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
97601111/01/1997605804Experiencing difficulty diagnosing vehicles with evaporative fuel system diagnostic trouble codes. *tt07/26/1999
BC10599970505/01/199752879Vehicles built between 1/4/97 and 4/14/97 may exhibit a concern of lack of power. *tw09/18/1997
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 - DELIVERY - FUEL PUMP
BC224197050105/01/199752780Vehicle may exhibit a lack of power. *tw09/12/1997
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
039805/12/200310002780Malfunction indicator lamp (mil) illumination with diagnostic trouble codes p0442, p0455, p0456, p0457, p1442 or check fuel cap lamp illuminated with diagnostic trouble code p0457. *tt09/17/2003
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
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.
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.

Consumer Complaints

Fail datemilesoccurencesPurchase date
FUEL SYSTEM, GASOLINE - CARBURETOR SYSTEM
01/10/200387000009/20/1997
 The intake manifold failed and coolant leaked from crack in the intake manifold. ford knows of the problem and has several recalls for the problem that covers only the fleet cars (taxi and police). the same defective part is used on consumer vehicles. i think that all 4.6l sohc v8 engines with this design defect should be covered.
09/19/20021
 Consumer states while driving 50mph the intake manifold cracked.*jb
09/15/2002
 While driving vehicle caught on fire from plastic manifold, and engine shut down.. dealer has been notified. any additional information feel free to add. *ak
08/18/2002111/01/2001
 Plastic intale manifold water tubes failed. cory ford binghamton, ny. parts dept related that this is a high rate failure mode. on ford & mercury w setries engines.re-engineered replacement manifold kit cost aprox $500.00 kit includes re designed intake manifold with aluminum encapsulated tubing , new gaskets & new design alternator bracket. total cost of repair over 1,000.00. this should be a recall it is a design error. it is not covered by warranty. with a heart condition i was fortunate that this failure did not occur in a remote area. this is a failure is directly related to an inherrant design deficiency. one only has to compare the kit to the oem part to verify this.*ak
08/13/2002
 While driving at highway speed vehicle started to shutter, and smoke was coming from engine. took vehicle to a mechanic, and they stated intake manifold was cracked. there is a recall 01 f 025 000 for same problem consumer's vehicle was not included due to vin. please provide any further information.*ak
06/20/2002102/01/2000
 Faint sudden noise from the engine compartment (coolant causing serpentine belt slippage, i believe) and then the engine overheated. due to roughly a 3 inch crack in the intake manifold plastic composite which dumped coolant into the back of the alternator. i was able to pull off before the engine was damaged. both the dealer, who is to be commended for a quick and effective repair (makes one wonder if the mechanics have had a lot pf practice with this repair), and ford motor company tell me there is no relief for repairs on a car with my vin although the replacement part is constructed of metal and composite rather than composite alone. i appreciate this design change which hopefully will ward off another similar failure but doesn't changing the design recognize that there was a weakness? on this same web-site i read that some ford fleet vehicles were recalled and repaired. concerning safety, the only issue this senior citizen faced was the stress of walking four tenths of a mile in the june heat and humidity to call for help and in paying the tow and repair expense. one is not surprised or greatly upset when the alternator wears out - but the intake manifold? what kind of stress testing did this non-moving part get when approved for production?*ak
 Intake manifold leak. *ak
1
 The consumer stated that under moderate acceleration front panel of the intake manifold water passage crossover failed and water sprayed under the vehicle resulting in temporary loss of control. *yh
03/01/20021
 Coolant was leaking from vehicle. dealer determined that intake manifold was cracked. there was a recall 01f02500on for this part, but only police cruisers and taxi vehicles were affected.*ak dealer replaced cracked intake manifold, also the fuel filter was replaced. *tt
1
 The consumer stated that under moderate acceleration front panel of the intake manifold water passage crossover failed and water sprayed under the vehicle resulting in temporary loss of control. *yh
10/27/2001107/01/1997
 Ford knows about this defect but will not offer any assistance to customers who own residential crown victorias. the design flaw (fatigue crack in composite intake manifold coolant crossover passage) affects vehicles with the 4.6 liter engines assembled between 8/8/95 and 11/22/97 at the st. thomas plant. the crack causes a rapid loss of coolant directly behind the alternator and can result in severe engine damage due to overheating. i was able to pull over after the engine started to overheat. the tow truck took it to the ford dealer where a redesigned manifold was installed at my cost. *ak
10/01/2001
 Consumer contacted dealership for recall 01f025000 repairs concerning intake manifold leak, but was unable to have work completed for lack of parts. please provide further details.*ak
07/08/2001104/01/2000
 Intake manifold developed a crack and i lost all of the coolant @ 65 mph, causing the vehicle to overheat. ford has issued a recall for fleet vehicles (taxis, police, limos) but does not cover the same part (same part #) on civilian vehicles. the replacement part is the same poorly designed unit, which over time, will most likely fail again.*ak
