Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING
04160111/14/20050522810018745Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running. *tt01/12/2006
1835112/01/200410014620Charging system limitations. *eh05/05/2005
022202/04/2002630628Some vehicles may exhibit an intake manifold crossover (first runner) coolant seepage condition. *tt04/19/2002
ENGINE AND ENGINE COOLING - COOLING SYSTEM - FAN
032602/03/200310002476Revised cooling fan motor available. *tt09/03/2003
ENGINE AND ENGINE COOLING - ENGINE
0721210/01/200710023943Some 1997-2008 vehicles equipped with a 4.6l 2v, 5.4l 2v, or 6.8l 2v engine--spark plug thread repair procedure--not covered under new vehicle limited warranty. *nj this includes f-53 motorhome chassis. updated 2/23/10. *pe02/20/2008
03140408/23/20040416110011162Engine misfire or running - coil on plug (cop) ignition systems - wds cop kit diagnostic tips. to include various 2005 models. * ar this article 04161 supersedes tsb 03-14-04.01/06/2005
1637811/01/200210008317Idle miss or surge at highway speeds. premature ignition coil-on-plug (cop) replacement / under investigation (qsf). *tt07/27/2004
1638011/01/200210008319Service cylinder head gasket for 4.6l applications. *tt07/27/2004
0320610/13/200310004889Some dedicated cng vehicles may exhibit various driveability conditions due to a loss of injector performance, resulting from fuel quality. loss of power at heavy load, diagnostic trouble codes (dtcs) for lean fuel, rough idle, hard start,01/14/2004
0314407/21/200310003744Engine misfire or rough running condition with coil on plug (cop) ignition systems may be more accurately diagnosed using the optional worldwide diagnostic system (wds) coil on plug (cop) kit. 2003 super duty f series included. *tt10/29/2003
1482104/01/2001619315Some vehicles equipped with 4.6l romeo engine may exhibit an oil leak from the cylinder head gasket area. *tt05/23/2001
1486404/01/2001619335Subject regarding certain vehicles with 4.6l romeo engines exhibiting an oil leak from the cylinder head gasket area. *tt05/23/2001
0021410/16/2000618547Information regarding revised engine mounts for severe duty vehicles. *jb04/16/2001
011101/22/2001618063On some vehicles, the engine mounts may not exhibit satisfactory durability under severe operating conditions that may be encountered by police, taxi or limo / livery vehicles such as extended idling at high ambient temperatures. *04/03/2001
994703/08/1999604763Engine experiencing roughness at idle due to exhaust system resonance. *tt05/12/1999
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
1576103/01/2002636408Some dedicated cng vehicles may exhibit driveability conditions of hard start / no start / rough running. *tt11/08/2002
0124612/10/2001630515Engine oil system priming procedures, service tips for reports of premature engine failure. *tt04/18/2002
021401/21/2002630001Some engine assemblies with aluminum cylinder heads repaired in-vehile have been found to leak coolant and/or oil from the cylinder head gasket area. *tt04/11/2002
0120510/15/2001627927Some vehicles may exhibit vacuum or air leaks in the intake manifold and / or engine system causing diagnostic trouble codes p0171 and or p0174. *tt02/26/2002
01211010/29/2001627768Some vehicles equipped with the romeo built 4.6l 2v engine may exhibit an engine oil leak or oil weepage from the cylinder head gasket at the right hand rear or the left hand front of the engine. *tt02/22/2002
1515808/01/2001624571Some vehicles may exhibit a fead belt jump-off toss. *yh11/07/2001
1502606/01/2001622846Some vehicles may exhibit a stall at idle after start-up condition. *tt10/23/2001
014703/05/2001619424Subject regarding engine oil recommendations for use in 2001 vehicles - sae 5w-20 motor oil. *tt05/30/2001
469908/01/1998615238On some vehicles, the engine may be overfilled with oil. this may be caused by misinterpretation of the oil level indicator (dipstick) markings. *tt01/09/2001
1344811/01/1999614618Some vehicles may exhibit engine oil that has a milky appearance at predelivery inspection due to condensation in the crankcase. *tt11/28/2000
1214711/01/1998613168Some crown victoria police vehicles engine may stall during braking over rumble strips, these vibrations may open the inertia fuel switch. *mjs06/19/2000
1217411/01/1998613224Some vehicles may exhibit a hard start/long crank, cold start stall, cold rough idle concern. *mjs06/19/2000
