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 | |||||
| 06213 | 06223 | 10019380 | White smoke, lacks power, exhaust odor, surges, runs rough, or no start - 6.0l. *tt | 03/13/2006 | |
| 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 |
| 18845 | 09/01/2005 | 10018073 | Flutter noise on deceleration. *tt | 12/14/2005 | |
| 051713 | 10/07/2005 | 05249 | 10018062 | Coolant degas bottle overflow. *tt | 12/14/2005 |
| 18525 | 04/01/2005 | 10017875 | Buck/jerk, lacks power, black smoke, rolling idle, surge, mil on, and diagnostic trouble codes p2263, p0299, or p0401. *tt | 12/06/2005 | |
| 18283 | 11/01/2004 | 10013425 | Oil leak from the oil filter cover. *eh | 04/18/2005 | |
| 04228 | 12/27/2004 | 04254 | 10013403 | Hard start or no start. *eh | 04/18/2005 |
| 18276 | 11/01/2004 | 10013419 | Air induction system appears to be warped and or not sealing. this includes super duty f series models. *eh | 04/18/2005 | |
| 041713 | 09/06/2004 | 10013119 | Hard start or no start. *eh | 04/08/2005 | |
| 18427 | 02/01/2005 | 10012974 | Vehicle with a 6.0l engine may exhibit any one or more of the following buck jerk lacks power black smoke rolling idle surge mil on and diagnotics trouble codes p02263 or p0299. also includes 2004-05 e-series 6.0l models. *eh | 04/05/2005 | |
| 17288 | 10/01/2003 | 10004931 | Lack of power and/or low boost pressure condition. this includes 2003-2004 super duty f-series. *tt | 01/20/2004 | |
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||||
| 052623 | 01/01/2006 | 0638 | 10019385 | Coolant degas bottle overflow - 6.0l. *tt | 03/13/2006 |
| 05249 | 01/01/2005 | 052623 | 10018939 | Coolant degas bottle overflow. *tt | 01/25/2006 |
| ENGINE AND ENGINE COOLING - COOLING SYSTEM - FAN | |||||
| 0714 | 10021236 | Lack of cooling fan operation. *kb | 03/23/2007 | ||
| 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 | |
| 16621 | 02/01/2003 | 10002500 | Loose radiator hose clamps. *tt | 09/03/2003 | |
| 16597 | 02/01/2003 | 10002486 | Coolant leak due to a broken lower radiator hose clamp. *tt | 09/03/2003 | |
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| TSB-09-15-6 | 12/09/2009 | 10030848 | Ford: some vehicles equipped with the 6.0l engine may experience a p006a, p132, p0401 or p0402 diagnostic trouble code (dtc) with a lack of power condition, surge, or turbocharger flutter after performing field service action (fsa) 06e17, | 12/09/2009 | |
| TSB-08-20-1 | 03/20/2009 | 10028284 | Ford trucks: misfire, lack of power, buck/jerk, excessive smoke, crank/no start-diagnostics for fuel system. there are several potential causes for these symptoms. *pe | 03/20/2009 | |
| 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 | |
| 062401 | 10022293 | 6.0l diesel engine - oil leak or boost pressure leak at hot side charge air cooler duct. *kb | 07/25/2007 | ||
| 06246 | 10022295 | Dtc's p006a or p132b - lacks power, surge, or flutter after field service action 06e17. *kb | 07/25/2007 | ||
| 19614 | 02/01/2007 | 10021619 | Air filter water ingestion / snow packing with codes p0103. *kb | 06/12/2007 | |
| 07515 | 10021464 | 6.0l oil seep or boost pressure leak at hot side charge air cooler duct. *kb | 04/27/2007 | ||
| 0754 | 10021462 | Cold start driveability - white smoke, lacks power, exhaust odor, surges, runs, rough, or no start. *kb | 04/27/2007 | ||
| 19375 | 09/01/2006 | 10021229 | Watch for oil flow from the base engine oil pump. vehicles equipped with a 6.0l diesel engine. *kb | 03/23/2007 | |
| 19247 | 06/01/2006 | 10021173 | Oil flow from the base engine oil pump. *kb | 03/19/2007 | |
| 19356 | 09/01/2006 | 10021174 | Driveability issues and/or dtc p132b, p006a immediately after reprogramming. *kb | 03/19/2007 | |
| 06232 | 07161 | 10020673 | 6.0l turbocharger carbon deposit diagnostics and service tips, lack of power, white or black smoke, surge, p0238, p0299, p0404, p0478, p0478, p2262, and/or p2263. *kb updated 11/05/07. *nj | 12/20/2006 | |
| 052625 | 01/01/2006 | 0697 | 10020069 | Misfire, lack of power, buck/jerk, excessive smoke or crank/no start. *tt | 07/18/2006 |
| 18362 | 01/01/2005 | 10013307 | Lack 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). *tt | 04/14/2005 | |
| 18397 | 02/01/2005 | 10012958 | Lack of power, surge, and/or diagnostic trouble codes p2263 or p0299. *tt | 04/05/2005 | |
| 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 | |
