Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||||
| 041601 | 11/14/2005 | 05228 | 10018745 | Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running. *tt | 01/12/2006 |
| 18351 | 12/01/2004 | 10014620 | Charging system limitations. *eh | 05/05/2005 | |
| 0361 | 03/31/2003 | 10001855 | Malfunction indicator lamp on with or without rough running, lack of power, surge or poor fuel economy with diagnostic trouble codes p0401, p0402, p1400, p1401. *tt *jb | 07/23/2003 | |
| ENGINE AND ENGINE COOLING - COOLING SYSTEM - FAN | |||||
| 15893 | 05/01/2002 | 637773 | Some vehicles may exhibit an inoperative engine cooling fan. *tt | 12/06/2002 | |
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| 07212 | 10/01/2007 | 10023943 | Some 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. *pe | 02/20/2008 | |
| 031404 | 08/23/2004 | 04161 | 10011162 | Engine 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 |
| 16378 | 11/01/2002 | 10008317 | Idle miss or surge at highway speeds. premature ignition coil-on-plug (cop) replacement / under investigation (qsf). *tt | 07/27/2004 | |
| 16380 | 11/01/2002 | 10008319 | Service cylinder head gasket for 4.6l applications. *tt | 07/27/2004 | |
| 03256 | 12/22/2003 | 10008278 | Engine-romeo built 4.6l 2v-tick noise from engine-engines built before 9/17/2003. *mj | 07/26/2004 | |
| 03206 | 10/13/2003 | 10004889 | Some 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 | |
| 03144 | 07/21/2003 | 10003744 | Engine 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. *tt | 10/29/2003 | |
| 03157 | 08/04/2003 | 10003187 | Grinding type noise from the timing chain area. *tt | 10/10/2003 | |
| 03164 | 08/18/2003 | 10003118 | Some vehicles, equipped with the 4.6l 2v engine, with an engine build date prior to 8/29/03 may exhibit an engine tick noise that is present at all temperatures during idle. 2004 models included. *tt | 10/08/2003 | |
| 0322 | 02/03/2003 | 10002472 | Streamlined diagnostic procedure for vehicles with malfunction indicator lamp (mil) on and diagnostic trouble codes (dtcs) p0401, p0402, p1400 or p1401, or runs rough, lacks power, surge, poor fuel economy, and the above listed dtcs without | 09/03/2003 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||||
| 15881 | 05/01/2002 | 637746 | Subject regarding engine stumble / hesitation cold only condition. *tt | 12/04/2002 | |
| 15761 | 03/01/2002 | 636408 | Some dedicated cng vehicles may exhibit driveability conditions of hard start / no start / rough running. *tt | 11/08/2002 | |
| 16068 | 07/01/2002 | 636263 | Some vehicles may exhibit an engine vibration at 1100-1500 rpm. *tt | 11/07/2002 | |
| 0254 | 03/18/2002 | 636045 | On some vehicles equipped with the 4.6l engine, the front end accessory drive (fead) belt may hydroplane on the water pump pulley whenthe belt is splashed with water. *tt | 11/04/2002 | |
| 15668 | 02/01/2002 | 630732 | Concerns with hesitation/stumble , cold only , when shifting from park to drive or park to reverse. *tt | 04/23/2002 | |
| 01246 | 12/10/2001 | 630515 | Engine oil system priming procedures, service tips for reports of premature engine failure. *tt | 04/18/2002 | |
| 15415 | 11/01/2001 | 630431 | Some vehicles may exhibit an engine vibration between 1100-1300 rpm when the transmission is placed in either park or neutral. *tt | 04/17/2002 | |
| 0214 | 01/21/2002 | 630001 | Some engine assemblies with aluminum cylinder heads repaired in-vehile have been found to leak coolant and/or oil from the cylinder head gasket area. *tt | 04/11/2002 | |
| 01205 | 10/15/2001 | 627927 | Some vehicles may exhibit vacuum or air leaks in the intake manifold and / or engine system causing diagnostic trouble codes p0171 and or p0174. *tt | 02/26/2002 | |
| 15158 | 08/01/2001 | 624571 | Some vehicles may exhibit a fead belt jump-off toss. *yh | 11/07/2001 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||||
| 16412 | 11/01/2002 | 10008342 | Sulphur smell from exhaust under investigation (qsf). *mj | 07/28/2004 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE) | |||||
| 02M01 | 06/01/2004 | 02M01 | 10007207 | Customer satisfaction program 02m01 supplement #4. certain ford 2000 through 2003 vehicles equipped with a tube-mounted egr pressure sensor - additional egr pressure sensor warranty coverage. *tt supplement #3. *mj supplement #6 | 06/03/2004 |