07/19/2001103/01/2000
 Sudden structural rupture of plastic intake manifold with resultant sudden lost of coolant. also, false coolant temperature reading due to no coolant. passing motorist alerted driver of depending problems.*ak
04/27/20011
 Intake manifold cracked causing vehicle to overheat, tsb 01m02, consumer requests reimbursement since there is a service bulletin regarding the problem. *slc
06/18/2001101/31/2000
 Engine manifold developed a crack and started to spit out anti-freeze and water. consumer stated that dealer replaced engine intake manifold. *ak consumer was told there was a recall on some models, however his was not included, consumer is requesting reimbursement. front brake rotors and front brake pads replaced. *slc
03/31/2001111/01/1997
 Plastic intake manifold cracked for no apparent reason. *ak
104/01/1997
 Intake manifold cracked where alternator is mounted. had noticed minilmal coolant leak and gradual increase in temp over the last year. finally found crack in plastic intake manifold. *ak
11/14/19991
 Intake manfold split. this is not the only problem with this vechile, but there is a vibration inthe transmission. this car was purchased under warranty, but because it's out ford motor co. doesn't want to respond in good faith.
07/27/1998
 When traveling on the highway about 50mph the intake manifold developed a crack, causing the anti-freeze to leak onto the engine compartment, resulting in an overheating conditions. consumer has contacted the dealer. please provide any further details. *ak
FUEL SYSTEM, GASOLINE - DELIVERY
12/29/1997105/12/1997
 Brake lines mounted under left of vehicle rubbed through causing brake failure.
FUEL SYSTEM, GASOLINE - DELIVERY - HOSES, LINES/PIPING, AND FITTINGS
107/23/1997
 A pin hole size leak developed in the high pressure fuel line, and was replaced along with the brake hydraulic line. mr scc
03/01/20021
 Coolant was leaking from vehicle. dealer determined that intake manifold was cracked. there was a recall 01f02500on for this part, but only police cruisers and taxi vehicles were affected.*ak dealer replaced cracked intake manifold, also the fuel filter was replaced. *tt
01/22/20001
 Brake line forward of rear axle and above fuel filter rubs on car body, resulting in a hole in brake line.
03/18/1998
 Vehicle caught on fire due to a faulty fuel line. no prior warning. *ak
FUEL SYSTEM, GASOLINE - FUEL INJECTION SYSTEM
03/22/2002107/01/1997
 Consumer state while traveling 60 mph notice anti freeze burning smell inside vehicle. consumer stopped a service station and notice anti freeze all over engine. vehicle was service by technician and replace intake manifold. nlm heater hose leaking coolant, also the brake lines were repaired. *yh referenced in rq03-004
08/24/2001106/01/1998
 This is apparently a widespread problem on 1996 and newer crown vics, t-birds, mustangs and lincolns. ford knows there is a design problem, but refuses to bear the cost. plenty of complaint info can be found on the web - see www.thecomplaintstation.com a ford recall is in effect for 96-98 crown vic taxis made in their st. thomas plant. very frustrating - my failure happened on the interstate at 75+ mph with no warning. luckily i could pull off the highway. going to cost $600+ to repair. ford doesn't seem to care. our city garage has replaced at least 5 failed manifolds on cv police cruisers with redesigned manifolds (ford must know there is an issue here to redesign the manifolds). mine is not an isolated incident - look at your complaint database and the website i referenced. please do something!!!no safety defec tlisted. *ak
FUEL SYSTEM, GASOLINE - STORAGE
11/30/20031111753
 I experienced the failure of both front hydraulic brake system and rear hydraulic brake system due to corroded(rusted) brake line (piping) within one year. i also experienced fuel tank failure due to rust at tank seam at approximately the same time. tank failed 11/30/03, front brake system failure 03/16/04, rear brake system failure 12/04, both due to piping rust out. *jb
FUEL SYSTEM, GASOLINE - STORAGE - TANK ASSEMBLY
1
 Email fm ellen row (nc) inquiring about the safety of her 1997 ford crown victoria, wants to know why recall was only for the police cars.*mr the consumers vehicle was identical to the police vehicles being recalled for fuel tank problems. the consumer paid to have the repairs made but cannot understand why her vehicle was not covered under the recall. *nlm *scc *jb
 Problems with police crusiers and rear end collision explosions. *mr the consumer was concerned her vehicle being the same as the police vehicle's. the vehicle was made at the same plant as the police cruisers). the consumer had the repair done to her vehicle but wondered why ford covered the police vehicle's even though they had higher mileage. the consumer requested to be treated fairly and equally. *scc
FUEL SYSTEM, GASOLINE - STORAGE - TANK ASSEMBLY - FILLER PIPE AND CAP
05/19/2001100006/01/1997
 I recently spent over $1,000 having the engine check light fixed along with other repairs. i took the car back to super lowe ford several times after i purchased it because the light stayed on. super lowe said it was gas cap is loose and it's a short, we can disconnet it if you want us to etc. it would be off for a few days, then right back on. i was also informed that it really doesn't mean anything, just don't drive in california. why does the light stay on?*ak

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