Recalls
| Campaign | Manufacturer | Manufacturing date | Type | # of units affected | Date Owner notified Mfg | Recall Initiated by | Manufacturers of recalled vehicles/products | Report Recieved Date | Record Creation Date | Regulation Part Number | FMVSS Number | |||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | ||||||||||||||||
| 07V553000 | FORD MOTOR COMPANY | V (Vehicle) | 1176000 | 12/29/2007 | ODI | FORD MOTOR COMPANY | 12/05/2007 | 12/05/2007 | ||||||||
| Defect Summary | On 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 Summary | In the event of an engine stall, a crash could result without warning. | |||||||||||||||
| Corrective Summary | Dealers 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. | |||||||||||||||
| Notes | Ford 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
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||||
| 041601 | 11/14/2005 | 05228 | 10018745 | Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running. *tt | 01/12/2006 |
| 04228 | 12/27/2004 | 04254 | 10013403 | Hard start or no start. *eh | 04/18/2005 |
| 15594 | 02/01/2002 | 630645 | Super duty erratic coolant temperature gauge readings - concerns. *tt | 04/19/2002 | |
| 15199 | 08/01/2001 | 624617 | Some vehicles may exhibit a condition where the transmisison temperature gauge reads in the middle at start up. *yd | 11/08/2001 | |
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||||
| 15398 | 11/01/2001 | 630414 | Some vehicles may exhibit a coolant leak due to a broken radiator hose clamp. *tt | 04/17/2002 | |
| 15397 | 11/01/2001 | 630412 | Some vehicles may exhibit a condition of oil contamination in cooling system. *tt | 04/17/2002 | |
| 01185 | 09/09/2001 | 625695 | Subject regarding engine cooling system.*jb | 11/30/2001 | |
| 01167 | 08/20/2001 | 624105 | Information regarding cooling system, motorcraft premium gold engine coolant, only for vehicles produced at kentucky truck plant. *slc | 11/01/2001 | |
| ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY | |||||
| 16921 | 06/01/2003 | 10002632 | Coolant leak due to broken radiator hose clamp. 1999-2003 models. *tt | 09/09/2003 | |
| 16597 | 02/01/2003 | 10002486 | Coolant leak due to a broken lower radiator hose clamp. *tt | 09/03/2003 | |
| 15678 | 03/01/2002 | 636306 | Coolant leak due to a broken lower radiator hose clamp. *tt | 11/07/2002 | |
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| 07212 | 10/01/2007 | 10023943 | Some 1997-2008 vehicles equipped with a 4.6l 2v, 5.4l 2v, or 6.8l 2v engine--spark plug thread repair procedure--not covered under new vehicle limited warranty. *nj this includes f-53 motorhome chassis. updated 2/23/10. *pe | 02/20/2008 | |
| 031404 | 08/23/2004 | 04161 | 10011162 | Engine misfire or running - coil on plug (cop) ignition systems - wds cop kit diagnostic tips. to include various 2005 models. * ar this article 04161 supersedes tsb 03-14-04. | 01/06/2005 |
| 02194 | 09/30/2002 | 10008589 | Driveability-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. *mj | 08/09/2004 | |
| 16403 | 11/01/2002 | 10008334 | Engine-light tick or rattle type noise from engine after cold start. *mj | 07/28/2004 | |
| 17406 | 09/01/2004 | 18147 | 10008288 | Low power, poor fuel economy, fuel gelling cold, excessive white smoke cold, or hard start. *mj this oasis updates previous oasis dated 12/01/03. *tt | 07/26/2004 |
| 17554 | 02/01/2004 | 10008119 | Oil/dust film at cac connections. *mj | 07/22/2004 | |
| 03205 | 10/13/2003 | 02194 | 10004888 | No start/repeat starter failure or a sticking/binding ignition lock cylinder, starter staying engaged at start up. also includes 2003 super duty f series. *tt | 01/14/2004 |
| 16589 | 10/30/2003 | 10004882 | Gradual loss of power at cruise. ford special service message. various models including 2003 super duty f series. *tt | 01/13/2004 | |
| 032146 | 10/30/2003 | 02205 | 10004857 | Engine oil pan corrosion on vehicles equipped with the 7.3l diesel engine. various models including 2003 super duty f series. *tt | 01/12/2004 |
| 032150 | 03/08/2004 | 0444 | 10004861 | High pressure oil pump leak on vehicles equipped with 7.3l diesel engine. *tt | 01/12/2004 |
| 032151 | 10/18/2004 | 04202 | 10004862 | Some 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. *tt | 01/12/2004 |
| 032145 | 10/30/2003 | 02204 | 10004856 | External oil leak diagnosis for 7.3l dit engines. various models including 2003 super duty f series. *tt | 01/12/2004 |
| 03144 | 07/21/2003 | 10003744 | Engine misfire or rough running condition with coil on plug (cop) ignition systems may be more accurately diagnosed using the optional worldwide diagnostic system (wds) coil on plug (cop) kit. 2003 super duty f series included. *tt | 10/29/2003 | |
