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 |
| 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 |
| 041511 | 08/09/2004 | 10011156 | Misfire at idle with diagnostic trouble codes p0300-p0308, p0316. *tt | 01/04/2005 | |
| 03256 | 12/22/2003 | 10008278 | Engine-romeo built 4.6l 2v-tick noise from engine-engines built before 9/17/2003. *mj | 07/26/2004 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||||
| 17135 | 09/01/2003 | 10004051 | Moaning noise from the exhaust system, or vibration in the rear passenger floor pan, when driving 45-55 mph and 1200-1400 rpm all without flex coupling in the exhaust. *tt | 11/17/2003 | |
| 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 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||||
| 0554 | 03/21/2005 | 10014685 | Use of stainless steel exhaust studs in service for 5.4l 2v engine. *tt | 05/05/2005 | |
| 17320 | 11/01/2003 | 10008169 | Broken exhaust manifold studs. *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 | ||||||
| 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 | |||
| 02/13/2013 | 142000 | ||
| I was driving down the interstate when i heard a pop from the engine compartment & smelled gas fumes. a spark plug (passenger side, 3rd plug back) had ejected and ruined the coil. i took it to a local auto service center & they immediately knew what had happened as they have worked on several of the ford 4.6l v8's with the same condition. checked for recalls & found nothing. this could have set the engine compartment on fire. this is a problem that has to be fixed. | |||
| ENGINE AND ENGINE COOLING | |||
| 03/12/2012 | 74000 | ||
| Tl- the contact owns a 2004 ford expedition eddie bauer edition. the contact was driving 45 mph when the engine fail safe warning light illuminated and the vehicle stalled. the vehicle was towed to the dealer. the manufacturer was contacted. the vehicle was not repaired and the vin was unavailable. the failure and current mileages were 74,000. kmj | |||
| 04/22/2012 | 107000 | ||
| Tl- the contact owns a 2004 ford expedition. the contact stated that the number three spark plug blew out of the head gasket. the spark plug ripped the treads in the slot where the spark plug was located. the contact spoke with the dealer and was told that the failure was a common issue. the manufacturer was also contacted but stated that since the vehicle was no longer under warranty, the vehicle would not be repaired at their expense. the failure and the current mileages were 107,000. kmj | |||
| 04/22/2012 | 107000 | ||
| Tl- the contact owns a 2004 ford expedition. the contact stated the number 3 spark plug blew out of the head gasket. the spark plug ripped out the treads in the slot where the spark plug was located. the contact spoke with the dealer and was told this is a known problem, but the manufacturer states that since it is not under warranty, it will not be replaced. the failure mileage and current mileages were 107,000.rl | |||
| 04/14/2012 | 195000 | ||
| Tl- the contact owns a 2004 ford expedition. the contact was informed by a neighbor that her vehicle was on fire. the fire department was called to extinguish the fire. there were no injuries reported. the vehicle was not destroyed nor was it taken for inspection or repairs. the cause of the fire was unknown. the current and failure mileages were 195,000. kmj | |||
| 04/14/2012 | 195000 | ||
| Tl- the contact owns a 2004 ford expedition. while in her home the contact was informed by her neighbor that the vehicle was on fire. the fire department was called to exstinguish the fire. the vehicle has not been diagnosed and has not been repaired. the current and failure mileages were 195000. bml | |||
| 03/09/2012 | 172000 | ||
| While driving down the road, taking my son to school, i had a spark plug blow out. immediately had to stop the vehicle and my son wasn't able to attend school because i had no ride. i have been reading online and this is an ongoing problem with ford and am furious that nothing has been done to remedy this problem for ford owners. | |||
| 02/10/2012 | 26000 | ||
| Tl* the contact owns a 2004 ford expedition. after starting the vehicle, the contact noticed a knocking sound coming from the engine. moments later the contact noticed that the vehicle had began to vibrate abnormally. the vehicle was not diagnosed or repaired. the current and failure mileages were 26,000. | |||
| 02/10/2012 | 26000 | ||
| Tl- the contact owns a 2004 ford expedition. after starting the vehicle, the contact noticed a knocking sound coming from the engine. moments later the contact noticed that the vehicle had began to vibrate abnormally. the vehicle was not diagnosed or repaired. the current and failure mileages were 26,000. kmj | |||
| 02/10/2012 | 26000 | ||
| Tl- the contact owns a 2004 ford expedition. after starting the vehicle the contact noticed a knocking sound coming from the engine, moments later the contact noticed that the vehicle had began to vibrate abnormally. the vehicle has not been diagnosed and has not been repaired. the current and failure mileages are 26000. bml | |||
| 07/22/2011 | 110238 | ||
| Tl-the contact owns a 2004 ford expedition. the contact stated while the vehicle was parked, he smelled a burning odor and noticed smoke emitting from the hood area. upon inspecting underneath the hood, the contact observed an excessive amount of smoke which originated from the engine oil reservoir. there were no flames. the contact allowed the engine to cool for a period of four hours and resumed in operation. the vehicle was taken to an independent mechanic who stated the abs module would need to be replaced. the vehicle was not repaired; however the abs sensor was disconnected. the manufacturer was not made aware of the defect. the approximate failure mileage was 110,238. js | |||
