WATER IN THE BLOWER CASEBLOWER MOTOR AND/OR RESISTOR FAILUREVEHICLES BUILT 5/1/2001 TO 12/15/2003

TSB 04-15-3

FORD: 2001-2004 Taurus

This article supersedes TSB 03-15-06 to update the vehicle model years and build date information.

MERCURY: 2001-2004 Sable

3. Remove the cowl vent screen per the Workshop Manual Section 412-01 Pollen Filter Removal and inspect the cabin filter to confirm it is fully seated. Re-seat the filter as necessary. Inspect rain-hat base to make sure it is secure and sealed to the body. Reposition and reseal as necessary using Clear Silicone Rubber TA-32. Remove the foam sealant expulsion at lower front outboard corner base of the rain-hat (Figure 1).

ISSUE
Some vehicles built between 5/1/2001 and 12/15/2003 may exhibit water in the blower case or on the passenger side floor, an inoperative climate control blower motor, a motor that operates on high speed only, and/or a blower motor resistor failure.

4.

ACTION
Inspect and seal cowl area and install Rain-Hat Extension Seal. Inspect and replace blower motor and/or blower motor resistor if there is evidence of water/corrosion. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Access blower motor and resistor per the Workshop Manual Sections 412-02 and 412-04. Inspect for evidence of water/corrosion. If water/corrosion are found or parts have failed, replace per Workshop Manual (blower motor 1F1Z-19805-AA and resistor F6DZ-19A706-AA). Visually inspect the Cowl Vent Screen located under the RH windshield wiper to verify if the screen is fully seated. Inspect the rubber seal on the vent screen which should be fully seated against the windshield. If the cowl vent screen is not fully seated and appears warped, it must be replaced (4F1Z-54018A16-BAA).

2.

Figure 1 - Article 04-15-3 5. Locate the tape as shown (Figure 2). Remove the tape and apply Clear Silicone Rubber TA-32 to the small hole as shown (Figure 2).

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by do-it-yourselfers. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article.The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates.The most recent information is available through Ford Motor Companys on-line technical resources.

Copyright 2004 Ford Motor Company

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TSB 04-15-3 (Continued)

Figure 2 - Article 04-15-3 6. Install the Rain-Hat Extension Seal or Shed Lip Seal 4F1Z-54022A54-AA to the outboard edge of the rain-hat (see Figure 2 for installation). The 10 mm by 10 mm (0.5 by 0.5) cut area, located 25 mm (1) from the end of the seal, will face down and locate at the 90 degree bend of the rain-hat on the fender side (Figure 3).

Figure 3 - Article 04-15-3

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TSB 04-15-3 (Continued)

7. Prior to installation of the cowl vent screen, verify that the cabin filter cover is properly snapped in place and the clip is located on the inboard side, (toward the center of the bulkhead), the cover will feel loose if not properly snapped in place. Reinstall the cowl vent screen per Section 412-01 of the Workshop Manual.
PART NUMBER 1F1Z-19805-AA F6DZ-19A706-AA 4F1Z-54022A54-AA 4F1Z-54018A16-BAA TA-32 PART NAME Blower Motor Resistor Rain-Hat Seal Cowl Panel Clear Silicone Rubber

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041503A Install Rain Hat Extension 0.7 Hr. Seal (Includes Time To Remove, Inspect, And Reinstall Or Replace If Necessary The Blower Motor, Blower Resistor, Or Cowl Panel) DEALER CODING CONDITION BASIC PART NO. CODE 54018A16 D8

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2003 Taurus/Sable Workshop Manual

SECTION 501-16: Wipers and Washers REMOVAL AND INSTALLATION

2003 Taurus/Sable Workshop Manual Procedure revision date: 06/17/2002

Wiper Mounting Arm and Pivot Shaft Removal and Installation

Printable View (71 KB)

1. Park the wiper pivot arms in the highest position on the glass. 2. Disconnect the battery ground cable. For additional information, refer toSection 414-01. 3. Remove the wiper pivot arm nut covers.

4. Remove the nuts and the wiper pivot arms.

5. Remove the cowl top vent panels. For additional information, refer to Section 501-02.

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2003 Taurus/Sable Workshop Manual

6. Remove the four bolts, wiper mounting arm and wiper pivot shaft assembly. Disconnect the electrical connector.

7. To install, reverse the removal procedure. Adjust the wiper pivot arms. Refer to Windshield Wiper Blade and Pivot Arm Adjustment in this section.

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2003 Taurus/Sable Workshop Manual

SECTION 501-02: Front End Body Panels REMOVAL AND INSTALLATION

2003 Taurus/Sable Workshop Manual Procedure revision date: 06/17/2002

Cowl Panel Grille

Printable View (62 KB)

Removal and Installation 1. Remove the wiper pivot arms. For additional information, refer to Section 501-16. 2. Remove the cowl grille clips.

3. NOTE: Remove the RH cowl grille first. Remove the cowl grilles.

4. To install, reverse the removal procedure.

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