| 0492 | 05/17/2004 | 10008548 | Water-in-fuel lamp illuminated after draining heated fuel conditioning module (hfcm) on vehicles built prior to 11/1/2003 with 6.0l engine. *tt | 08/04/2004 | |
| 16403 | 11/01/2002 | 10008334 | Engine-light tick or rattle type noise from engine after cold start. *mj | 07/28/2004 | |
| 16343 | 11/01/2002 | 10008315 | Hard start, hesitation with malfunction indicator lamp (mil) light on diagnostic trouble code (dtc) p0340/p0344 - contact request. *tt | 07/27/2004 | |
| 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 |
| 04115 | 06/14/2004 | 04186 | 10008255 | No start or constant engine misfire - fuel injection control module (ficm) diagnosis - 6.0l diesel. *tt | 07/23/2004 |
| 17869 | 06/01/2004 | 10008263 | Air induction system appears to be warped and/or not sealing. *tt | 07/23/2004 | |
| 17683 | 04/01/2004 | 10008208 | Engine oil leaks at lower crankcase. *tt | 07/23/2004 | |
| 17554 | 02/01/2004 | 10008119 | Oil/dust film at cac connections. *mj | 07/22/2004 | |
| 17667 | 03/01/2004 | 10007424 | Oil leak from front or rear of engine. *tt | 06/22/2004 | |
| 17530 | 01/01/2004 | 10007355 | Moan/drone noise and tactile vibration between 1500-2000 rpm. *tt | 06/14/2004 | |
| 17460 | 01/01/2004 | 10007317 | Oil leak that seems to be coming from head gasket area. including ford f450/550 my2003. *tt | 06/10/2004 | |
| 17266 | 10/01/2003 | 10004917 | Low base engine oil pressure caused by high pressure oil system leak. *tt | 01/20/2004 | |
| 17252 | 10/01/2003 | 10004906 | Oil leak at, or near, the rear main seal. this includes 2003-2004 super duty f-series. *tt | 01/14/2004 | |
| 032012 | 10/13/2003 | 10004895 | Rough/rolling idle when the engine is warm and/or white smoke after hot restart; lacks power after initial start-up; cold idle kicker performance at warm ambient temps; u0306 codes after reprogramming; p2263 code set during extended idle; f | 01/14/2004 | |
| 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 | |
| 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 |
| 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 |
| 032150 | 03/08/2004 | 0444 | 10004861 | High pressure oil pump leak on vehicles equipped with 7.3l diesel engine. *tt | 01/12/2004 |
| 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 |
| 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 | |
| 17091 | 08/01/2003 | 10003183 | No crank after powertrain control module (pcm) programming. *tt | 10/09/2003 | |
| 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 | |
| 16821 | 05/01/2003 | 10002756 | Air induction systems housing may appear to be warped and/or not sealing. *tt | 09/16/2003 | |
| 16774 | 04/01/2003 | 10002659 | Low power condition. variable geometry turbocharger - service solenoid. *tt | 09/10/2003 | |
| 030708 | 04/01/2003 | 10002679 | Diluted oil, runs rough and/or low power. *tt | 09/10/2003 | |
| 16884 | 06/01/2003 | 10002601 | Moan/drone noise and tactile vibration between 1500-2000 rpm due to turbocharger mounting components resonating at the engine firing frequency. *tt | 09/08/2003 | |
| 16874 | 06/01/2003 | 10002594 | Rough/rolling (surging) engine speed, at idle only, when the engine is at normal operating temperatures. the surging may often occur following a restart after a hot soak. this condition may clear up with a throttle tip in. engineering is | 09/08/2003 | |
| 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 | |
| 16609 | 02/01/2003 | 10002494 | Low power condition and/or diagnostic trouble code (dtc) p2263 (turbo/super charger system performance). engineering is investigating. *tt | 09/03/2003 | |
| 16607 | 02/01/2003 | 10002492 | Rough idle, rolling idle, poor idle return, lacks power, injector fault codes, or increased exhaust smoke. *tt | 09/03/2003 | |
| 03B06 | 04/01/2003 | 10002181 | Cold operation calibration product enhancement for reduced cold weather engine performance and rough idle due to powertrain calibration concerns. customer satisfaction program. *tt | 08/14/2003 | |
| 16697 | 03/01/2003 | 10001943 | Exhaust air rush noise and lower power. *tt *jb | 07/28/2003 | |
| 16670 | 03/01/2003 | 10001931 | Rough rolling idle, poor idle return, low power, injector fault codes, or increased smoke caused by possible bad icp sensor. *tt *jb | 07/28/2003 | |
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||||
