Lock Replacement TSB 99-24-2

99-24-2, Publication Date: NOVEMBER 12, 1999

FORD:

1996-2000 CROWN VICTORIA, MUSTANG, TAURUS

1997 THUNDERBIRD

1996 BRONCO, F-150-350 SERIES

1996-97 AEROSTAR

1996-2000 ECONOLINE, EXPLORER, RANGER

1997 F-250 HD, F-350

1997-2000 EXPEDITION, F-150, F-250 LD

1998-2000 WINDSTAR

1999-2000 SUPER DUTY F SERIES

1996-2000 F & B SERIES

LINCOLN:

1996-2000 TOWN CAR

1997-98 MARK VIII

1997-2000 CONTINENTAL

1998-2000 NAVIGATOR

MERCURY:

1996-2000 GRAND MARQUIS, SABLE

1997 COUGAR

1997-2000 MOUNTAINEER

This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart.

ISSUE:

The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lockset (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected.

ACTION:

Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details.

NOTE:

MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCKSET. THE TWO STYLES ARE NOT INTERCHANGEABLE.

SERVICE PROCEDURE

l For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04.

l Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14.

Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application.

HOW TO READ A KEY CODE

Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station).

l Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215).

l Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights.

l Using the customers key, measure the key cut depth at each key station using figure 2 of the instruction sheet contained within each lock service package.

One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle.

Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00AM and 4:30PM ET (all U.S. and Canadian dealers only).

For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041.

A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-051A).

NOTE:

THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS.

A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number on the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to «Figure 1».

NOTE:

THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT.

NOTE:

SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR.

1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages.

NOTE:

1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES.

PACKAGES.