Recalls

CampaignManufacturerManufacturing dateType# of units affectedDate Owner notified MfgRecall Initiated byManufacturers of recalled vehicles/productsReport Recieved DateRecord Creation DateRegulation Part NumberFMVSS Number
FUEL SYSTEM, GASOLINE - STORAGE - TANK ASSEMBLY
02I003000FORD MOTOR COMPANYfrom 07/01/1992 to 10/21/2002I350000ODIFORD MOTOR COMPANY10/15/200211/21/2002
Defect SummaryIn order to enhance police office safety, model year 1992-2003 crown victoria police interceptor (cvpi) vehicles will be equipped with shields designed to help protect the fuel tank in high-speed rear-impact crashes. ford also will be offering an optional trunk package designed to improve the safe transport of sharp-edged, heavy equipment in these vehicles.
Consequence SummarySome high-speed rear-impact crashes have resulted in fuel tank punctures and fires in cvpi vehicles.
Corrective SummaryFord has advised us that shield kits have been available since late october and will be installed on police interceptor vehicles at no cost. the optional trank package will be available by the end of 2002. ford has established a new web site at www.cvpi.com to answer additional questions about the safe use of cpvi vehicles.
NotesCustomers can also contact the national highway traffic safety administration's auto safety hotline at 1-888-dash-2-dot (1-888-327-4236).
FUEL SYSTEM, OTHER - STORAGE - TANK ASSEMBLY
03V472000FORD MOTOR COMPANY V (Vehicle)421801/07/2004ODIFORD MOTOR COMPANY11/06/200311/19/2003
Defect SummaryOn certain natural gas vehicles, if a flame from a vehicle interior fire becomes locally directed at the natural gas fuel tank located immediately behind the rear seat, the flame could damage the fiberglass wrap on the tank weakening the tank.
Consequence SummaryIf the strength of the tank is significantly compromised, it could rupture, increasing the risk of a fire.
Corrective SummaryDealers will install an insulator behind the current seat back. owner notification began on january 7, 2004. owners should contact ford at 1-800-392-3673.
NotesFord recall no. 03s08.customers can also contact the national highway traffic safety administration

Bulletins

BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
FUEL SYSTEM, GASOLINE
0122111/12/2001630320Some dedicated compressed natural gas (cng) vehicles may exhibit a rough idle, or no start in cold conditions. *tt04/16/2002
FUEL SYSTEM, GASOLINE - CARBURETOR SYSTEM
01M0205/01/2001620174Some of the composite intake manifolds used on 4.6l sohc engines may develop fatigue cracks at the coolant crossover duct. this condition could result in engine coolant leakage which, if not serviced, may cause engine overheating. compl07/19/2001
01M0203/01/2001619445Owner notification program regarding additional coverage on certain 4.6l sohc intake manifolds. some of the composite intake manifolds may develop fatigue cracks at the coolant crossover duct. *tt05/31/2001
97B1302/01/1998605630Various information regarding intake manifold inspection / replacement. *tt07/15/1999
97M9101/19/1998605621Information regarding additional coverage for intake manifold malfunctions. *tt07/14/1999
9622510/21/199650944Mass air flow sensor - replacement as an assembly - service tip. *tw06/17/1997
FUEL SYSTEM, GASOLINE - STORAGE - TANK ASSEMBLY
CSP 08B0405/15/200810026401Ford/lincoln mercury: certain 1992-2001 model year crown victoria, grand marquis, and town car vehicles registered in the states of wisconsin and connecticut upgrade modifications for high speed rear impacts. *pe10/24/2008
02050303/21/20050556636417Guidance for cng tank inspection for vehicles produced after december 2, 1996. *tt update. *tt11/08/2002
01211410/29/2001627791Parts and procedure to reduce the potential of fuel tank punctures during rare and extremely high-speed rear impacts. *tt02/25/2002
1486204/01/2001619299Information on replacing fuel tank strap bolts. *tt05/23/2001
650507/01/1999610662Brief information on removing the fuel tank solenoid valve on natural gas vehicles. *tt05/10/2000
1289006/01/1999606919Brief information on removing the fuel tank solenoid valve thread. *tt09/08/1999
FUEL SYSTEM, OTHER
03040902/01/200310002519Possible fuel leak at fill valve - fill valve service part revisions - cng vehicles only. *tt09/04/2003
034903/03/200310001901A possible fuel leak may occur at the fuel fill valve on some cng (compressed natural gas) vehicles. *tt *jb07/25/2003
FUEL SYSTEM, OTHER - STORAGE - TANK ASSEMBLY
CSP 08B0405/15/200810026401Ford/lincoln mercury: certain 1992-2001 model year crown victoria, grand marquis, and town car vehicles registered in the states of wisconsin and connecticut upgrade modifications for high speed rear impacts. *pe10/24/2008
025303/18/2002636042Subject regarding alternative fuel vehicle compressed natural gas tank inspection. *tt11/04/2002
1511308/01/2001624689Some vehicles may exhibit a fuel fill valve sealing condition. *yd11/08/2001
99E0310/01/19996089616Emission recall for vehicles that were built with a fuel filler-valve which could leak while the vehicle is being operated which can exceed evaporative emissions standards. *tt02/09/2000
FUEL SYSTEM, OTHER - STORAGE - TANK ASSEMBLY - FILLING/CHARGING
1527109/01/2001625804Dedicated cng regulator bowl kit available. *jg12/03/2001

Investigations

NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
FUEL SYSTEM, GASOLINE - STORAGE
SQ01014FORD MOTOR COMPANY11/27/200110/03/2002POST REAR END COLLISION FIRES02I003000
 Allege fuel tank can rupture following a high-energy rear collision resulting in severe fires.
