NHTSA ID Number: 10216489
Manufacturer Communication Number: 21M05-S1
TSB/Document Date: 2022-07-28
Summary
Certain 2017-2022 Model Year Super Duty Vehicles Equipped with a Power Release Tailgate - Unintended Tailgate Opening. In the affected vehicles, some customers report experiencing an unintended tailgate opening and may have previously serviced their vehicle for this concern. Ford
had developed an enhanced remedy for customers who may want this enhanced repair performed n their vehicle.
ROOF OPENING PANEL
DRAIN TUBE
20036D
FIGURE 4
10. Inspect the roof opening panel drain tube and grommet.
- Is the drain tube and grommet in the correct position? See Figure 5.
Yes - Proceed to Step 17 (Page 6).
No - Proceed to Step 11.
ROOF OPENING PANEL
DRAIN TUBE
GROMMET
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
ROOF OPENING PANEL DRAIN
NUT
TUBE INCORRECT POSTIONMISSING
20036E
ROOF OPENING PANEL DRAIN
TUBE CORRECT POSITION
FIGURE 5
PLACE COPY HERE
PLACE COPY HERE
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
PLACE COPY HERE
ATTACHMENT III
PAGE 4 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
11. Is the grommet attached to the roof opening panel drain tube as seen in Figure 6?
Yes - Proceed to Step 12.
No - Proceed to Step 13.
ROOF OPENING PANEL
DRAIN TUBE
ROOF OPENING PANEL DRAIN
TUBE RUBBER GROMMET
20036F
FIGURE 6
12. Install the roof opening panel drain tube into the body panel making sure that the grommet is fully
seated. Perform a 2 tug test on the roof opening panel drain tube.
- Did the drain tube and grommet remain in place? See Figure 7.
Yes - Proceed to Step 17 (Page 6).
No - Proceed to Step 13.
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
TUG TEST X2
STUD FOR
MISSING NUT
20036G
PLACE
COPY HERE
FIGURE 7
PLACE COPY HERE
PLACE COPY HERE
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
ATTACHMENT III
PAGE 5 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
13. Remove the RH A-Pillar Trim Panel. Please follow the WSM procedures in Section 501-05.
14. Lower the front RH corner of the headliner. See Figure 8.
CAUTION: Do not bend or crease the headliner.
FRONT OF
VEHICLE
FRONT RH CORNER
OF HEADLINER
20036H
FIGURE 8
15. Remove the roof opening panel drain tube. See Figure 9.
1. Remove the drain tube grommet located behind the BCM.
2. Disconnect the drain tube at the roof opening panel.
3. Release the drain tube retainers located along the RH A-pillar down through the Instrument
Panel (IP).
4. Remove the drain tube out the top of the IP.
x7
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
FRONT OF
VEHICLE
FRONT OF
VEHICLE
FIGURE 9
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
PLACE COPY HERE
20036I
PLACE COPY HERE
PLACE COPY HERE
ATTACHMENT III
PAGE 6 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
16. Install a new roof opening panel drain tube by reversing Step 15.
17. Pour a glass of water into the roof opening panel drain tube channel and immediately inspect the roof
opening panel drain tube grommet for water leakage. See Figure 10.
- Is there water leakage inside the vehicle at the grommet?
Yes - Proceed to Step 18.
No - Proceed to Step 19.
FRONT OF
VEHICLE
20036J
FIGURE 10
18. Check that the roof opening panel drain tube rubber grommet is fully seated, then repeat Step 17.
- Is the roof opening panel drain tube rubber grommet fully seated and still leaking after
the second inspection?
Yes - Proceed to Step 15.
No - Proceed to Step 19.
19. Using a garden hose, spray the upper RH side of the engine compartment fire wall. See Figure 11.
SPRAY WITH
GARDEN HOSE
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
FRONT OF
VEHICLE
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
PLACE20036K
COPY HERE
FIGURE 11
PLACE COPY HERE
ATTACHMENT III
PAGE 7 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
20. Immediately inspect under the RH side IP, near the BCM, for any sign(s) of water leakage and/or
moisture.
- Was any sign(s) of water leakage and/or moisture present?
Yes - Proceed to Step 21.
No - Proceed to Step 25 (Page 8).
21. Remove the Instrument Panel. Please follow the WSM procedures in Section 501-12.
22. Verify the location of the water leak by repeating Step 19.
23. Using Motorcraft® TA-32 Clear Silicone Rubber Sealer or equivalent, apply a bead along the body
patch and allow it to dry. See Figure 12. Retest by performing Step 19 once the Clear Silicone Rubber
is dry.
- Was any water leakage found after sealant has dried?
Yes - Apply more sealant by performing Step 23.
No - Proceed to Step 24.
AREA TO SEAL USING
MOTORCRAFT® TA-32
FRONT OF
VEHICLE
20036L
FIGURE 12
NOTE: Do not install the RH A-pillar, scuff plate, or BCM cover at this time.
24. Install the Instrument Panel. Please follow the WSM procedures in Section 501-12.
STUD FOR
MISSING NUT
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
ATTACHMENT III
PAGE 8 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
25. Inspect the front RH side door weatherstrip for any rips or deformity. See Figure 13.
- Were any rips or deformity present?
Yes - Install a new Front Passenger Door Weatherstrip. Proceed to Step 26.
No - Proceed to Step 26.
FRONT OF
VEHICLE
20036M
FIGURE 13
26. Using a garden hose, spray down the RH side of the windshield, then immediately inspect the A-pillar
area within the vehicle for signs of moisture and/or leakage. See Figure 14.
