Recalls

CampaignManufacturerManufacturing dateType# of units affectedDate Owner notified MfgRecall Initiated byManufacturers of recalled vehicles/productsReport Recieved DateRecord Creation DateRegulation Part NumberFMVSS Number
ENGINE AND ENGINE COOLING
04V445000FORD MOTOR COMPANYfrom 04/23/2002 to 04/30/2004V (Vehicle)25307609/27/2004MFRFORD MOTOR COMPANY09/13/200409/16/2004
Defect SummaryOn certain vans, the air filter element material process resulted in an air filter paper element that can smolder or burn. this change in filter paper composition combined with the configuration of the air induction system, may allow hot carbon particles to contact the air filter element during certain driving conditions that create hot particles.
Consequence SummaryThese hot particles may ignite the air filter element with the potential for air induction system damage or underhood fire.
Corrective SummaryDealers will inspect and replace the air filter element. the recall began september 27, 2004. owners should contact ford at 1-800-392-3673. also ford is extending the limited warranty (for a one time replacement) of the abs module for a total of 10 years or 150,000 miles from the warranty start date, whichever occurs first. if your vehicle has already accumulated more than 150,000 miles, this coverage will last until september 30, 2005.
NotesFord recall no. 04s23/customer satisfaction program 04n03. customers can also contact the national highway traffic safety administration

Bulletins

BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING
0518510/07/200510018056Rpm surge at idle - audible egr surge - low power/exhaust smoke/rough idle following cold start - high rpm in battery charge protection mode - diagnostic trouble code p0488 and p1334 - 6.0l engine. *tt12/14/2005
1859805/01/200510017911Intermittent crank no start due to an egr throttle plate that is stuck closed. the engine may seem like it has no compression due to a faster than normal cranking speed of greater than 200 rpm. dtc p0488 or p1334 may or may not be present12/07/2005
1852504/01/200510017875Buck/jerk, lacks power, black smoke, rolling idle, surge, mil on, and diagnostic trouble codes p2263, p0299, or p0401. *tt12/06/2005
1873407/01/200510017864Diagnostic trouble code p0488 set after reflash. *tt12/05/2005
0521510/31/200510017806Buck/jerk or surge - 6.0l vehicles built before 8/22/2005. *tt11/30/2005
ENGINE AND ENGINE COOLING - COOLING SYSTEM
052502/07/200510012935Coolant leak from the front heater core. vehicles built between 01/20/2004 and 05/29/2004. 6.0l engine. *tt04/04/2005
ENGINE AND ENGINE COOLING - ENGINE
1836201/01/200510013307Lack of power or runs rough condition, and/or the malfunction indicator light on with egr related diagnostic trouble codes (p0401, p0402, p0403, p0404, p0405, or p0406). *tt04/14/2005
1839702/01/200510012958Lack of power, surge, and/or diagnostic trouble codes p2263 or p0299. *tt04/05/2005
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
1759703/01/200410007392Low engine rpm and/or other driveability concerns when performing a long deceleration in manual second or third gear. cut-away/chassis cab vehicles equipped with a 6.0l diesel engine built before 2/27/2004. *tt06/17/2004
ENGINE AND ENGINE COOLING - ENGINE - DIESEL
TSB-08-26-306/01/200910028826Ford: some vehicles with diesel engines may experience no starts, hard starts or rough running when cold and may be accompanied with diagnostic trouble codes (dtcs) p0611, p1378 and/or all 8 injector circuit codes. *pe06/01/2009
0513901/01/200510016842Diesel exhaust smell in cab-6.0l engine. *sc10/12/2005
0314605/17/2004049310003746Engine oil diluted with fuel, runs rough and/or a low power condition. *tt10/29/2003
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER
1869406/01/200510017873Lack of power and/or dtc p2263 or p0299 after turbocharger replacement - service tip. *tt12/06/2005
1806908/01/200410011181Low power and/or diagnostic trouble code p0299 or p2263 - turbocharger diagnostic service tip. *tt01/07/2005
1788506/01/200410008269Lack of power and/or diagnostic trouble code (dtc) p2263 after turbocharger replacement. *tt07/23/2004
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
05E1508/18/200510017996Voluntary emission recall 05e15 - supplement #2. exhaust pressure sensor replacement, on-board diagnostic system and engine control module recalibrations. *tt12/12/2005
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
1732011/01/200310008169Broken exhaust manifold studs. *tt07/22/2004

