Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ELECTRICAL SYSTEM | |||||
| 06510 | 01/01/2006 | 06112 | 10020135 | 6.0l - mil on with dtc p0460. *tt | 07/26/2006 |
| 06111 | 01/01/2006 | 10020136 | 6.0l - mil on with dtc p2138, p2139, p2140. *tt | 07/26/2006 | |
| 19082 | 10019810 | Lack of power or mil on - turbocharger sticking - revised diagnostics. *tt | 04/28/2006 | ||
| 04194 | 01/01/2006 | 06310 | 10010715 | Water-in-fuel (wif) lamp. *tt | 12/07/2004 |
| ELECTRICAL SYSTEM - BATTERY | |||||
| 19019 | 01/01/2006 | 10019079 | Low battery voltage - 6.0l diesel with single alternator. *tt | 02/10/2006 | |
Investigations
| NHTSA ID | Manufacturer | Date open | Date close | Subject | Recall campaign | |
|---|---|---|---|---|---|---|
| ELECTRICAL SYSTEM - WIRING - INTERIOR/UNDER DASH | ||||||
| EA10003 | FORD MOTOR COMPANY | 04/13/2010 | 03/05/2012 | HVAC Switch Failures | ||
| This investigation was opened based on one complaint and reports from four transportation fleets alleging 182 blower motor control switch failures.odi was concerned that these melting and burning switches could lead to an open flame that could spread throughout the vehicle.after a comprehensive review of all data related to overheating blower motor control switches in the subject vehicles, odi did not identify the existence of a safety defect trend.odi reviewed 1,036 complaints, claims, and field reports of failed blower motor control switches and determined that only two fires were likely to have been caused by a failing subject blower motor control switch.this represents a failure rate of 0.2 r/100k on a population of 1,076,975 vehicles that have been in service for up to 14 years.odi has found that when the subject switches do fail and begin to melt, they are constructed in a manner that typically prevents the failing switch from igniting and developing into an open flame.ford motor company has agreed to take two actions to further reduce the likelihood an overheated blower motor switch in the subject vehicles.ford informed odi that it has implemented a series of design changes to the subject switch that will help prevent it from developing internal high resistance short circuits.ford has also informed odi that it would release a technical service bulletin (tsb-11-11-21) instructing subject vehicle owners to replace the electrical connector at the same time a failed switch is replaced.in light of the low rate of failure resulting in open flame and fire spread on the subject vehicles, and ford's actions to reduce the likelihood of a switch failure through switch design changes and a tsb, further use of agency resources does not appear to be warranted.the closing of this investigation does not constitute a finding by nhtsa that no safety-related defect exists.the agency reserves the right to take further action if warranted by the circumstances.the odi complaints cited above can be reviewed at www-odi.nhtsa.dot.gov/complaints under the following (odi) numbers: 10427875, 10114393, 10257890for additional information, see the attached closing report. | ||||||
| PE09055 | FORD MOTOR COMPANY | 12/07/2009 | 04/21/2010 | HVAC Switch Failures | ||
| Odi has received 1 complaint and reports from 4 transportation fleets alleging 182 switch failures.each fleet operates mini buses built on a ford e350 or e450 cutaway chassis.the oem hvac blower switches have melted, smoked, burned or experienced open flame and become inoperable on vehicles in each fleet.some drivers have reported a burning smell or smoke coming from the dash.one fleet reported a vehicle fire.no injuries were sustained.however, the bus was carrying special needs children when the driver noticed smoke coming from the dash.the driver was able to evacuate the children prior to the vehicle becoming engulfed in flames.this pe has been upgraded to an engineering analysis (ea) to determine if the blower motor switch failures create a situation where a vehicle fire is possible and presents a safety risk to the driver and other passengers. | ||||||
| EA10003 | FORD MOTOR COMPANY | 04/13/2010 | HVAC Switch Failures | |||
| Odi has received 1 complaint and reports from 4 transportation fleets alleging 182 switch failures.each fleet operates mini buses built on a ford e350 or e450 cutaway chassis.the oem hvac blower switches have melted, smoked, burned or experienced open flame and become inoperable on vehicles in each fleet.some drivers have reported a burning smell or smoke coming from the dash.one fleet reported a vehicle fire.no injuries were sustained.however, the bus was carrying special needs children when the driver noticed smoke coming from the dash.the driver was able to evacuate the children prior to the vehicle becoming engulfed in flames.the 55 fires referred to in the manufacturers column is based on the early warning reporting definition of fire, which is as follows: fire means combustion or burning of material in or from a vehicle as evidenced by flame. the term also includes, but is not limited to, thermal events and fire-related phenomena such as smoke and melt, but does not include events and phenomena associated with a normally functioning vehicle such as combustion of fuel within an engine or exhaust from an engine.this engineering analysis (ea) has been opened to determine if the blower motor switch failures create a situation where a vehicle fire is possible and presents a safety risk to the driver and other passengers. | ||||||
Consumer Complaints
| Fail date | miles | occurences | Purchase date |
|---|---|---|---|
| ELECTRICAL SYSTEM | |||
| 11/29/2012 | 155000 | 1 | |