742411/01/1999610813Information on vehicles exhibiting engine oil that has a milky appearance at predelivery inspection. *tt05/15/2000
1295007/01/1999610750Some vehicle engines may crank without starting. *tt05/12/2000
9981605/03/1999606420Ford motor company now recommends sae 5w-30 viscosity grade for servicing any ford gasoline-powered vehicle regardless of model year. *tt08/19/1999
994703/08/1999604763Engine experiencing roughness at idle due to exhaust system resonance. *tt05/12/1999
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
1177408/01/1998615274Some vehicles may exhibit a rattle noise from the exhaust system nvh damper on the left hand damper only. *tt01/10/2001
465608/01/1998615192Some vehicles may exhibit a rattle noise from exhaust system nvh damper on the left hand damper only. *tt01/03/2001
830004/01/2000613634Some vehicles may exhibit a bang / popping noise heard from the exhaust system during cool-down. **mr07/26/2000
1302507/01/1999610768Some vehicles may exhibit a bang popping noise heard from the exhaust system during cool-down. *tt05/12/2000
650607/01/1999610663Some vehicles may exhibit an exhaust moan / roar heard on slight acceleration and at speeds near 42 mph for single exhaust and near 62 mph on dual exhaust cars. *tt05/10/2000
1289306/01/1999606922Some vehicle may exhibit an exhaust moan hear on slight acceleration. *tt09/08/1999
98201010/12/1998603695Experiencing a buzzing or rattling noise from the exhaust system. *yc03/02/1999
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
98231011/23/1998603724Mass air flow (maf)- sensor contamination- service tip. *ak03/03/1999
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR
CSP-08B0105/16/200810026389Ford: certain 1999-2001 model year vehicles up to 6000 lb gvwr registered in new york and certain 2001 vehicles up to 6000 lb gvwr registered in the state of maine, certified for sale in california-federal emission warranty refund. *pe10/23/2008
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
05N0412/14/200510018959Extended coverage program 05n04 - extended coverage for composite intake manifold. this program is being provided as a settlement to a class action lawsuit. the terms of the settlement extend the coverage of the all-composite intake manif01/25/2006

Investigations


NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
ENGINE AND ENGINE COOLING
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK PLUG EJECTION FROM CYLINDER HEAD
 On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi
ENGINE AND ENGINE COOLING - ENGINE
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK PLUG EJECTION FROM CYLINDER HEAD
 On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK PLUG EJECTION FROM CYLINDER HEAD
 On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi

Consumer Complaints


Fail datemilesoccurencesPurchase date
ENGINE AND ENGINE COOLING
12/14/2011
 My intake manifold went bad. this is a known issue and a lawsuit was filed. it cost me $1,600 and ford won't reimburse me.
12/14/2011
 My intake manifold went bad. this is a known issue and a lawsuit was filed. it cost me $1,600 and ford won't reimburse me.
12/14/2011
 My intake manifold went bad. this is a known issue and a lawsuit was filed. it cost me $1,600 and ford won't reimburse me.
12/14/2011
 My intake manifold went bad. this is a known issue and a lawsuit was filed. it cost me $1,600 and ford won't reimburse me.
12/14/2011
 My intake manifold went bad. this is a known issue and a lawsuit was filed. it cost me $1,600 and ford won't reimburse me.
05/07/2010139000
 Intake manifold crak causing a major coolant leak and engine malfunction cause coolant runing to last espark plug hole in passenger side. engine size 4.6 8cyl. same as my esxplorer 2002.
05/07/2010139000
 Intake manifold crak causing a major coolant leak and engine malfunction cause coolant runing to last espark plug hole in passenger side. engine size 4.6 8cyl. same as my esxplorer 2002.
05/07/2010139000
 Intake manifold crak causing a major coolant leak and engine malfunction cause coolant runing to last espark plug hole in passenger side. engine size 4.6 8cyl. same as my esxplorer 2002.
05/07/2010139000
 Intake manifold crak causing a major coolant leak and engine malfunction cause coolant runing to last espark plug hole in passenger side. engine size 4.6 8cyl. same as my esxplorer 2002.
