Prepared by the Recall Analysis Division Office of Defects Investigation Safety Assurance

National Highway Traffic Safety Administration U.S. Department of Transportation

Vehicles: Jeep 1990-1991 Cherokee, Wrangler, Comanche and 1993 Grand Cherokee and 1989-1991 Eagle Premier and Dodge Monaco vehicles manufactured from July 1989 through July 1991.

Population: 293,369 multi-purpose and passenger vehicles sold in or currently registered in the states of Connecticut, Illinois, Indiana, Maine, Maryland, Massachusetts, Michigan, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, or Wisconsin, and the District of Columbia.

Problem: The front disc brake rotors can experience severe corrosion if operated for an extensive period in the 'salt belt.' If the rotors are not replaced, the corrosion can eventually compromise the structural integrity of the stamped steel center hub section of the rotor. The reduced strength can allow the cast iron wear surface to separate from the hub, reducing the brake effectiveness of the vehicle.

Remedy: Dealers will replace these rotors with rotors that are coated with a corrosion protection. Owners should contact Chrysler at 1-800-992-1997.

Vehicles: Ford 1987-1994 B600 and B700 medium duty school bus chassis equipped with hydraulic brakes, tilt hoods, 5.9L, 6.6L, or 7.6L diesel engines or 6.1L or 7.0L gasoline engines.

Population: 3,660 chassis sold or registered in the states of Connecticut, Illinois, Indiana, Maine, Massachusetts, Michigan, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, and Wisconsin.

Problem: The battery power junction block mounted on the right fender apron, which serves as an electrical connection point for several engine compartment systems, is susceptible to road splash. The terminals at the junction block can experience corrosion and can fracture, causing loss of electrical power and engine shutdown. Engine shutdown, loss of power steering assist, or loss of hydraulic brake boost can occur which could result in loss of vehicle control and a crash.

Remedy:Dealers will replace the junction box, main power terminal, the starter or starter relay, and terminals at the existing junction block. The wiring of the hydraulic brake circuit will also be modified by bypassing the junction block. The new terminals will be made from an alloy material more resistant to salt corrosion. Owners who are unable to have their vehicle serviced for this recall should contact Ford at 1-800-392-3673.

Vehicles:Ford 1993-94 Ranger Pickup Trucks equipped with the 2.3L engine and manufactured from August 1, 1992, and December 1, 1994.

Population:26,000 trucks registered in Alaska, Montana, North Dakota, Minnesota, Wisconsin, Michigan's Upper Peninsula, New York, Maine, Vermont, and New Hampshire.

Problem:During extreme cold, ice can form in the throttle body of the engine causing the throttle plate to remain in the highway cruising position after the accelerator pedal is released, or if the cruise control was active, after the cruise control was deactivated. This can cause extended stopping distances, increasing the risk of a crash.

Remedy:Dealers will replace the air intake duct and valve assembly with revised units. Owners who are unable to have their vehicle serviced for this recall should contact Ford at 1-800-392-3673.

Vehicles: Ford 1991-1994 Explorer and Ranger vehicles manufactured from March 1991 through November 1993.

Population:108,000 multi-purpose vehicles and light duty trucks originally sold or currently registered in the Southern California counties of Los Angeles, Orange, San Bernardino, San Diego, Riverside, Ventura, Santa Barbara, San Luis Obispo, Imperial, and Kern.

Problem:The studs which attach the brake master cylinder to the power brake vacuum booster assembly can develop stress corrosion cracking after being operated for an extended period of time in the Southern California location. If a crack occurs, it could result in one or both studs fracturing. The master cylinder could then separate from the vacuum booster, when the brakes are applied, preventing the service brakes from activating increasing the risk of a vehicle accident.

Remedy:Dealers will replace the power brake vacuum booster assembly.Owners who are unable to have their vehicle serviced for this recall should contact Ford at 1-800-392-3673.

Vehicles: Ford 1997 F150 pickup trucks manufactured from November 1995 through July 1996.

Population:22,000 pickup trucks registered in Alaska, Montana, North Dakota, Minnesota, Wisconsin, Michigan (Upper Peninsula), New York, Maine, Vermont, and New Hampshire.

