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 - ENGINE - DIESEL
07V553000FORD MOTOR COMPANY V (Vehicle)117600012/29/2007ODIFORD MOTOR COMPANY12/05/200712/05/2007
Defect SummaryOn certain heavy duty trucks equipped with 7.3l diesel engines, the camshaft position sensor located on the engine of the vehicle may function intermittently, possibly resulting in an engine stall.
Consequence SummaryIn the event of an engine stall, a crash could result without warning.
Corrective SummaryDealers will inspect the sensor and replace it with an improved camshaft position sensor free of charge. the recall began on december 29, 2007. owners may contact ford at 1-866-436-7332.
NotesFord recall no. 07s57.customers may also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov.

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
1424810/30/200310004877Film of oil/dust at the charge air cooler (cac) hose connections. *tt01/13/2004
ENGINE AND ENGINE COOLING - COOLING SYSTEM
1539711/01/2001630412Some vehicles may exhibit a condition of oil contamination in cooling system. *tt04/17/2002
1517208/01/2001624688Some vehicles may exhibita coolant leak from the water pump weep hole. *yh11/08/2001
1435001/01/2000620421Information on vehicles exhibiting a water pump shaft seal leak. *tt08/07/2001
788401/01/20007884612268The vehicle equipped with 5.4l or 6.8l gas engines may exhibit an overheating condition during predelivery inspection. this may be caused by a low coolant level.06/07/2000
ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY
1692106/01/200310002632Coolant leak due to broken radiator hose clamp. 1999-2003 models. *tt09/09/2003
1659702/01/200310002486Coolant leak due to a broken lower radiator hose clamp. *tt09/03/2003
ENGINE AND ENGINE COOLING - ENGINE
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
0219409/30/200210008589Driveability-no start/repeat starter failure-repeat starter replacement. electrical-sticking or binding ignition lock cylinder between start and run. engine-starting-starter staying engaged at start up. *mj08/09/2004
0222711/11/200210008310Engine-cylinder head deck leak-4.6 and 5.4l engines-new service-only gasket and cylinder head kits availability. *mj07/27/2004
1740609/01/20041814710008288Low power, poor fuel economy, fuel gelling cold, excessive white smoke cold, or hard start. *mj this oasis updates previous oasis dated 12/01/03. *tt07/26/2004
1755402/01/200410008119Oil/dust film at cac connections. *mj07/22/2004
0320510/13/20030219410004888No start/repeat starter failure or a sticking/binding ignition lock cylinder, starter staying engaged at start up. also includes 2003 super duty f series. *tt01/14/2004
1658910/30/200310004882Gradual loss of power at cruise. ford special service message. various models including 2003 super duty f series. *tt01/13/2004
03214510/30/20030220410004856External oil leak diagnosis for 7.3l dit engines. various models including 2003 super duty f series. *tt01/12/2004
03214610/30/20030220510004857Engine oil pan corrosion on vehicles equipped with the 7.3l diesel engine. various models including 2003 super duty f series. *tt01/12/2004
03214910/30/20030314910004860A loss of power, oil leaks around the turbo, and/or excessive exhaust noise from the turbo. *tt01/12/2004
03215110/18/20040420210004862Some 7.3l diesel turbocharger pedestals may leak oil around the exhaust back pressure actuator (ebp). *tt this article supersedes tsb 03-21-51 dated 10/30/2003. *tt01/12/2004
03214210/30/2003019510004853A lack of power under a load, at cruise or on acceleration may occur on some vehicles built before 11/25/2000 equipped with the 7.3l dit engine. *tt01/12/2004
03214010/30/20030025410004851Engine buck, surge or jerk (also known as hitching/hesitation) while the speed control is active through all engine temperatures. *tt01/12/2004
03215003/08/2004044410004861High pressure oil pump leak on vehicles equipped with 7.3l diesel engine. *tt01/12/2004
03213910/30/200300221100048507.3l powerstroke diesel engine with engine serial number 661894 through 1311240 may exhibit a knock noise above the normal sound of the diesel combustion. this bulletin also replaces 01146. *tt01/09/2004
03213610/30/200399251010004847Glow plug control module on 7.3l diesel vehicles with california emissions - service tip. *tt01/09/2004
03213810/30/20030017410004849Vehicles equipped with 7.3l dit engine built after engine serial number 896812 may have a injection control pressure (icp) oil aeration reading that is higher than the specification. *tt01/09/2004
0314907/21/200310003749A loss of power, oil leaks around the turbo, and/or excessive exhaust noise from the turbo. *tt10/29/2003
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
0391105/12/200310002783Rough idle and/or hesitation when acclerating on certain super duty vehicles equipped with a 5.4l or 6.8l engine. *tt09/17/2003
1666202/01/200310002512Lack of power, smoke, or oil leaks around the charge air cooler (cac). 1999-2003 super duty/excursion vehicles equipped with 7.3 or 6.0 ford navistar diesel engine. *tt09/04/2003
1669703/01/200310001943Exhaust air rush noise and lower power. *tt *jb07/28/2003
ENGINE AND ENGINE COOLING - ENGINE - DIESEL
1658901/01/200310005093Gradual loss of power at cruise. use fuel additive to prevent his condition. all super duty f-series 1999-2003 included. oasis *tt01/29/2004
0319209/29/200303141010004032Leak oil around the exhaust backpressure actuator (ebp) - 7.3l diesel turbocharger pedestals. *tt11/14/2003