12/26/2009236561
 1999 ford crown victoria blew out original spark plug and a fire was ignited as the fuel vapor was ignited by the coil pack. *tr
08/20/200691400104/18/2003
 I began noticing problems with my 1999 crown victoria in early 2005. my check engine light kept coming on and it kept using a lot of coolant. a ford technician told me during a recent repair that it needed another intake manifold and that it would cost me $800 to fix it at the dealership. i asked him if it was covered under any warranty and i was told no. the other night i was driving down i-35 headed towards dallas when the high temperature gauge started going off. i slowed down and pulled over and when i opened the hood, there was coolant spraying from the front of the intake manifold (near the thermostat). i was able to cool the car down by putting water in the radiator. however, i had to do this every couple of miles because the water kept shooting out of the top of the engine. i finally got to a well lit area and was able to isolate the leak. there is a gash in the intake manifold approximately 2 inches long. i just checked the internet for solutions to my problem and i found out that ford was sued in a class action lawsuit for their defective plastic intake manifolds. it turns out, my vehicle is one of the vehicles that was covered in the class action suit. (and, it was covered when ford told me it wasn't!!!) so i called ford to have them come pick up my vehicle and repair it. now they tell me i have to pay for it myself!? could someone please help me? i don't think i should have to pay for something that ford already knows is a defective part. i mean, who would make engine parts out of plastic anyway? i don't know if anyone can help me but if you can, please let me know. i have taken the rest of the week off work so i can try to resolve this. thank you. *jb
11/05/20025200006/25/2001
 Engine on my car just stopped working and when towed to facility the mechanic informed me the engine was gone. warranty people came to look at the vehicle and stated i used bad gasbecause carbon had built up on the rings and would not honor warranty. all fluids were clear and car has been properly maintained.
ENGINE AND ENGINE COOLING - COOLING SYSTEM
07/21/200679511502/17/2004
 I own a 1999 ford crown victoria with 79,514 miles on it. approximately 2 months ago, i started experiencing problems with the engine running hot but not overheating and what appeared to be a coolant leak. i immediately replaced the radiator hose. it did not help. i took the vehicle to have the oil changed and asked that the coolant system be pressure tested for leaks. it was determined that the increased temperature of the engine had caused the thermostat housing to crack and it was also diagnosed to need the intake manifold replaced. i parked the vehicle for the next 2 1/2 months. due to financial obligations, i could not afford the repair which was estimated to be $750 -850. now that i am able to make the repairs, a call to a local ford dealer made me aware of the fact that the intake manifold was defective, however since my vehicle was put in production in december 1999, i had missed the recall deadline. i have owned this vehicle for almost 3 years. in that time, i have not received any information on the recall or the class action suit against ford. my vehicle has had maintenance performed by local ford dealers at which time, i was never made aware of the faulty part. i don't feel as though this is fair. i was not made aware of this factory defect, nor warranty extension to have it replaced. if i had been aware, i would have had the part replaced. now, because of failure by the manufacturer to inform the consumer of this defective part and the recall, i am forced to pay to have this defective part replaced. this is an unexpected expense that will definitely cause a strain on my family finances. not only that, upon calling to get the price of the intake manifold, i was informed that i missed the extended warranty deadline for my vehicle (december 2005). i do not think this is fair. i would like to know if i can pursue action to have my expenses reimbursed and if not, how can i pursue legal action. respectfully, otha farris, jr. *nm
10/10/2005160000212/04/2003
 I own a 1999 ford crown victoria police package with 160,000 miles on it now,i bought it in 2003 with 145,000 miles on it, on october,10,2005 the plastic intake manifold starting leaking water from the back of the manifold from a crack in it,i have talked to numerous ford dealers about this,and they give me the run around saying it is out of warranty,and i was told a new one would cost 800.00 dollars,that is a real rip off, a intake manifold should last the life of the engine,i will never buy a ford vehicle again. *jb
07/05/200402
 Reference odi id 752976 - i had a similar experience and failure of the same equipment and parts described in the refereneced complaint. these are latent design/material/manufacturing defects. i was originally told, under warranty, that the shudder was due to the traction control sensors. this apparently was incorrect. now that the vehicle is just over 100,000 mi, ford will do nothing to correct this defect. the dealer to their credit is trying to correct the shudder problem by servicing the transmission with additives. the intake manifold cracking is a design/material defect which was finally discovered after the warranty period although i had complained about coolant odor several times while in warranty. ford split the difference with me on the cost of repair, they should have sholdered the entire cost. now we have another problem which ford, according to the service supervisor is unwilling to correct. there is a serious problem with the brake booster, it has a tendency to crack internally and cause a hard pedal. this defect was discovered on my wife's mercury sable at about 38,000-mi and now is be exhibited on my crown victoria. catastrophic failure of this component at high speed could cause an accident, loss of control in a panic stop because the driver would have to exert an unusual amount of of pressure on the pedal to apply the brakes and activate the abs. i was told that ford as a general policy will not do anything to correct problems on vehicles over 100,000 mi. the manufacturer should not have indemnity relief on safety issues and latent defects.*ak