Problem:Operation at highway speeds during extreme cold, northern climate winter conditions, can result in ice forming in the throttle body of the engine. This ice can cause the throttle plate to remain in the highway cruising position after the accelerator is released or the speed control is deactivated. Under such conditions, the vehicle stopping distances would be increased possibly resulting in a crash.

Remedy: Dealers will install a foam insulating sleeve on the line from the PCV to the hose fitting on the throttle plate. Owners who are unable to have their vehicle serviced for this recall should contact Ford at 1-800-392-3673.

Vehicles: Ford 1992-1994 Tempo and Mercury Topaz vehicles with 3.0L engines; 1994 Tempo/Topaz vehicles with 2.3L engines; 1992-1995 Taurus and Mercury Sable vehicles with 3.8L engines; 1994-1995 Taurus/Sable models with 3.0L engines; and 1992-1994 Lincoln Continental vehicles with 3.8L engines manufactured from July 1991 through November 1994.

Population: 75,200 passenger vehicles registered in Alaska, Iowa, Minnesota, Nebraska, North Dakota, and South Dakota.

Problem: During high winds, heavy, blowing, and drifting snow, and low temperatures, the engine cooling fan can become blocked or frozen with snow. The fan motor may not rotate and could overheat. This condition can cause smoke or flames from the fan and/or shroud, the fan electrical wiring, or the fan motor, resulting in a vehicle fire.

Remedy: Dealers will install an electrical jumper harness containing an automatic resetting circuit breaker to protect the fan motor low speed circuitry from overheating. Owners who are unable to have their vehicle serviced for this recall should contact Ford at 1-800-392-3673.

Vehicles: Ford 1991-1994 Taurus, Mercury Sable and Lincoln Continental model vehicles equipped with 3.8L engines and manufactured from August 1990 through November 1994.

Population: 212,700 passenger vehicles registered in Alaska, Colorado, Iowa, Idaho, Illinois, Indiana, Kansas, Massachusetts, Maine, Michigan, Minnesota, Missouri, Montana, North Dakota, Nebraska, New Hampshire, New York, Ohio, Pennsylvania, South Dakota, Vermont, Wisconsin, and Wyoming.

Problem: Water can accumulate within the speed control cable conduit. If enough water accumulates, it could freeze within a low area of the cable routing when exposed to a long term cold soak at temperatures at least several degrees below freezing. Driver control of vehicle speed using the speed control system or the accelerator control system would be diminished increasing the risk of a crash.

Remedy: Dealers will add a boot to the speed control cable. Owners who are unable to have their vehicle serviced for this recall should contact Ford at 1-800-392-3673.

Vehicles: Ford 1996-1997 Explorer and Mercury Mountaineer model vehicles manufactured from February 1996 through February 1997.

Population: 23,000 sport utility vehicles registered in the states of Alaska, Idaho, Iowa, Maine, Michigan (Upper Peninsula only), Minnesota, Montana, Nebraska, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, and Wyoming.

Problem: These vehicles, when operated for extended period of time at highway speeds and temperatures below -20 degrees Fahrenheit, do not return to idle due to ice in the throttle body. Although the vehicle can be controlled by either applying the service brakes or shifting the transmission to neutral, increased brake pedal efforts or some increase in stopping distance can result.

Remedy: Dealers will install a revised PCV system with water-heated vacuum source. Owners who are unable to have their vehicle serviced for this recall should contact Ford at 1-800-392-3673.

Vehicles: Ford 1995 Escort and Mercury Tracer model vehicles equipped with 1.9L engines and manufactured from April through October 1995.

Population: 64,000 vehicles built at the Hermosillo or Wayne Assembly Plants, and originally sold or is currently registered in Alabama, Arkansas, Arizona, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, Oklahoma, South Carolina, and Texas.

Problem: Cracks can develop in the fuel tank near the heat shield attachment resulting in fuel leakage if the cracks go through the fuel tank wall. Fuel leakage in the presence of an ignition source can result in a vehicle fire.

Remedy: Dealers will remove the heat shield attachments. This will not affect heat shield location or function, as the attachments are intended to keep the shield in place until the fuel tank is installed in the vehicle. After installation, the fuel tank straps retain the heat shield. Owners who are unable to have their vehicle serviced for this recall should contact Ford at 1-800-392-3673.

