On certain 2011 Ranger vehicles, the multi-function switch, installed during vehicle assembly, could malfunction and fail. Additionally, other vehicle models may have received the affected switch as a replacement part during service, and are therefore also involved in this campaign. Failure of the multi-function switch could result in a loss of turn signal, tail lamp, hazard warning signal flasher and/or stop lamp function. Failure of these lighting components to illuminate may result in the following road users being unaware of the driver's intentions, as well as reducing vehicle conspicuity during hours of darkness, which could increase the risk of a crash causing property damage and/or personal injury. Correction: Dealers will inspect and, if necessary, replace the multi-function switch.
On certain vehicles, the speed control deactivation switch may overheat, smoke, or burn, potentially resulting in an underhood fire. The condition may occur either when the vehicle is parked or when it is in operation. Correction: Dealers will install a new switch or fused wiring harness. Note: This is an expansion of recall 2005028 (05S28) for vehicles not previously included in the campaign.
On certain vehicles equipped with a 7.3L diesel engine, the camshaft position sensor may fail, causing the engine to stall. Engine stalling would result in lost propulsion which, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash. Correction: Dealers will inspect and, if required, replace the camshaft position sensor.
On certain vehicles equipped with a 6.0L diesel engine, the Fuel Injection Control Module (FICM) wire harness may chafe against an engine bolt. Also, the Injection Control Pressure (ICP) sensor connector terminals may have an improper crimp height that may result in intermittent or permanent loss of the ICP sensor signal. FICM wire harness chafes or improper ICP sensor connector crimps may cause the vehicle to stall without warning while driving. If the vehicle stalls, it may or may not restart. Correction: For all F-Superduty and Excursion vehicles, dealers will inspect the FICM wire harness for chafing. If bare wires have not been exposed, dealers will install a wire protection kit. If bare wires have been exposed, dealers will install a new wire harness. For all E-Series and, depending on build date, some F-Superduty and Excursion vehicles, dealers will install a new ICP sensor connector with certified crimps.
On certain vehicles, the speed control deactivation switch may overheat, smoke, or burn, potentially resulting in an underhood fire. The condition may occur either when the vehicle is parked or when it is in operation. Correction: Initially as an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available, owners will be instructed to return to the dealers for installation of a new switch or fused wiring harness.
On certain vehicles, the ground stud that retains the negative battery terminal eyelet to the engine block may be loose. A loose battery ground wire may produce high resistance to current flow. As a result, current may take an alternate path to ground through the radio suppression strap causing it to heat and potentially melt or ignite adjacent components. Correction: Dealers will replace the engine ground stud. The radio suppression strap and adjacent components will be inspected for damage, and if necessary, replaced.
Certain passenger cars, sport utility vehicles, and light and medium duty pickup trucks. A switch located in the plastic cover of the wiper motor gear case could malfunction and overheat, potentially resulting in loss of intermittent wiper function, loss of wiper park function, complete loss of wiper function, smoke or, potentially, ignition of the plastic cover material. Switch malfunction is most likely to occur when the intermittent setting of the wipers is being used, or when snow or ice obstructs the blades from returning to the "parked" position at the bottom of the windshield. Loss of visibility while driving increases the risk of a crash. Correction: Dealers will inspect the date code on the wiper motor. Motors built with the suspect time frame will have the wiper motor gear case cover replaced.
Certain passenger and sport utility vehicles, pickup trucks, and minivans equipped with seat belts supplied by TRW. It is possible that the driver's and/or front passenger's outboard seat belt buckle may not fully latch. In the event of a crash, the restraint system may not provide adequate occupant protection, increasing the risk of personal injury to the seat occupant. Correction: Dealers will inspect the front outboard seat belt buckles and if the buckle fails the inspection process, it will be replaced.
On certain vehicles, the headlamp switch knob may have been molded from a plastic material that is more brittle than the intended material. This material may be overstressed when the knob is installed on the switch, leading to a later fracture, and in some cases, separation of the knob from the headlamp switch. If this should occur, it may be difficult for the driver to activate the headlamps. Correction: Headlamp switch knob will be replaced with one made of the intended material.