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Recall in Review - Safety Recall 05S34
June 10, 2005 Ford Motor Company announced what should come as a relief to many
owners of 6.0L Power Stroke Diesel engine equipped F-Series Super Duty, Econoline Vans and Excursion sport
utility trucks. Owners of 2004 models have been dealing with many problems concerning engine performance and
reliability that has left many owners stranded and technicians feeling frustrated. Most of the affected
vehicles may experience a no crank/no start condition, cranks/no start condition, bucking and stalling. The
causes have been identified as fuel injection and control wiring issues that short out on engine bolts and
components due to chafing Ford Motor Company has voluntarily issued a recall to address these issues
affecting almost 200,000 vehicles with 6.0L Power Stroke Diesel Engines.
 05S34 Recall Facts
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2004 F-Series F250 though F550 Super Duty trucks and Excursion sport utility vehicles built from
September 29, 2003 though November 30, 2003 will have the Fuel Injection Control Module (FICM) wire
harness inspected for wire chafing and exposure. If no exposure is found, a repair kit is installed on
the harness to prevent chafing and damage. A harness that is damaged and has exposed wiring that causes
symptoms like stalling, will be replaced. A road test will also be performed to verify any repairs and
identify additional driveability concerns that may exist.
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2004 F-Series F250 though F550 Super Duty trucks and Excursion sport utility vehicles built from December
1, 2003 though May 31, 2004 will have the Fuel Injection Control Module (FICM) wire harness inspected for
wire chafing and exposure. If no exposure is found, a repair kit is installed on the harness to prevent
chafing and damage. A harness that is damaged and has exposed wiring that causes symptoms like stalling,
will be replaced. The Injection Control Pressure (ICP) sensor connector will also be replaced. A road
test will also be performed to verify any repairs and identify additional driveability concerns that may
exist.
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2004 Econoline E350 & E450 vans built from December 9, 2003 though May 31, 2004 will have the
Injection Control Pressure (ICP) sensor connector replaced. A road test will also be performed to verify
any repairs and identify additional driveability concerns that may exist.
The Technicians Perspective
The technician must identify the vehicle build date, inspect and make the appropriate repairs according to
the vehicle model and vehicle build date as outlined above. Checking for driveability concerns by poking and
squeezing the harness with the engine running will help quickly identify harness problems. Accessing the FICM
harness involves the removal of the right side CAC tube, air inlet tubing to the turbocharger, the coolant
de-gas bottle and the FICM itself. The technician is to disconnect the harness from the injectors and closely
inspect the harness for chafing and damage caused by the left valve cover, valve cover bolts and intake
manifold bolts. A good technician will inspect the entire harness as well as the engine sensor harness for
the same issues. Any damage to the wiring itself requires replacing the FICM harness.
Photo 1
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Photo 2
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The photographs above show a harness that has passed the inspection (Photo 1) and is being prepared to be
returned to service. In the first step of the repair process, plastic covers are installed onto the back of
the FICM harness connectors (see A in Photo 2) These covers protect the wiring from contacting the left valve
cover edge and valve cover bolts and neatly positions the wiring upwards toward the main harness. Next,
convolute tubing is sized and installed on the harness (see B in Photo 2) and a plastic collar is locked into
place. This collar is positioned where the harness tends to rest on an intake manifold bolt head which is an
area of high failure rates. Adding this shielding will protect the wiring from chafing and crushing.
Photo 3
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Photo 4
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The final step in repairing the harness is to wrap the area with vinyl electrical tape (see Photo 3) to
secure the convolute tubing and the tee collar that was installed. The tape will also provide some
protection. This is what the harness should look like when finished and it is ready to be re-installed,
properly routed and secured. Photo 4 shows the ICP (Injection Control Pressure) sensor and the harness
connector. This is the final appearance after the connector has been replaced. Note that all three wires in
the connector are purple which makes it easy to identify the repair has been made. This sensor and connector
are easy to locate on the right valve cover just behind the glow plug control module. The ICP sensor
connector replacement is only performed on certain vehicles as identified above.
This article is only to provide information. It is hoped that this review has clarified this recall in a
simple and easy to understand presentation and that we clearly illustrated what the technician does while
performing this recall. This is not intended to replace any official instructions, authorization or
documentation of any Ford Motor Company recall or program. You can read more about this harness and the
troubles related to it by reading our previously published article "6.0L Injector Harness."
 FDDTS
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