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
DP05005ACCUBUILT, INC.09/22/200501/04/2006SPARK 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
DP05005ACCUBUILT, INC.09/22/200501/04/2006SPARK 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
DP05005ACCUBUILT, INC.09/22/200501/04/2006SPARK 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
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
12/04/2006340001
 Dt*: the contact stated while driving 25 mph, the engine stalled. the vehicle was able to be restarted after 20 minutes, and was taken to a service dealer where the problem was unable to be determined. there was a nhtsa recall # 05v270000, which pertains to the wiring. the vehicle was not included in the recall due to the vin.
04/25/2005111/01/2004
 2004 ford e-450 ambulance 5/31/06 crew stated the engine was surging, egr valve replaced by dealership. 5/31/06 crew stated a/c quit blowing and grinding noise heard larger fuse installed by dealership. dealership stated all other a/c test checked out ok. dealership added booster replaced to diesel fuel also replaced filter, drained water separator. 9/1/06 engine oil leaking, crew also had a/c concerns again dealership replaced geo rotor oil pump cover gasket and seal wear sleeve and reassemble post road. dealership found compressor shaft broke replaced a/c compressor and clutch assemble accumulator and front orifice tube. dealership also replaced fuel injector control module harness, and exhaust pressure sensor secondary to recall. 10/12/05 crew complains that engine sound like it is sucking air dealership stated nothing wrong, later that week crew members found air leak at turbo bracket contacted dealership they advised that nothing was wrong and that was the way it should sound. we still have this extreme surging sound in the cab on acceleration, the sound is so loud that we can not hear the communication radio. this truck is a 2004 ambulance with only 24,964 miles on it and is housed inside a climate controlled station. we are again making an appointment to have turbo check because of air leak. *nm
07/31/2005132862104/30/2004
 Dt: contact stated on 7-31-05 was traveling north on i-81 70 mph and carrying 3000 lbs of steel and engine shut off 2 miles south of exit #66. engine sounded like a washing machine afterwards. contact was able to restart the vehicle briefly in order for the wrecker to load it. contact received recall 05s34 on 07/29/2005. dealer said this vehicle was not covered under the recall. this was the first problem contact had with the engine. *ak
ENGINE AND ENGINE COOLING - ENGINE
09/12/20071006991
 I have a ford e-350 super duty van that has had drivable problems since it was new. after many trips to dealerships i was told that there was no fix at this time and ford should come out with a fix in the future. the engine dies when hot at times causing hard braking and loss of steering. at 100699 miles, just 699 miles out of warranty the engine quite running when hot. if it sits for 6 or more hours it will restart and run for only 20 minutes. ford told me it was no longer under warranty and would provide no assistance. *tr
ENGINE AND ENGINE COOLING - ENGINE - DIESEL
11/03/200534000405/01/2004
 Oil leaking from 2004 f-350 6.0l diesel engine. egr failure causing truck to shut off on road. *jb
12/14/20046004012/10/2004
 Dt: the contact owns a 2004 ford e 350 a conversion van which will not start. the van has a power stroke diesel engine. the van was towed twelve or more times to multiple dealerships to locate the problem. the contact stated that no dealer could figure out what the problem was. a diagnostics test was performed on the vehicle about fifteen times. the contact has talked to ford numerous times. he invested $96,000 in the vehicle and would like to be able to drive it. this i happened at all times of the day. the contact was living out of the vehicle and was having thousands of dollars in towing expenses. also, there were rental car and medical expenses as a result of the failure.*ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
06/30/200515000803/03/2004
 Ford e-450 6.0l engine loses power, stalls, will not restart. bayshore ford service (wilmington de) results in identified problems of defective exhaust back pressure sensors, throttle bodies and underhood wiring harness. this is a safety issue as vehicle stalls in traffic with passengers on board. these defects should be added to nhtsa recall # ) 05v270000. *nm
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR
09/24/200520703/14/2005
 2004 ford wagon e350 with floor lowered by vantage mobility int. for handicap people. during stop and go driving like traffic jams while pulling a trailer the floor between front seats gets more than hot enough to burn your foot. sliding door opener has broken 6 times leaving the door free to slide open and shut. i keep a bungy cord to tie it up but interior lights come on and off when using bungy cord. the original latch by ford was removed to install the door opener. split drive shaft installed to make room for under vehicle lift by braun corp has a low roar to it. bicycle type chain for the sliding door opener at wheelchair lift drags across part of door jamb.(no pulley or sprocket). paid $48,000 for this new 2004 model in april, 2005 i'm asking for my money back. please help us. *nm
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE)
11/03/200534000405/01/2004
 Oil leaking from 2004 f-350 6.0l diesel engine. egr failure causing truck to shut off on road. *jb
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
09/09/200449600101/07/2003
 I have 3 vehicles with 5.4 liter exhaust manifold leak, several bolts are craked i have 50,000 mi just short of warr.my mechanic won't touch it.*ak

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