Vehicles: Ford 1992-1993 Thunderbird and Mercury Cougar vehicles manufactured from August 1991 through September 1993.

Population: 125,000 vehicles registered in Connecticut, District of Columbia, Delaware, Iowa, Illinois, Indiana, Kentucky, Massachusetts, Maryland, Maine, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Wisconsin, and West Virginia.

Problem: Movement of the fuel lines causes the nylon fuel line jumper to chafe against the floor pan. This wear can cause a pin hole in the fuel line resulting in fuel leakage. This fuel leakage results in dampness and fuel odor, and if an ignition source was present, a fire could result.

Remedy: Dealers will install a plastic convolute covering around the fuel lines. If the lines show a leak, the lines will be replaced first. Owners who are unable to have their vehicle serviced for this recall should contact Ford at 1-800-392-3673.

Vehicles: Ford 1997-1998 F150 pickup trucks equipped with 4.2L engines and manufactured from November 1995 through November 1997.

Population: 45,000 pickup trucks originally sold or currently registered in Alaska, Colorado, Iowa, Idaho, Illinois, Indiana, Kansas, Massachusetts, Maine, Michigan, Minnesota, Missouri, Montana, North Dakota, Nebraska, New Hampshire, New York, Ohio, Pennsylvania, South Dakota, Vermont, Wisconsin, and Wyoming.

Problem: The throttle is unable to return to idle due to ice forming in the throttle body when the temperature ranges from -10 to -40 degrees Fahrenheit. Increased brake pedal efforts or some increase in stopping distance could result.

Remedy: Dealers will install a revised PCV system on these vehicles. Owners who are unable to have their vehicle serviced for this recall should contact Ford at 1-800-392-3673.

Vehicles: Ford 1993 Taurus/Sable model vehiclesmanufactured August 1992 and July 1993.

Population: 281,000 vehicles currently registered in Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin.

Problem: The front coil springs can fracture as a result of corrosion in combination with small cracks in the springs. The front tire could deflate due to a broken front coil spring contacting the tire, increasing the risk of a vehicle crash.

Remedy: Dealers will install a spring catcher bracket which will prevent a fractured spring from contacting a tire. Owners who are unable to have their vehicle serviced for this recall should contact Ford at 1-800-392-3673.

Vehicles: Ford 1988-1990 Aerostar mini-vans manufactured from October 1987 through November 1989.

Population: 140,000 mini-vans currently registered in Alabama, Arizona, Arkansas, California (10 southern counties of Los Angeles, Orange, San Bernardino, San Diego, Riverside, Ventura, Santa Barbara, San Luis Obispo, Imperial, and Kern), Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada (Clark County), Oklahoma, South Carolina, and Texas, and in the U.S. Territories covered by the Federal statutes.

Problem: The upper portion of the fuel tank can develop small cracks due to extended exposure to very high ambient temperatures. Fuel vapor or leakage could occur at these cracks. If an ignition source is present, a fire could result.

Remedy: Dealers will replace the fuel tank, regardless of mileage, through march 31, 2002. This coverage will only be structural cracks at the top of the tank and will not include other damage caused by an accident or road debris. Owners who are unable to have their vehicle serviced for this recall should contact Ford at 1-800-392-3673.

Vehicles: Ford 1986-1995 Ford Taurus and Mercury Sable vehicles manufactured from October 14, 1985, through June 27, 1995; and certain 1988-1994 Lincoln Continental vehicles manufactured from November 4, 1987 through November 18, 1994.

Population: 2,697,000 vehicles sold, or currently registered, in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Kansas, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, Nebraska, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, and Wisconsin.

Problem:The rear lower subframe mount plate nut can experience stress corrosion cracking if subjected to long term exposure to road salts which are used extensively in the above listed states. Detachment of the body mounts at the rear corners of the subframe, which supports the engine and transmission, would allow the rear corners of the subframe to drop. If both rear corners of the subframe drop, steering could become suddenly very difficult, adversely affecting vehicle control and possibly result in a crash.

Remedy: Dealers will install subframe rear mount bolts, reinforcement plates, and plate nuts. Owners should contact Ford at 1-800-392-3673.

Vehicles: GM 1991-1992 Chevrolet Caprice model vehicles manufactured from July 1991 through July 1992.

