash necessitating airbag deployment. A ruptured inflator can send inflator parts toward vehicle occupants resulting in serious injury or death. Additional information regarding Takata recalls can be found at www.nhtsa.gov  and www.safercar.gov  .

SERVICE ACTION

For known affected vehicles, dealers are to inspect, and if necessary, replace the driver and/or passenger airbag inflators per the technical instructions.

Additionally, dealers are to review the part numbers in Attachment XIV: Recall Notice and identify any related part sales records. Contact any customers to whom a suspect airbag module was sold, provide them with a copy of the Recall Notice (Attachment XIV), and schedule a service date for an inspection and repairs as needed.

For any vehicle that is not identified in OASIS or FSA VIN Lists that is suspected to have an affected airbag module installed, please contact the Special Service Support Center (SSSC) via the Web Contact Site to request adding an affected VIN to this equipment recall prior to performing this service action. Use a VIN specific Non-Involved Vehicle Request.

This service must be performed on all vehicles at no charge to the vehicle owner.

Dealers must also return any remaining in-stock parts listed in Attachment XIV: Recall Notice.

OWNER NOTIFICATION MAILING SCHEDULE

Owner letters are expected to be mailed the week of March 8, 2021. Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

PLEASE NOTE: 

Federal law requires dealers to complete this recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $21,000 per vehicle. Correct all vehicles in your new vehicle inventory before delivery. 

ATTACHMENTS

1. Attachment I: Administrative Information
2. Attachment II: Labor Allowances and Parts Ordering Information
3. Attachment III: Technical Information - 2005-2014 Mustang
4. Attachment IV: Technical Information - 2005-2006 Ford GT
5. Attachment V: Technical Information - 2004-2006 Ranger
6. Attachment VI: Technical Information - 2007-2011 Ranger
7. Attachment VII: Technical Information - 2006-2009 Fusion and Milan
8. Attachment VIII: Technical Information - 2010-2012 Fusion and 2010-2011 Milan
9. Attachment IX: Technical Information - 2006-2009 MKZ/Zephyr
10. Attachment X: Technical Information - 2010-2012 MKZ
11. Attachment XI: Technical Information - 2007-2010 Edge
12. Attachment XII: Technical Information - 2007-2010 MKX
13. Attachment XIII: Airbag Inflator Core Return
14. Attachment XIV: Recall Notice
15. Owner Notification Letters

QUESTIONS & ASSISTANCE

For questions and assistance, contact the Special Service Support Center (SSSC) via the SSSC Web Contact Site. The SSSC Web Contact Site can be accessed through the Professional Technician Society (PTS) website using the SSSC link listed at the bottom of the OASIS VIN report screen or listed under the SSSC tab.

Sincerely,

David J. Johnson

OASIS ACTIVATION

OASIS will be activated on February 17, 2021.

FSA VIN LISTS ACTIVATION

FSA VIN Lists will be available through https://web.fsavinlists.dealerconnection.com  by February 19, 2021. Owner names and addresses will be available by March 19, 2021.

SOLD VEHICLES

• Ford has not issued instructions to stop selling/delivering or driving used vehicles under this safety recall. Owners should contact their dealer for an appointment to have their vehicles remedied as soon as practicable. Owners can continue to safely drive their vehicles.
• Immediately contact any of your affected customers whose vehicles are not on your VIN list but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date.
• Correct other affected vehicles identified in OASIS which are brought to your dealership.
• Dealers are to prioritize repairs of customer vehicles over repairs of new and used vehicle inventory.

STOCK VEHICLES

• Use OASIS to identify any affected vehicles in your used vehicle inventory.

DEALER-OPERATED RENTAL VEHICLES

The Fixing America's Surface Transportation (FAST) Act law effective June 2016 prohibits a rental company from selling, renting or leasing vehicles subject to a safety or compliance recall. Please consult your legal counsel for legal advice.

TITLE BRANDED/SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this recall.

OWNER REFUNDS

Refunds are not approved for this program.

RENTAL VEHICLES

With proper parts ordering and service appointment scheduling, rental vehicles should not be required. However, if a customer requests a rental vehicle while their vehicle is being repaired, dealers are pre-approved for up to 4 days of rental reimbursement (no approval code required). See below for approved dollar amounts.

If more than 4 rental days are required, dealers must request prior-approval from the SSSC for any additional days before  the initial 4 days expire. Submit an SSSC web contact for all required rental days and provide details outlining why the additional days are required.

If a customer requests a rental vehicle, dealers must retain the customer's vehicle until the recall repair is completed and the rental vehicle is returned. Dealers must also notify the customer promptly once the recall repair is completed. Rentals exceeding 7 days from the date the customer is notified that their vehicle is repaired, will not be reimbursed.

