Deja Vu

[DavidA]

Some of us 'oldtimers' remember when Ford had problems with the first batch of 2002 Thunderbirds and many, (including mine), were recalled back to Michigan for repairs before they could be delivered, Rouch Performance did the repairs, but it was painfully slow getting them fixed and delivered. Mine took over 2 months before it finally came back to the dealer after first arriving in August.

Well, it's happening again. 2020 Explorers and Aviators are piling up at the Chicago plant and many are being shipped to Rouch to handle the overflow. The problems are not being disclosed, but it is assumed they are serious, not something typical dealers can fix.

While there were hundreds of Thunderbirds stacked up at Rouch back on 2002, this time between 7000 and 10,000 SUV's are being held and repaired before they can be shipped to dealers.

[BLACK BEAUTY]

Interesting David. You were one of the retro pioneers! The retro entered my radar in 2012...thanks for sharing

[Sunnybird]

Will you share what the overflow issue is on the 2002’s please and how does the issue present.

Thank you
Melissa

[merlot4]

Here's a (the?) recall for the Explorer, and Aviator:
https://www.autonews.com/regulation-...20Ford%20said.

[yelobird2002]

Mine was one of those original 1,200 or so 2002 returned to the Factory. Arrived by rail in August 2001, then was loaded onto a Hadley Auto Transport truck on Labor Day weekend and shipped back to Factory. Re-arrived via rail 10-9-2001. Bill Greens (15again) Bird arrived on same rail as mine and shipped back on the same truck & trailer. Because the person running the railhead is a friend of mine, I have pictures of it being unloaded from the railcar, being loaded onto the transport truck, and being unloaded from the second railcar. Because of my friend running the railhead I have copies of all the documentation from Ford putting a "HOLD" on these vehicles, copies of orders to ship back these vehicles and copies of Bill of Ladens for both rail trips and the transport trip listing VIN of every car on the railcars it arrived on both times and the transport truck. Because the railhead is only about two miles from the Dealership and me knowing the Railhead Manager, my salesman and I drove the T-Bird from the railhead to the dealership instead of it being brought over on transport truck. It still had all the white plastic on the paint. I used to work at the dealership so I got preffered treatment and the car was Pre-Delivered, Detailed, and delivered to me the same day it came into the rail yard 10-9-2001.

[007Cruiser]

Cool, Lon!

[DavidA]

Will you share what the overflow issue is on the 2002’s please and how does the issue present.

Thank you
Melissa

The issue was with a power steering valve. Not a big deal, but Ford didn't want any issues with the cars when delivered to customers. At the time, they were overly picky about the quality.

[5bird7]

The issue was with a power steering valve. Not a big deal, but Ford didn't want any issues with the cars when delivered to customers. At the time, they were overly picky about the quality.

power steering valve? I thought it was an issue with the hydraulic pump (a part not up to specs) and they had to replace the hydraulic pumps.

Lon had already heard at his dealer sometime in early August about a traveling customer from out of state coming in with his brand-new retro and reporting that his brand new car was overheating and he was on his way to someplace in Colorado. Customer was madder than ever.

[Sunnybird]

Thanks for sharing guys. I just started having a very small leak noticed on the garage floor. Looks like a pale yellow and the garage thinks it is coming from the ac. How does one know. Seems to be from the right front of car located in from the tire location.

Sunnybird

[Gobird]

power steering valve? I thought it was an issue with the hydraulic pump (a part not up to specs) and they had to replace the hydraulic pumps.

Lon had already heard at his dealer sometime in early August about a traveling customer from out of state coming in with his brand-new retro and reporting that his brand new car was overheating and he was on his way to someplace in Colorado. Customer was madder than ever.

Dot I agree with you on the hydraulic pump usual. Mine wasn't recalled but the pump did go out 2 weeks before the 3 year warranty ended at 30,000 miles and was replaced. Been just fine since then 151,000 miles late.

[007Cruiser]

Thanks for sharing guys. I just started having a very small leak noticed on the garage floor. Looks like a pale yellow and the garage thinks it is coming from the ac. How does one know. Seems to be from the right front of car located in from the tire location.

Sunnybird

Your best bet would be to start another thread for this where it would be easier for people to see your problem. The shop should be able to use a dye to check the AC system for leaks.

[yelobird2002]

It was the Hydraulic Fan Motor Dot. The bores for the main shaft were mis-machined by a few thousandths putting a bind on the shaft. At an idle the bind was great enough to stop the shaft shaft from being rotated by hydraulic pressure created by the Hydraulic Pump thus allowing the engine to overheat at an idle. Above an idle there was enough hydraulic pressure to overcome the bind put on the shaft allowing it to rotate. So overheat was an issue only at an idle.

[HKS]

Thanks for sharing guys. I just started having a very small leak noticed on the garage floor. Looks like a pale yellow and the garage thinks it is coming from the ac. How does one know. Seems to be from the right front of car located in from the tire location.

Sunnybird

Mine leaked from the same place.
It was a pressure switch/sensor on the power steering pump.

[4LOWBIRDS+7]

Back to subject, I have one of my best men on the job in Chicago and things are getting better.

[Skip]

power steering valve? I thought it was an issue with the hydraulic pump (a part not up to specs) and they had to replace the hydraulic pumps.

Lon had already heard at his dealer sometime in early August about a traveling customer from out of state coming in with his brand-new retro and reporting that his brand new car was overheating and he was on his way to someplace in Colorado. Customer was madder than ever.

My '02 was built on August 7, 2001 but did not arrive at my dealer until September 28th. It was prepped and delivered the same day. To the best of my knowledge it never left the factory until the repair was made. I, too, was advised it was a cooling system/overheating issue.