03141007/21/200310003750Turbo pedestal seal oil leak around the exhaust back pressure (ebp) actuator. 2003 super duty f series included. *tt10/29/2003
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
1588805/01/2002637757Some vehicles may exhibit a fead belt squeal. *tt12/04/2002
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
1443401/01/2000620447Some vehicles may exhibit a buck or jerk (also known as hitching) during highway driving at speeds 40 mph or greater with the cruise control engaged. *tt08/08/2001
1418401/01/2000620373Some vehicles equipped with 7.3l dit engine may exhibit an engine that runs rough, misses, buck / jerk, hesitate / stumble, surge, lacks power, various idle symptoms, malfunction indicator lamp on. *tt08/07/2001
019505/14/2001620158A condition may exist with lack of power under a load, at cruise or on acceleration may occur on some vehicles built before 11/25/2000 equipped with the 7.3l dit engine. this may be caused by a collapsed air filter element or defective ai07/19/2001
014403/05/2001619421Fuel quality and moisture in certain diesel fuels may cause some vehicles to exhibit a no start, gradual loss of power, or a rough idle condition due to fuel gelling during extreme cold weather operation. *tt05/30/2001
014703/05/2001619424Subject regarding engine oil recommendations for use in 2001 vehicles - sae 5w-20 motor oil. *tt05/30/2001
1465802/01/2001619161Some vehicles equipped with 4r100 transmission and 7.3l engine or with 4r100 6.8l may exhibit engine stall after transmission engagement into reverse and a tip in backout of the throttle. *tt05/17/2001
0022110/30/2000618555Some vehicles equipped with powerstroke diesel engines after serial number 0896812 (engine build date), may exhibit a noise above the normal sound of the diesel combustion.*jb04/16/2001
1351911/01/1999614643Some vehicles with the 6.8l v-10 engine and california emissions may exhibit an engine miss or exhaust flutter noise. *tt11/29/2000
1418406/01/2000613885Some vehicles equipped with 7.3 dit engine may exhibit engine roughness, misses, buck / jerk, hesitation / stumble, surge, lack of power, various idle symptoms, malfunction indicator lamp on, etc. *tt09/20/2000
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS
1436509/01/2000618636This bulletin addresses concerns a noise at intial engine startup when cold from the accessory drive belt. *jb04/18/2001
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER
1685910/30/200310004883Some vehicles built after 12/7/1998 equipped with a 7.3l dit engine may exhibit a hoot or howling noise from the turbocharger. 2003 super duty f series also included. *tt01/13/2004
1403203/01/2001620294Some vehicles with 7.3l dit engines may exhibit loose turbo bolts on the turbo housing. typical symptoms of loose bolts include lack of power and an oil leak. *tt07/24/2001
1475303/01/2001619485Some vehicles equipped with a 7.3l dit engine may exhibit loose turbo bolts on the turbo housing. *tt06/01/2001
1434809/01/2000618621Concerns with a turbo hoot condition. *jb04/18/2001
846504/01/2000613644Informtion regarding turbo bolts coming loose. **mr07/26/2000
1403203/01/2000612982Some vehicles with 7.3l dit engines may exhibit loose bolts on the turbo housing. *tt06/14/2000
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
011301/22/2001618067Some vehicles equipped with 5.4l or 6.8l engine built through 9/10/2000 may exhibit a miss sound from the exhaust. this may be cuased by the design of the exhaust y-pipe which can cause a miss like sound known as impingement. *04/03/2001
754311/01/1999610869Some vehicles equipped with the 6.8l v-10 engine and california emissions may exhibit an exhaust flutter noise. this noise may also be described as an engine miss or exhaust leak. *tt05/16/2000
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE)
0541703/07/200510014666Intermittent rough idle - non-commanded egr (exhaust gas recirculation valve) flow. *tt05/05/2005

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 - DIESEL
PE06011FORD MOTOR COMPANY02/27/200606/23/2006ENGINE STALLING
 The cam position sensor (cps) provides a critical signal to the subject vehicle (sv) engine management system, the loss of which results in an engine stall.during pe06-011, ford stated in their response to odi that it is continuing to investigate allegations of cps related engine stall and further advised that an update will be provided upon completion of the investigation.ford data shows that 20% of the 716,000 svs are equipped with manual transmissions which are capable of back-driving the engine when a stall occurs; power assisted steering and braking are not lost during engine back-drive.ford data also indicates that back-drive occurs in automatic transmission vehicles above certain road speeds.the manufacturer reports noted reference 755 unique vehicles; 2 are duplicative of odi reports.in its review of customer and field reports, ford identified some 800 reports alleging one or more engine stalls potentially related to a cps failure in these 755 vehicles (ford
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
10/29/2012
 Tl* the contact owns a 2000 ford excursion. the contact stated that while pulling into the residential driveway, the check engine warning lamp illuminated and the vehicle made a loud noise. the vehicle was taken to an independent mechanic who refused to repair the vehicle. the manufacturer was made aware of the failure who did not offer any assistance and referred her to nhtsa. the vehicle was not repaired. the vin was not available. the failure mileage was unknown.