FUEL SYSTEM, GASOLINE - STORAGE - TANK ASSEMBLY
PE02071FORD MOTOR COMPANY10/01/200201/27/2003CNG TANK EXPLODING IN A FIRE
 An explosion of a compressed natural gas (cng) tank should not be able to occur, as the tank is fitted with a pressure relief device (prd). this prd should release the cng in the tank, prior to the pressure reaching the tank burst pressure.the prd did not release in the subject wisconsin police cruiser explosion.nhtsa has recovered the prd valve from the tank that exploded and testing will be necessary to establish why this tank safety valve did not release in the very high temperature fire that occurred in the police cruiser.there is only the single known event, but due to the catastropic force of such an explosion and the potential for injury and loss of life, this investigation is being upgraded.
EA03001FORD MOTOR COMPANY01/27/200311/19/2003CNG TANK EXPLOSION03V472000
 In september 2002, a fuel cylinder in a natural gas powered vehicle (ngv) exploded during a fire.ford and vrtc test engineers jointly examined the incident vehicle and reviewed testing to determine whether the performance of the pressure relief valve (prd) was proper.the purpose of a prd is to protect a compressed natural gas tank from overpressure by allowing the cng to vent when the temperature reaches a specific point.the prd was removed from the failed tank and subjected to a yield temperature determination test. it was concluded that a direct flame (from the interior of the vehicle) onto the cylinder (located behind the rear seat in the trunk)compromised the hoop strength of the natural gas cylinder, thus allowing the cylinder to fail prior to the prd releasing at itsdesigned temperature.as a result of this testing and review of the involved vehicle, ford has developed an insulator to insulate the natural gas fuel tank from a locally directed flame projecting from the interior of the vehicle.insulators will be installed behind the back seat on subject vehicles to prevent future failures of this type. ford's action addresses the concerns of odi.therefore, this investigation is closed.

Consumer Complaints

Fail datemilesoccurencesPurchase date
FUEL SYSTEM, DIESEL - STORAGE - TANK ASSEMBLY
12/03/2002
 Consumer stated having the same problems as recall #021003000 fuel tank/police vehicle. dealer will not repair because vin# was not included. ts
FUEL SYSTEM, GASOLINE
10/24/201135
 I purchase my vehicle on october 24th, 2011 from a private party who said, the coolant leak, but the vehicle over heated when i drove it home less than 3 miles away the hood of my car was smoking. after taking it to a local mechanic with my friend who drove his car to ensure my safety, my car began to over heat after driving it for 10 minutes! i was so frantic that i thought i was going to burned up in the car. the mechanic told me the next day it was the intake manifold and inform me that this may be a recall and to check with the ford corporation and i did called ford corporation and found out this vehicle had control cruise harness and a intake manifold recall id is 01m02, the dealership for camelback ford in phoenix, mr. chad mcdowell offer this recall number but his employee kevin offer to help me fix the both problems, then later on negated. i feel a recall of any vehicle should never be expired base on these issues of safety and regardless of a settlement that may have been reached, there are millions of people who need to have their vehicle repair to make it at least a whole again as much as possible and avoid a possible injury or death. i found the recall of this intake manifold offering consumer up to $ 750 to repair the car without any receipts? what about the people who purchase the vehicle afterwards, is that fair. now my concern is that i am smelling gasoline when i am driving and i believed it may have something to do with the gas line or the sensor, and i hate putting more money into the vehicle. i fear that the mechanic will tell me its going to be a costly matter and it's never going to stop with this car and i just want to get rid of it or have it repair as it should of been by the dealership but the ford company would not approve it.
