this seal leaked, it would affect the front brakes only. Replacement units were supplied to dealers who were furnished with serial numbers and requested to call in cars involved. Our records indicate 6,623 cars were inspected and corrections made as required. (Rear lower control link attaching screw modification) Bulletin date: November 28, 1961. All series except comm'l chassis. Factory inspection of parts furnished by the supplier revealed incorrect hardness of some screws retaining the forward end of the rear lower control link on certain early production cars. Dealers were supplied with serial numbers of the 20,211 cars possibly affected and instructed to replace all eight screws in each of the cars. According to our records 18,781 cars were corrected. (Steering gear adjuster plug modification) Bulletin date: May 4, 1962. There were isolated field reports of failed upper thrust bearings on early production 1962 model cars equipped with power steering, which could cause binding or roughness in the steering gear. Dealers were furnished serial numbers of the 87,014 cars possibly affected and were requested to call in such cars for replacement of the upper thrust bearing. According to our records, 76,958 cars were corrected. 1963 MODEL YEAR (Four blade fan modification) Bulletin date: December 13, 1962. All series except series 75 and comm'l chassis. Proving Ground durabiilty testing indicated that engine fans used in early production non-air conditioned cars had a short service life. An improved fan was introduced in production. The modification involved 10,992 cars and dealers were supplied with serial numbers of these cars and requested to replace fans with the improved type. According to our records, 10,694 cars were corrected. (Engine water outlet pipe) Bulletin date: March 29, 1963. Factory inspectors reported that the by-pass opening in the cylinder head water outlet pipe was not drilled on certain engines during part of a day's production. Dealers were advised of the 272 cars involved and requested to inspect for and drill the by-pass opening if required prior to delivery to owners. According to our records, 227 cars were corrected. 1964 MODEL YEAR (Twilight sentinel modification) Bulletin date: October 31, 1963. From field reports and subsequent testing, it was determined that some of the first cars produced were equipped with a Twilight Sentinel accessory which might have an inadequate thermal circuit breaker causing erratic operation. Dealers were furnished with serial numbers of the 3,963 cars involved and reqeusted to install an improved amplifier and photocell package. According to our records, 3,794 cars were modified. (Hood latch modification) Bulletin date: November 1, 1963. Field reports were received of improper hood lock adjustment and secondary latch engagement of early 1964 model cars. Design improvements were made in production and dealers were furnished with serial numbers of the 23,011 cars involved. Cars were called in for modification of the hood latch assembly and according to our records 21,921 cars were corrected. (Engine coolant modification) Bulletin date: January 6, 1964. Factory inspection discovered that only ethylene glycol was installed in the cooling system of a few cars instead of the proper glycol and water mixture. The 543 cars possibly involved were all in dealer stock and they were requested to check coolant before delivery to owners and correct if necessary by adding water. Many dealers would not report on this problem; however, our records show 275 cars were corrected. (Front suspension upper ball stud lock washer modification) Bulletin date: January 16, 1964. All series. Factory quality inspection revealed that lock washers of insufficient hardness were used at the front suspension upper ball stud during a short period of production. It was determined that 4,620 cars were possibly affected and dealers were furnished with serial numbers these cars. No effect on the suspension was ever observed, but it was decided to replace washers as a precautionary measure. Dealers reported correcting 4,579 cars. (Steering tie rod modification) Bulletin date: March 6, 1964. Examination revealed that some inner tie rods installed on certain cars did not meet metallurgical specifications. Dealers were furnished with serial numbers of the 21,177 cars involved and requested to call them in for inspection to locate and replace any questionable parts. According to our records, 19,561 cars were inspected and/or replaced. (Convertible top hydraulic hoses) Bulletin date: April 2, 1964. Factory inspection revealed that a few cars were built which may have improperly positioned folding top upper hoses that could break when the top was lowered. Dealers were furnished with serial numbers of the 81 cars involved and requested to reposition these hoses if required. According to our records, 59 cars were corrected. 