| TSB-08-26-3 | 06/01/2009 | 10028826 | Ford: 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. *pe | 06/01/2009 | |
| TSB-08-20-1 | 03/20/2009 | 10028284 | Ford trucks: misfire, lack of power, buck/jerk, excessive smoke, crank/no start-diagnostics for fuel system. there are several potential causes for these symptoms. *pe | 03/20/2009 | |
| TSB-08-23-8 | 03/04/2009 | 10028125 | Ford: vehicles may exhibit fuel in the engine coolant, due to leaks in the cylinder head fuel injector area. symptoms may include fuel in engine coolant and coolant expulsion from the degas bottle. *pe updated 3/20/09. | 03/04/2009 | |
| 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 |
| 05135 | 01/01/2005 | 10016846 | Oil leak or boost pressure leak at hot side charge air cooler (cac) duct-6.0l diesel engine. *sc | 10/12/2005 | |
| 05139 | 01/01/2005 | 10016842 | Diesel exhaust smell in cab-6.0l engine. *sc | 10/12/2005 | |
| 17472 | 01/01/2004 | 10007321 | Low power condition and/or diagnostic trouble code (dtc) p2263. 6.0l diesel engine. also includes my2003 ford f450/550. *tt | 06/10/2004 | |
| 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 | |
| 16506 | 01/01/2003 | 10005086 | Vehicles with a 6.0l diesel engine - possible oil overfill after delivery. this includes 2003 super duty f-series. 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 |
| 03146 | 05/17/2004 | 0493 | 10003746 | Engine oil diluted with fuel, runs rough and/or a low power condition. *tt | 10/29/2003 |
| 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 | |
| 16910 | 06/01/2003 | 10002621 | 6.0l diesel engine may exhibit a passive anti-theft system (pats) no crank after powertrain control module (pcm) reprogramming. *tt | 09/08/2003 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||||
| TSB-08-20-1 | 03/20/2009 | 10028284 | Ford trucks: misfire, lack of power, buck/jerk, excessive smoke, crank/no start-diagnostics for fuel system. there are several potential causes for these symptoms. *pe | 03/20/2009 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS | |||||
| 17716 | 04/01/2004 | 10008221 | Belt noise. *tt | 07/23/2004 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER | |||||
| TSB-08-16-13 | 05/01/2009 | 10028730 | Ford: some vehicles equipped with 6.0l diesel engine may exhibit any one or combination of the following concerns-lack of power, white/black smoke or a surge. *pe | 05/20/2009 | |
| 19245 | 06/01/2006 | 10020150 | Repeat turbocharger or vgt replacement. *tt | 07/28/2006 | |
| 18694 | 06/01/2005 | 10017873 | Lack of power and/or dtc p2263 or p0299 after turbocharger replacement - service tip. *tt | 12/06/2005 | |
| 18069 | 08/01/2004 | 10011181 | Low power and/or diagnostic trouble code p0299 or p2263 - turbocharger diagnostic service tip. *tt | 01/07/2005 | |
| 17885 | 06/01/2004 | 10008269 | Lack of power and/or diagnostic trouble code (dtc) p2263 after turbocharger replacement. *tt | 07/23/2004 | |
| 17566 | 02/01/2004 | 10008129 | Turbo moan/drone noise and tactile vibration between 1500-2000 rpm. *tt | 07/22/2004 | |
| 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 - ENGINE - OTHER FUEL TYPES - TURBO-CHARGER | |||||
| TSB-08-16-13 | 05/01/2009 | 10028730 | Ford: some vehicles equipped with 6.0l diesel engine may exhibit any one or combination of the following concerns-lack of power, white/black smoke or a surge. *pe | 05/20/2009 | |
| 08-2-11 | 03/01/2008 | 08-4-7 | 10024325 | 6.0l turbocharger carbon deposit diagnostics and service tips. *nj updated 5/29/08. *nj | 04/04/2008 |
| 06171 | 06183 | 10021232 | 6.0l turbocharger carbon deposit diagnostics and service tips - lack of power, white or black smoke, surge, p0238, p0299, p0404, p2262, and/or p2263. *kb | 03/23/2007 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||||
| TSB-09-15-6 | 12/09/2009 | 10030848 | Ford: some vehicles equipped with the 6.0l engine may experience a p006a, p132, p0401 or p0402 diagnostic trouble code (dtc) with a lack of power condition, surge, or turbocharger flutter after performing field service action (fsa) 06e17, | 12/09/2009 | |
| 0617 | 04/01/2006 | 10019945 | Voluntary emission recall 06e17 supplement #1: control module recalibration. corrosion may exist at the electrode surface on the exhaust pressure (ep) sensor; fuel delivery timing during cold weather may not be optimal; and/or exhaust gas | 05/17/2006 | |