01/15/20030
 First i would like to say that what i hear about the grand marquis having problem with the fuel tank is rather disturbing to me i am aware now that these cars are capable of catching on fire if hit from behind. i carry three small children to school every morning in "this car" i have contacted the ford corp. about this problem and they seem to not be bothered about this fact. now to my other problems. i have just replaced my intake manifold because the one that came with the car cracked while i was driving it. my mechanic stated that he found out that it was a very common problem with the 1996 mercury grand marquis. the ford corp. has redesigned the intake manifold for this model and raised the price from about 250.00 to almost 500.00. in july of 2002 there was a part that went out on my a/c unit that i had to replace (i have to contact my mechanic to see what part it was that was replaced) in july 2002 i had to have my roters turned, in january 2003, i had to have them turned agian and have my right back roter repaced because it was no longer good. (all this was done on january 10 2003 now it is jan. 20, 2003 and my right front roter is grinding again (i also had new brakes put on all around jan.10,2003. my driver side door is drooping because it needs a new pin put in... my car also seems to balk when i push on the gas peddal,my car also has a popping noise when i hit a hole or turn. when i called the ford corp. on these issues they seemed liked they really didn't care about any of these things. maybe you might know someone that i could contact in the ford corp. that is "high up" and that would listen to my oncerns. thank you for your time, sincerly, diane
03/26/20011
 The arizona dept public safety & phoenix police dept are reporting high occurences of fires associated with rear-end collision of the crown victoria vehicles, as the police officer had just begun to accelerate from a stop light, his vehicle was struck from behind and burst into flames, the officer suffered severe burns, authorities suspect possible fuel system related.*jb
12/09/19981
 The arizona dept public safety & phoenix police dept are reporting high occurences of fires associated with rear-end collision of the crown victoria vehicles, an officer was killed when his vehicle was struck from behind and burst into flames, the officer was stopped at a collision scene and the other vehicle was traveling inexcess of 66 miles mph at impact, authorities suspect fuel system related(no vin given)*jb
04/26/19963
 Chief of police called to inform of recall notice received concerning ford crown victoria lower ball joint failure. *ak door handles were replaced. rear brake pads and rotors replaced at 18290, front pads and rotors were replaced at 28679 miles, front and rear brake pads replaced at 51031 miles. intake manifold replaced twice. heater hose replaced. passenger side tail light replaced. tire rotations are done every 3000 miles, however tires had to be replaced at approximately 9600 miles and at 600000 miles, no specific tire information given. cooling fant and motor replaced. tpc, pvc, and fuel regulator replaced. *slc
FUEL SYSTEM, GASOLINE - CARBURETOR SYSTEM
06/27/20021
 Consumer states while driving 50mph the intake manifold failed.*jb consumer stated that sudden failure of intake manifold caused the vehicle to overheat. the intake manifold was on recall, but the manufacturer refused to honor the recall. *yh
08/18/2002106/01/2096
 I was forced to stay at a hotel overnight until monday afternoon when the car was repaired with a replacement manifold made of metal by ford. the hotel bill came to $220.