1965 MODEL YEAR (Rear coil spring to frame interference) Bulletin date: September 18, 1964. Factory road testing revealed that a few of the first 1965 model cars might produce a noise going over bumps due to interference between the rear coil springs and frame. Dealers were requested to check the 2,212 cars involved and correct those which were noisy prior to delivery to owners. According to our records the 361 cars that dealers found requiring changes were corrected. (Front inner wheel bearing lubrication) Bulletin date: November 23, 1964. It was found through factory inspection that some cars assembled during a period involving 675 cars had insufficient lubricant in the front inner wheel bearing. Dealers were advised of the cars involved and requested to inspect for this condition and lubricate if required prior to delivery to customers. According to our records dealers found that 547 cars required lubrication. (Differential lubricant modification) Bulletin date: January 19, 1965. All series. Factory inspection discovered water in the differential lubricant used during a short period of production. Since this could eventually cause differential noise and gear failure, dealers were advised of serial numbers of the 3,790 cars involved and requested to change the contaminated lubricant. According to our records, 3,732 cars were corrected. (Heater circuit modification) Bulletin date: March 8, 1965. All series except 75 series. Factory inspection discovered that the heater circuit on some nonair conditioned cars was incorrect and could possibly result in an electrical failure. Dealers were advised of the 9,236 cars affected and requested to relocate the resistor and to install a heater circuit kit. According to our records, 8,938 cars were corrected. (Convertible top weathersealing modification) Bulletin date: April 29, 1965. Inadequate weathersealing on 11,349 early convertibles could cause water leaks. Dealers were requested to install an improved design weatherstrip on cars requiring a correction. According to our records, 5,911 cars were corrected. 1966 MODEL YEAR (Fuel pump) Bulletin date: September 23, 1965. Factory inspection revealed that the fuel pump might become inoperative on about 5% of the first 699 cars produced. A new pump was shipped with each car which dealers were requested to install prior to delivery to the customer and according to our records, new pumps were installed on all of the cars. (Bumper jack hook) Bulletin date: September 29, 1965. All series except 75 series and comm'l chassis. The The bumper jack hooks were omitted from the first 2,082 cars shipped. parts were furnished to dealers in time so that installation was made on all cars before delivery to owners. (Automatic level control compressor) Bulletin date: October 21, 1965. All series except comm'l chassis. Factory inspection determined that the automatic level control compressor valve could stick. It involved 1,707 cars equipped with this feature. The failure of this device did not affect vehicle operation. Its only function is to maintain body level regardless of variations in passenger or cargo load. Dealers were furnished with serial numbers of cars which may be affected and were requested to call in owners for replacement of the compressor. According to our records, all of the cars involved were corrected. (Fleetwood seventy-five rear A/C unit modification) Bulletin date: October 28, 1965. 75 series only. Factory testing indicated inadequate condensate drains on the first 93 SeventyFive series cars equipped with air conditioning. Dealers were requested to call in cars involved and install an additional drain and according to our records, 79 cars have been corrected to date. (Cruise control throttle linkage modification) Bulletin date: December 7, 1965. Factory engineering tests revealed interference between the Cruise Control throttle linkage and the air cleaner air horn if the latter was improperly installed in service. This could occur only in reverse at wide-open throttle. This possibility involved 5,535 cars and dealers were furnished with serial numbers of cars involved and requested to install a linkage shield to eliminate possibility of interference. According to our records, 4,499 cars have been corrected to date. (Seventy-Five series sedan six-way seat interference) Bulletin date: January 31, 1966. 