Recalls
| Campaign | Manufacturer | Manufacturing date | Type | # of units affected | Date Owner notified Mfg | Recall Initiated by | Manufacturers of recalled vehicles/products | Report Recieved Date | Record Creation Date | Regulation Part Number | FMVSS Number | |||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| POWER TRAIN - TRANSFER CASE (4-WHEEL DRIVE) | ||||||||||||||||
| 97V204000 | FORD MOTOR COMPANY | from 01/31/1992 to 01/20/1997 | V (Vehicle) | 75000 | 02/16/1998 | MFR | FORD MOTOR COMPANY | 11/13/1997 | 11/20/1997 | |||||||
| Defect Summary | Vehicle 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 Summary | This condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur. | |||||||||||||||
| Corrective Summary | Dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed. | |||||||||||||||
| Notes | Owner 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
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| POWER TRAIN | |||||
| 0282 | 04/29/2002 | 637922 | Some vehicles built prior to 9/15/2001 may exhibit low line pressure readings while in drive, no 2nd gear, no 3rd gear, no engine braking in manual 1st and slipping shifts and / or delayed engagements. *tt | 12/09/2002 | |
| 15887 | 05/01/2002 | 637755 | Some vehicles may exhibit a no 1-2 upshift, no 2-3 upshift, a no engine braking condition in manual 1 or diagnostic trouble code p0732 (gear 2 incorrect ratio) or p0733 (gear 3 incorrect ratio). *tt | 12/04/2002 | |
| 9943 | 03/08/1999 | 604751 | Information regarding reprogramming powertrain control modules (pcms). *tt | 05/11/1999 | |
| POWER TRAIN - AUTOMATIC TRANSMISSION | |||||
| 99152 | 07/26/1999 | 608431 | Information on the new flush and fill tool available through rotunda. *tt | 01/05/2001 | |
| 96726 | 03/25/1996 | 613348 | When replacing an internal wiring harness on 4r44e/4r55e transmissions built before 11/30/95 with a new harness, the fluid pan must be replaced also. failure to change over or convert the fluid pan may result in a transmission fluid leak | 06/22/2000 | |
| 0015 | 01/10/2000 | 612203 | Information regarding the new transmission cooler flusher- service tip. *mjs | 06/06/2000 | |
| 983080 | 02/26/1998 | 607372 | Information regarding transfer case rear housing and driveshaft replacement. *tt | 09/21/1999 | |
| 98112 | 01/19/1998 | 605573 | Subject regarding a new service center support that uses a thrust bearing (#3 and #4) in place of thrust washers has been released. *tt | 07/12/1999 | |
| 9888 | 04/27/1998 | 601238 | Information on a new transmission fluid usage chart. *yc | 07/10/1998 | |
| 97511 | 03/03/1997 | 51945 | Fluid- transmission fluid usage charts. *jd | 07/17/1997 | |
| BC5191961001 | 10/01/1996 | 50469 | For concerns of stalling, reflash pcm w/ 1996 calibration (r11 level). *tt | 04/24/1997 | |
| 951912 | 09/01/1995 | 46468 | On transmissions built before 6/20/95 (fig 1) an extended shift and a higher engine rpm than expected and/or no shift condition, possibly along with a flashing 'o/d off' lamp and/or the diagnostic trouble codes (dtcs) listed above, may occ | 04/25/1996 | |
| POWER TRAIN - AUTOMATIC TRANSMISSION - COOLING UNIT AND LINES | |||||
| 03148 | 07/21/2003 | 10003748 | New transmission cooler flusher - service tips. 2003 escort and super duty f series included. *tt | 10/29/2003 | |
| 002310 | 11/13/2000 | 616522 | Subject regarding contamination from prior transmission concerns or excess wear may be trapped in the transmission fluid cooling system. *tt | 03/05/2001 | |
| POWER TRAIN - AUTOMATIC TRANSMISSION - PARK/NEUTRAL START SWITCH | |||||
| 01181 | 09/17/2001 | 625715 | Brake shift interlock.*jb | 11/30/2001 | |
| POWER TRAIN - AUTOMATIC TRANSMISSION - TORQUE CONVERTER | |||||
| 96249 | 11/18/1996 | 50908 | Torque converter - leak test procedure - service tip. *tw | 06/17/1997 | |
| 962612 | 12/16/1996 | 50997 | Transaxle - torque converter replacement guidelines and torque converter/transaxle cooling system cleaning procedures - service tip. *tw | 06/17/1997 | |
| POWER TRAIN - AXLE ASSEMBLY | |||||
| 98233 | 11/23/1998 | 603717 | Concerns with front drive axle fluid may leak out of the vent under some driving modes on some vehicles. *yc | 03/03/1999 | |
| BC2431970501 | 05/01/1997 | 52834 | Aerostar e4wd models may experience front axle lubricant leakage from the vent tube under some driving conditions. *tw | 09/18/1997 | |
| POWER TRAIN - MANUAL TRANSMISSION | |||||
| 02138 | 11/10/2003 | 032210 | 635998 | Low line pressure reading at wide open throttle (wot), slipping shifts and / or delayed engagements with possible diagnostic trouble codes p0732, p0733, p1762 set on vehicles built before 12/1/2001. *tt | 11/04/2002 |
Investigations
| NHTSA ID | Manufacturer | Date open | Date close | Subject | Recall campaign | |
|---|---|---|---|---|---|---|
| POWER TRAIN | ||||||
| EA99002 | FORD MOTOR COMPANY | 01/07/1999 | 11/14/2000 | TRANSFER CASES AND REAR DRIVE SHAFT | 99V094000 | |
| 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) | ||||||
| RQ98012 | FORD MOTOR COMPANY | 07/31/1998 | 01/07/1999 | TRANSFER CASES AND REAR DRIVESHAFT | 97V204000 | |
| 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 date | miles | occurences | Purchase date |
|---|---|---|---|
| POWER TRAIN | |||
| 05/01/2011 | 160000 | ||