06/20/2002101/01/2002
 In 4-1999 a recall owner letter was sent to all ford dealers in regard to fatigue cracks in the intake manifolds used on the 4.6 l schc engines. the recall is for 1996-1998 crown victoria taxis and i feel since i had the same problem with my intake manifold i should be reimburse for the repair. ford has had recalls for the intake manifolds every year up to 2002.ford dealer in town is no help nor the 1-800 customer assistance number. i had the car towed to a local garage for repair since they were cheaper the ford dealer. bryan walker at the garage said his 96 ford crown had the same problem last year and the ford dealer did help him get a refund so i know they are helping some people.i know there is no recall on my car but since there is one for the taxix and i had the same problem i feel it should be under the same recall.*ak
06/28/2002
 While driving intake manifold cracked and was leaking anti freeze, causing engine to overheat. contacted dealer ,and dealer wasnot willing to do anything.*ak
06/06/2002
 While driving heard a noise/pulled over, and anti freeze had leaked out due to a broken intake manifold. *ak
05/26/2000106/01/2096
 The intake manifold cracked near the thermostat and all the coolant leaked out causing the car to overheat. took it to randall noe ford dealership to have it fixed. they told me what the problem was. at that time i told them it sounded like a design defect. they said they had seen a lot of failures like this. i asked them to check for recalls which they did but none were found. about 30 days ago (around march 15, 2002) a relative sent me an email showing that many 1996 crown victorias were being recalled for the exact same problem. i contacted ford and they said ours was not included. i would like the ntsa to make them include it. i know, according to the mechanic, that there are many other people with the same problem. it was clearly a design defect and ford should be required to reimburse me for the $800+ that i paid to have it fixed. thanks mike parks
03/29/2002
 Having problems with intake manifold. *ak
03/10/2002110/01/1995
 Their have been 3 vin# recalled police cars,tow truck driver new when i told him what part had failed intake manifold. new manifold front part is now made of metal. this a manufactor problem not a dealer problem. a man came up to me and asked if i had a problem with intake manifold his had done the same thing. *ak
12/04/2001
 Recall 01 f 025 000/intake manifold; intake manifold cracked and caused coolant to leak, and engine to overheat. dealer notified, and informed consumer that this vehicle was not covered under recall due to vin.feel free to provide any further information. *ak
 While driving at speed limit vehicle lost power steering without warning.*ak
12/01/20011
 A corner seal for intake manifold is cracking, causing engine to overheat. dealership informed consumer this vehicle was not included in recall campaign 01f025000. please provide any additional information / documentation.*ak
 While pulling into a parking space heard noise. consumer got out of vehicle and noticed a large crack in front of the manifold, it leaked coolent. please provide further information. *ak
10/06/2001107/01/1999
 Intake manifold had cracked due to being made out of plastic. this caused coolant fluid to leak onto alternator and motor. steam was coming from under the hood. temperature gauge had shown vehicle running hot while driving. *ak *jb
06/06/2001101/01/1996
 My intake manifold cracked, and according to ford (service center rep) and my mechanic this part is under recall. please advise who i contact for reimbursement.*ak
08/02/2001101/01/1996
 While driving vehicle engine stalled and fluid was coming from the bottom. then, vehicle was towed to a near dealer, where they found out that there was a crack on intake manifold. also, there was a recall, but did not include this vehicle due to vin and mileage over the warranty.*ak vehicle was had also overheated, mechanic found the front of the plastic intake manifold was cracked badly at manufacturing seam and stated that this was a factory defect. consumer states vehicle shudders, there are several service bulletins relating to this, however consumer states she paid for repairs and feels this too should be a recall item. *slc
05/01/20013
 Intake manifold has cracked, allowing water to leak and spray into alternator and destroy it. manifold needs to be replaced. *ak also overheating caused transmission to fail, when the manifold leaked out all the coolant, there was no indication of it, because the temperature sensor does not register unless its in liquid.*jb
05/04/2001112/30/1995
 While traveling at 70 mph for about two hours consumer noticed a rattle and smoke coming from engine. pulled over and noticed all radiator fluid had leaked to ground. took car to ford, and they said intake manifold was cracked, and whole engine needed to be replaced.*ak
05/05/20010
 Consumer was traveling 45mph on highway and was in process of passing another vehicle. he noticed that vapor trail steam and anti freeze coolant was puring onto the engine. he was able to pull over to shoulders. vehicle had to be towed. ford dealership told him that intake manifold was made out of plastic. *ak
04/02/2001103/01/1998
 The intake manifold cracked, leaking coolant. ford refuses to repair it because it is not a fleet vehicle (refer to ford program #01m02).*ak
04/10/2000105/01/1996
 4.6l engine plastic intake manifold crack leaking hot coolant.*ak
04/11/2001
 Intake manifold blewout. ford has an extended warranty program for this, but will not cover this vehicle.*ak
04/02/20010
 While driving temperature gauge went up, car over heated. consumer later noticed that intake manifold cracked.*ak
02/07/2001112/01/2000
 4.6l engine plastic intake manifold crack leaking hot coolant. *ak
10/20/20000
