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The paper describes the application of surface mounted technology to cost reduce and downsize an existing electronic control module. Ford Motor Company's Lamp Outage Module was chosen to demonstrate the advantages of this technology. The application of this new manufacturing technology to an automotive product required careful printed circuit board design and component selection. The design considerations, test plan and reliability results are presented. The test results indicate that with proper component selection performance can be obtained that surpasses the existing manufacturing process. This technology does promise vehicle cost reductions as it is applied to other automotive products.