Alternative Transportation:  If a customer is unable or does not wish to use a rental vehicle, the rental reimbursement allowance can be used for alternative transportation if necessary. The maximum reimbursement amounts listed below apply. Examples of alternative transportation includes taxis, public transportation (subway, train, bus, etc.), or ridesharing services (Uber, Lyft, etc.).

If a customer has paid for a rental vehicle or alternative transportation for the purpose of this recall, they are eligible for reimbursement within the guidelines outlined above. Dealers must follow the same process for claiming rental vehicle reimbursement and then refund the customer.

ADDITIONAL REPAIR (LABOR TIME AND/OR PARTS)

Additional repairs identified as necessary to complete the FSA should be managed as follows:

• For related damage and access time requirements, refer to the Warranty and Policy Manual/Section 6 - Ford & Lincoln Program Policies/General Information & Special Circumstances for FSA's/Related Damage.
• For vehicles within new vehicle bumper-to-bumper warranty coverage, no SSSC approval is required, although related damage must be on a separate repair line with the "Related Damage" radio button checked.
  • Ford vehicles - 3 years or 36,000 miles
  • Lincoln vehicles - 4 years or 50,000 miles
• For vehicles outside new vehicle bumper-to-bumper warranty coverage, submit an Approval Request to the SSSC Web Contact Site prior to completing the repair.

CLAIMS PREPARATION AND SUBMISSION

• Claim Entry:  Enter claims using Dealer Management System (DMS) or One Warranty Solution (OWS) online.
  • When entering claims, select claim type 31: Field Service Action. The FSA number 21S05 is the sub code.
  • For additional claims preparation and submission information, refer to the Recall and Customer Satisfaction Program (CSP) Repairs in the OWS User Guide.
• Related Damage/Additional labor and/or parts  : Must be claimed as Related Damage on a separate repair line from the FSA with same claim type and sub code as described in Claim Entry above.
  IMPORTANT: Click the Related Damage Indicator radio button.
• Rentals:  Dealers are pre-approved for up to 4 days of rental vehicle reimbursement with the following maximum rates:

  Make of Recalled Vehicle	Maximum Reimbursement per Day (including tax)
  Ford	$44
  Mercury	$44
  Lincoln	$55

  • If the rental period does NOT exceed 4 days  , submit the rental expense on the same claim and RO line as the repair. Use Misc. Expense Code "RENTAL". No approval code is needed  .
  • If the rental period exceeds 4 days  , a web contact must be submitted to the Special Service Support Center (SSSC) before  the initial 4 days expire to request approval. Include details outlining why additional rental days are required.
    • The SSSC web contact must include all rental expenses, parts costs, and labor costs. All of these amounts are required so the approval code will cover the entire RO line amount.
      • Submit the rental expenses on the same claim and RO line as the repair. Use Misc. Expense Code "RENTAL".

LABOR ALLOWANCES

2005-2014 Mustang 

2005-2006 Ford GT 

2004-2006 Ranger 

2007-2011 Ranger 

LABOR ALLOWANCES ARE CONTINUED ON THE FOLLOWING PAGE 

2006-2009 Fusion and Milan 

2010-2012 Fusion and 2010-2011 Milan 

2006-2009 MKZ/Zephyr 

2010-2012 MKZ 

2007-2010 Edge 

2007-2010 MKX 

PARTS REQUIREMENTS/ORDERING INFORMATION

Order your parts through normal order processing channels.

Driver Airbag Inflators and Modules 

Passenger Airbag Inflators and Modules 

PARTS RETENTION AND RETURN

It is critical that all original airbag inflators removed from vehicles are returned to ensure that they are not allowed back into the market. 

The return mechanism for airbag inflators under this safety recall varies based on the part number of the new airbag module or inflator. Parts will either have a $100 core charge or will be issued an FCS-700 tag.

Review Attachment XIII: Airbag Inflator Core Return in full for the appropriate part return instructions.

EXCESS STOCK RETURN

To support NHTSA-assigned completion mandates for the Takata airbag recalls, and the numerous Ford and Lincoln vehicles that require repairs under the Takata airbag recalls, excess stock returns will not be accepted for unused new recall remedy parts until 85% of all affected vehicles have been repaired. Dealers should utilize their FSA VIN Lists and DMS information to contact their affected customers and repair all vehicles that are brought to your dealership with an open Takata airbag recall (FSAs 15S21 , 17S42 , 18S02 , and 19S01 ).

SERVICE PROCEDURE

2005-2014 MY DRIVER AIRBAG INFLATOR INSPECTION

WARNING: Failure to follow the instructions and warnings in the Workshop Manual may result in injury.