| Tl* the contact owns a 1996 ford aerostar. while driving approximately 50 mph the front drivers side tire began to vibrate. the vehicle was taken to an independent mechanic. the technician stated the transfer case would have to be replaced. the vehicle was not repaired. nhtsa recall campaign id number: 97v204000 (power train:transfer case (4-wheel drive)) may be related to the failure. the manufacturer was made aware of the failure and stated the vin was not included. the approximate failure mileage was 160,000. | |||
| 05/01/2011 | 160000 | ||
| Tl- the contact owns a 1996 ford aerostar. while driving approximately 50 mph the front drivers side tire began to vibrate. the vehicle was taken to an independent mechanic. the technician stated the transfer case would have to be replaced. the vehicle was not repaired. nhtsa recall campaign id number: 97v204000 (power train:transfer case (4-wheel drive)) may be related to the failure. the manufacturer was made aware of the failure and stated the vin was not included. the approximate failure mileage was 160,000. rvk | |||
| POWER TRAIN - AUTOMATIC TRANSMISSION | |||
| 02/01/1996 | 1 | 01/01/1996 | |
| Was transmission on a tech list for repairs or recall list for problems at highway speed and low speed problems. *ak( dot number: tire size: 215/75/14 ) | |||
| 1 | 01/24/1996 | ||
| Noise in transmission. | |||
| 07/21/1996 | 1 | 02/26/1996 | |
| Transmission seal defective. | |||
| POWER TRAIN - AUTOMATIC TRANSMISSION - LEVER AND LINKAGE - COLUMN SHIFT | |||
| While driving transfer case broke, causing the vehicle to stop moving while engine remained on. owner could not switch gears. dealer said vehicle needed a new transfer case. *ak | |||
| 1 | |||
| Consumer is having trouble receiving recall repair work on the transfer case by dealership. | |||
| 04/01/1998 | |||
| Nhtsa recall 97v204000, manufacturer 97s83, transfer case; dealer's letter was received in march, and in april when contacted the dealer again, they didn't have the parts, when contacted again, the parts were in, but could not be located. *ak | |||
| POWER TRAIN - AXLE ASSEMBLY | |||
| 02/01/1999 | 1 | ||
| Front axle broke causing wheel to come off, and damaging other components. | |||
| POWER TRAIN - DRIVELINE | |||
| 12/14/1998 | 1 | 12/01/1996 | |
| Similar to safety recall # 97s83 for which service was performed, but affecting front shaft and transfer case instead of rear. had seal leak on front transfer case under 30k miles warranty. transfer case bearing failure on front drive shaft in transfer case ruined transfer case at a cost of $1,985.00 to repair. this vehicle has been treated very well, with no heavy loads or towing of trailers. | |||
| POWER TRAIN - DRIVELINE - DRIVESHAFT | |||
| 05/04/2006 | 214000 | 1 | 09/01/1998 |
| Dt*: the contact stated the vehicle was taken to a tire dealer for replacement of the tires. after the tires were replaced and vehicle was being driven home at 45mph, the vehicle hesitated as if the gears were not changing properly. the vehicle was returned to the tire dealer who determined the drive shaft was loose. the dealer recommended the vehicle not be used until the drive shaft was welded and the universal joint was replaced. | |||
| 04/22/1998 | |||
| Recall (97v204000), driveshaft; not satisfied with work done pertaining to recall. had taken vehicle in for repairs in april. picked vehicle up & then had to return it the next day. *ak | |||
| 07/21/1996 | 1 | 02/26/1996 | |
| Driveshaft defective. | |||
| POWER TRAIN - DRIVELINE - UNIVERSAL JOINT | |||
| 05/04/2006 | 214000 | 1 | 09/01/1998 |
| Dt*: the contact stated the vehicle was taken to a tire dealer for replacement of the tires. after the tires were replaced and vehicle was being driven home at 45mph, the vehicle hesitated as if the gears were not changing properly. the vehicle was returned to the tire dealer who determined the drive shaft was loose. the dealer recommended the vehicle not be used until the drive shaft was welded and the universal joint was replaced. | |||
| POWER TRAIN - TRANSFER CASE (4-WHEEL DRIVE) | |||
| 04/22/2004 | 81000 | 100 | |
| I bought a used 1996 ford aerostar awd van from a used car dealer about 10 months ago. i had some problems with the van immediately but the dealer declined responsibility. today i have learned that the transfer case in the van needs, minimally, repair or total replacement. i have already replaced a ball joint for $320, which the used car dealer said he had checked and there was no problem. we are retirees without a huge income and so we decided to investigate whether ford was in some way responsible. we learned that a recall for transfer cases was issued in 1998 so my wife called ford, where she was, of course, told that our vehicle was not involved in the recall. i want to know how i can learn if this is true or whether i can make ford responsible for this major malfunction. they say they are not in any way responsible!!!! over the years, i have owned many, many vehicles and have never had a transmission problem before. because of the transfer case, my front tires are bald and i need two tie rod ends after the transfer case repair. my vehicle will not pass inspection and i do not know how i will pay for all of these repairs. i also still have two years' car payments left!!!*ak | |||