| 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 | |
| 16662 | 02/01/2003 | 10002512 | Lack 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. *tt | 09/04/2003 | |
| 16697 | 03/01/2003 | 10001943 | Exhaust air rush noise and lower power. *tt *jb | 07/28/2003 | |
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||||
| CSP-48B01 | 05/26/2008 | CSP-08B02-48B01 | 10026321 | Ford: vehicles mistakenly charged $100 powertrain warranty deductible for fuel injector repair or repairs. no model or model years provided. *pe econoline, excursion and f-series super duty vehicles, model years 2002-2005. updated | 10/17/2008 |
| 16589 | 01/01/2003 | 10005093 | Gradual loss of power at cruise. use fuel additive to prevent his condition. all super duty f-series 1999-2003 included. oasis *tt | 01/29/2004 | |
| 03192 | 09/29/2003 | 031410 | 10004032 | Leak oil around the exhaust backpressure actuator (ebp) - 7.3l diesel turbocharger pedestals. *tt | 11/14/2003 |
| 031410 | 07/21/2003 | 10003750 | Turbo pedestal seal oil leak around the exhaust back pressure (ebp) actuator. 2003 super duty f series included. *tt | 10/29/2003 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||||
| 15888 | 05/01/2002 | 637757 | Some vehicles may exhibit a fead belt squeal. *tt | 12/04/2002 | |
| 01246 | 12/10/2001 | 630515 | Engine oil system priming procedures, service tips for reports of premature engine failure. *tt | 04/18/2002 | |
| 15581 | 01/01/2002 | 630132 | Some vehicles may exhibit an inoperative charging system and/or a no start condition. *tt | 04/15/2002 | |
| 0214 | 01/21/2002 | 630001 | Some engine assemblies with aluminum cylinder heads repaired in-vehile have been found to leak coolant and/or oil from the cylinder head gasket area. *tt | 04/11/2002 | |
| 01205 | 10/15/2001 | 627927 | Some vehicles may exhibit vacuum or air leaks in the intake manifold and / or engine system causing diagnostic trouble codes p0171 and or p0174. *tt | 02/26/2002 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS | |||||
| 16291 | 10/01/2002 | 10013071 | Loud squealing noise from the engine area when the engine fan clutch is under load while operated in hot dusty climates. vehicles equipped with a 7.3l engine. *tt | 04/07/2005 | |
| 15593 | 01/01/2002 | 630152 | Some vehicles built between 11/29/01 and 11/30/01 may exhibit a serpentine belt squeal. *tt | 04/15/2002 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER | |||||
| 16859 | 10/30/2003 | 10004883 | Some 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. *tt | 01/13/2004 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE) | |||||
| 05417 | 03/07/2005 | 10014666 | Intermittent rough idle - non-commanded egr (exhaust gas recirculation valve) flow. *tt | 05/05/2005 | |
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 | |||
| 06/12/2011 | 110000 | ||
| Was starting from a stop to make a left turn when driver heard a loud pop. there was a sudden loss of power and some smoke. the vehicle was towed and diagnosed. the #3 plug on the right bank has blown completely out and damaged the coil pack. a phone call to the dealer yielded no help other than we can have it towed there to be repaired, as it likely needs a new head. some internet research and talking to other ford owners definitely suggest that this is a design problem with the alum heads blowing out spark plugs, and the #3 r plug seems to be common. this could cause fuel/vapors to be exhausted and sprayed on a hot manifold and cause a fire. it sounds like there may have already been some fires attributed to this problem. this sound like a case where the dealer/ford refuses to admit that it is a problem and fix it for owners. before there are serious injuries from a crash or a fire, ford should be compelled to fix this issue. its unlikely that ford will answer the call without pressure from nhtsa. there seem to be far too many of the same type of problems with this 5.4l motor for it to be a coincidence. | |||
| 01/25/2010 | 120000 | ||
