Ok, so I called Ford Customer Service, and they tell me that my 1993 F150 Dual tank/fuel pressure regulator is still an active recall...!!!

So I called a local dealer (here in the Tulsa area), and they are ordering parts in order to perform the recall. I am not sure if this includes sending units for the tanks/pumps/etc..., but neither are the guys in the service dept. I am hoping to get to keep fuel in both tanks, and switch it at will, all on Ford's dime. We shall see, and I will keep you updated.

 

If this is the same recall I had done on one of my old 1993 Lightnings all they did was replace the fuel pressure regulator.

 

They are also to install two high pressure check valves on the lines coming from both tanks.
They do not replace the bad Fuel Delivery Modules that has the bad check valve in of them after they were blown out by the bad regulator letting the pressure go to high.
They do not replace the fuel tanks either just the regulator.

I think you are talking about recall 93S68.
The recall is attached below.

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SAFETY RECALL
93S68 All 1990, 1991, 1992 and certain 1993 Model Year F-Series Vehicles equipped with 4.9, 5.0, 5.8 or 7.5 Liter Engines and Dual Fuel Tanks

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ir93s681.gif

To:
All Ford Dealers

Subject:
Safety Recall 93S68 - All 1990, 1991, 1992 and certain 1993 Model Year F-Series Vehicles equipped with 4.9, 5.0, 5.8 or 7.5 Liter Engines and Dual Fuel Tanks

Affected Vehicles

All 1990, 1991, 1992 and certain 1993 model F-Series vehicles equipped with 4.9, 5.0, 5.8 or 7.5 Liter engines and dual fuel tanks.

Reasons For Recall

Some of the affected vehicles may experience a cross tank fuel flow condition due to the damaged check valve in the fuel pump/sender assembly. Fuel may be supplied from one tank and some or all of the unused fuel may be returned to the other tank. Should this occur, the capacity of the receiving tank may be exceeded and fuel may overflow from the filler cap. Fuel spillage in the presence of an ignition source could potentially result in a fire.

To correct this condition, the fuel pressure regulator will be replaced and a check valve will be installed between each fuel supply line and fuel tank.

Free Fuel Line Removal Tool

Standard fuel line removal tools can be used to disconnect fuel lines. However, because of the number of vehicles to be serviced, two free tools (#T93T-9550-AH) will be provided to each Ford dealer. These tools will be in your next Dealer Mail System (DMS) shipment (DMS packing slip #930902).

Parts Kit Codes

The required parts kit code for each vehicle will be shown on the attached VIN listing and will be printed at the top of each Owner Letter. Ask owners for the kit code shown on their letter when the owner calls for a service appointment.

Attachments

Attachment I
Administrative Information
Attachment II
Labor Allowances
Parts Ordering Information
Attachment III
Technical Information
regards2.gif


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ATTACHMENT I
Safety Recall 93S68


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OASIS

You must use OASIS to determine if a vehicle is eligible for this recall.

Please Note

Correct all vehicles in stock before delivery.

Federal law requires dealers to complete any outstanding safety 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 $1,000 per vehicle.

Promptly Correct

Affected vehicles on the enclosed list.

Other eligible vehicles which are brought to your dealership.

Dealer-Owner Contact

Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter and arrange a service date.

District Contact

Advise district office if:

an owner cannot be contacted.
an owner does not make a service date.
FCSD Contact

Talk with your FCSD Service Zone Manger about all matters.

Form 1863/64

Submit 1864 claims using DWE for all completed vehicles. You may use your original 1863 for your record file copy.

Warranty And Policy Manual

See Section 6.3 pages 5 through 8 of your Warranty and Policy Manual for claims preparation.


NOTE:
Refunds, use "Customer Condition Code" X99 for safety recalls.