| 17774 | 05/01/2004 | 10008551 | Exhaust leak noise. *tt | 08/04/2004 | |
| 0494 | 05/17/2004 | 10008549 | Turbo-induced exhaust moan/drone at 1600-1800 rpm on 6.0l built prior to 9/29/2003. *tt | 08/04/2004 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE) | |||||
| 07219 | 10/01/2007 | 10023855 | 6.0l--mil on--p0401, p0402, p0404, p1335--lack of power or surge with some 2003-2007 f-super duty, 2003-2005 excursion and 2004-2008 e-series vehicles. *nj | 02/06/2008 | |
| 05417 | 03/07/2005 | 10014666 | Intermittent rough idle - non-commanded egr (exhaust gas recirculation valve) flow. *tt | 05/05/2005 | |
| 17568 | 02/01/2004 | 10008131 | Normal egr (exhaust gas recirculation) operation - service tip. *tt | 07/22/2004 | |
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 | ||||||
| EA05003 | FORD MOTOR COMPANY | 02/15/2005 | 11/02/2005 | ENGINE STALLING | 05V270000 | |
| In a june 7, 2005 letter, ford notified odi that it would be conducting a safety recall of approximately 180,000 ford f-super duty, excursion and e-series vehicles equipped with 6.0l diesel engines to correct two wiring related conditions that could result in engine stall (nhtsa recall no. 05v-270, ford no. 05s34).the affected vehicles were built between september 29, 2003 and may 31, 2004.according to ford, vehicles with the conditions may stall without warning and may or may not restart.ford will instruct owners of vehicles included in the recall to take their vehicles to a dealer to have the fuel injector control module wire harness upgraded or replaced and or have a new injection control pressure sensor connector installed.during a may 2005 presentation to odi, ford identified a number of potential failure mechanisms that could affect engine performance in various segments of the subject vehicle population, including the wiring conditions addressed by 05v-270.the wiring conditions, which both affect engine fueling, were the most likely conditions to result in engine stall.the recalled vehicles comprise approximately 43% of the subject vehicle population and account for 75 of the 113 odi reports that have a valid vin (66%).the voq complaint rate for the recall population is 45/100k while the rate for vehicles outside the recall population is 17/100k and their trend (by date of receipt) is declining.based on the analysis, odi believes ford | ||||||
| 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 - DIESEL | ||||||
| PE04070 | FORD MOTOR COMPANY | 10/07/2004 | 02/15/2005 | ENGINE STALLING | ||
| Twenty five of the odi failure reports are duplicative of ford complaints.twenty odi reports do not contain a vin (and may or may not be duplicative of ford reports).the 14 alleged crashes and 2 alleged injuries were all minor.submitted during preliminary evaluation (pe) 04-070, ford's response to odi's information request (ir) letter contained about 5,000 consumer reports (mors) and 8,700 field reports (cqis).ford reviewed the complaints and categorized them.the manufacturer reports shown above represent a count of unique vehicles that ford categorized as allegedly stalling due to a subject engine component ('a' category, see ford's ir response letter for further detail); some of these vehicles received multiple reports.odi has not yet confirmed ford's categorization of these reports, nor has odi confirmed ford's categorization of the remaining reports (which ford states do not pertain to the alleged defect).ford submitted nearly 19,000 warranty claims, many of which involved claims for a technical service bulletin (tsb 04-13-08) and field service action (fsa 03b05) which ford identified as potential remedies for stalling complaints.odi has not confirmed that either of these are a remedy for engine stalling complaints.several other dealer communications related to engine stall were also submitted as well as over 50 product modifications, 15 of which involve revisions to the software for the electronic engine control unit.further investigation is required and odi is upgrading pe04-070 to an engineering analysis (ea).during the ea, odi will establish and update manufacturer failure report counts, further investigate the frequency and trend of stalling complaints, and determine the scope and safety implication of stalling events.odi will also investigate ford's remedies, their effectiveness, and whether further action is required. | ||||||