| My 2002 ford lexcursion blew out it's spark plug yesterday. you all know the story by now: corporate will not help. my local dealer will not help. and, as most of you already know, the government to this date has done nothing to help either. these kinds of things are exactly what is wrong with this country: more often than not there is no accountability for things that go wrong. i will never buy a ford again, this whole situation is breaking my heart because i really do love america and my beautiful american-made ford truck. it's a excursion, people. my point is that it was built here in america, not outside our borders like some of the other cars we buy. the manufacturer includes a numbered certificate with each lexcursion to verify that it was built by americans, in america, for americans. i am ashamed of ford, and of my govenment for letting this go on for so long. this has been happening with ford v8,v10 all trition engines spanning back 11 years, and that's just what i've found so far: i've been searching online for only about ten minutes now. when i googled the issue i didnt even put ford's name in the search box. i just typed why do spark plugs blow out?, and it spit out a ton stuff about fords, in particular their triton 6.8 v10. how many millions of these have they installed? good people of america: they won't acknowledge the problem because to do that would cripple them. this is their version of the toyota accelerators. i even called my congressman today, left a message, which breaks my heart even more because i already know i probably won't be called back. i am a ford owner, and now i own a truck that i no longer trust or believe in, built by a company that i no longer trust or believe in. my family was with me and i was stuck on the beltway disable and anything could had happen. there are thousands and thousands of the same problem. i dont know what to do. please help. this issue keeps happening over and over and seems there is no fix. | |||
| 06/16/2009 | 54062 | 1 | |
| Exhaust manifold bolts, rusted and broken off, right bank. *tr | |||
| 08/15/2009 | 68500 | 1 | |
| While driving down the highway at approx 60 mph the spark out of the # 1 cylinder was ejected from engine. brought to local mechanic who installed a heli coil and replaced spark plug. *tr | |||
| 06/12/2009 | 116000 | 1 | |
| I have a ford excursion 2002 v10 with 116000 miles on it. after 8 hours of a road trip one of the spark plugs ejected from the engine. this is the second time this has happened with this motor. i purchased the vehicle at 100,000 miles and the owner had it happen once to him. *tr | |||
| 12/17/2008 | 112500 | 1 | |
| 2002 ford excursion with 6.8l v10 triton blew a spark plug out. spark plug had been in engine for 30000+ miles and was professionally installed and torqued. *tr | |||
| 05/03/2007 | 76827 | 1 | |
| Camshaft position sensor needed to be replaced. i had defective part replaced at my expense and then received safety recall notice for same part. i am having trouble being reimbursed for the cost of the repair. *tr | |||
| 05/05/2008 | 57844 | 1 | |
| Slight ticking sound, like an exhaust leak, leading to the spark plug blowing out of the cylinder head, damaging the threads and also coil pack to break. *tr | |||
| 10/23/2007 | 6 | 08/02/2002 | |
| Auto stalls without warning and will not start - has occurred several time every years starting in 2003. i have had it!- i do not know where to turn to. hopefully you will e able to do something. *tr | |||
| 04/05/2006 | 39888 | 1 | 01/01/2002 |
| Truck started to stop and stall. happened approximately 5 times leaving me stranded on the side of the road when it finally stopped the truck dead. *tr | |||
| 02/07/2006 | 79284 | 1 | 02/01/2002 |
| Dt*: the contact stated while merging with traffic on the interstate at 55mph, a spark plug blew upward into the engine which caused the vehicle to stall and operate at a reduced speed. the contact managed to pull the vehicle to the side of the road. the vehicle was towed to a local dealer. the dealer suggested replacing the engine because of the damage sustained by the spark plug, but no repairs were made. | |||
| 03/20/2005 | 51000 | 1 | 10/28/2002 |
| The vehicle caught on fire under the hood while being parked in the driveway for more then 10 hours or more. the local fire department arrived to extinguish the fire. the cause of the fire was not determined. the consumer notified the dealer and the manufacturer. *ak the main body of the fire was coming from the engine. *sc *jb | |||
| 08/26/2002 | 1 | 02/18/2002 | |
| The vehicle has a front suspension problem which causes the vehicle to vibrate, the vehicle has been to the dealer 3 times but the problem still exist, both driver side doors are misaligned with respect to the fender trim, the differential was originally misaligned with respect to the rear fender trims, now the differential is properly aligned and the consumer questioned the technicians who stated that they did nothing to correct the misalignment, the consumer feels this is a definite safety problem if the differential goes in and out of alignment on is own, the a/c was not cooling and needed to be recharged, the consumer can hear static in radio when turning on the rear tv switch, a/c and turn signal, steering gear and hydro boost line replaced, tire out of balanced causing vibration at 75-70 mph, steering out of adjustment (off center), calipers replaced, transmission experiencing a delay when shifting, both wiper blades off center, drain plug leaking oil, weather stripping on right rear door failed, headliner is coming loose on the left side, windshield washers inoperative, fuel gauge read incorrectly, faulty accelerator pedal caused the vehicle to stall when coming to a stop. nlm | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 02/21/2011 | 84800 | ||