- Was any sign of moisture and/or leakage found around the A-pillar?
Yes - Remove, then reseal the windshield. Please follow the WSM procedures in Section 501-11.
Repeat Step 26.
No - Proceed to Step 27.
FRONT OF
VEHICLE
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
20036N
FIGURE 14
PLACE COPY HERE
PLACE COPY HERE
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
ATTACHMENT III
PAGE 9 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
27. Using a garden hose, run water over the front RH roof ditch, immediately inspect the A-pillar inside the
vehicle for signs of moisture and/or leakage. See Figure 15.
- Was any signs of moisture and/or leakage found around the A-pillar?
Yes - Proceed to Step 28.
No - If equipped with a roof opening panel, Proceed to Step 29.
If NOT equipped with a roof opening panel, Proceed to Step 36 (page 12).
FRONT OF
VEHICLE
20036O
FIGURE 15
28. Apply some Motorcraft® TA-32 Clear Silicone Rubber to the front RH roof ditch. See Figure 16. Allow
the sealer to cure, then proceed to Step 27.
FRONT OF
VEHICLE
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
20036O
FIGURE 16
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
PLACE COPY HERE
ATTACHMENT III
PAGE 10 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
CAUTION: Do not bend or crease the headliner.
29. Lower the front RH corner of the headliner. See Step 14, Figure 8. Pour a glass of water into the roof
opening panel drain tube channel and immediately inspect the drain tube, at the roof opening panel
for water leakage. See Figure 17.
- Is there water leakage from the roof opening panel drain tube?
Yes - Proceed to Step 30.
No - Proceed to Step 33.
FRONT OF
VEHICLE
20036P
FIGURE 17
30. Check that the roof opening panel drain tube is fully seated, then repeat Step 28.
- Is the drain tube fully seated and still leaking after the second inspection?
Yes - Proceed to Step 31.
No - Proceed to Step 33.
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
PLACE COPY HERE
ATTACHMENT III
PAGE 11 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
31. Remove the roof opening panel drain tube. See Figure 18.
1. Remove the drain tube grommet located behind the BCM.
2. Disconnect the drain tube at the roof opening panel.
3. Release the drain tube retainers located along the RH A-pillar down through the IP.
4. Remove the drain tube out the top of the IP.
x7
FRONT OF
VEHICLE
FRONT OF
VEHICLE
20036Q
FIGURE 18
32. Install a new roof opening panel drain tube by reversing Step 31.
33. Position back the front RH corner of the headliner. See Figure 19.
FRONT OF
VEHICLE
FRONT RH CORNER
OF HEADLINER
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
FIGURE 19
20036R
STUD
FOR
MISSING NUT
PLACE
COPY HERE
34. If the previous water leak testing has not been successful in finding the source of the BCM
contamination, please refer to WSM procedures under diagnosis and testing found in
Section 501-00 to isolate and fix the water leak prior to continue with these instructions. PLACE COPY HERE
35. Install the RH A-Pillar Trim Panel. Please follow the WSM procedures in Section 501-05. PLACE COPY HERE
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
ATTACHMENT III
PAGE 12 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
36. If the BCM is to be replaced due to corrosion and/or moisture, transfer all fuses to a new BCM.
• Replace any corroded fuses with a new one.
• Discard the old BCM.
37. Install the BCM and retainer. See Figure 20.
FRONT OF
VEHICLE
20036S
FIGURE 20
38. Inspect all the harness side BCM connectors for sign(s) of moisture and/or corrosion.
- Was any moisture and/or corrosion present?
Yes - For moisture ONLY - Blow dry the affected connector(s) and reconnect the BCM electrical
connectors, then proceed to Step 39.
For corrosion - Order and install the appropriate terminal kit(s) for the affected terminal(s),
reconnect the BCM electrical connectors, and then proceed to Step 39.
No - Reconnect the connector(s) to the BCM, then proceed to Step 39.
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
ATTACHMENT III
PAGE 13 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
Complete Tailgate Actuator Ground Wiring Part Kit
B2
B1
A
D
C
F
E
20036T
FIGURE 21
ITEM
DESCRIPTION
QUANTITY
A
Relay Harness
1
B1
Floor Board Jumper (3 end version)
*1
B2
Floor Board Jumper (2 end version)
*1
C
Tailgate Jumper Harness
1
D
Tie Strap
-
E
Heat Shrink Tubing
4
F
Under Body Harness Jumper
1
* Kit will include either B1 or B2 Floor Board Jumper Harness.
STUD FOR
MISSING NUT
NOTE: The parts being installed in this procedure are not labeled. Refer to Figure 21 for component
identification.
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
ATTACHMENT III
PAGE 14 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
39. Position aside the weatherstrip, release the clips and remove the RH instrument panel finish panel.
See Figure 22.
x6
20036U
FIGURE 22
40. Remove the Glove Compartment. Please follow the WSM procedures in Section 501-12.
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
ATTACHMENT III
PAGE 15 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
41. Place the relay, included in the kit, onto the instrument panel wiring harness and secure using a tie
strap. See figure 23.
INSTRUMENT PANEL
WIRING HARNESS
FRONT OF
VEHICLE
20036V
FIGURE 23
42. Lower the steering column opening trim panel. See Figure 24.
STUD FOR
MISSING NUT
STUD FOR
20036W
MISSING
NUT
FIGURE 24
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TSB/Document ID: 21M05-S1
Replacement Service Bulletin Number:
MFR Communication Date: 2022-07-22
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
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