Attachment III - Technical Instructions

ATTACHMENT III

SAFETY RECALL 93S66

1990 and 1991 Model Year Econoline E-250 Cargo Van Rear Shock Crossmember

TECHNICAL INSTRUCTIONS

WARNING

The low pressure gas shock absorbers are charged with nitrogen gas to 931KPa (135psi). Do not attempt to open, puncture or apply heat to the shock absorber.

REMOVAL

1. Raise the vehicle on a hoist.

2. Support the rear axle with suitable jack stands.

NOTE:
Use an open end wrench on the shock mounting stud to prevent the shock absorber from turning while removing the retaining nuts.

3. Remove the upper shock absorber retaining nuts and disconnect the shock absorbers from the rear shock crossmember.

4. Disconnect the nuts retaining the exhaust hanger to the crossmember and the exhaust hanger to the tail pipe.

WARNING:
ALWAYS WEAR APPROVED PROTECTIVE EYE WEAR WHEN OPERATING AIR TOOLS.

5. Using an air chisel, sheer the heads off the top and bottom of the crossmember to frame attaching rivets. Remove the rivet shanks from the frame and remove the crossmember.

Note:
Drilling may be necessary to thoroughly remove all of the rivets.

INSTALLATION

6. Using a right angle drill and a 15/32" stubby drill bit (no longer than 3.5 inches in length) enlarge the six holes in the new crossmember and in the frame where the rivets used to be. Apply Super Seal (or equivalent) to exposed metal of drilled hole.

7. Transfer the shield for the left rear shock absorber from the old crossmember to the new one. Torque the bolts to 10-14 N-m (7.3-10 Ft.Lbs.).

8. Install the new crossmember in the vehicle using the bolts and nuts supplied. Torque nuts to 45-68 N-m (33-50 Ft.Lbs.).

9. Connect the exhaust hanger to the crossmember. Install and torque nuts to 16-23 N-m (12-17 Ft.Lb.).

10. Connect the exhaust hanger to the tail pipe. Install and torque bolt to 6-7 N-m (4.4-5 Ft.Lb.).

1990 and 1991 Model Year Econoline E-250 Cargo-Van Rear Shock Crossmember

11. In the very rare cases where the crossmember separated from the frame rail, the fuel and/or brake lines may have been damaged. If the crossmember was separated, inspect the brake and fuel lines in the area of the rear crossmember for evidence of contact with the crossmember. Repair the line(s) showing any evidence of contact with the crossmember. Submit claims for fuel and/or brake line repair on a separate 1863, "Related damage" as outlined in the Warranty and Policy Manual.

If the fuel line is steel, replace the line

NOTE:
Refer to the appropriate 1990 and 1991 Truck Shop Manual for removing/replacing brake and/or fuel lines and appropriate Parts Catalog for part numbers.