75 series only. The first few Seventy-Five series cars equipped with a six-way front seat might have an interference condition between the seat and the auxiliary folding seats. This makes it difficult to pull down the folding seats. Dealers were furnished with serial numbers of the 50 cars involved and requested to replace front seat adjusters and align the folding seats on cars affected. According to our records 46 cars have been corrected to date. (Fuel tank vent modification) Bulletin date: April 29, 1966. All series except comm'l chassis. Field information indicated a fuel tank venting problem on the first 12 models. Improper venting could cause abnormal fuel overflow and difficulty filling tank completely. Dealers were furnished serial numbers of 23,491 c involved and requested to call them in for installation of an improved vent system. This modification program has just been released; therefore, no corre tions have been reported by dealers. FORD MOTOR CO. FORD MOTOR CO., Dearborn, Mich., May 5, 1966. Hon. ABRAHAM RIBICOFF, DEAR SENATOR RIBICOFF: In response to your request, Ford Motor Co. herewith makes available to you a complete report on product service campaigns conducted by the company from 1960 to the present. Campaigns are the means by which we make corrections in cars awaiting shipment, in transit, already in dealer stocks, or in customers' hands. They are made without charge to the customers. For each campaign we have included the title, a description including corrective action taken, the number of units involved and a report on results. In addition, we have included samples of letters prepared for dealers to send to customers who have not responded to telephone calls. As will become apparent, many of the campaigns in this report involved modifications intended to maintain or improve customer satisfaction. They had nothing to do with safety. They were made to correct problems such as water or dust leaks, wind noise, vibrations, loose ornaments, missing ashtray lights, and malfunctioning clock reset cables. We replaced oil dipsticks that were too short, corrected station wagon tailgate handles that damaged paint, and stopped condensation leaks from air conditioners. Usually, these problems occur in only a small number of units from a single assembly plant or parts supplier. Even though they are superficial, these conditions detract from customer satisfaction and from a quality reputation that we are working very hard to maintain. Most campaigns, whether related to safety or to customer satisfaction, correct potential problems detected before the products get to the customers. During the past 2 model years, for example, 49 of a total of 57 campaigns were initiated on the basis of information derived from our engineering testing and quality inspection systems, and without a single report of problems with cars in customer use. In a new car, the chance of experiencing any significant mechanical problem affecting safety is very slight. Our comprehensive system of inspection and quality control, including the service campaign, provides effective protection to our customers. I The attached exhibits document the exhaustive and careful attention we devote to maintaining the safety and quality of our products and reflect the current policy of Ford Motor Co.: 1. To be conscientious and persistent in dealing with product problems. Customer confidence in our products is a vital company asset demanding constant management attention. 2. To campaign all potential safety hazards. If a product problem involves safety, it is campaigned. 3. To campaign all problems importantly affecting customer satisfaction. Our concern for the comfort, convenience, and enjoyment of our customers is to be demonstrated by prompt correction of such problems. 4. To communicate promptly and effectively with dealers and customers in matters concerned with product safety. Customers are reached by telephone, telegraph, and registered mail. Under our current policy, all recall notifications to customers spell out the exact nature of the complaint and, when safety is involved, contain an explicit reference to that effect. 5. To upgrade the speed, efficiency, and thoroughness of our campaign procedures. By using the most advanced techniques available, including electronic data processing, we are continually improving our identification, reporting, and followup systems. The number of service campaigns in which we have engaged is a measure of the stringent criteria we apply to product problems, and not an index of quality. The systems and procedures we follow are detailed and comprehensive. We take pride in the lengths to which we go to assure our customers that they can have confidence in the safety, reliability, durability, and performance of our products. In our service campaigns, we have achieved a high overall percentage of recall and correction of defects. A response of 100 percent is not usually possible because some owners refuse to bring in their cars. In other cases, cars are "lost" through theft, export, or a variety of other reasons over which we have no control. The procedures involved in a service campaign, starting with detection of the problem and proceeding through the many steps taken to complete the campaign, are illustrated in an attachment to this report. The modern automobile is a machine conceived by human minds, built by human hands, and used by human beings under a wide variety of conditions. No other functional consumer product embodies so many interdependent operating systems. No other consumer product is subject to so wide a variance in use and abuse, and to such critical performance standards. |