| 2002 ford triton 6.8l v10 engine in an excursion vehicle ejected an original (unchanged, factory torqued) spark plug with great force and damage in the engine compartment. coil was immediately damaged as spark plug ricocheted around the engine compartment followed by the smell of gasoline vapors and loud noise from the engine compression being directly vented from the vacated spark plug hole. the five threads of the triton spark plug hole were damaged by the force of the ejection. this should not happen with the ford engine to the customers safety given this was an original plug (at 85,000 miles). the weather at the time of the spark plug ejection was -4f, and the spark plug ejected as the vehicle was beginning to accelerate from a standstill. ford has a major and costly defect with their triton engines they sold to customers (engine replacement is estimated at $4000) and the government should enforce ford to recall and repair all spark plug holes in these aluminum engines spanning years 2000 to 2004 given they only used 5 threads in each spark plug hole, which is insufficient for an aluminum block. how is it that this widely known issue is not getting the federal government's attention given this is a demonstrated major defect and a safety issue (could have had a fire in the engine compartment if a spark from the ejected spark plug occurred). | |||
| 11/12/2009 | 40000 | ||
| Tl*the contact owns a 2002 ford excursion. the contact stated that after opening the hood there was gasoline fumes coming from the engine and fuel was spraying all over the engine. the fuel continued to spray throughout the engine while the vehicle was on; however, when the vehicle was turned off there was a puddle of fuel under it. the dealer observed the fuel leak while performing an additional recall repair and refused to address or repair the fuel leak unless the contact paid $200 for the repair. the manufacturer stated that the fuel leak was not a part of the recall. there was routine maintenance performed on the vehicle prior to the failure. the failure mileage was 40,000. | |||
| 08/03/2008 | 82000 | ||
| Tl*the contact owns a 2002 ford excursion. while the vehicle was parked in the driveway, it burst into flames without warning. the vehicle was completely destroyed. the fire department was called to the scene and a report was filed. the representative stated that the failure originated from the engine. the vin was unknown. the failure and current mileages were 82,000. | |||
| 03/31/2007 | 59000 | 1 | 01/07/2002 |
| Our 2002 ford excursion, with the 5.4l motor, had just turned 59,000 miles last week when my wife was driving home from picking up the kids from school. my wife calls to tell me that she had to pull to the side of the road because the truck began experiencing severe power loss and what sounded like a major exhaust leak. upon having the vehicle towed to the local ford dealer, the service writer tells me it's most likely a blown spark plug and the repair will be in the $500 range. the service writer calls back the next day and confirms the blown spark plug and tells me it's a $725 repair. he goes on to tell me that he's been seeing a lot of this type of problem lately (just had one last week). after a couple of hours of haggling, i got the cost down to the original $500 range. the next day i check with my trusted independent mechanic on the problem to see if i should have him check the other seven plugs. he tells me he won't even touch the plugs because of the history with these heads and the blown spark plug problem. he goes on to tell me that the problem will most likely occur with the seven remaining cylinders. upon conducting a quick web investigation, i learn that this is a major problem that ford is not stepping up to help resolve. help?!*jb | |||
| 12/09/2006 | 100000 | 1 | |