Investigations
| NHTSA ID | Manufacturer | Date open | Date close | Subject | Recall campaign | |
|---|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK 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 | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK 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 | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK 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 date | miles | occurences | Purchase date |
|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||
| 11/24/2011 | 40134 | ||
| The engine stalled while driving, for no apparent reason. driver (my retired mother, age 72) had to get car off road and restart car to continue. the power steering disabled when the car engine stalled. this has happened multiple times (2-3) over the past month, and the local ford dealership cannot replicate the problem and is unable to correct it. on another occasion there was a thumping noise and the car slowed considerably, but then picked back up again. the engine heat/thermometer light has flashed also, but the engine temperature heat is normal. i consider this a very dangerous situation for my motor if it would happen in a heavily congested, high traffic area and could cause a vehicle crashes. it is a very stressful situation. | |||
| 08/26/2011 | 116954 | ||
| I had been driving 250 miles or so and drove down a long winding incline, as the road flattened out i heard a noise from the engine compartment. the noise sounded like a hole in the first part of the exhaust system. i found a safe place to pull over and turned off the vehicle. there was a slight odor of natural gas as this vehicle is fueled with natural gas. after the odor passed, i opened the hood to find that the #2 ignition coil mount was broken, and the coil and spark plug assembly were loose in the spark plug well. my initial thought was the the spark plug had loosened and ejected. i attempted to re-install the spark plug but the threads in the cylinder head were ineffective. the spark plug had blown out of the cylinder head. i have subsequently found out that this is not an uncommon defect for these ford engines. the repair involved reaming and tapping the spark plug hole and placing an insert in the hole. the spark plug coil had to be replaced too. the repair cost was $450 and the repair shop warned that this may happen again. this is a design defect that could potentially be dangerous under different circumstances. if i was not able to stop in a safe place fairly quickly, there could have been more fuel air mixture accumulation under the hood and since the spark plug was still operative, an ignition source was present too. | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 02/10/2009 | 67425 | 1 | 07/30/2002 |
| Tl*the contact owns a 2002 ford crown victoria. while driving between 55-60 mph on normal road conditions, the vehicle began to hesitate and vibrate. in addition, the check engine warning indicator illuminated on the instrument panel and remained lit until the engine was turned off. the vehicle was taken to an authorized dealer for diagnostic testing and stated that there was an internal coil shortage. the misfire cylinder 5, coil pack, and spark plugs were replaced in the vehicle. the vehicle was taken to an authorized dealer on a separate occasion for the identical failure and the misfire cylinder 7, coil pack, and spark plugs were replaced at that time. the failure mileage was 67,425 and current mileage was 68,045. updated 03-27-09 *bf updated 03/31/09.*jb | |||
| 04/11/2008 | 118000 | 1 | |
| Just cruising through a parking lot on my way into work and had a spark plug blowout. damaged the spark plug coil as well. had to buy a new coil, and a helicoil kit to re-tap the spark plug hole. *tr | |||
| 06/15/2003 | 1 | ||
| Complaint regarding county of tuolumne california sheriff's department four new crown victorias.*mr (nar) *cb | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS | |||
| 02/15/2002 | 12000 | 1 | |
| Drove car through large water puddle and accessory drive belt came off. *ak | |||