10/29/2012
 Tl - the contact owns a 2000 ford excursion. the contact stated that while pulling into the residential driveway, the check engine warning lamp illuminated and the vehicle made a loud noise. the vehicle was taken to an independent mechanic who refused to repair the vehicle. the manufacturer was made aware of the failure who did not offer any assistance and referred her to nhtsa. the vehicle was not repaired. the vin was not available. the failure mileage was unknown. pmb
10/29/2012
 Tl - the contact owns a 2000 ford excursion. the contact stated that while pulling into the residential driveway, the check engine warning lamp illuminated and the vehicle made a loud noise. the vehicle was taken to an independent mechanic who refuse to repair the vehicle. the manufacturer was made aware of the failure who did not offer any assistance and referred her to nhtsa. the vehicle was not repaired. the vin was not available. the failure mileage was unknown. pm
08/04/2012168000
 Tl-the contact owns a 2000 ford excursion. the contact stated that the vehicle caught on fire while parked and unoccupied. the fire originated in the engine area. the contact was able to extinguish the fire by disconnecting the battery and determining that the cruise control deactivation switch failed and caused an electrical fire. the contact repaired the vehicle. the cruise control smart switch harness was replaced. the manufacturer was made aware of the failure. the approximate failure and current mileage was 168,000. kmj
08/04/2012168000
 Tl-the contact owns a 2000 ford excursion. the contact stated that the vehicle caught fire while parked and unoccupied. the fire originated in the engine area. the contact was able to extinguish the fire disconnected the battery and located that the cruise control deactivation switch failed and caused an electrical fire. the contact repaired the vehicle. the cruise control smart switch harness was replaced. the manufacturer was made aware of the failure. the approximate failure and current mileage as 168,000. li
05/02/20121380001
 How can a company as ford claim to be an honest american car company...they should be stripped of their title of american and given their own identity of corporate cause they obviously do not care about the safety or their own integrity with the united states the people and we the people are just dollar signs to them. i have two fords and lets just say i should have learned after my second found on the road dead vehicle to not have been suckered into buying the american made ford again. i own a 2000 ford excursion and have had four spark plugs blown in the last two months...two in the last week. my truck barely hit 143,000....work trucks, dependable family vehicles...not so much. my truck has been taken care of immaculantly since 2000 and many who are not familiar with body details mistake it for the newer versions. this is a common problem that has been in existence since the truck came out...so much a problem ford came out with a special repair kit for it that will only be warranteed if you go to ford to fix it...sounds like a racket to me. a racket the government has looked into and approved. i have a family and am trying to get through this recession but seem to be going bankrupt not on gas prices from overseas or inflation but from repairs for an american, excuse me corporate american made vehicle that has taken almost every pint of blood my family has collectively. after a decade of continued complaints ford and the safety agency does nothing...my truck sits in my drive way because i choose to buy school clothes for my children and groceries vs. repairing it again. beyond disgusted on behalf of the american ford owners...who have walked in my shoes. after so many complaints how can the government and consumer affairs allow this corporate company not be held accountable? *tr
05/02/2012138000
 How can a company as ford claim to be an honest amercian car company...they should be stripped of their title of american and given their own identity of corporate cause they obviously do not care about the safety or their own integrity with the united states the people and we the people are just dollar signs to them. i have two fords and lets just say i should have learned after my second found on the road dead vehicle to not have been suckered into buying the american made ford again. i own a 2000 ford excursion and have had four spark plugs blown in the last two months...two in the last week. my truck barely hit 143,000....work trucks, dependable family vehicles...not so much. my truck has been taken care of immacutately since 2000 and many who are not familiar with body details mistake it for the newer versions. this is a common problem that has been in existence since the truck came out...so much a problem ford came out with a special repair kit for it that will only be warranteed if you go to ford to fix it...sounds like a racket to me. a racket the governemt has looked into and approved. i have a family and am trying to get throught this recession but seem to be going bankrupt not on gas prices from overseas or inflation but from repairs for an american, excuse me corparte american made vehicle that has taken almost every pint of blood my family has collectively. after a decade of continued complaints ford and the safety agency does nothing...my truck sits in my drive way because i choose to buy school clothes for my children and groceries vs. repairing it again. beyond disgusted on behalf of the american ford owners...who have walked in my shoes. after so many complaints how can the government and consumer affairs allow this corporate company not be held accountable?