NOTE: If the Airbag Readiness light indicates no Supplemental Restraint System (SRS) faults are present, it is not necessary to follow the WSM SRS Depowering and Repowering steps when performing this service procedure. Turn the ignition to OFF and wait 1 minute, then it is safe to proceed with airbag inflator or airbag module replacement.

NOTE: The ignition must remain OFF until this service procedure is completed.

1. Remove the driver airbag module. Please follow the Workshop Manual (WSM) procedures in Section 501-20.
2. Set the airbag face down onto a surface that will not scratch or damage the airbag face.
3. Inspect the label on the Driver Airbag inflator as shown in Figure 1. Is the label white in color?

   Yes - PASS

   • Reinstall the Driver Airbag. Please follow the WSM procedures in Section 501-20.
   • Proceed to the Passenger Airbag Inflator Inspection on Page 6.

   No - DOES NOT PASS - Proceed to Driver Airbag Module or Inflator Replacement per MY below.

   • 2013-2014 MY Vehicles - Proceed to Replace Driver Airbag Module on Page 3. 
   • 2005-2012 MY Vehicles - Proceed to Replace Driver Airbag Inflator on Page 4. 
   NOTE: If the label cannot  be read or is missing entirely, perform the Driver Airbag Module or Inflator Replacement per MY above.

SERVICE PROCEDURE

SERVICE PROCEDURE

SERVICE PROCEDURE

ATTACHMENT XII

CERTAIN 2007 - 2010 MODEL YEAR MKX VEHICLES - PASSENGER AIRBAG INFLATOR INSPECTION 

SERVICE PROCEDURE

PASSENGER AIRBAG INFLATOR INSPECTION

1. Fully lower the glove compartment door and look up at the passenger airbag module. Inspect the passenger airbag inflator end for the presence of a plastic end cap as shown in Figure 1. Is the plastic end cap present on the airbag inflator?

   Yes - PASS - Inspection Complete. Raise and close the glove compartment door.

   No - DOES NOT PASS - Proceed to the Passenger Airbag Module Replacement on Page 2.

PASSENGER AIRBAG MODULE REPLACEMENT

WARNING: Failure to follow the instructions and warnings in the Workshop Manual (WSM) may result in injury.

NOTE: If the Airbag Readiness light indicates no Supplemental Restraint System (SRS) faults are present, it is not necessary to follow the WSM SRS Depowering and Repowering steps. Turn the ignition to OFF and wait 1 minute, then it is safe to proceed with airbag inflator replacement.

NOTE: The ignition must remain OFF until this service procedure is completed.

1. Record the 13 character serial number of the new  airbag module on the repair order. See Figure 2.
2. Replace the passenger airbag module. Please follow the WSM procedures in Section 501-20.
   NOTE: When reinstalling the airbag module, hand-tighten the bolts and then torque to specification. Overtightening the bolts may result in instrument panel damage.
3. Package the replaced airbag module in the new  part box and provide to the appropriate dealership personnel for part returns.

RETURN PROCESS - PARTS WITH FCS-700 TAG

Dealers must monitor their OWS parts status report. An FCS-700 tag will be generated for each applicable airbag inflator. Parts will be picked up by the RCRCs, except for dealerships outside the 48 contiguous United States.

Key Information: 

• All replaced driver airbag inflators and modules must be returned in the new part box with original packaging. If the new part box is damaged or lost, contact XPO logistics at 210-250-5079 or SCFieldAction.14305@xpo.com  for a replacement box.
  • Ensure that you have processes in place to safeguard the packaging.
  • The dealer-provided Haz-Mat Materials must also be returned in the packaging. The new replacement service part packaging is certified with the appropriate DOT marks and labels.
  • RCRCs will not accept any airbag inflators without correct packaging or Haz-Mat documentation.
  • Ensure that all marks and labels are present prior to tendering to the RCRC for core credit.
• Disregard prepaid FedEx shipping instructions that may be included in new part boxes.

Part Return Instructions - Dealers in the 48 Contiguous United States: 

1. Package the airbag inflator or module in the new part box as outlined above.
2. Print and provide both of the following completed documents to the RCRC driver:
   • Hazardous Materials Shipping Document (Page 4)
     • In the box titled Shipper, enter your dealership name and address.
     • In the box titled Receiver, enter the address of your Regional Core Recovery Center.
       NOTE: Page 6 contains a list of RCRC locations. If you are unsure of which RCRC location services your dealership, consult the RCRC driver.
     • In the box titled Number/Type of Package, enter the number of boxed inflators.
     • In the box titled Weight, enter the total shipment weight of all boxed inflators.
     • At the bottom of the Hazardous Materials Shipping Document, complete the Shipper's Certification
   • North American Emergency Response Guide 171 (Page 5)

Part Return Instructions - Dealers Outside of the 48 Contiguous United States: 

1. Contact Miguel Prigadaa at 210-250-5078 or Miguel.Prigadaa@email.xpo.com  for instructions on returning the airbag inflator(s) via FedEx.