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ATTACHMENT II
Safety Recall 93S68


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Affected Vehicles:

1990 - 1992 And Certain 1993 Model Year F-Series Vehicles With 4.9, 5.0, 5.8, Or 7.5 Liter Engines And Dual Fuel Tanks

Labor Allowances

Install new fuel pressure regulator and check valves (or new fuel lines with built-in check valves):



APPLICATION PARTS KIT TIME LABOR CODE
1990/91 4.9L Engine AA 1.6 Hrs. Insert in Box "B" on Form 1864
1990/91 5.0L/5.8L/7.5L Engine BB 1.5 hrs. Insert in Box "B" on Form 1864
1992/93 4.9L Engine CC 1.9 hrs. Insert in Box "B" on Form 1864
1992/93 5.0L/5.8L/7.5L Engine DD 1.8 Hrs. Insert in Box "C" on Form 1864
1990/91 Chassis Cab 4.9L Engine EE, GG 2.5 Hrs. Insert in Box "C" on Form 1864
1990/91 Chassis Cab 5.0L/5.8L/7.5L FF, HH 2.4 Hrs. Insert in Box "C" on Form 1864


NOTE:
Add 0.1 hour Administrative Allowance to the total repair time.

Add additional 0.3 hour if truck is equipped with fuel tank skid plates.


Add additional 0.1 hour if truck is over 8,500 lbs. and equipped with a 5.8L engine.




Parts Requirements

Parts will not be direct shipped for this recall.

For Kits AA, BB, CC, and DD, order your parts requirements through normal order processing channels.

For Kits EE, FF, GG, and HH, order your parts by calling Renkim Corporation at 1-800-325-5621. When calling, be prepared to announce Recall 93S68, give your name, dealer name, P & A code, the VIN number of the vehicle to be serviced, and the kit part number required (do not order Kits AA, BB, CC or DD by calling this number.).



PART NUMBER DESCRIPTION CLASS DEALER PRICE
F4PZ-9155-A Kit AA - 1990/91 4.9L (all wheel bases except 137" WB and 161" WB) AG $25.00
F4PZ-9155-B Kit BB - 1990/91 5.0L/5.8L/7.5L (all wheel bases except 137" WB and 161" WB) AG $25.00
F4PZ-9155-C Kit CC - 1992/93 4.9L Engines AG $25.00
F4PZ-9155-D Kit DD - 1992/93 4.9L Engines AG $25.00
F4PZ-9155-E * Kit EE - 1990/91 4.9L Chassis Cab 137" WB AG $50.00
F4PZ-9155-F 1 Kit FF - 1990/91 4.9L Chassis Cab 161" WB AG $50.00
F4PZ-9155-G 1 Kit GG - 1990/91 4.9L Chassis Cab 161" WB AG $50.00
F4PZ-9155-H 1 Kit HH - 1990/91 5.0L/5.8L/7.5L Chassis Cab 161" WB AG $50.00

* Must be ordered by calling 1-800-325-5621 - see instructions above.


Parts prices current until next issue of Master Price Book. For latest prices, check or call your:

Order Processing Center
DOES II
Updated Price Book
Special Parts Ordering Instructions

Parts will be available for dealer ordering on the dates shown below. Backorders will be cancelled if parts are ordered before availability dates. After these dates, parts will be shipped as orders are received.


NOTE:
Owner letters will be mailed to coincide with parts availability.


KIT VEHICLES PART NUMBER ORDER DATE
AA 1990/91 4.9L Engine F4PZ-9155-A NOW
BB 1990/91 5.0L/5.8L/7.5L Engine F4PZ-9155-B NOW
CC 1992/93 4.9L Engine F4PZ-9155-C 10/11/93
DD 1992/93 5.0L/5.8L/7.5L Engine F4PZ-9155-D 10/11/93
EE 1990/91 4.9L Chassis Cab 137" WB F4PZ-9155-E NOW - SEE BELOW a
FF 1990/91 5.0L/5.8L/7.5L Chassis Cab 137" WB F4PZ-9155-F NOW - SEE BELOW 1
GG 1990/91 4.9L Chassis Cab 161" WB F4PZ-9155-G NOW - SEE BELOW 1
HH 1990/91 5.0L/5.8L/7.5L Chassis Cab 161" WB F4PZ-9155-H NOW - SEE BELOW 1

a For Kits EE, FF, GG, and HH, order your parts by calling Renkim Corporation at 1-800-325-5621. When calling, be prepared to announce Recall 93S68, give your name, dealer name, P & A code, the VIN number of the vehicle to be serviced, and the kit part number required (do not order Kits AA, BB, CC or DD by calling this number.)