ENGINE AND ENGINE COOLING
02/25/2012
 While driving the vehicle made a loud bang and smoke began coming out of hood. once we got the engine turned off and the emergency was over we discovered the spark plug had blown up. when it blew up the head became stripped and we had to have a plug installed into the defective head and replace the coil. i have since found out this is a very common problem with ford excursions
12/05/2011154000
 Spark plug blowout.
09/17/201192000
 Tl* the contact owns a 2000 ford excursion. while driving highway speeds, the contact heard a loud popping noise followed by an abnormal ticking. the contact then noticed smoke coming from the hood of the vehicle. the dealer diagnosed that the spark plugs exploded and blew a hole in the engine. the vehicle was repaired. the failure and current mileage was 92,000.
09/17/201192000
 Tl- the contact owns a 2000 ford excursion. while driving highway speeds, the contact heard a loud popping noise followed by an abnormal ticking. the contact then noticed smoke coming from the hood of the vehicle. the dealer diagnosed that the spark plugs exploded and blew a hole in the engine. the vehicle was repaired. the failure and current mileage was 92,000. kmj
09/17/201192000
 Tl- the contact owns a 2000 ford excursion. while driving highway speeds, the contact heard a loud popping noise. the vehicle began to make a ticking noise and the contact noticed smoke coming from the hood of the vehicle. the dealer diagnosed that the spark plugs exploded and blew a hole in the engine. the vehicle was repaired. the failure and current mileage was 92,000. kmj
09/05/2011124000
 I was driving my excursion aeound 25 mph and as i accelerated to 35 mph i heard a loud bang and thought my exhaust manifold may have cracked or came loose. after further investigation i found the spark plug wire and spark plug were blown out. called local mechanic and said i needed to bring it to ford for approx 4k, ford would replace the head. i went on line and purchased a kit, ford is aware of the problem with the spark plug being blown out of the head but will not recall the truck.note that this is affecting many vehicles, not only ford. this is a huge issue and very unfair that the manufacturer of the head is getting away with the poor quality control and the fact that they are not correcting the issue for the consumer.
11/18/2010116000
 Ford excursion with the spark plug blowing out of the engine. this is a very common known defect in the ford 4.6, 5.4, & 6.8 liter engines and the government has done absolutely nothing to protect the citizens of this country from the fraud that has been sold to the american people. the average repair cost is over $3,000.00 to fix a ford design flaw and one that they should be held responsible for repairing. since this would require the largest recall in world history our government sits by and does absolutely nothing to protect innocent lives that are in danger from these literal time bombs that can ignite escaping fuel vapors from the hole they just exited and burn a vehicle to the ground. it is disturbing that you are a government agency yet you refuse to do your job. since the government is in the car business now and competing with foreign companies it is amazing that with little to no reported cases you will force them to repair gas pedals that were manufactured by amercans but you won't do anything when it involves legitimate problems with a a garbage american product. and you wonder why the american cars have such a horrible reputation. because they fully have earned it. they are garbage and they receive immunity from the government that protects them and not the people. you should be ashamed to cash your paycheck which comes from us the taxpayers. please change your ways and do your job and protect innocent lives that god will surely hold you accountable for.
06/01/200630000
 Tl*the contact owns a 2000 ford excursion. the contact stated that the rpms would increase suddenly and the engine would shut down. the contact had the starter replaced two times. a local mechanic informed the contact that the failure was caused by a sticking throttle body and not the starter. the contact filed a complaint with the manufacturer. the failure mileage was approximately 30,000. the current mileage was approximately 75,000.
03/12/20101750001
 We stopped at a motel at about 10:00 p.m. and the car started shaking so we turned it off. when i restarted the car we heard a bang and the car started chugging and after reading the reports on ford v10's i figured it was a plug. the family had to catch a plane the next morning at 6:00 a.m. so i drove it to the airport as is figuring the damage was done. we made it to the airport just fine except for the loud chugging. we returned i drove it home 300 miles and other than the noise i didn't have any other problems. lucky for me the plug that blew was easy to reach so it didn't cost much to repair but the mechanic told me he had repaired many of the v8's as well. he put a stainless insert in the plug hole and reused the coil so the total cost was less than $200. if it would have been one further back it would have been up to 10 times the cost. ford does need to address this issue. *tr
02/02/2010
 On two separate occasions spark plugs have blown out of the cylinder heads my 2000 ford excursion v10. ford disclaims any responsibility for the damage and costs incurred. when the spark plugs blow out of the cylinder heads they also destroy the coils on's.
