[Shotimes] Recall 98S01 (was What next?)

[Justin Schick]

My 92 had the same problem, even though it wasn't covered by the recall.
I put a new switch in the melted plug and it worked fine the rest of the
time I owned the car.

Justin
parted 92 - need something?  

>>> "Russ M." <rm1012@yahoo.com> 11/23/2005 9:11 am >>>
Have seen the problem with build dates prior to the recall period, so
I suppose it might be possible that it could affect a 1995 as well:

May, 1998

To: All Ford and Lincoln-Mercury Dealers

Subject:  Safety Recall 98S01 - 1993 and 1994 Taurus, Sable, Mark
VIII,
and Continental Headlamp Switch

AFFECTED VEHICLES
All 1993 and 1994 Taurus, Sable, Mark VIII and Continental vehicles
produced from December 1, 1992 through September 30, 1993.

REASONS FOR RECALL
Over time some headlamp switches in the affected vehicles may develop
excessive electrical resistance as a result of inadequate swage
between
the bimetallic strip and the copper contact.The excessive electrical
resistance may generate heat inside the switch causing the circuit
breaker to cycle resulting in the headlamps flickering.

SERVICE ACTION
The owners will be requested to return the vehicle to their dealers to
have the headlamp switch connectors inspected and headlamp switches
replaced. Headlamp switch connectors will be replaced if they show
signs of heat damage. On all affected vehicles equipped with Autolamp,
the B3 terminal in the headlamp switch connector will be replaced.

QUESTIONS?
Claims Information: 1-800-423-8851
Other Recall Questions: 1-800-325-5621

Safety Recall 98S01
HEADLAMP SWITCH AND ELECTRICAL CONNECTOR REPLACEMENT

AFFECTED VEHICLES:
1993-1994 CONTINENTAL, MARK VIII, SABLE AND TAURUS

TAURUS:

1. Install memory saver, then disconnect battery negative cable.
2. Remove knee bolster.
3. Remove headlamp switch knob, then the headlamp switch retaining
nut.
4. Apply parking brake.
5. Position gearshift selector in First gear position.
6. Remove instrument panel cluster opening finish panel.
7. Remove and discard headlamp switch.
8. Inspect headlamp switch electrical connector for heat damage. If
the
electrical connector exhibits obvious heat damage, it must be
replaced.

Obtain harness kit part # F8DZ-11654-EA for non-autolamp and
F8DZ-11654-DA for Taurus cars with autolamp and install harness
connector according to the instructions on Page 15 for autolamp and
Page 17 for non-autolamp cars of this attachment. 
If the electrical connector does not exhibit obvious heat damage,
proceed to next step.
 
9. NOTE: Perform the following step only if the headlamp switch
electrical connector is not damaged.
 
10. On vehicle equipped with auto lamp option, remove terminal B3 from
the headlamp switch electrical connector.  Cut terminal end off wire
13mm (1/2 inch) from connector. Splice on new wire with correct
terminal end obtained from switch + B3 kit, F8DZ-11654-FA. 
Install terminal into B3 terminal slot of connector.
11. Connect new headlamp switch to its electrical connector, then
install headlamp switch.
12. Install instrument panel cluster opening finish panel.
13. Position gearshift selector in Park position and release parking
brake.
14. Install headlamp switch retaining nut, then install the headlamp
switch knob.
15. Install knee bolster.
16. Connect battery negative cable, then remove memory saver.
17. Check operation of headlamp switch.

SECTION 2:HEADLAMP SWITCH ELECTRICAL CONNECTOR REPLACEMENT

TAURUS/SABLE (AUTO LAMP VEHICLES HARNESS KIT PART # F8DZ-11654-DA)

1. Remove headlamp switch connector from the wire harness by cutting
the wires 1/2 inch (13 mm) from the connector. Discard the old
connector.
2. Refer to the table below for wire color codes and splices to be
used.
    
CIR.  WIRE COLOR     GAUGE LENGTH  SPLICE   SPLICE COLOR

15   Red w/Yellow Stripe    14    12"  E6EB-14488-BA  Blue
221  Orange w/White Stripe  14    16"  E6EB-14488-BA  Blue
195  Tan w/White Stripe     20    15"  E6EB-14488-AA  Red
14   Brown                  20    13"  E6EB-14488-AA  Red
38   Black w/Orange Stripe  12    14"  E6EB-14488-CA  Yellow
293  Orange w/Red Stripe    20    17"  E6EB-14488-AA  Red
231  Black w/Yellow Stripe  20    18"  E6EB-14488-AA  Red
484  Orange w/Black Stripe  20    19"  E6EB-14488-AA  Red

3. Strip wires 0.5 inch (7.6 mm), then insert each wire into correct
crimp barrel.
4. Using Crimp Tool (AD-1522), crimp all wires.
5. Heat splice with heat gun until tubing shrinks and adhesive flows
from each end.
6. Temporarily connect new headlamp switch and install knob.
7. Connect battery negative cable.
8. Check operation of headlights, marker lights, tail lights and
instrument panel lights.
9. Disconnect battery negative cable.
10. Remove headlamp knob and disconnect headlamp switch.
11. Fold wiring back in an "S" onto the harness and wrap with
electrical tape to allow the extra wiring to be fitted into the
instrument panel. 
12. Return to Step 12 on Page 8 of this attachment for Sable vehicles
or Step 11 on Page 10 for Taurus vehicles.


  Russ
  RCM Automotive Performance
  http://home.earthlink.net/~rcm_automotive/