| I had an issue with the vehicle having a sudden miss from the engine while on the freeway. saturday the sparkplugs and one coil pack was replaced. the vehicle was next driven on sunday evening where approx. 1/2 mile from the home the vehicle shut off without any power to the steering and brakes. instruments lights were still working but dropped to the off position. i opened the hood and smelled electrical fumes, not being able to see what was wrong, i disconnected the battery with a pair of channelocks. the vehicle was towed home and i began to investigate the issue. i found that the pcm/ecm had been rendered permanently nonfunctional causing the vehicle shut off. the wiring had a 1.5 by 2 & 3/4 deep burnt/melted area on a roughly 2 round harness. i further found that the main wiring harness from the pcm/ecm in the factory installed position had been rubbing for some time on an exhaust component wrapped with fiberglass. the plastic wrapping and metal wrapping was obviously breached and exposed the wiring to be grounded to the exhaust component and also was the fiberglass on the exhaust component had worn off exposing bare heated metal. the excessive heat helped to melt into the wiring and no fuses were blown. the protection had been inadequate to provide a safe operation of the vehicle. the engine is a 5.4l gasoline which the sealed fuel source is approx. 1 ft. away. i think any of the e-series vans that year need to be inspected because of stalling and fire issues. i am a 6'2 230 lb person and had difficulty slowing the vehicle on a vacant street, steering wasn't as bad but required adequate force. i do have photos of the harness and exhaust component. the ecm/pcm is roughly $1200.00 and the wiring harness is around $670.00 before any labor or technical costs. i will inspect all the other wire locations for other issues. *tr | |||
| 11/29/2012 | 155000 | ||
| I had an issue with the vehicle having a sudden miss from the engine while on the freeway. saturday the sparkplugs and one coil pack was replaced. the vehicle was next driven on sunday evening where approx. 1/2 mile from the home the vehicle shut off without any power to the steering and brakes. instruments lights were still working but dropped to the off position. i opened the hood and smelled electrical fumes, not being able to see what was wrong, i disconnected the battery with a pair of channelocks. the vehicle was towed home and i began to investigate the issue. i found that the pcm/ecm had been rendered permanently nonfunctional causing the vehicle shut off. the wiring had a 1.5 by 2 & 3/4 deep burnt/melted area on a roughly 2 round harness. i further found that the main wiring harness from the pcm/ecm in the factory installed position had been rubbing for some time on an exhaust component wrapped with fiberglass. the plastic wrapping and metal wrapping was obviously breached and exposed the wiring to be grounded to the exhaust component and also was the fiberglass on the exhaust component had worn off exposing bare heated metal. the excessive heat helped to melt into the wiring and no fuses were blown. the protection had been inadequate to provide a safe operation of the vehicle. the engine is a 5.4l gasoline which the sealed fuel source is approx. 1 ft. away. i think any of the e-series vans that year need to be inspected because of stalling and fire issues. i am a 6'2 230 lb person and had difficulty slowing the vehicle on a vacant street, steering wasn't as bad but required adequate force. i do have photos of the harness and exhaust componant. the ecm/pcm is roughly $1200.00 and the wiring harness is around $670.00 before any labor or technical costs. i will inspect all the other wire locations for other issues. | |||
| 07/16/2007 | 23000 | 12 | 09/30/2005 |
| Ford 2005 e350 diesel both new still under warranty breakdown over a dozen times wouldn't start sometimes after 20 min. trying it starts roadside assistance. tow it 5 times to difference ford certified technician they change parts but same problem it stall once my dad hit a parked truck damage hood and fender i can contacted ford many times i got two letters from (we are not doing anything for you ) i paid $35 k w/extended warranty and still making payments i am vary upset. *jb | |||
| 12/01/2005 | 12650 | 3 | 01/01/2005 |
| 2005 ford e-350 had alternator problems, a short in the dashboard wiring and check engine light illuminated. *kb *nm | |||
| ELECTRICAL SYSTEM - ALTERNATOR/GENERATOR/REGULATOR | |||
| 04/09/2007 | 29000 | 22 | 08/16/2005 |
| 6.0 power stroke, many problems since new . purchased in aug, 05 *jb | |||
| 08/01/2006 | 3 | ||
| 2005 ford e-350 had alternator problems, the a/c compressor has been replaced twice, the engine was rebuilt and check engine light illuminated. *kb *nm | |||
| ELECTRICAL SYSTEM - WIRING | |||
| 07/09/2007 | 101000 | 3 | 05/21/2007 |
| Tl*the contact owns a 2005 ford e-350. the contact stated that the vehicle stalled on three occasions. on the first occasion, he took the vehicle to the dealer, but they were unable to determine the cause of failure. on the second occasion, the vehicle failed to restart and was towed to the dealer. the cam sensor was replaced. the vehicle stalled the following day and was towed to the dealer once again. the vehicle started the following day without incident. the vehicle was still at the dealer as of july 27, 2007. the dealer stated that recall number 05v270000 (electrical system:wiring) did not apply to his vehicle. the contact stated that the vehicle has no throttle response before the stalling occurs. during stalling, the vehicle lost all power and was difficult to steer and brake. all of the lights on the instrument panel illuminated during the failure. the vin and speed were unknown. the current mileage was 104,000 and failure mileage was 101,000. | |||
| 08/25/2005 | 5050 | 4 | 01/01/2005 |
| 2005 ford e-350 had a wiring harness defect which caused the vehicle to run trough. the serpentine belt was replaced, the check engine light illuminated and the engine had to be rebuilt. *kb *nm | |||