| EA05003 | FORD MOTOR COMPANY | 02/15/2005 | 11/02/2005 | ENGINE STALLING | 05V270000 | |
| In a june 7, 2005 letter, ford notified odi that it would be conducting a safety recall of approximately 180,000 ford f-super duty, excursion and e-series vehicles equipped with 6.0l diesel engines to correct two wiring related conditions that could result in engine stall (nhtsa recall no. 05v-270, ford no. 05s34).the affected vehicles were built between september 29, 2003 and may 31, 2004.according to ford, vehicles with the conditions may stall without warning and may or may not restart.ford will instruct owners of vehicles included in the recall to take their vehicles to a dealer to have the fuel injector control module wire harness upgraded or replaced and or have a new injection control pressure sensor connector installed.during a may 2005 presentation to odi, ford identified a number of potential failure mechanisms that could affect engine performance in various segments of the subject vehicle population, including the wiring conditions addressed by 05v-270.the wiring conditions, which both affect engine fueling, were the most likely conditions to result in engine stall.the recalled vehicles comprise approximately 43% of the subject vehicle population and account for 75 of the 113 odi reports that have a valid vin (66%).the voq complaint rate for the recall population is 45/100k while the rate for vehicles outside the recall population is 17/100k and their trend (by date of receipt) is declining.based on the analysis, odi believes ford | ||||||
| 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 | |||
| 02/24/2010 | 6000 | 10 | |
| 2003 ford excursion will sporadically not start. when this happens, it will crank but will not fire. it will not start with a jump start. typically, after several tries the battery will drain. at that point it will start with a jump start. it also usually starts after it sits for at least 1 day. this sporadic incident has been occurring over 6 months. i've had it checked 4 times by a trusted and capable auto service center. they have run comprehensive diagnostics, reviewed every possible source of the problems, have researched every possible issue and have found nothing. otherwise the vehicle runs well - when it starts. the latest incident was today feb. 24, 2010. this has occurred at least 10 times in 6 months. *tr | |||
| 02/25/2009 | 146000 | 1 | |
| Spark plug blown out of 8th cylinder of v10 ford triton. *tr | |||
| 03/22/2008 | 77965 | 5 | 10/01/2002 |
| Over the last 1 1/2 year, veh dies and wont restart or slower to start eventually will not start. all gauges go full tilt, abs light comes on, loss of all electrical systems, will not restart, just clicks, then nothing. have to disconnect and fully recharge batteries to restart,,,, then,,,, problem recurs in few weeks. new batteries 11/07, cam shaft sensor replaced 3/07. code p0603. *tr | |||
| 01/27/2008 | 106000 | 1 | 11/14/2003 |
| Spark plug blow out on 2003 ford excursion limited v-10 gas engine. this was spark plug on driver's side, rear of engine, closest to dashboard. pulled head and found three of the remaining four threads to be worn. considered same issue could be present on other side of engine, so replaced engine. engine had approx. 106k miles. was driving about 25 mph when problem occurred. *tr | |||
| 03/11/2007 | 78000 | 1 | 11/01/2004 |
| Crank position failure , pn f7tz12k073a, at 80,000 miles on the 2003 ford excursion 7.3 ltr diesel. back up sensors failed intermittantly. *ak | |||
| 06/25/2006 | 40000 | 6 | 12/26/2002 |
| Dt*: the contact stated while driving 60 mph on normal road conditions, the check engine light illuminated intermittently and then remained illuminated. the illuminated light indicated the cam shaft was off center which created undesirable emissions. the epa was contacted who declared it should be under warranty for 5 years or 50,000 miles however the manufacturer refused repair the defect without a cost.*ak | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 02/25/2009 | 146000 | 1 | |
| Spark plug blown out of 8th cylinder of v10 ford triton. *tr | |||
| 05/13/2008 | 110000 | 1 | |