02/10/20101430001
 Sparkplug ejection. *tr
01/30/20101270001
 2000 ford excursion with 6.8l v10 engine and 127,000 miles ejected the #4 spark plug at relatively low speed (less than 20mph). this is a serious fire hazard as fuel is also ejected into the engine compartment. this needs to be taken seriously by ford motor company or the nhtsa as eventually, considering the number of online complaints regarding this issue; someone will be injured or killed. also - the fact that fords with modular engines ejecting spark plugs is so common place that new businesses and aftermarket products have actually been developed to address it. ford motor appears to claim that it is the spark plug manufacturers problem (remember firestone?) yet it also occurs with oem plugs. the repair cost will be anywhere from $700 to over $3500 depending on whether an aftermarket solution will fix the head or if the head requires replacement. *tr
01/15/20101590001
 2000 ford excursion v10 triton, #7 plug blew out of engine, 159,000mi on engine, plugs changed at dealer. repair was $300 for helicoil, plug, and coil for engine. no reason given for plug failure. immediate loss of power but was able to pull to side of highway. vehicle towed from site. *tr
01/04/20101560001
 While me and my family headed out on the highway to visit family, we began to hear a noise coming from the engine, soon after it sounded as if the engine had exploded, and almost loosing control from the noise that it created, i was able to drive off to the shoulder and park my vehicle. once i opened the hood of my truck i found that a spark plug had blown out of the socket and had also broken the ignition coil, soon after i ran to turn the engine off, do to smell of gas fumes. thinking this was a one time only incident and not knowing that ford had these problems. i had the truck towed to a mechanic only to hear that this was a common problem with the excursions for this year. i then paid a couple hundred dollars and thought the problem was fixed. going back home and taking the highway back home another spark plug blew out and once again broke the ignition coil with it as well. i was furious to find out that ford has no re call and when i tried taking the truck to a pep boys auto or any other shop they told me that they would not lay a hand on the truck and that i had to take it to the ford dealer ship if i wanted to get it fixed. not happy i called ford they wanted over $1,500 to fix the problem. this is really sad that this could possibly be the reason why i will possibly sell my truck and never buy ford again. but this is a real safety problem that needs to get fixed, or it may end up killing someone later down the road. *tr
09/26/20092230801
 Our 2000 ford excursion was sitting in the driveway and caught on fire. there was no one in the car at the time. the fire department was called and the fire was extinguished but the truck is damaged beyond repair. *tr
07/03/20091010921
 Spark plug ejection 2000 ford excursion v10 6.8l. *tr
10/31/2008970001
 A spark plug blew out of my 2000 ford excursion today on my way home. it was a loud bang, i thought the exhaust manifold cracked or muffler went. apparently this is a common problem that ford will not repair. it will cost about $4500. to fix. i am very surprised that i did not hear this on the news, it has happened to many ford owners but never heard about it until i had this issue. it is very unfair that it is a common problem with ford and the government does not enforce a recall. ford recalled but did not correct the cruise control defect that could cause a fire. fire...that is enough reason to recall the vehicle. *tr
09/30/20081363261
 2000 ford excursion spark plug blown out of head on 9/30/2008 has not been fixed yet. *tr
06/07/20081457581
 Blown spark plug from 2000 ford excursion v-10 triton engine. 3rd time. first time on new years eve 2007 while driving through town of houghton michigan. was able to insert new plug as old plug was completely blown out from under hood and could not find. had to replace plug coil as mounting bracket was broken and coil jacket and spring destroyed as well. second time same plug, this time no threads left to seat spark plug. thread insert installed by local high performance engine garage. they viewed problem as poor design and manufacturing practices by ford motor company. third time just happened earlier today while on us-41 traveling through l'anse michigan ironically just a few miles after passing the old ford alberta michigan lumber mill where the sideboards for the ford woodsies were milled. contacted friends at the high performance engine shop to have a new thread insert placed into the cylinder. the nhsta and the federal government needs to reopen this case and take action and get ford to replace the faulty heads on all triton engines. this could cause a serious fire or accident. but most of all it is a very expensive repair and the ford dealerships will not do anything other than replace the aluminum head at the owners expense of $4,000 plus dollars. 3 incidents of this kind are ridiculous. *tr
04/06/2006140000109/01/2000
 Dt*: the contact stated while the vehicle was parked, flames and black smoke came from the driver's side underhood area. the contact extinguished the fire with a water hose. the fire department was not contacted. minor fire damage was visible inside the engine compartment. the vehicle was towed to a dealer to await further inspection.