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ATTACHMENT III
Safety Recall 93S68


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Technical Instructions

Affected Vehicles:

1990 - 1992 and certain 1993 Model Year F-Series vehicles with 4.9, 5.0, 5.8 or 7.5 Liter Engines and Dual Fuel Tanks

warning.gifWARNING:
DO NOT SMOKE, CARRY LIGHTED TOBACCO OR ANY OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.

warning.gifWARNING:
FUEL SUPPLY LINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVE BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN.

caution.gifCAUTION
Each kit and instruction sheet is unique. Be sure to use the kit and instruction sheet that matches the vehicle to be serviced. Detailed instructions are not reproduced here but are included in each kit.


Follow all instructions in each kit carefully. In particular, note the following items:

Be sure to leak test each truck before returning it to the customer.
Be careful not to kink fuel lines when reinstalling fuel tanks.
Do not mix parts. Some parts look similar. For example, some kits contain short check valve connectors (orange tag with part number imprinted); other kits contain long check valve connectors (white tag with part number imprinted).
(See detailed instructions included in each kit)

Kit AA:

(I.S. 8115) 1990/91 F-Series with Dual Fuel Tanks and 4.9L Engine (except 137" and 161" WB).

Kit BB:

(I.S. 8116) 1990/91 F-Series with Dual Fuel Tanks and 5.0L/5.8L/7.5L Engine (except 137" and 161" WB).

Kit CC:

(I.S. 8117) 1992/93 F-Series with Dual Fuel Tanks and 4.9L Engine (except 137" and 161" WB).

Kit DD:

(I.S. 8118) 1992/93 F-Series with Dual Fuel Tanks and 5.0L/5.8L/7.5L Engine (except 137" and 161" WB).

Kit EE: (Chassis Cab)

(I.S. 8122) 1990/91 F-Series Chassis Cab 137" WB with Dual Fuel Tanks and 4.9L Engine.

Kit FF: (Chassis Cab)

(I.S. 8123) 1990/91 F-Series Chassis Cab 137" WB with Dual Fuel Tanks and 5.0L/5.8L/7.5L Engine.

Kit GG: (Chassis Cab)

(I.S. 8124) 1990/91 F-Series Chassis Cab 161" WB with Dual Fuel Tanks and 4.9L Engine.

Kit HH: (Chassis Cab)

(I.S. 8125) 1990/91 F-Series Chassis Cab 161" WB with Dual Fuel Tanks and 5.0L/5.8L/7.5L Engine.


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po1904.gif

September, 1993

Serial Number: 12345678901234567 93S68 KIT AA

Mr. John Sample
123 Main Street
Anywhere, USA 12345


This notice is sent to you in accordance with the requirements of the National Traffic and Motor Safety Act.

Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in 1990, 1991, 1992 and certain 1993 Model Year F-Series vehicles equipped with 4.9, 5.0, 5.8 or 7.5 liter engines and dual fuel tanks.

Safety Defect

The dual fuel tanks have fuel delivery modules designed to direct fuel to the engine from one tank and to return unused fuel to the same tank.

It is possible that one or both fuel delivery modules on your truck could allow a portion of the unused fuel to be directed to the tank other than from which it was drawn.

Should this occur when one tank is at or near full capacity, fuel could overflow from the filler pipe past the cap. Fuel spillage in the presence of an ignition source could potentially result in a fire.

To correct this condition, the fuel pressure regulator will be replaced and a check valve will be installed between each fuel supply line and fuel tank.

Repairs

At no charge to you, your dealer will replace the fuel pressure regulator and install the check valves. Dealers currently have instructions and parts or parts ordering information.

How Long Will It Take?

The time needed for this service is about three hours. However, due to service scheduling times, your dealer may need your vehicle for one full working day.

Call Your Dealer

Call your dealer without delay. Ask for a service date and whether parts are in stock. When calling, be prepared to tell the dealer the two-letter parts kit code printed at the top of this letter (for example, "Kit AA").

