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PE10-019 FORD 9-9-2011 Appendix B C PAGE 3 E PAGE 4 H PAGE 19 I PAGE 131 K PAGE 133 L PAGE 135 M PAGE 139 N PAGE 143 Q PAGE 209 R PAGE 211 S PAGE 213 PE10-019 Supplement Appendix B 2006 thru 2011 Model Year Ford Fusion, Mercury Milan, Lincoln Zephyr/MKZ Accelerator Pedal Assembly Application Chart 2006 MY 2007 MY 2008 MY 2009 MY 2010 MYa 2011 MYa Engineering Supplier All All All All 2.5L 3.0L 2.5L HEV 3.5L 2.5L 3.0L 2.5L HEV 3.5L Part Number Name 6E53-9F836-AF Birkby's XXXX 9E5A-9F836-BC KSR XX 9E5A-9F836-AB Hella X X X 9E5A-9F836-AC Hella Xb Xb Xb XXX BE5C-9F836-AA Hella Xc Xc Xc Notes: a - all engines may not be available on all models b - running change, supplier first shipped 9E5A-9F836-AC on 7/30/2009 c - running change, supplier first shipped BE5C-9F836-AA on 2/2/2011 PE10-019 Supplement Appendix C Supplier Contacts Hella Electronics Corporation Kevin Leonard [email protected] Desk: 734-456-2067 Cell: 734-578-4412 43811 Plymouth Oaks Blvd. Plymouth, MI 48170 KSR International Co. Larry Willemsen [email protected] (519) 674‐5413 Ext. 230 95 Erie Street South Ridgetown, Ontario, Canada N0P 2C0 Birkbys Plastics LTD Stephan Kiss Title: FORD / JLR Quality Engineer Telephone: +44 (0) 1924 414310 Headlands Road Liversedge West Yorkshire England WF15 6QA PE10-019 Supplement Appendix E 2006 through 2011 Model Year Ford Fusion, Mercury Milan, Lincoln Zephyr/MKZ Accelerator Pedal Assembly Part Change Log A BC D E F G HI Original Modified Disposition of Original Parts New Component Date Incorporated New Component Interchangeable With Model and Withdrawn from Ford Into Vehicle Description of Change Reasons for Change Production Inventory Service Part Old Model Year Ford Engineering Part Ford Service Part Ford Engineering Part Ford Service Part Production Supplier (Scrap/ Effective Date Availability Date (Y/N - Intended versus Number Number Number Number Consume/ Possible) Rework) 2006-2009 MY Fusion, New pedal assy for new 8/1/2005 New vehicle for 2006 MY. N/A N/A 6E53-9F836-AF 6E5Z-9F836-AA Birkby's N/A N/A 8/1/2005 N/A Milan, Zephyr/MKZ vehicle platform. New design to mount to new dash panel common 2010 MY - Present 3.5L New design for 2010 MY N 12/1/2008 with Mazda 6. Common 6E53-9F836-AF 6E5Z-9F836-AA 9E5A-9F836-BC 9E5Z-9F836-B KSR International Scrap 12/1/2008 2/4/2009 Fusion, MKZ from new supplier. (Not Possible) mounting with new 2.5L, 3.0L, 2.5L HEV New design to mount to new dash panel common 2010 MY - 2.5L, 3.0L, New design for 2010 MY N 12/1/2008 with Mazda 6. New 6E53-9F836-AF 6E5Z-9F836-AA 9E5A-9F836-AB 9E5Z-9F836-A Hella Scrap 12/1/2008 2/4/2009 2.5L HEV Fusion, Milan from new supplier. (Not Possible) sensor for requirements of new control system. 2010-2011 MY - 2.5L, 3.0L, 2.5L HEV Fusion, Commonize pedal Increase lower mounting Running Y Milan 7/30/2009 /a housing with Mazda 6 9E5A-9F836-AB 9E5Z-9F836-A 9E5A-9F836-AC 9E5Z-9F836-A Hella Consume N/A hole size by 0.2mm Change (Intended) 2011 MY - 2.5L HEV pedal. MKZ Robustness action to 2011 MY - 2.5L, 3.0L, prevent ETC system from Running Y 2.5L HEV Fusion, Milan, 2/2/2011 /a Revised sensor. 9E5A-9F836-AC 9E5Z-9F836-A BE5C-9F836-AA BE5Z-9F836-A Hella Consume 3/16/2011 going into reduced power Change (Intended) MKZ or limp home modes. Note a/ Date that supplier first shipped modified part Page 1 of 1 PE10-019 Supplement Appendix F Subject Vehicles: 2006-2011 Ford Fusion/Mercury Milan/Lincoln Zephyr-MKZ Alleged Defect: Engine Speed and/or Engine Power Output Failing to Decrease When Accelerator Pedal Is No Longer Depressed and/or Floor Mat Interference With Accelerator Pedal Operation OWNER REPORTS As the agency is aware, within FCSD's North American Customer Service Operations, there is a Customer Relationship Center (CRC) that is responsible for facilitating communication between customers, dealerships and Ford Motor Company. Among other things, the CRC handles telephonic, electronic, and written inquiries, suggestions, informational requests, and concerns ("contacts") from Ford and Lincoln-Mercury vehicle owners about their vehicles or sales and service experience. The contacts are handled by CRC customer service representatives who enter a summary of the customer contact into a database known as CuDL (Customer Data Link). Certain contacts, such as letters from customers, are entered into the CuDL database. Those that were entered into the earlier MORS II system were also microfilmed. More recently, the records in MORS III/CuDL are imaged and stored electronically. The CRC assigns to each vehicle-related contact report a "symptom code" or category that generally characterizes the nature of the customer contact or vehicle concern, as described by the owner. The CRC does not undertake to confirm the accuracy of the description provided by the owner; they simply record what is reported. Therefore, given the complexity of