07/13/200573000106/09/2000
 Louise sudduth had driven her 2000 ford excursion to sudduth farms in mayo, s.c. she had parked the vehicle, and the vehicle caught fire while it was not running. mrs. sudduth received serious and ultimately fatal burns. *jb
11/09/2005801/28/2004
 Dt: contact states vehicle had sporadic surging. the vehicle tended to surge at lower speeds. in may 2005 a mechanic replaced the spark plugs, isc motor, fuel filter. the vehicle ran well until 11-9-2005. while driving slowly exiting a parking lot the vehicle started surging. she pressed on the brakes as hard as possible and the vehicle went out of control. the vehicle went across 2 lanes of traffic. at this time the vehicle is at a local mechanic.*ak
09/23/2005568832
 Dt: the contact owns a 2000 ford excursion. spark plugs were ejected out of cylinder heads. no longer had threads. incident happened on september, 23, 2005. no crash. involved. vehicle was at a stop sign. then vehicle took a right turn, and that was when the incident happened. no damage to the hood. the spark plug wire that had the coil in it was damaged . *ak
05/02/200520000101/02/2000
 Dt: the oil pan rusted and the consumer had it replaced. this was in a 2000 ford excursion. there were never any problems before. the consumer noticed that oil was leaking on the ground, and the vehicle was using more oil than usual. the price of $892.00 at ford to have it replaced. this could cause trouble on the road for others because it could result in a wreck with these cheap oil pans. *ak *sc *jb
10/18/200449590110/12/1999
 Spark plug blowout on 6.8 liter v-10 engine - 2000 ford excursion at under 50,000 miles. problem appears to be widespread and ford will not admit to fault. ford dealer cannot, or will not explain cause. online forums discuss problem as common. cost is $3000.00.*ak
06/01/20041
 Consumer started vehicle early in the morning and heard a loud noise comingfrom the engine. independent mechanic indicated one of the spark plug came out of the head gasket. need to be replaced the engine. *ak
03/09/20041
 While driving 45 mph vehicle stalled. this caused the driver to drift to side of the road. consumer had the vehicle towed to the dealer, and mechanic determined that engine spark plugs blew out of the engine. mechanic replaced the spark plugs. *ak
ENGINE AND ENGINE COOLING - ENGINE
02/16/20101170001
 Recently had #2 spark plug blow out of my excursion. *tr
02/10/20101165001
 Spark plug blow off. *tr
01/09/2010100000
 Tl*the contact owns a 2000 ford excursion. the contact stated that her vehicle caught fire while it was parked. the fire was under the drivers side wheel and then the entire engine was engulfed in flames. the fire department extinguished the fire. a fire report is available. an insurance adjuster will inspect the damages. the cause of the fire was unknown. there were no injuries. the manufacturer has not been notified. the vin was unknown. the failure mileage was 100,000.
12/30/20091270001
 Having just made it over the mountain pass with no previous trouble, we stopped at gas station for more wiper fluid. when starting up our 2000 ford excursion a loud boom came from the truck. this startled us and others outside of vehicle including a sheriff that heard it and came next to us to see what is was. we immediately turned off vehicle - sheriff and passer bys thought maybe exhaust?? we made it home but truck now sounds like a loud putt putt truck. we smelled fuel all the way home. as it turns out #10 sparkplug blew out hitting firewall. from two repair shops it is in a very difficult spot and is not likely will hold. so, we took it to ford dealership to see what they can do. we have been told by ford dealership that a bandage fix will probably not hold and other plugs could also blow or may not - apparently this is not new news to ford or the other repair shops we spoke with. so to replace just one side of head we are looking at $3680 or $5900 + for new engine. vehicle is not worth that in trade in per ford dealership - even before blowout . needles to say, we could have been on freeway and been forced off road (it was snowing badly and a bang that loud could have spooked many.) so that is why i stated there was a crash as there could have been if we had been driving. also, not sure if the fumes were cause of illness we had that evening and next day. we smelled fuel and smoke/exhaust all the way home. also, plug was not found and may have damaged or injured someone or something else. it is very dangerous and irresponsible of ford to not recall this problem. only to wait until someone tragically is injured or dies. it will happen. there is no control over where plug blows and what it will take out in its path. it seems this is and has been a problem with various model fords from 1999 to 2004. waiting for recall... or ford to step up and repair this problem at their cost. this is not my design flaw! thank you for your help. *tr
01/02/20101480001
 Spark plug blew out of my 2000 ford excursion v10 and i am now seeing that this is a growing problem with these engines. i have 5 trucks with these engine and now i am very worried. *tr
05/27/20091100001
 I have owned by 2000 ford excursion with the triton 5.4 for 3 years. i have barely put 20,000 miles on it. it know has 110,000 mi. when the spark plug blew on it. i was driving down the road when i heard a loud popping noise and then sputtering. i had to have it towed to my mechanic and had a costly repair done. as i have done research on it this is a ongoing problem with fords because of the design flaw in the head. i am very disappointed to find out ford has not recalled this. there is thousands of complaints with the same problem. ford are you listening? when are you going to do something about this? if this is not recalled soon i will be trading this in and buying a chevy or a honda. no more fords for me. *tr
01/10/2008100000
 Tl*the contact owned a 2000 ford excursion. while driving less than 55 mph, the vehicle shut off. the vehicle was left on the shoulder until a tow truck arrived. the vehicle then caught fire and a police report was filed. five months later, the contact was notified by the manufacturer that there was a recall on his vehicle that could result in a fire. his vin was included in the recall. the recall number was unknown. the failure and current mileages were over 100,000.