If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week.

When you bring your truck in, give the dealer this letter.

If you misplace this letter, your dealer will still do the work, free of charge.

Changed Address Or Sold The Truck?

Please fill out the enclosed prepaid postcard and mail it to us if you have changed your address or sold the truck.

If the dealer doesn't repair your vehicle promptly and without charge, you may contact the Ford Customer Assistance Center, 300 Renaissance Center, P.O. Box 43360, Detroit, Michigan 48243. You also may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590 or call the toll free Auto Safety Hotline 1-800-424-9393 (Washington, D.C. area residents may call 366-0123).

We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Ford-built truck.

regards1.gif

SAFETY RECALL
93S68 KIT AA


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SAFETY RECALL
93S68
Supplement - October, 1993 Certain 1990/1991/1992 Trucks Have Been Added to Original Recall

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flogo.gif

To:
All Ford Dealers

Subject:
Safety Recall 93S68 Supplement #1 - Additional Units

The purpose of this bulletin is to advise you that a small number of 1990/1991/1992 trucks have been added to the referenced recall. According to our records, the additional involved vehicle(s) shown on the enclosed listing have been delivered to your dealership.

Notification Of Owners

Vehicle owners whose names and addresses are shown on the enclosed listing are being notified by First Class Mail. If the owner of any vehicles cannot be contacted or does not make an appointment to have his vehicle corrected, advise your FCSD District Office of the owner's name and address so that we can handle further notification.

Recall Procedures

Refer to the Recall 93S68 Bulletin, dated September, 1993 for technical instructions, parts information and reporting procedures.

If you have any questions concerning this supplement, please contact your Ford Customer Service Division District Office.

regards2.gif




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CPR © 1993 FORD MOTOR COMPANY
Published By: Recall/Service Programs Department
Ford Customer Service Division

 

Whew! So much info! But good! Thanks.

I was pleasantly surprised by the fact that Ford would still have an active recall for this vehicle.

 

The local Ford dealer never did that. At the time I was not aware there were check valves involved. Not the first time this dealer has performed marginal service on one of my vehicles. I rarely go there.....

 

Just like Ford to only recall as little as they have to. My '87 started overfilling the rear tank from the front. I never used the rear tank, so I took it off, it was rusted out on top anyway, removed the dual selector, and ran a new line directly from the front tank to the frame mounted pump.

It was dangerous as crap when it started. Fuel was coming out and running all around the top of the tank and onto the ground. I kept wondering where the smell of gas was coming from. Every Ford truck with the dual tanks should have been recalled.

 

I am so happy to find this post. Our 1990 F150 recently started a terrible problem with the tanks. Did you not have a problem with ford customer service at all? I'm so inexperienced at this sort of thing. My husband counts on this truck for work. I'm sort of a neighbor, just a bit south of Sperry. If you could share any helpful hints for getting this process started, I would be so grateful. Thank you.

 

Id be interested in finding out if there was a recall and if it is still active for the Australian built trucks as Im experiencing issues with the selector valve.

 

Well, Hello, Neighbor!
I did call the Ford Customer Service line, which is a nationwide 800 number. They looked up my VIN and told me that I was still eligible for the fix. They told me to contact a local dealership and they would straighten it out. So I called Bob Hurley Ford, (918) 445-6700. They ordered parts from Memphis, which arrived yesterday, so I am going in this coming Tuesday. I will let you know more when I know more. Nobody gave any trouble at all, but they did look it up by VIN, and I'm not sure if that is a limiting factor. Couldn't hurt to try! The worst that could happen is they wouldn't fix any. Even if they fix part of the problem, it's better than nothing.

 

Color me un-surprisedly disappointed...
That's all this dealership did. And the service guy admitted that this is not the oldest service he had performed. One good part, though: quicker start time. Less cranking. Also, the peace of mind that my pressure regulator will not allow the system to be harmed now. Another way of getting FoMoCo parts without cost. If the FDM is already damaged in either tank, I'll have to replace it myself. At least they will live long now that I have a good fuel pressure regulator.