TO: All U.S. Ford and Lincoln Mercury Dealers

SUBJECT: Customer Satisfaction Program 04B23:
Certain 2004 and 2005 Model Year F150 Style Side Pick-up Trucks with 6 - 1/2 Foot Box
Butyl Pad Removal

PROGRAM TERMS

This program will be in effect until December 31, 2005.

AFFECTED VEHICLES

Certain 2004 and 2005 Model Year F150 Style Side Pick-up Trucks with 6 - 1/2 foot box built at:

Norfolk Assembly Plant From Job #1 through September 10, 2004.
Kansas City Assembly Plant from Job #1 through September 10, 2004.
Dearborn Truck Plant from Job #1 through September 10, 2004.
Affected vehicles are identified in OASIS. In addition, for a list of vehicles assigned to your dealership, <link edited out> This information will be available on 2/10/05.

REASON FOR THIS PROGRAM

In some of the affected vehicles, an aluminum-backed butyl pad may have been applied to the inside surface of the RH box outer panel in front of the tail lamp (see Attachment III, Figure 1). Some of these pads may trap moisture between the box outer panel and the butyl pad. The trapped moisture could cause corrosion to develop on the back side of the box outer panel.

SERVICE ACTION

At no charge to the vehicle owner, dealers are to remove the butyl pad from the inside of the box outer panel, clean the area where the pad was applied, and apply a two-step coating to restore protection against corrosion. In the rare case where a box outer panel has paint blistering on the outside painted surface or any sign of perforation where the butyl pad was applied, the box outer panel will be replaced. The approved procedure for box outer panel replacement will be provided in a bulletin supplement to be published in the second half of February, 2005. If you encounter a vehicle that requires box outer panel replacement, please wait for the approved repair procedure.

All in-stock vehicles must be inspected and completed prior to delivery.

 

That's cool. But what was the purpose of the sticky pad inside the fender to begin with?

 

Hell if I know. They're typically installed to keep moisture out. I haven't ran OASIS on my truck yet, but according to the build date, mine is one of the affected. If it's got the patch, I'll do it myself and take some pics so folks can see what's involved.

 

Dont know if this is part of this or not but my Dk. shadow truck is a early 04 and the right t-lamp holds water in it. Its not the only truck I saw that does this. I dont care because its leased though.

The blue one I own is fine though, but its a late 04.

 

Quinton, do you work for Ford?? Just wondering how you have access to OASIS.

I have checked my truck and it has the pad inside the right rear fender, and I am going in for a reflash and to get the back window squeak fixed on Feb. 22, so I will bring this to their attention then. Thanks!

 

Quintin, can that pad be removed without paint damage, with a heat gun perhaps? I just hate to have somebody mucking around under the bedside and defeat the zinc primer and galvanizing on the sheet metal.

 

Hate to ask a dumb question, but what is OASIS?

 

OASIS is the Ford internal computer information system they use to distribute service bulletins and other information to dealerships.

 

I work for a Lincoln-Mercury dealership in southeast Georgia.
The bulletin explicitly states not to use a heat gun, since that'll make the butyl gooey and harder to remove. Use of a scraper is how the pad is supposed to be removed, then a two step undercoating is applied to restore corrosion protection.

 

I just checked mine and sure enough the pad is there. There is not one on the other side though. What was the point of putting it on one side and not the other?

EDIT: To answer my own question. I bet it has something to do with heat from the exhaust collecting up inside the bedside causing some sort of problem when standing still with the engine running. Purely a guess.

 

I may be missing somehting, but what was the point of that butyl pad anyways ?

 

Quintin,

Thanks very much for the information!

Would you be able to post the drawing that was referenced?

...see Attachment III, Figure 1...

Thanks!

 

zinc-phosphating is easily redone and is probably part of the aforementioned 2 stage resealing processs

 

I don't think technically I can...I don't wanna do anything that'd get the bosses around here in hot water, since this stuff technically is copyright of Ford Motor Company. Moderators?

 

Just so you guys know, I posted about this the other day, so I figured I would post a link to it here in case theres any info in that thread that may help anyone else.

To add to it, I said in my original post I had three bubbles all together. I looked at it today and now there's about 7 bubbles....Time for a new bed side.
https://www.f150online.com/forums/sh...hreadid=185308