08/29/20071
 Spark plug blow out on 5.4 triton engine. *jb
12/04/2006750001
 2000 ford excursion v-10 ejected a spark plug while i was taking my kids to school this morning. this appears to be a known manufacturing flaw that ford refuses to stand up to. cost to repair was quoted at $3,750. i believe that ford motor company should be held accountable for their inaction to correct a well documented defect. *nm
10/05/200589651108/05/2000
 My wife was driving the vehicle and she heard a big pop. vehicle became immediately disabled. she called tow company and sent to neighborhood ford dealer. they stated that a spark plug had popped out of the aluminum engine. i immediately thought defect as spark plugs should not be flying out of engine blocks. i took my complaint to the dealer customer service manager & owner. she (amanda) stated that there is a serious problem with ford engines and that this is problem that they know about. she said they know the threads were too short and that it could happen again at any time to other spark plugs. i fear for the safety of my family but with six kids we need the vehicle run our daily lives. i have been advised after the re-tapping repair at the dealership that the only ford authorized repair is a full replacement of the cylinder heads that would cost $ 6,000. this is a whole other issue. please do not let them get away with this. i am informed that there are thousands of others that are having the same problem. *nm
05/06/200577321311/29/2003
 Our 2000 ford excursion keeps having the spark plugs shoot out of their holes damaging the head and individual spark plug coils (3 replaced so far). we have spent nearly $500 repairing the heads/coils so far. i expect additional plugs to fail on the v-10 engine. i am afraid of continued head and coil damage and even fuel line damage leading to an engine fire and total vehicle loss. i want ford to recall the vehicle and replace the heads with new heads with a better spark plug hole design. *jb
590001
 Vehicle caught on fire while parked and turned off. the alarm was also on. the fire originated from the engine compartment on the driver's side, per the fire inspector. *ak
01/20/2001
 Oil leakages due to engine galley plug coming out of it housing on two other occasio. dealer notified, and unwilling to assist in this matter. feel free to provide any further details on this matter. *ak
07/11/2000512/20/1999
 While driving and when making a right or a left hand turn consumer has noticed a very loud knocking noise when turning. consumer has contacted dealer. *ak sway bar repaired. mounts, bushings, bolts and springs were missing. steering was lost twice. the dealer had tried to repair but the problem still continued. *yh
ENGINE AND ENGINE COOLING - ENGINE - DIESEL
06/05/200550000205/28/2002
 Cam position sensor on ford excursion power stroke diesel has gone out twice. the first time at 50,000 miles, while pulling a boat on a busy highway. luckily we were able to pull over, as the vehicle died. the second time it went was right at 100,000. *jb
09/13/200386000105/20/2000
 1) engine would stall or completely quit going down the road in traffic any were it wanted 2)cam shaft position sensor was going out truck would stall 3)ford service department changed cam shaft position sensor. *tr
02/09/200586835204/06/2004
 Cam positioning sensor on my 2000 ford excursion 7.3 powerstroke failed, leaving me stranded. this is the second time this item has failed and needed to be replaced. i am advised that there are a number of failures with respect to the same part. *jb
08/13/200676540103/17/2005
 While driving down a steep grade, engine cut out and set a ses code. had a hard time getting the suv to stop and almost lost control of vehicle, but due to the slow nature of driving i kept it under control with 8 occupants in suv. once stopped, i got out code reader and found out that the cps (cam position sensor) had failed. i had a spare in the suv and replaced it. contacted ford main office and they have known it to be a problem with the diesels and nothing is being done to get a recall or replacement part to fix cps problem. *jb
07/04/200652150107/15/2000
 Cps failed on 2000 ford 7.3l diesel. *jb
07/13/2006101600211/21/2003
 I own a 2000 ford excursion with the opt. 7.3 diesel engine. i have had 2 engine failures were my engine would quit and not restart. the cps (cam position sensor) failed. this is my wife's truck. when the engine just stops you must be prepared to take emergency action to keep the suv under control. i have talked to other owners that this has happened also in f250 and f350 pickups with the 7.3 motor. *jb
02/25/200664192506/02/2001
 On 2/25/06 my wife was at work and called due to our 2000 ford excursion not starting. i then went to the vehicle and proceeded to change all filtration except the oil. it did run for a short time but died again. i continued to get it started after that and again dying after every short start. we eventually had to have it towed to faulkner ciocca ford in souderton pa. with us living in royersford pa it was some distance to the souderton shop. they were not able to work on it until monday 27th. the diagnosis was a camshaft position sensor. this is described in your findings under investigation pe06-011 by mr. scott yon opened on 2/27/06. the resulting financial hit was $561.06 including the towing. not counting my time lost at work due to having to try to get the vehicle running since it was a saturday and having to change all filtration due to the unknown but pointing to fuel delivery. this was an additional $130.43 from napa in telford pa. *nm
