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Some 2006-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC’s) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM). ACTION: Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14. 2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1) Figure 1 – Article 07-14-1 3. Look for evidence of water within the PCM (liquid water, rust, water stains or deposits). (Figure 2) If found – obtain a replacement PCM before continuing on to Step 4. If no water is found, continue on to step 4 with the vehicle’s original PCM. Figure 2 – Article 07-14-1 4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage. 5. With the PCM cover removed, drill a 1/4″ hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3) Figure 3 – Article 07-14-1 6. De-burr the edges on both inside and outside surfaces. (Figure 3) Be sure to vacuum off all chips and wipe off all metal dust and any machining oil. 7. Clean the surfaces of the PCM cover with Motorcraft ZC-21 (Metal Surface Cleaner) or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8. 8. Apply Motorcraft TA-29 Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 – do not let the sealant skin over. NOTE: Motorcraft TA-32 can NOT be used since its constituents may damage the PCM circuitry.

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TRANSMISSION HARSH SHIFTING – NO DTCS – MILEAGE OVER 20,000 MILES (32,187 KM) FORD: 2005-2006 Five Hundred MERCURY: 2005-2006 Montego ISSUE Some 2005-2006 Five Hundred and Montego vehicles equipped with Aisin six speed transmissions and built prior to 10/17/2005 may experience shift concerns when the vehicle mileage gets above 20,000 miles (32,187 km). Shifting concerns are generally noticed during passing maneuvers with transmission temperatures greater than 212° (100° operating temperatures. Symptoms may be present F C) during downshift 5-3 at 35 mph (56 km/h) and/or 4-3 at 20 mph (32 km/h) with throttle opening at approximately 50% or greater and include: ^ Harsh shift and/or clunk noise ^ Delayed shift and/or perceived slip / engine flare ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. If DTCs are present in the transmission control module (TCM) / powertrain control module (PCM), perform normal diagnostics. Refer to Workshop Manual (WSM), Section 307-01B. 2. If no DTCs are present and mileage is below 20,000 miles (32,187 km) reprogram TCM / PCM and retest. 3. If no DTCs are present and mileage is over 20,000 miles (32,187 km), fluid should be drained and checked for excessive contamination. If fluid is clean, the valve body should be replaced and TCM / PCM updated to the latest calibration level. Refer to WSM, Section 307-01B for main control valve body replacement. 4. If excessive contamination is present, install a new transaxle assembly following normal prior approval guidelines. Reprogramming Reprogram the PCM and TCM to the latest calibration using IDS release 45.8 and

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IGNITION KEY DIFFICULT OR UNABLE TO BE TURNED OR REMOVED – KEY-IN-IGNITION WARNING CHIME SOUNDING WITH KEY REMOVED Some 2000-2005 Focus vehicles may exhibit ignition key related issues including difficulty or an inability to turn the key, an inability to remove the key, or (2005 only) the key-in-ignition warning chime continuing to sound even when the key is removed. ACTION Based on the vehicle’s symptom, refer to the appropriate Service Procedure. SERVICE PROCEDURE UNABLE TO REMOVE IGNITION KEY 1. Check if the inability to remove the key is the result of normal operation of the key removal inhibit circuit: In automatic transmission equipped vehicles, the key removal inhibit solenoid (within the ignition switch assembly) is energized when the gear selector is moved out of the park position, and prevents the ignition key from being removed. If the gear selector is in any position other than park when the key is rotated or turned off, the key removal inhibit circuit will not release the key (key cannot be removed). To remove the key, the gear selector must first be placed in the park position, then the ignition must be cycled to run and back to lock. This is normal, do not replace the ignition lock cylinder if it is operating as described. 2. Refer to Workshop Manual, Section 307-05 and follow diagnostics for the “shift interlock system”. The shift interlock system includes the key removal inhibit circuit, which may be causing the concern. If the shift interlock system is operating correctly, replace the ignition lock cylinder. Refer to Workshop Manual, Section 501-14, “Ignition Lock Cylinder Functional” removal and installation procedure. DIFFICULT OR UNABLE TO TURN IGNITION KEY

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TRANSAXLE – CD4E – HARSH AND DELAYED 1-2/2-3 UPSHIFTS – AFTER TRANSAXLE OR TURBINE SHAFT SPEED SENSOR (TSS) REPLACEMENT – POSSIBLE DIAGNOSTIC TROUBLE CODES (DTC) 628, 642, 645, 646, 647, 648, P0731, P0732, P0734, P0741, AND P1744 ISSUE Some vehicles equipped with the CD4E transaxle may exhibit harsh and delayed 1-2/2-3 upshifts along with DTCs for gear ratio errors after the Transaxle or Turbine Shaft Speed sensor (TSS) have been replaced. DTCs may include OBD1 codes 628, 642, 645, 646, 647, 648, or OBD II codes P0731, P0732, P0734, P0741, and P1744 ACTION If the condition occurred after servicing the Transaxle or TSS, refer to the following TSS Selection Chart and select the correct TSS for the vehicle application. Note that each TSS has the Ford engineering part number on it. Also note that there is a TSS kit that includes an instruction sheet, TSS sensor and correct bolt. SERVICE PROCEDURE If the condition occurred after replacing the Transaxle or TSS, use the TSS Selection Chart and determine the correct sensor for the vehicle. 1. Remove the existing TSS from the CD4E pump body. 2. Reinstall the original TSS sensor, if available, or install the correct TSS as indicated in the Selection Chart. 3. Clear all codes and verify repair. 4. If the condition still exists, follow normal diagnostics as listed in the appropriate model year Workshop Manual.

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ISSUE Various vehicles equipped with a 3.8L, 3.9L or 4.2L engine and Split Port IMRC may exhibit spark knock under light load and acceleration. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Inspect for disconnected IMRC actuator rods. 1. Check both right hand and left hand side IMRC rods are properly attached to the actuator motor and intake manifold runner. 2. If the IMRC actuator rods are found to be connected properly, do not continue with this TSB. Refer to Powertrain Control/Emission Diagnosis Manual. 3. If any IMRC actuator rods are disconnected, refer to Workshop Manual (WSM), Section 303-14 for IMRC service. 4. If any IMRC actuator rod linkages are found disconnected, replace all four (4) linkage rod retainers. (Figure 1