| While driving about 25 mph, the engine stalled and i lost steering control. luckily no other cars were approaching because i was making a left turn on to a busy street. very dangerous. the stall has also occurred at least 5 other times, usually when decelerating when coming to a stop light. today, the abs light came on, then i heard a click and all the gauges lost power, the radio display went out. i could not restart the vehicle - only heard a click sound. after waiting an hour, the vehicle started. batteries have already been replaced by dealership a couple months ago. it was in the shop because under aggressive acceleration, the glow plug light would come on and there was no power. sensor replaced along with batteries. problem occurred again when driving it home from the shop. talked to ford and they do not seem concerned about potentially dangerous problems that dealership can not fix. *tr | |||
| 08/21/2003 | 140 | 08/21/2003 | |
| Dealership has refused to repair ( warranty ) my 4 month old 2003 ford excursion. the door locks do not work, the roof leaks, the hood is crooked. the cruise control sticks and the truck accelerates but when the off button is pushed the engine dies. the paint has 100,000 rust particles in the finish, the primer is showing through the white paint in places on the truck, strange noise when the truck is first started. *nlm | |||
| 04/01/2003 | 12000 | 4 | 11/14/2002 |
| Without warning the vehicle stalled. dealer had attempted to repair the vehicle three times, but was unable to determine the cause of the problem. dealer was processing this vehicle under the lemon law. *ak ford removed the entire motor they had the vehicle for 1 week for the second time. their solution was that the problem was the front tires. (the consumer disagreed and stated vehicle did not stall because of bad tires. *scc *jb | |||
| 01/15/2003 | 3753 | 4 | 12/21/2002 |
| Consumer states that while driving and with no warning, the vehicle stalled , which made the vehicle difficult to control. dealer notified.*ak vehicle completely shut down which caused poor steering. consumer avoided several collisions. the vehicle had been in the shop numerous times and no one was able to repair it. *ph *jb | |||
| 03/12/2003 | 13000 | 25 | 12/18/2002 |
| 2003 ford excursion 6.0 triton diesel engine stalls (both high and low speeds), brakes and steering lock up.*ak | |||
| 01/27/2003 | |||
| The engine shut down causing lost of power steering. please provide any additional information. ph | |||
| While driving at highway speed the engine shut down causing lost of power steering and power brakes. please provide any additional information. ts | |||
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||
| 12/25/2009 | 78000 | 1 | |
| Tl*the contact owns a 2003 ford excursion. the contact was driving approximately 65 mph on a wet road and suddenly, excessive white smoke expelled from the rear tail pipe exhaust system. the driver pulled over to the side of the road and the engine stalled without warning. the vehicle restarted and resumed normal operation. the engine stalled again and the vehicle was towed to an authorized dealer. the technician stated that the failure was contributed to a broken fuel injector which also resulted in damages to the engine. the estimated repair cost was $12,000. the vehicle has not been repaired for the malfunction at this time. the failure and current mileages were 78,000. updated 02/01/10 *bf the consumer stated that the vehicle ran rough and it lacked power. the dealer found the #1 cylinder had a broken piston. the consumer stated the check engine light never illuminated to warn him there was problem. updated 02/02/10.*jb | |||
| 12/05/2008 | 67000 | 1 | |
| 2003 ford excursion limited with 6.0l diesel engine. only two weeks ago, my truck began to surge in acceleration at both idle and while cruising. it has also begun to stall out at both idle and while cruising. also the vehicle has begun to have a strong smell of diesel fuel which enters the passenger cabin at start up. my service engine light has begun to light up and i checked the light with a digital diagnostic code reader. the code was p2285 (injector control pressure sensor circuit low). the situation is quite dangerous. my wife had complained that the vehicle surged ahead and she almost hit the car in front of her while stopped at a red light. when i drove the vehicle, it also began to buck and surge in both forward and reverse. while backing out of my driveway, the vehicle accelerated rearward and only by my having my foot near the brake