Population: 20,000 vehicles in the states of Connecticut, Illinois, Indiana, Maine, Massachusetts, Michigan, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, and Wisconsin.

Problem: An electrical ground-out condition can exist between the 12 volt junction block and the metal inner fender skirt. This condition can cause a melted junction block, smoke, and burned underhood wiring, resulting in a disabled vehicle or a vehicle fire. This condition can occur while the vehicle is in operation or while the vehicle is parked and the ignition is in the 'Off' position.

Remedy: Dealers will install a shielding insulator under the junction block. Owners should call Chevrolet at 1-800-222-1020.

NHTSA Recall No. 97V058/GM Recall No. 97016

Vehicles: GM 1988-1991 Buick Regal, Oldsmobile Cutlass, Pontiac Grand Prix, and 1990-1991 Chevrolet Lumina, Monte Carlo, Lumina APV, Oldsmobile Silhouette, and Pontiac Transport model vehicles manufactured from May 1987 through January 1991.

Population: 676,535 passenger vehicles and mini-vans registered in Connecticut, Illinois, Indiana, Maine, Massachusetts, Michigan, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, and Wisconsin.

Problem: The rear cradle bolts pull through the retainers due to corrosion of the retainer. If both bolts pull through, the rear cradle would no longer be supported at these mounting locations and the steering intermediate shaft can separate from the steering gear. If this were to occur while the vehicle was in motion, a vehicle crash could result.

Remedy: Dealers will replace the rear cradle bolts and retainers. Owners should contact Buick at 1-800-521-7300, Chevrolet at 1-800-222-1020, Oldsmobile at 1-800-442-6537, or Pontiac at 1-800-762-2737.

Vehicles: Toyota 1998-1999 Camry and RAV4 passenger and sport utility vehicles equipped with an Audiovox Securikey+ security system or Securikey+ system with remote starter system and distributed by Gulf States Toyota, Inc. from July through October 1998.

Population: 1,519 vehicles sold in the states of Texas, Oklahoma, Louisiana, Arkansas, and Mississippi only.

Problem: The wiring harness in these security systems can malfunction causing an electrical failure. This condition can cause intermittent performance of the vehicle's electrical components such as the dash warning lights and/or HVAC fan speed controls. Also, the vehicle may not run smoothly and could stall.

Remedy: Dealers will inspect the Securikey+ wiring harness and, if necessary, replace the harness. Owners can contact Gulf States Toyota Distributor at 1-800-444-1074.

Vehicles: Toyota 1998-1999 Camry, Corolla, 4Runner, Tacoma, T100, and Sienna sport utility vehicles, light duty pickup trucks and passenger cars equipped with wheel lug nuts, Part No. 1207, supplied by Prime Wheel Corporation, and distributed by Gulf States Toyota, Inc. from April through August 1998.

Population: 7,794 vehicles sold in the states of Texas, Oklahoma, Louisiana, Arkansas, and Mississippi only.

Problem: The lug nuts contain a defect which could cause loss of the lug nuts, and possible loss of the wheel. This condition could cause loss of vehicle control, increasing the risk of a crash.

Remedy: Dealers will replace all the wheel lug nuts and also perform a complimentary wheel rotation when the repair is done. Owners should contact Gulf States Toyota Distributor at 1-800-444-1074.

Vehicles: Mazda 1994 B2300 pickup trucks equipped with 2.3L engines and manufactured from April 1993 through December 1994.

Population: 2,000 trucks registered in Alaska, Montana, North Dakota, Minnesota, Wisconsin, Michigan's Upper Peninsula, New York, Maine, Vermont, and New Hampshire.

Problem: During extreme cold, ice can form in the throttle body of the engine causing the throttle plate to remain in the highway cruising position after the accelerator pedal is released, or if the cruise control was active, after the cruise control was deactivated. This can cause extended stopping distances, increasing the risk of a crash.

Remedy: Dealers will replace the air intake duct and valve assembly with revised units. Owners who are unable to have their vehicle serviced for this recall should contact Mazda at 1-800-222-5500.

Vehicles: Mazda 1992-1995 MX3 vehicles manufactured from August 1991 through August 1994.

Population: 25,000 vehicles registered in Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, and the District of Columbia.