1
 The thermostat housing is leaking causing a bad odor inside the vehicle resulting in the driver becoming nauseous depending on the severity of the leak. nlm
1
 The thermostat housing is leaking causing a bad odor inside the vehicle resulting in the driver becoming nauseous depending on the severity of the leak. nlm
ENGINE AND ENGINE COOLING - ENGINE
03/23/2008146875209/30/2006
 I have 2 crown victoria sedans and both have spit spark plugs out of their respective cylinder heads. i am neither amused by these occurrences nor satisfied when i spoke with ford customer service. listed below is the last time this incident occurred - the 4th blown plug. *tr
12/14/2006676581
 Engine #3 cylinder valve seat failed. *nm
02/02/200498501101/01/1999
 My car has 98501 miles on it and the plastic intake manifold is cracked with coolant seeping into the spark plug chamber, per ted britt ford in va. i believe that the cause of the crack is a latent defect in the plastic manifold. i would like to have ford replace it free of charge since it was a latent defect of the manufacturer. i also believe that this condition was there since i purchased the car (original owner), because during the early part of my ownership of the vehicle, there was always a faint odor of coolant in the passenger cab. this was also reported and documented with the service adviser early in my ownership of this vehicle. *jb
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
12/22/2003139771105/20/1999
 (1) driving on interstate highway car engine suddenly lost power while changing lane. was almost hit from behind but luckily the other car was able to stop. (2) the engine in my car, '99 ford crown victoria, had blown a spark plug.*ak (3) repair involved changing the cylinder head in the engine or replace the whole engine that i opted to do. at first i thought this is just a single incident but i later learned that there are a lot of people who have experienced the same mainly on ford pick-up trucks but also on other vehicles with the same engine / cylinder head design. a ford dealer who did the work for replacing the engine said they have not heard about this before. i have later also learned that a lot of people experience the same with ford, i.e. they claim not knowing about the issue but they must as so many people have complained about this. in my lifetime i have always believed that car engines wear out over time. it is not a normal mode of failure that car engine blows spark plugs and causes thousands of dollars of unexpected cost to consumers like me. nearly $5000 'christmas present' was not in my plans. what does it take to get ford to stand behind their product in this case? as it might not sound a safety issue at first just think what might happen if a spark plug blows during a passing of another vehicle on a 2-lane highway when another vehicle is approaching in not so far distance? it becomes a safety issue in a hurry! about this issue can be read in the interned. jus search blown spark plug and it's all in front of you. thank you, ari rousu
11/05/20025200006/25/2001
 Engine on my car just stopped working and when towed to facility the mechanic informed me the engine was gone. warranty people came to look at the vehicle and stated i used bad gasbecause carbon had built up on the rings and would not honor warranty. all fluids were clear and car has been properly maintained.
02/16/2001404/01/1999
 While driving lost all engine power, but engine never stalled. when stepping on gas pedal nothing happened. it happened before on a incline hill, and could not hold vehicle from rolling back. then, took vehicle to dealer, and they did not find anything. consumer believed problem was traction control. *ak
10/22/2000201/01/1999
 No summary listed for above vehicle. *ak
08/19/20000
 While driving vehicle just totally stopped and died, consumer felt this was unsafe if it happened in traffic, someone could be killed.*ak
06/01/1999402/01/1999
 Repeated trips to dealer in new hampshire could not fix problem which is causing check engine light to come on.
03/06/1999
 While parked for two days the engine compartment caught on fire. fire marshall determined it was a defect in the engine compartment. manufacturer contacted. please provdie further information. *ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
10/28/2002470171
 Intake manifold cracked, resulting in loss of coolant. this failure was due to a design flaw. dealership installed an upgraded design manifold.*ak
11/12/20031
 Consumer took vehicle to dealer for inspection, and mechanic noticed that intake manifold cracked, allowing fluid to leak onto the engine. *ak
10/01/20011
 Rear bumper has a large vertical crack in it where exhaust pipe comes from underneath the vehicle. consumer feels that heat from exhaust pipe has caused this crack, and changed stability of the bumper. please provide any additional information / attachments.*aik