Recalls

CampaignManufacturerManufacturing dateType# of units affectedDate Owner notified MfgRecall Initiated byManufacturers of recalled vehicles/productsReport Recieved DateRecord Creation DateRegulation Part NumberFMVSS Number
POWER TRAIN - TRANSFER CASE (4-WHEEL DRIVE)
97V204000FORD MOTOR COMPANYfrom 01/31/1992 to 01/20/1997V (Vehicle)7500002/16/1998MFRFORD MOTOR COMPANY11/13/199711/20/1997
Defect SummaryVehicle description: all wheel drive passenger minivans. these vehicles can develop powertrain bending resonance or transfer case output shaft bushing displacement. the powertrain bending resonance or the output shaft bushing displacement can result in structural failure of the transmission and/or transfer case. fluid explusion, driveshaft separation or loss of vehicle drive can result.
Consequence SummaryThis condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.
Corrective SummaryDealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.
NotesOwner notification is expected to begin february 16,1998.owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact ford at 1-800-392-3673.also contact the national highway traffic safety administration's auto safety hotline at 1-800-424-9393.

Bulletins

BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
POWER TRAIN - AUTOMATIC TRANSMISSION
9915207/26/1999608431Information on the new flush and fill tool available through rotunda. *tt01/05/2001
001501/10/2000612203Information regarding the new transmission cooler flusher- service tip. *mjs06/06/2000
98308002/26/1998607372Information regarding transfer case rear housing and driveshaft replacement. *tt09/21/1999
9811201/19/1998605573Subject regarding a new service center support that uses a thrust bearing (#3 and #4) in place of thrust washers has been released. *tt07/12/1999
988804/27/1998601238Information on a new transmission fluid usage chart. *yc07/10/1998
9751103/03/199751945Fluid- transmission fluid usage charts. *jd07/17/1997
BC438095090609/01/199545767Availability of high altitude transmission. *tw04/25/1996
95101205/01/199542097Transfer case may leak fluid from the case vent tube. *tw11/01/1995
POWER TRAIN - AUTOMATIC TRANSMISSION - COOLING UNIT AND LINES
0314807/21/200310003748New transmission cooler flusher - service tips. 2003 escort and super duty f series included. *tt10/29/2003
00231011/13/2000616522Subject regarding contamination from prior transmission concerns or excess wear may be trapped in the transmission fluid cooling system. *tt03/05/2001
POWER TRAIN - AUTOMATIC TRANSMISSION - PARK/NEUTRAL START SWITCH
0118109/17/2001625715Brake shift interlock.*jb11/30/2001
POWER TRAIN - AUTOMATIC TRANSMISSION - TORQUE CONVERTER
9624911/18/199650908Torque converter - leak test procedure - service tip. *tw06/17/1997
96261212/16/199650997Transaxle - torque converter replacement guidelines and torque converter/transaxle cooling system cleaning procedures - service tip. *tw06/17/1997
POWER TRAIN - AXLE ASSEMBLY
9823311/23/1998603717Concerns with front drive axle fluid may leak out of the vent under some driving modes on some vehicles. *yc03/03/1999
BC243197050105/01/199752834Aerostar e4wd models may experience front axle lubricant leakage from the vent tube under some driving conditions. *tw09/18/1997
POWER TRAIN - MANUAL TRANSMISSION
BC067896102510/25/199650356Information on aode/4r7w transmission main control & case replacement. *tt04/24/1997

Investigations

NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
POWER TRAIN
EA99002FORD MOTOR COMPANY01/07/199911/14/2000TRANSFER CASES AND REAR DRIVE SHAFT99V094000
 Powertrain bending resonance and/or transfer case rear drive shaft bushing displacement can cause structural failure of the transmission
POWER TRAIN - TRANSFER CASE (4-WHEEL DRIVE)
RQ98012FORD MOTOR COMPANY07/31/199801/07/1999TRANSFER CASES AND REAR DRIVESHAFT97V204000
 Powertrain bending resonance or transfer case output shaft busihing displacement, resulting in structural failure of the transmission and/or transfer case driveshaft separation, loss of fluid and fire potential