Problem: In areas where large quantities of road salt are used, corrosive pits can develop on the surface of the front suspension coil spring. Repeated use can eventually cause the coil spring to break and tire could be punctured from contact with the broken coil spring. This condition increases the risk of a crash.

Remedy: Dealers will install a guard assembly which will prevent the broken coil spring from contacting the tire. In addition to performing the recall campaign, Mazda is extending the warranty coverage on the front coil springs for the lift of the vehicle. If owners have already paid for the repair or replacement of these front coil springs, due to road salt damage, Mazda will reimburse these owners for reasonable expenses. Owners who are unable to have their vehicle serviced for this recall should contact Mazda at 1-800-222-5500.

Vehicles: Nissan 1989-1993 Maxima and 1990-1992 Stanza model vehicles manufactured from August 1988 through February 1994.

Population: 747,000 vehicles registered Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, and the District of Columbia.

Problem: Mud and salt can get trapped between the fuel filler tube and wheel housing resulting in corrosion of the fuel filler tube and the wheel housing. Significant corrosion of the fuel filler tube can result in fuel leaks which in the presence of an ignition source can result in a fire. In addition, the left rear seat belt retractor is mounted to the wheel housing and in the event of significant corrosion, and the mounting could fail in a crash.

Remedy: Dealers will inspect these vehicles and corrective action will be taken depending upon the extent of the corrosion. Owners should contact Nissan at 1-800-647-7261.

Vehicles: Nissan 1991-1996 Infiniti G20 model vehicles manufactured from July 1990 through May 1996.

Population: 85,000 vehicles registered Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, and the District of Columbia.

Problem: Corrosion of the fuel filler tube assembly can occur, especially those vehicles operated in the 'salt belt,' resulting in fuel leakage. Fuel leakage in the presence of an ignition source can result in a fire.

Remedy: Dealers will inspect the fuel filler tube and replace the tube with a new one. Any other components of the fuel filler tube assembly which are damaged or deteriorated will also be replaced. Owners should contact Nissan at 1-800-647-7261.

Vehicles: Toyota 1998-1999 RAV4, Avalon, and Sienna model vehicles equipped with a Theft Deterrent System (TDS) supplied by Audiovox Corporation and distributed by Southeast Toyota Distributors, Inc. from July through October 1998.

Population: 1,960 sport utility, passenger vehicles and mini-vans distributed in Alabama, Florida, Georgia, North and South Carolina only.

Problem: The alarm wiring harness plugs into the vehicle's ignition switch and the vehicle's ignition switch wiring harness plugs into the alarm harness to complete the circuit. A percentage of the female terminals used in the alarm connector were found to be defective, causing an 'open circuit' condition when mated to the male ignition switch terminals. This condition can cause intermittent performance of the vehicle's electrical components such as the dash warning lights and/or HVAC fan speed controls. Also, the vehicle may not run smoothly and could stall.

Remedy: Dealers will inspect the date code label on the security system harness and any displaying the manufacturing/final date code will be replaced with newly produced harnesses. The date codes are: RAV4 - 6/24/98, 6/25/98, 6/26/98; Sienna - 6/25/98, 6/29/98; and Avalon - 6/30/98, 7/1/98, 8/31/98, 9/1/98, and 9/3/98. Owners should contact Southeast Toyota at 1-800-301-6859.

Vehicles: Toyota 1997 Avalon, Camry, and Lexus ES300 vehicles manufactured from July 1996 through February 1997.

Population: 18,746 passenger vehicles registered in Alaska, Colorado, Idaho, Illinois, Iowa, Kansas, Maine, Michigan, Minnesota, Montana, Nebraska, Nevada, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, and Wyoming.

Problem: A condition can occur where accumulated moisture can temporarily freeze in the brake vacuum hose if the vehicle is used in extremely cold climates for an extended period of time. This can result in the elimination of vacuum assist to the brakes that increases stopping distances and could lead to a crash.

Remedy: Dealers will install a new design brake vacuum hose. Owners should contact Toyota at 1-800-331-4331.

Copyright � 2004 Auto World / VIS. All rights reserved. *Values are subjective opinions based on the Staff of NABA / VIS and recent market conditions. National Automobile Bankers Associates / Vehicle Information Services is not responsible for actual or claimed deviation. Copyright 2004 NABA/VIS. Auto World a service of VIS. 7278219779