Body - Rear License Plate Housing Cracking

TSB 05-12-7

06/27/05

REAR LICENSE PLATE HOUSING CRACKING

FORD:
2004-2005 Freestar

MERCURY:
2004-2005 Monterey

ISSUE





Some 2004-2005 Freestar/Monterey vehicles may exhibit vertical cracks in the rear license plate housing. The cracks will appear at the top of the two (2) upper outer-most stud attachments points (Figure 1).

ACTION
Enlarge the sheet metal slots on the liftgate. Refer to the following Service Procedure.

SERVICE PROCEDURE

1. Remove the cracked rear license housing, refer to Workshop Manual Section 501-08 for 2005 or 501-00 for 2004 vehicles.

2. Enlarge the width of the three (3) upper sheet metal slots on the liftgate by 1.3 mm, to change the slot width from 6.0 mm to 7.3 mm as follows:





a. For the two (2) outer-most slots (upper), enlarge towards the center of the vehicle (Figure 2).





b. For the one (1) center slot (upper), enlarge equally around the centerline of the existing slot (Figure 3).

3. Apply Motorcraft Sealer PM-12-A to the enlarged sheet metal slots.

4. Install a new rear license housing.

5. Secure the new rear license housing studs using five (5) M4 nuts. Torque to 16 lb-in (1.8 N.m).





Parts Block

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

OPERATION DESCRIPTION TIME

051207A 2004-2005 0.4 Hr.
Freestar/Monterey Replace
The Rear License Plate
Housing Following TSB
Service Procedure (Do Not
Use With 46404B,
46404B1, 46404B9)

051207B 2004-2005 1.3 Hrs.
Freestar/Monterey
Additional Time To Paint
Rear License Plate
Housing Includes Time For
Basic Paint Operation
P101 (Do Not Use With
P42, P42C, P42D)

DEALER CODING
CONDITION
BASIC PART NO. CODE
17A385 12





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