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
02/03/20083
 I have had three spark plugs that blew out of the head. ford does not state that this is a problem and the cost for repair is on the owner. *tr
04/25/200791655106/01/2004
 At 90,000 miles after my first tune up i blew a spark plug off of my head on my 2000 ford excursion. i was told by my local mechanic and many other people that ford's in this year range have been streaming into his shop with blown spark plugs. i also stated that ford is refusing to recognize this huge safety issue and that the government needs to get involved. please take this complaint seriously. my wife and 5 kids were in the car in a unknown area to them at 10:00pm when this breakdown occurred. this story is very similar to 1000's of other stories on the internet. just type in blew a spark plug into a search engine and start reading. *jb
02/24/200781300109/28/2000
 I had been out of town when my 2000 ford excursion had a door ajar dummy light fail to shut off. i attempted to figure out what was causing the door ajar light to remain on but never did find the problem. i ended up driving home so i could make an appointment with my dealer to have it checked out. i was able to get the truck home, but as i was driving through my subdivision my truck made a noise, then made a much louder noise, and began running really rough. a strong odor of fuel filled the passenger compartment of my truck. i immediately shut off the engine so my truck wouldn't ignite, but that left me stranded in the middle of the road. i have since been told that the triton v10 engine blew a spark plug and it's been quoted at $4200 to be repaired at the closest dealership and $3500 at the dealership where i purchased the truck but i have to have it towed again. *jb
08/07/2005670001
 I own a ford excursion with a 6.8 v10 motor. while traveling on an interstate at posted speed one or more (waiting to here from repair shop) spark plugs were blown from the cylinder head without warning and could have caused a very serious accident. fortunately at the time i was able to pull over to the side of the road safely just avoiding a fast over taking transport truck. from what research i have done on the internet this is an all too common problem with the ford v10's and some v8's. i am now looking at a minimum of a replacement head and it might require a replacement motor. this is a safety issue and could have ended in an accident or fire. *jb
 While warming vehicle and without any indication vehicle stalled, and could not be restarted. vehicle was towed to dealer, technician couldn't duplicate problem. please provide further information. *ak
10/08/2001
 While driving 70 mph took foot off accelerator while getting ready to exit, and vehicle started to lose power, which it actually did. also, stated by vehicle was stopped, it has lost power steering and v stalled. had not contacted dealer. *ak
04/01/20010
 When applying brakes lost control of vehicle. engine slowed down. also, hesitated without prior notice. *ak
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER
 Intermittently turbo-charger malfunctioned, causing oil to leak from the vehicle and vehicle to stall. dealer has repaired the vehicle trhee times. *ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
05/18/20072
 I own a 2000 ford excursion with a v10. while driving home from my son's track meet in a construction zone on i94 in mount clemens michigan during rush hour i had a spark plug blow out. we (my wife, my son and i) were moving about 10 miles an hour in the construction traffic when we began to slowly speed up. i accelerated and boom, there was a very loud sound of knocking. i nearly hit the dividing wall it scared me so bad. i was able to pull over about 150-200 feet ahead through the construction barrels. i opened my hood and discovered that one of my coil packs was sticking up a few inches and broken. i called my insurance company (usaa) for roadside assistance. within an hour and a half they sent a tow truck and had me towed (about 7 miles) home. the next day i was able to better inspect what had gone wrong. the motorcraft spark plug had completely un-threaded itself and the compression of the motor turned the spark plug into a projectile that completely demolished the coil pack. the coil pack snapped from its retaining bolt and was beating against my fuel rail. luckily i was able to pull over as soon as i did because i could only imagine if i had been in an area where i was traveling the actual 70 mph speed limit and the damage to my fuel rail could have been disastrous possibly causing a fire. i contacted russ milne ford in clinton twp michigan about this issue and they stated that it would cost over $1000 to replace the head and that it was caused by the threads on the head or improper torquing of the spark plug. i found that amazing since i had my truck serviced by them about a year before because of an slight engine knock that i had on the passenger side of the motor along with a few other minor things. they never were able to find the cause of the engine knock. unfortunately for me the engine knock was a sign of the pending failure that i wish had been discovered before the blow out. no repairs yet. *jb

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