pedal, stopped it from racing rearward. the vehicle has also cut off while at idle and while driving now. again, a very dangerous condition. i have seen on the ford truck enthusiast websites that i am not alone. there have been many complaints of this condition and faulty injector control pressure sensors especially in the '03 models but even later models. i am just out of warranty by a week, and ford said they could do nothing for me. i have seen what the dealers have quoted others to fix the problem up to $2000.00 for wide ranging solutions (replacing turbos, replacing all injectors, etc.) i use this truck to transport my disabled child and definitely cannot afford the dealer to rip me off for $2000. it is a $140 part and should take no longer than an hour of a technician's time to replace the sensor and pigtail harness. clearly, ford knows that they have a problem as they had a cust. service program 03b05 and 03b06 regarding this issue for 47,000 other '03 trucks with the 6.0l engine. they said my vehicle's vin did not fall into those 47,000. obviously it affects many more trucks than the 47,000. *tr | |||
| 03/15/2004 | 700 | 5 | 12/25/2003 |
| I purchased a new ford excursion in late december of 03. it leaked oil from the engine block due to defects in its manufacture. the engine was replaced after much conflict by the dealer with a used remanufactured engine under warranty after only 11,700 miles. the used engine leaked from the rear of the block in the same way as the original engine. ford refused to replace the engine with a new motor. the used engine suffered from erratic idle, leakage etc. it seemed destined to fail as the original engine did. i lost over $20,000 after accepting an arbitration decision. the vehicle did not make it to 13,000 miles. unbelievably poor quality and no support. simply a rip off to consumers. the vehicle was towed to the dealer once, and was driven there 4 times, totaling over 100 miles and 72 days out of service. *nm | |||
| 06/23/2004 | 9404 | 3 | 08/01/2003 |
| Faulty fuel injectors in the 6.0 liter diesel engine resulting in excessive amounts of diesel fuel to enter the oil crankcase. oil level in crankcase is diluted with fuel to the extent of being measured on the dipstick by several inches and flash point of oil reduced to half of the flash point of the oil. *jb | |||
| 07/21/2003 | 3 | 06/24/2003 | |
| Ford excursion 6.0l powerstroke diesel.*mr the consumer has taken the vehicle to the dealership on three separate occasions because the engine failed to respond to the throttle while in drive, also a leak is coming from the rear main seal. to date ford motor company has failed to fix the problem. please respond promptly in resolving matters. the consumer wa stold the injection control pressure sensor needed to be repalced. there was a customer service program regarding the problem. *cb *jb | |||
| 12/26/2003 | 1049 | 1 | 12/05/2003 |
| My 2003 excursion had a major turbo failure while traveling on i-10 on 12-26-03. my family and myself were traveling to houston. the vehicle only had a total of 1,049 life to date miles. while on the interstate for about 30 to 45 minutes we hear a larger pop noise and a large drop in the engine power. i only had a flash of a dash light and it went right back off. i was trying to get off the interstate. was driving about 25 to 35 mph trying to get to the next exit. notice large volume of smoke coming from the rear of the vehicle. i pulled over asap after seeing this. the smoke came into the cab from the ventilation system (a/c). pulled my daughter from the vehicle, also had my wife get out of the vehicle. at this point released the hood lock, checking the heat on the hood first. raised the hood found fire coming from exhaust pipe from the turbo. just smother the fire out to ensure it would not spread. saw the oil around the exhaust system through out the system. the vehicle has a 6.0 diesel engine and is a 4x4 excursion. im filing this report for the safety of others not for myself. my concern is for other people who are not exposed to this type of condition which can happen with a diesel engine. im a vehicle superintendent of a large city transit system. and have seen fires from a turbo failures. 6.0 diesel is a international product, and the series 40 engines are prone for this type of failures. this may be the only failure that is reported for the 2003 6.0 diesel. but with only 1,049 miles this failure should have not occurred. their should be some way to ensure the check engine light should have came on and stayed on for this condition for a failed turbo. its at the dealer at this time getting repaired. best regards, bryan j. garner | |||