| In early december 2006 we were out christmas shopping when i heard a loud pop followed by a sharp decrease in power and following pop sounds. i pulled over and checked the engine. at first i just noticed the coil had blown off the head. i thought it may have just been a weird occurrence with a bad cop but later found that the spark plug had blown out of the #6 cylinder destroying the cop. the truck was towed back to my residence and the next morning i looked it over. the spark plug had blown out stripping the threads. after looking on the net, i found that this a common issue with this year and engine type. *jb | |||
| 10/21/2006 | 42800 | 1 | 10/21/2001 |
| Cam position sensor failure on a 2002 ford excursion with a 7.3l powerstroke at 42,800 miles. *nm | |||
| 11/12/2005 | 39000 | 1 | 06/01/2002 |
| While driving my 2002 ford excursion on the interstate at about 65 mph, i heard a thump under the hood and then my engine began to make a loud clunky sound (almost as if there were no muffler). one of the sparks plugs had blown out of the engine! luckily, my excursion was still drivable and i was within a few miles of my home and could park it until i could seek repairs on monday. i did not take it to the ford dealership (trust issues). i took it to tune-up 2000, where they told me the spark plug threads had stripped out causing it to blow form the engine. it had to be re-threaded, costing me $500. this puts my repair bills, for my less than four year old excursion, at over $3500 in 2005. the entire transmission had to be rebuilt this summer due to a cracked transmission case. *jb | |||
| 12/27/2005 | 68000 | 1 | 03/01/2002 |
| Dt: the contact stated while driving a spark plug blew out of the engine ,causing a hole to be blown in the ignition coil. the independent repair shop personal replaced the coil pack, drilled and tapped the motor head on the number three cylinder. *ak | |||
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||
| 03/31/2008 | 0 | ||
| Tl*the contact owns a 2002 ford excursion. the contact received two safety recall notices for nhtsa campaign id number 07v553000 (engine and engine cooling: engine: diesel). he took the vehicle to the dealer for repair and was informed that there were no safety recalls on his vehicle. there had been no failure to date. the purchase date was unknown. the current mileage was 104,000. | |||
| 09/05/2007 | 71000 | 1 | 02/05/2002 |
| Crank position sensor failed without warning, vehicle motor immediately shutoff and was unable to restart. vehicle was towed to dealer for repairs. fortunately this happened in a parking lot. if this happened on the highway while towing 10,000 lbs, loss of engine power would cause a inability to control the vehicle resulting in a likely accident with possible injuries or deaths. *jb | |||
| 02/13/2004 | 4 | 03/09/2002 | |
| A sensor fails and causes engine to stop running - has happened while going 65mph on an interstate hiway - engine may restart but car is left coasting, totally without power at hiway speeds. engine has stopped 4 times now. only last occurrance is listed here. *ak | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| 01/16/2005 | 71436 | 1 | 11/14/2002 |
| The spark plug popped out of the head of my 2002 ford excursion. the dealer repaired it at a cost of around $500.00. they told me they never heard of this before and i was lucky i didn't blow the motor at a $7000,00 cost. i first felt lucky when i called customer service they too said it was new to them also. many of my friends say this problem is a common one. now i want to know how common and if so why do i have to pay for their design flaw. | |||
| 06/05/2002 | 3017 | 12 | 05/04/2002 |
| 2002 ford excursion, limited. engine stalls when coming to stop at traffic signs, signals. will restart in park but die immediately upon being put back in gear. has been to authorized ford service dealership, now 5 times, multiple testing with flight recorders, multiple part replacements, still no appropriate resolve. currently back at dealership for another probable excuse, without definitive correction. | |||
| 05/16/2002 | 4 | 10/01/2001 | |
| Truck dies when you slow down or apply brakes. then will not remain running when put into drive, it will die immediately when taken out of park. have to start car in n gear, bring engine speed over 1500 rpm's then pop it into drive for truck to remain running. has now happened four times.*ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||
| 02/12/2011 | 103500 | ||
| I'm the original owner of my ford excursion 2002; while driving down a 40 mph road (with the original motor and parts) the spark plug popped out of the motor block!!! this was under normal easy driving conditions in a very well maintained automobile. this is a very expensive repair on something that to me seems very defective! | |||