(This Ford TFI Module is located on the front of the radiator core support on a 1988 Cougar with the 3.8 V6.)

What is the problem with the modules?

Due to excessive heat from the engine, the module has been known to stop working or intermittently work, resulting in stalling or cutting out of power to the vehicle's ignition system. This situation has been known to cause stalling and accidents.

What Ford vehicles are affected by this problem?

Any Ford vehicle with the EEC-IV engine system, from late-1983 through the mid-1990's, has a TFI spark module, including Cougars and Thunderbirds. Pre-1983 vehicles do not have this module. Vehicles with DIS (distributorless ignition system) also do not have a spark module.

Is Ford recalling cars because of the TFI modules?

As of right now, there is no recall from Ford. However, as pressure increases on Ford due to the Firestone tire situation, there may be some type of action. Technically a federally-mandated (government) recall can only go back 7 model years. During the mid-1990's, Ford redesigned the ignition systems on engines so that they didn't need a TFI module. Therefore, not many cars would be recalled if Ford was prompted by the government. HOWEVER, if Ford is either responsible enough or is pressured from external sources, they MAY voluntarily recall all affected vehicles. Recently Ford recalled all vehicles from 1994-up with the 3.8 V6 for head gasket replacement. Similar action has taken place for 1994-95 vehicles with the cracking plastic intake on 4.6 V8 motors. Keep in mind that Ford Motor Company absolutely does NOT have to recall any vehicles if it feels that the problem is not serious enough.

However, there is no precedent for a statewide recall notice through a court. As of Wednesday, October 11, 2000, a California judge has ordered Ford to recall 1.2 million vehicles in California only with the TFI modules in question. The judge was hearing a class-action lawsuit filed by Ford vehicle owners in the state. The list of cars affected is below:

1983 Capri (2.3L)
1983 Escort/Lynx (1.6L)
1983 Mustang (1.6L)
1983 Thunderbird (2.3L)
1983 Ranger (2.8L)
1984 Crown Victoria (5.0L)
1984-85 Escort/Lynx (1.6L)
1984-86 Escort/EXP TC (1.6L)
1986-88 Escort/Lynx (1.9L)
1985-90 Escort/Lynx HO (1.9L)
1985-1989 Merkur (2.3L)
1984-90 Tempo/Topaz (2.3L)
1985-94 Tempo/Topaz HSC (2.3L)
1984-89 Mustang/Capri (2.3L)
1984-86 Mustang SVO TC (2.3L)
1984-86 Mustang/Capri (2.3L)
1984-85 Mustang/Capri (3.8L)
1984-94 Mustang/Capri HO (5.0L)
1984-88 Thunderbird Turbo Coupe/Cougar XR7 (2.3L)
1984-87 Thunderbird/Cougar (3.8L)
1984-91 Thunderbird/Cougar (5.0L)
1986-87 Taurus/Sable (2.5L)
1986-95 Taurus/Sable (3.0L)
1986-87 Taurus/Sable (3.8L)
1986-87 Continental (3.8L)
1984-92 Mark VII (5.0L)
1984-89 Town Car (5.0L)
1984-85 LTD/Marquis (2.3L)
1984-86 LTD/Marquis (3.8L)
1984-94 LTD/Marquis (5.0L)
1985-87 Aerostar (2.3L)
1986-90 Aerostar (3.0L)
1984-89 Ranger (2.3L)
1986-91 Ranger/Bronco II (2.9L)
1984-90 Bronco (4.9L)
1984-91 Bronco (5.0L)
1984-85 & 1988-91 Bronco (5.8L)
1984-91 F-150 Pickup (4.9L)
1984-91 F-150 Pickup (5.0L)
1984-91 F-250 Pickup (4.9L)
1984-91 F-250 Pickup (5.0L)
1984-85 & 1988-91 F-150 Pickup (5.8L)
1984-85 & 1988-91 F-250 Pickup (5.8L)
1984-85 & 1988-91 F-350 Pickup (5.8L)
1984-91 E-150 Van (4.9L)
1984-91 E-150 Van (5.0L)
1984-85 & 1988-91 E-150 Van (5.8L)
1990-92 Probe (3.0L)
1995 Sable (3.0L)
1995 Taurus (3.0L)

Ford is appealing the case, so it may not be resolved for quite some time. There are also similar class-action lawsuits pending in several other states. Depending upon the final outcome of the California case, it may be years until the problem is fully resolved.

In the meantime, I'm concerned. What should I do with my vehicle?

If you are concerned about your car's TFI module, the first thing you should do is have a qualified mechanic inspect it physically. This requires removal with a special tool. There are two Torx screws sunk into the module that hold it to the distributor (or heat sink). Once they are removed, the module unsnaps from its base, and then the wiring harness can be unhooked. On the top (grey) side is an inspection cover, under which is the thick film. There should be no seepage of film, nor should the film be dried up. Also, the plastic around the mounting screws should not be cracked at all. ANY cracks will allow the module to pull away from its base, cutting out power and possibly hampering ignition. The module's halves should be flush and fitted tightly against one another. There should be no brownish discoloration at the harness end. Finally, there should be a generous spattering of dielectric grease (clear or white in color) on the metal backside of the module. This is to help promote electrical conductivity with the base. Upon replacement, the old grease should be wiped off and a new fresh coat applied, approximately 1/32 of an inch thick. Be sure to inspect all wiring around the module to make sure there are no breaks or pinholes that may short out the system. In an electrical test with an ohmmeter, the TFI module should be below 800 ohms or over 975 ohms. If the module falls between 800 and 975 ohms, it must be replaced.

Can I replace the part myself?

If you feel that you can do this yourself, the tool to remove the module is only a few dollars at any good auto parts store (Auto Zone, NAPA, All Pro, etc.). Be sure to disconnect the vehicle's battery before attempting to remove this or any other electrical component of the car. Use a name brand (Wells, Motorcraft, etc.) to be sure you are getting a quality TFI module. The cost of the part itself should be anywhere from $15 - $50 U.S. for your vehicle. Keep in mind that there is no guarantee that the new part will be assembled better, or less prone to the problem, than the old module. However, a new module will at the very least provide more accurate information to the computer and is very inexpensive insurance.

Owners of vehicles with the TFI modules mounted on the radiator core probably will not have any problems with excessive heat affecting the module. This is because of a large heat sink (dissipator) around the module itself, and the cooling effect of incoming air as you drive. However, it is still recommended that you have it inspected for other problems mentioned above.