RETURN PROCESS - PARTS WITH A CORE CHARGE

Parts subject to a core charge will be identified as such with the yellow core label on the packaging. The Regional Core Recover Center (RCRC) will pick up these airbag inflators along with other core returns during your normal core retrieval visit. This includes  dealers in Alaska and Hawaii.

Key Information: 

• All replaced driver airbag inflators and modules must be returned in the new part box with original packaging. If the new part box is damaged or lost, contact XPO logistics at 210-250-5079 or SCFieldAction.14305@xpo.com  for a replacement box.
  • Ensure that you have processes in place to safeguard the packaging.
  • The dealer-provided Haz-Mat Materials must also be returned in the packaging. The new replacement service part packaging is certified with the appropriate DOT marks and labels.
  • RCRCs will not accept any airbag inflators without correct packaging or Haz-Mat documentation.
  • Ensure that all marks and labels are present prior to tendering to the RCRC for core credit.
• Disregard prepaid FedEx shipping instructions that may be included in new part boxes.

Part Return Instructions - All Dealers: 

1. 3. Package the airbag inflator or module in the new part box as outlined above.
2. 4. Print and provide both of the following completed documents to the RCRC driver:
   • Hazardous Materials Shipping Document (Page 4)
     • In the box titled Shipper, enter your dealership name and address.
     • In the box titled Receiver, enter the address of your Regional Core Recovery Center.
       NOTE: Page 6 contains a list of RCRC locations. If you are unsure of which RCRC location services your dealership, consult the RCRC driver.
     • In the box titled Number/Type of Package, enter the number of boxed inflators.
     • In the box titled Weight, enter the total shipment weight of all boxed inflators.
     • At the bottom of the Hazardous Materials Shipping Document, complete the Shipper's Certification
   • North American Emergency Response Guide 171 (Page 5)

SERVICE PROCEDURE

SERVICE PROCEDURE

PASSENGER AIRBAG MODULE REPLACEMENT

WARNING: Failure to follow the instructions and warnings in the Workshop Manual (WSM) may result in injury.

NOTE: If the Airbag Readiness light indicates no Supplemental Restraint System (SRS) faults are present, it is not necessary to follow the WSM SRS Depowering and Repowering steps. Turn the ignition to OFF and wait 1 minute, then it is safe to proceed with airbag inflator replacement.

NOTE: The ignition must remain OFF until this service procedure is completed.

1. Record the 13 character serial number of the new  airbag module on the repair order. See Figure 1.
2. Replace the passenger airbag module. Please follow the Workshop Manual procedures in Section 501-20.
3. Package the replaced airbag module in the new part box and provide to the appropriate dealership personnel for part returns.

SERVICE PROCEDURE

PASSENGER AIRBAG INFLATOR INSPECTION

1. Fully lower the glove compartment door and look up at the passenger airbag module. Inspect the passenger airbag inflator end for the presence of a plastic end cap as shown in Figure 1. Is the plastic end cap present on the airbag inflator?

   Yes - PASS - Inspection Complete. Raise and close the glove compartment door.

   No - DOES NOT PASS - Proceed to the Passenger Airbag Inflator Replacement on Page 2.

SERVICE PROCEDURE

PASSENGER AIRBAG MODULE REPLACEMENT

WARNING: Failure to follow the instructions and warnings in the Workshop Manual (WSM) may result in injury.

NOTE: If the Airbag Readiness light indicates no Supplemental Restraint System (SRS) faults are present, it is not necessary to follow the WSM SRS Depowering and Repowering steps. Turn the ignition to OFF and wait 1 minute, then it is safe to proceed with airbag inflator replacement.

NOTE: The ignition must remain OFF until this service procedure is completed.

1. Record the 13 character serial number of the new  airbag module on the repair order. See Figure 1.
2. Replace the passenger airbag module. Please follow the Workshop Manual procedures in Section 501-20.
   NOTE: Use caution when removing the 5 instrument panel trim panel fasteners or the studs may strip out. Submit a contact to the SSSC if damage to the trim panel does occur.
3. Package the replaced airbag module in the new  part box and provide to the appropriate dealership personnel for part returns.

SERVICE PROCEDURE

PASSENGER AIRBAG INFLATOR INSPECTION

1. Fully lower the glove compartment door and look up at the passenger airbag module. Inspect the passenger airbag inflator end for the presence of a plastic end cap as shown in Figure 1. Is the plastic end cap present on the airbag inflator?

   Yes - PASS - Inspection Complete. Raise and close the glove compartment door.

   No - DOES NOT PASS - Proceed to the Passenger Airbag Inflator Replacement on Page 2.