Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| 03911 | 05/12/2003 | 10002783 | Rough idle and/or hesitation when acclerating on certain super duty vehicles equipped with a 5.4l or 6.8l engine. *tt | 09/17/2003 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||||
| 16055 | 07/01/2002 | 636252 | Some vehicles equipped with a 5.4l engine / 4r100 transmission federal emissions powertrain may exhibit a rough idle and / or hesitation when accelerating. *tt | 11/07/2002 | |
| 15626 | 02/01/2002 | 630674 | Concerns with intermittent rough idle on initial start up. *tt | 04/19/2002 | |
| 15056 | 07/01/2001 | 621054 | Vehicles equipped with a 5.4l engine may exhibit a rough idle or miss on initial startup that will last for a couple of minutes. *tt | 09/06/2001 | |
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 | |||
| 03/12/2010 | 79500 | 1 | |
| We have a 2001 ford e-350 van with less than 80,000 miles. a spark plug has ejected from the engine, stripping the block. of course, gasoline spews from the open cylinder, and the spark plug is still sending out a spark. a very dangerous defect, one that i read is commonplace, from the website : http://www.fordproblems.com/spark-plug-ejected-from-engine.shtml. *tr | |||
| 12/24/2009 | 14000 | 1 | |
| Spark plug blew out of triton v10 engine almost causing a fire. truck only has 14,000 miles on it. very costly repair and could have caused a fire or injuries. *tr | |||
| 11/05/2009 | 149000 | 1 | |
| Normal use .ford e-350 5.4 2001.sudden failure of right no.2 cylinder .sparkplug ejected. coil-over damaged.;repair by coil insert. *tr | |||
| 02/15/2008 | 89000 | 2 | 08/31/2002 |
| Twice within the past two years i have been driving down the road, at reasonably low speeds, and a spark plug has blown completely out of my engine ,with no advance warning . twice i have had to bring it back to the dealer . he now tells me ,and the extended warranty company confirmed it ,that the heads for the 5.4 litre engine were not milled properly (only 4 threads for each spark plug, causing the plug to strip and come out of the engine) and that this is an enormous problem with this engine . the last repair cost over $4,000 but since the problem has been occurring outside of the 36,000 mile warranty that ford provides, ford has done nothing about it and in fact, it has generated much business for the dealerships. both the dealer and the warranty company confirmed this. *tr | |||
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||
| 11/01/2010 | 167350 | ||
| Tl-the contact owns a 2001 ford e350 . the contact stated that while driving 25 mph there was a loud popping noise coming from the engine compartment. the contact then pulled over and then noticed that the spark plug came out of place as well with the coil pack. the vehicle was repaired by the contact. approximately two weeks later it occurred once again and then the vehicle was towed to his garage. the dealer was informed about the failure and stated that they will file a report . the vehicle was repaired temporary. the failure was 167350 and the current mileage was 167422.cv | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 09/15/2010 | 193000 | ||
| Spark plug blow out on ford engine for the third time different plug each time and also has happened over the interval of 80,000 miles | |||
| 07/07/2007 | 113000 | 1 | |
| Our family was riding in our 2001 ford e-350 super duty 15-passenger van powered by fords 5.4l v8 255 hp on i-80 eastbound near milesburg, pa this past saturday afternoon (july 7,2007) and one of the spark plugs blew out of the cylinder head. i am awaiting repairs even now. i have noticed our government's reluctance to issue a recall on what appears to be a recurring problem for '97-04 ford engines with the aluminum heads. the repairs are very expensive! please help! thanks, david lipsy *tr | |||
| 07/10/2006 | 100000 | 1 | 04/08/2002 |
| Spark plug blown out x3, each time a different plug, date listed below is the latest. *jb | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| 02/15/2008 | 89000 | 2 | 08/31/2002 |
| Twice within the past two years i have been driving down the road, at reasonably low speeds, and a spark plug has blown completely out of my engine ,with no advance warning . twice i have had to bring it back to the dealer . he now tells me ,and the extended warranty company confirmed it ,that the heads for the 5.4 litre engine were not milled properly (only 4 threads for each spark plug, causing the plug to strip and come out of the engine) and that this is an enormous problem with this engine . the last repair cost over $4,000 but since the problem has been occurring outside of the 36,000 mile warranty that ford provides, ford has done nothing about it and in fact, it has generated much business for the dealerships. both the dealer and the warranty company confirmed this. *tr | |||
| 04/01/2001 | 5 | 03/01/2001 | |
| At slow speed (less thatn 30 mph) travelling down hill at idle, engine has stalled 5 times in the 6500 miles on the vehicle. power steering and brakes are lost.the engine starts up immediately with the key. *ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||
| 07/07/2007 | 113000 | 1 | |
| Our family was riding in our 2001 ford e-350 super duty 15-passenger van powered by fords 5.4l v8 255 hp on i-80 eastbound near milesburg, pa this past saturday afternoon (july 7,2007) and one of the spark plugs blew out of the cylinder head. i am awaiting repairs even now. i have noticed our government's reluctance to issue a recall on what appears to be a recurring problem for '97-04 ford engines with the aluminum heads. the repairs are very expensive! please help! thanks, david lipsy *tr | |||