the modern motor vehicle, it is Ford's experience that a significant percentage of owner contacts do not contain sufficient information to make a technical assessment of the condition of the vehicle or the cause of the event reported. Accordingly, although MORS contact reports may be useful in identifying potential problems and trends, the records are not the empirical equivalent of confirmed incidents and/or dealership's diagnosis. In the interest of responding promptly to this inquiry, Ford has not undertaken to gather the electronic images related to these contacts because of the largely duplicative nature of the information contained in the images, as well as the time and the burden associated with locating and producing those documents. The pertinent information related to those contacts generally would be included in the contact reports obtained from the CuDL system. To the extent that those documents exist, they are characterized in the comments of MORS III contact reports. Upon request, Ford will attempt to locate any specific items that are of interest to the agency. In responding to this information request, Ford electronically searched CuDL using the following criteria: Subject Vehicle: 2006-2010 model year Ford Fusion, 2006-2010 model year Mercury Milan, 2006 model year Lincoln Zephyr, and 2007-2010 model year Lincoln MKZ vehicles manufactured for sale or lease in the United States, District of Columbia, Puerto Rico, Northern Mariana Islands, Guam, American Samoa and the Virgin Islands. Date Parameters: January 1, 2011 through July 22, 2011 (the date of this inquiry) Types of Contacts: All, including suspended data, canceled contacts and inquiries 1 PE10-019 Supplement Appendix F Subject Vehicle: 2011 model year Ford Fusion, Mercury Milan, and Lincoln MKZ vehicles manufactured for sale or lease in the United States, District of Columbia, Puerto Rico, Northern Mariana Islands, Guam, American Samoa and the Virgin Islands. Date Parameters: January 1, 2010 through July 22, 2011 (the date of this inquiry) Types of Contacts: All, including suspended data, canceled contacts and inquiries MORS III Symptom Codes: Symptom Symptom Category Code Symptom Description Body 1074xx Interior Trim – Carpet/Mats Driveability 612xxx Surge Driveability 617xxx Slow Return to Idle Driveability 619xxx Fast Idle Driveability 620xxx Engine Speed-Up Driveability 624xxx Accelerator Pedal Driveability 6305xx EV/Hybrid - Surge Driveability 6995xx Not Listed Driveability - Acceleration MORS III Reason Codes: Reason Code Description 07xx All legal reason codes LEGAL CONTACTS Beginning in early 2008, most consumer complaints and all legal claim processing has been centralized in OGC within the Consumer Litigation team. A transition has occurred such that all legal contacts (including those formerly handled by "Litigation Prevention") are coordinated through this team. Prior to the transition, there was a Consumer Affairs Department within FCSD that managed customer concerns, which could not be resolved by the Customer Relationship Center (CRC). Among other things, the Consumer Affairs Department had a section, known as "Litigation Prevention," that handled a variety of informal (i.e., non-litigation) claims, such as property damage claims or attorney demand claims. The Litigation Prevention section had been centralized in the Consumer Affairs Department since 1995, in Dearborn, Michigan. Prior to that time, Litigation Prevention personnel operated on a regional basis. For matters that the Litigation Prevention section handled, there were typically paper files that reflected the handling, investigation and resolution of property damage claims. The claims, known as "Legal Contacts" are entered into the CuDL database that the CRC uses to enter other customer communications. When a customer contact is designated as a Legal Contact, it is so indicated near the top of the contact report. 2 PE10-019 Supplement Appendix F FIELD REPORTS Within FCSD, there is a Vehicle Service & Programs Office that has overall responsibility for vehicle service and technical support activities, including the administration of field actions. That Office is the primary source within Ford of vehicle concern information originating from Ford and Lincoln-Mercury dealerships, field personnel, and other sources. The information is maintained in a database known as the Common Quality Indicator System (CQIS). The CQIS database includes reports compiled from more than 40 Company sources (e.g., Company- owned vehicle surveys, service technicians, field service and quality engineers, and technical hot line reports, etc.) providing what is intended to be a comprehensive concern identification resource. As with MORS contact reports, CQIS reports are assigned a "symptom code" or category that generally reflects the nature of the concern.

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