Consumer Complaints

Fail datemilesoccurencesPurchase date
POWER TRAIN - AUTOMATIC TRANSMISSION
01/01/20002
 Transmission/gears failed more than once. *ak the consumer says the cost for replacing the transmission that failed again was paid by the consumer. *yh
12/06/2000
 Transmission has been replaced 4 times.vehicle stalled in middle & when going in reverse. problem is intermittent. dealer just rebuilds transmission, not knowing if parts are defective. *ak
05/01/2000
 Consumer found out through a technical service bulletin that transmission had a design flaw. they had to alter the original design to repair the problem. opening to transmission pump was too small, allowing the pump to become clogged up. it built presure to blow the front seal. *ak
05/01/2000103/01/1996
 Continual loss of torque over last seven months. dealer has always said it was the small engine until on 5-1-00 it refused to take off when stopped at a stop sign and had a leak coming from the transmission. leak later stopped and a check of the fluid level showed it to be normal. ron clark ford checked it out today and said the torque converter and entire transmission was worn out and estimated replacement at $2,800 for a rebuilt transmission. it was brought to their attention that each time we have taken it in for a check for the symptom that lead to this failure we have been told that nothing could be found wrong. *ak
03/03/19991211/01/1998
 Ford refunded us $1000.00 for 1 transmission, the first one was still on warranty, the most recent transmission failure occured at 55 miles per hour and it was the tourque converter that blew in this case. *ak
 Vehicle will not shift into park, cause unknown. please give any further details. *ak
08/01/1998108/01/1995
 Very disappointing vehicle! np safety defect mentioned in summary. *ak
 Auto-transmission; system has history of stalling or not responding to acceleration, putting owner in jeopardy. please describe details. *ak
POWER TRAIN - AUTOMATIC TRANSMISSION - GEAR POSITION INDICATION (PRNDL)
02/07/1997109/01/1995
 Transmission gear shifter sticks from park to drive.
POWER TRAIN - AUTOMATIC TRANSMISSION - LEVER AND LINKAGE - COLUMN SHIFT
01/01/19973
 Recall 97v204000: transfer case: recall been repaired twice by two ford dealers quality ford, whiteville, nc and pervis brothers, fayetteville, nc 910-864-3983. the problem is still occurring, remedy did not fix the safety defect. owner has been trying to get rid of the van, dealer would not take it for a trade in. *ak *ml
07/04/1998
 Received recall notice 97v204000 concerning 4-wheel drive & contacted dealer. took vehicle to dealer for repairs. picked up vehicle. was not satisfied with the recall repairs. *ak
09/14/19981
 Recall work performed on the transfer case/driveshaft, was not completed in a timely manor. (# 97s83).
3
 Recall remedy did not correct the problem which has reoccurred with the transfer case that was replaced, but problem was not corrected. recall number 97v204000. *ak
07/06/1998106/30/1995
 Consumer took vehicle in for recall on transfer case, recall no.97v204000. vehicle was repaired, but problem reoccurred. *ak upon deceleration from speeds 55 to 70 mph, creates a grining noise in the area where the parts were replaced, consumer is concerned that current parts would fail and cause problems controlling the vehicle, consumer states that the grining noise was not occurring before the factory recall and parts replacement. *slc
05/29/1998
 Consumer received recall letter for transfer case/drive shaft,consumer called two dealers for an appointment. both refused to order the part until they have a primary inspection. recall letter stated that the vehicle must be serviced without delay. *ak
09/19/199704/02/1997
 Transfer case failed due to driveshaft vibration. *ak
POWER TRAIN - AUTOMATIC TRANSMISSION - PARK/NEUTRAL START SWITCH
08/01/1997105/28/1996
 Transmission cable is built too close to transmission by design causing cable to melt and result in vehicle roll resulting in collision. yh
POWER TRAIN - AUTOMATIC TRANSMISSION - TORQUE CONVERTER
05/01/2000103/01/1996
 Continual loss of torque over last seven months. dealer has always said it was the small engine until on 5-1-00 it refused to take off when stopped at a stop sign and had a leak coming from the transmission. leak later stopped and a check of the fluid level showed it to be normal. ron clark ford checked it out today and said the torque converter and entire transmission was worn out and estimated replacement at $2,800 for a rebuilt transmission. it was brought to their attention that each time we have taken it in for a check for the symptom that lead to this failure we have been told that nothing could be found wrong. *ak
03/03/19991211/01/1998
 Ford refunded us $1000.00 for 1 transmission, the first one was still on warranty, the most recent transmission failure occured at 55 miles per hour and it was the tourque converter that blew in this case. *ak
POWER TRAIN - CLUTCH ASSEMBLY
09/12/1998
 Aluminum front clutch piston is causing the transmission to become inoperative or defective at approximatly 40,000 miles. dealer and manufacturer are aware of problem. *ak
POWER TRAIN - DRIVELINE - DRIVESHAFT
08/21/1999303/01/1997
 This vehicle is exhibiting some of the same symptoms as previously experienced with the recall number indicated (97v204000). this recall was done in early march 1998. the resonance, which occures while the vehicle is neither being pulled by the drive train nor the engine being pushed by the drive wheels(floating between acceleration and decelleration), is begining to be in the drive train, just as it had been before the recall. is it possible that the recall procedure was incorrect, or not completely engineered? gibbons motor sales, dickson city, pa has in my past experience been competent. they were the servicing dealer. i feel that the problem is returning. i am unsure if the company would be obligated to repair this problem again?
09/19/199704/02/1997
 Transfer case failed due to driveshaft vibration. *ak
POWER TRAIN - TRANSFER CASE (4-WHEEL DRIVE)
08/17/19981
 Consumer had new tires put on vehicle due to vibration, problem still exist. however, the drive shaft / transfer case was replaced which was the cause of the vehicle experiencing sudden acceleration and vibration, prior to recall notice (97v-204). *yc
03/31/1996203/16/1995
 Transfer case failure.
1
 Transfer case exploded causing extensive damage to transmission components prior to recall notice.

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