| 07/11/2003 | 483 | 6 | 07/11/2003 |
| Smell in passenger cab. high idle--8 mph. high road idle:40 mph. stalling, surging. air conditioning loses charge. *la | |||
| 09/15/2003 | 500 | 04/21/2003 | |
| When the engine is started, it frequently runs roughly for several seconds or more. it causes the vehicle to lurch when put in gear and has almost led to me striking vehicles parked in front and behind me when i have tried to pull out of parellel parking spaces. it has also caused me to strike my trailer as i attempt to hitch up to it and makes that process very challenging. this vehicle has done this since it was new and has been back to the dealer twice for repairs which have failed to correct the problem. | |||
| 09/01/2003 | 5 | ||
| Truck purchased march 31, 2003. 7 days later took truck in for transmission replacement. truck was in shop for 9 days. 7 days after truck was out of shop went into shop again for 23 days for defective paint job. took truck in again on august 21, 2003 for ac not working and clicking sound in transmission. still in shop. *ak | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| 04/07/2006 | 86000 | 1 | 03/05/2003 |
| I have a 2003 ford excursion with the triton v10 gas engine. i was driving on the highway and heard an exhaust sound. i drove directly to pasadena ford and as i drove in a salesman told me that it was the #3 cylinder and that the spark plug had blown out of the head. he stated that it was common and he saw it all the time. i proceeded to drop off the truck and my service tech called me back and indeed the spark plug had blown out and stripped the head. he told me the repairs would cost $4,000.00. i checked with the company that tows my trucks all the time and said that it was very common and he had towed 5 or 6 in the last month with the same problem. he recommended a service company to me that has done almost all of universal pictures and other studio trucks, he says about 30 of them. he told me that the threads for the spark plugs were one turn to short and caused the failure. i contacted another service company and they confirmed his explanation. when i contacted pasadena ford they told me i was wrong and when i picked up my truck my service tech was actually confrontational. i explained that i would not have the truck repaired there and i would not pay $4,000. he told me that was the only way to fix the problem. i took it to the other mechanic and he fixed the one cylinder for $300.00 and i have not had any problems and neither has any of his studio trucks. i called magic ford in valencia, ca and they confirmed the defect of the head being short one thread and when i called pasadena ford again and spoke with someone else they confirmed the same thing. i was told that ford knows of the problem and has recommended the repair but ford service departments do not offer or recommend the repair. two different ford dealers confirmed the defect with the threads but they do not agree that it is a item that should be recalled. *nm | |||
| ENGINE AND ENGINE COOLING - ENGINE - OTHER FUEL TYPES - TURBO-CHARGER | |||
| 05/02/2004 | 11000 | 8 | 04/20/2003 |
| When driving the vehicle stalls and also occasionally losses turbo power. has stalled at stop signs and when pulling into parking spaces. at this time you lose brakes and steering, very dangerous!! when loses turbo, it takes about a minute or two for it to kick back on. | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||
| 11/03/2004 | 17910 | 80 | 08/05/2004 |
| Our vehicle has been to three different ford dealers for the same repair. the vehicle develops a miss. it will show up while driving at about any speed under very light acceleration. the only thing consistent that was said by all the dealers is that many 6.0l engines had the same problem, that ford was developing a repair plan, that the engine was sooting up a sensor, and that they didn't know how to stop the problem. they said they could keep replacing the same sensor that would temporarily resolve and clear codes, problem would likely return. *jb | |||