Attachment III - Technical Information

AFFECTED VEHICLES:
CERTAIN 1992-1993 THUNDERBIRD AND COUGAR VEHICLES EQUIPPED WITH FOGLAMPS

OVERVIEW
When performing this Recall procedure, you will:

^ Replace the headlamp switch with a new, redesigned headlamp switch.

^ Inspect, and if necessary, replace the existing wiring harness connector.

^ Verify the repair.

SERVICE PROCEDURE

1. Install the memory saver, then disconnect the battery ground cable.

2. Remove the headlamp switch knob by releasing the retainer and then pulling the knob from the shaft.

3. Remove the two retaining screws from the instrument panel (IP) finish panel.

4. Release the IP finish panel retaining clips by gently pulling on the panel, and then position the IP finish panel away from the IF. Disconnect the auto lamp and electronic automatic temperature control (EATC) sensor, if equipped.

5. Remove the headlamp switch actuator shaft. Pull the shaft to the ON position. Press and hold the release button on the switch and pull the shaft from the switch.





6. Remove the headlamp switch retaining nut, then remove and disconnect the headlamp switch connector and autolamp harness connector, if equipped. See Figure 1.

7. Carefully examine the headlamp switch connector for evidence of melting. If melting is noted, replace the headlamp switch connector as outlined in step 8. If the headlamp switch connector is not melted, proceed to Step 9.

8. Install the new headlamp switch connector kit as follows:

a. Obtain Headlamp Switch Connector Repair kit # E9SZ-11654-CA.

b. Select the first circuit to be spliced from the vehicle wiring harness and cut it as close as possible to the headlamp switch connector.

c. Select the corresponding circuit from the new H/L switch connector.

d. Strip 1/4" insulation from the selected wires.

e. Install the appropriate splice connector using crimp tool # AD 1522 or equivalent ratchet action crimp tool.

f. Test the integrity of each splice after crimping. Grasp the wires at each splice and pull gently. If any wire is not attached securely, replace the splice connector and repeat this step.

g. Repeat Steps B through F for the remaining wires.

h. Using Rotunda Heat Gun R07-10300 or equivalent, heat each splice connector thoroughly until the tubing shrinks and adhesive flows from each end.

i. Neatly bundle the wires and wrap with tape.

9. Connect and install the new headlamp switch, then install the headlamp switch retaining nut.

10. Connect the autolamp harness to the headlamp switch, if equipped.

11. Install the headlamp switch actuator shaft.

12. Install the IP finish panel, connecting the autolamp harness and EATC sensor connectors, if equipped.

13. Install the two IP finish panel screws.

14. Install the headlamp switch knob.

15. Connect the battery negative cable, then remove the memory saver.

16. Test operation of the lighting system.