 While driving 60 mph intake manifold cracked and coolants was all over the engine. it was almost inpossible to keep control of vehicle. lower ball joints were cracked. technician stated that ford was fixing this problem on the police vehicles. *ak
 Intake manifold has malfunctioned which caused anti freeze to leak into engine compartment, resulting in a possible fire hazard. consumer has contacted dealer, dealer has replaced intake manifold. please provide any further details.*ak
08/01/2000103/01/1997
 The intake manifold on the 1996 crown victoria is made out of plastic. i began noticing an antifreeze smell several weeks before the problem was finally isolated. evidently, the manifold was cracked and would not open up until the engine reached a certain temperature. then when the temperature reached that point the antifreeze would spew out on top of the hot engine. when the hood was raised you could see the moisture on the non-hot parts. the reservoir would be down about one or two inches. i kept refilling it with antifreeze. finally, i carried it to the shop thinking it was a pin hole in the hose or a hung thermostat. it was neither. it was a cracked intake manifold. the repair cost $583.41. i have the part and a copy of the invoice. *ak
109/01/1995
 Defect in design caused the intake manifold to fail, manifold is constructed of plastic which is too weak of a material. yh
06/20/2000
 Intake manifold had a crack in the mold line, causing a coolant leak. manufacturer notified, and informed consumer that the vehicle was not covered under manufacturer's recall. feel free to provide further details. *ak
04/21/1999311/01/1997
 The intake manifiold cracked, causing the coolant to keep running out, that crack sucked in so much air, causing the coolant to steam and then causing my engine to seize up. also the coolant was pouring onto the alternator, causing it to go bad. ford will not cover one single bit of their defect. they recalled the 96-97 taxis, interceptors, and mustangs for the same problem, just not my car. *ak
FUEL SYSTEM, GASOLINE - DELIVERY - FUEL PUMP
12/12/1998104/03/1996
 The consumer has experienced problems with electrical wiring. vehicle was parked for 24 hours before it burst into fire. the consumer put the fire out. the manufacturer has yet to be contacted. *ak consumer states there were signs of a short under the front right fender by the trailer wires, a ford mechanic informed consumer that he did not believe the fire was caused by the trailer wires. *adj referenced in ea02-025
FUEL SYSTEM, GASOLINE - DELIVERY - HOSES, LINES/PIPING, AND FITTINGS
04/16/20001
 Brake line foward of rear axle and above fuel filter rubs on car body resulting in a hole in brake line
FUEL SYSTEM, GASOLINE - FUEL INJECTION SYSTEM
07/02/2002101/01/2097
 How many complaints are required before a recall is issued, forcing a manufacturer to make repairs for a manufacturer to make repairs for a manufacturing defect ? on your site, there are 24 complaints about the same coolant leaking problem with the plastic intake manifold on ford's 4.6l engines. why was the action already taken only applied to police vehicles ? i'm sure the leak is the same problem we all have had. mine is number 25 and these are only the owners who have taken the time to pursue the issue with nhtsa. my cost for the part alone is $650.00. since this is an obvious manufacturing defect and ford has changed the design of the replacement part, i feel the manufacturer should be required to repair it for free.*ak
11/25/1998111/01/1998
 Problem involves nhtsa recalls 98i001000 and 98v322000. dealer and ford say my car does not have these problems. i do not want to take the chance of having my steering control fail, or having my brakes fail. please help. also, the transmission has an extremely long shift from first to second. ford has a tsb on this, and states this will not affect the transmission,but it will shorten the life and lead to possbile accumulator bore scuffing. thanks! *ak
11/14/1998406/01/1997
 Car has been in the shop 2 times for gas vapors inside the car, the second time they replace a gas line o-ring but that did not help.i will be sending it back for the same problem this is the third time. the car engine shuts down at any speed and has done it four times, and this will be the second time for this problem, last time my car was in the shop for 5 days and they were unable to find any thing wrong with it.no gas vapors or the engine shutting down.
07/25/1996107/24/1996
 Engine idle high.
FUEL SYSTEM, GASOLINE - STORAGE - TANK ASSEMBLY
01/16/2007108000108/08/2006
 Tl* - the contact has a 1996 ford crown victoria police interceptor with 108000 miles and the protective shield that covers the fuel tank has not been installed. the contact found that there was a recall (02i003000): and (96v135000) for steering:linkages that had not been fixed on his vehicle. when he took the vehicle to the dealer they told him that his vehicle did not fall under the recall. the contact has not experienced any problems with his vehicle in regards to the recall to date. *jb
03/14/20031460001
 The fuel tank had no shield behind it, if the vehicle was hit from behind it could catch fire. the dealer stated there was a recall regarding the issue, however the recall only related to police interceptor vehicle's. *jb
01/07/20031
 The vehicle is a police interceptor model. the consumer contacted the dealer regarding recall 02i003000 and the dealer advised him that they could not perform the recall because vehicle was not a part of the fleet of law enforcement vehicles. ts scc
4
 There has been 3 deaths and 1 critical injury within the arizona law enforcement, regarding the ford crown victoria police cruiser's, the design and placement of the fuel tank has been known to catch on fire if the vehicle is involved in a rear side impact collision.*jb *tt
FUEL SYSTEM, OTHER
08/12/19961
 Gas gauge failed. gauge does not return to empty when vehicle motor is off.

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