| 05/04/2011 | 88800 | ||
| Spark plug ejected from engine | |||
| 01/25/2010 | 50000 | 1 | |
| A popping noise from the engine and the smell of gas while driving 25mph in town. i took it to the mechanic and he said it was a spark plug ejection from the engine & would cost $1200+ to repair. *tr | |||
| 10/10/2007 | 97000 | 1 | |
| Tl*the contact owns a 2004 ford expedition. the contact stated that there was inadequate sealant on the front windshield. in rainy conditions, water would leak into the vehicle. in addition, when the windshield wiper unit was activated, the windshield cleaner would also leak into the vehicle. the contact could hear a crackling sound coming from the dashboard. all the digital components on the instrument panel became inoperable due to the leak in the front windshield. the dealer stated that the windshield could be resealed at the cost of less than $100. if the windshield needed to be replaced, it would cost over $200. there were no recalls for the failure. on a separate occasion, the engine started on its own. the vin was unable to be accepted by the system. the current and failure mileages were less than 97,000. updated 04-20-09 *bf updated 04/24/09.*jb | |||
| 01/27/2005 | 65000 | 3 | 08/29/2004 |
| While driving at any speed steering vibrates violently. dealer states the steering rod malfunctioned. *ak all 4 wheels were balanced, however steering wheel is still vibrating and noisy. blue smoke from exhaust. no problem found. all windows slow to go down and squeaks. no problem found. abnormal starting. engine fan noisy. dealer found normal operation. clanking noise in steering column. lower steering shaft was replaced. *tt | |||
| 05/03/2004 | 13000 | 3 | |
| Intermittently when the vehicle was put into drive, it stalled. also, air bag warning and tire pressure lights came on. dealership provided no assistance.*ak | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 12/27/2010 | 2 | 02/01/2004 | |
| 2003 ford f250 and 2004 ford expedition. consumer states right rear spark plug blew out of the cylinder head. this happened on both vehicles *tgw the consumer was informed an adapter was made as a temporary fix. about 500 miles later, the same problem happened again. the consumer took the vehicle to a repair shop where the mechanic stated the heads or engine would need to be replaced at a cost of $3000-$4000. *jb | |||
| 06/06/2011 | 110000 | ||
| On two separate occaisions, while driving my 2004 ford expedition, a spark plug has been ejected from the engine. one time, at city speeds, a second time at 65 miles per hour. both times, there was an instant loss of power and the smell of gasoline filled the passenger compartment. after the original failure, i took it to an auto mechanic who replaced the spark plug and installed a replacement coil on plug assembly. i have not yet repaired the second incident as it occurred last night. it seems to me that this is a very dangerous condition that initially didnt seem that significant, but after the tow truck operator said, that he thought there was a recall, it prompted me to research further. his tow service operates in the harrisburg, pa area and he claimed that he sees this happen nearly 1-2x/week with ford 5.4l v8 engines. he said, that he's seen so many of them, that they've got to have a recall | |||
| 11/16/2010 | 109000 | ||
| Engine hood insulator material began to smolder and smoke. needed to remove before vehicle caught fire. burned two fingers. | |||
| 04/16/2010 | 138000 | ||
| Starting vehicle spark plug broke loose,damaging threads for spakr plug and breaking coil pack.this is the second time this has occured.first time the vehicle was at freeway speeds and blew the spark plug out into the engine compartment.the spark plugs had never been changed before the first incident.in order to fix the problem the spark plug hole will have be repaired before a new plug can be put in. | |||
| 10/19/2009 | 119680 | ||
| Tl* the contact owns a 2004 ford expedition. while parked three sparks plugs/engine misfired. the failure caused $1700.00 worth of damage. the vehicle was towed to the ford dealer and all of the wires under the cylinder head were repaired. the failure mileage was 119,680. | |||
| 03/11/2006 | 38000 | 1 | 01/01/2004 |
| My vehicle's engine has failed. the dealer will not honor the warranty claiming i didn't change the oil, they have no record of me coming in for maintenance, i change my own oil and brought receipts in. this was not good enough. they have had my vehicle for 18 weeks with no rental. i have contacted the company the bbb a news channel in my area and i also work for ford which makes it even worse that they are denying my claim. *jb | |||
| 12/27/2004 | 4400 | 2 | 10/26/2004 |
| 2004 ford expedition. since i took delivery, the vehicle has a rough idle in any gear once the vehicle has been brought up to operating temperature (approximately 15 minutes). the truck has been returned to original dealership twice for this problem. the original solution was stated that due to the change in gas types from summer to winter the difference in oxygen in the fuel was causing the problem. i was told to drive it using a mid-grade gas for approximately 30 days and if the problem was still present return it to the dealer. the vehicle now has about 5,900 miles on it and the rough idle continues after it warms up. the vehicle is only getting about 10.6 mpg which is significantly less than mfg stated and less than the 1997 4.6l expedition i previously owned. i returned the vehicle to the dealer approximately 30 days from the original visit complaining of the same rough idle problem and reduced mileage. on the second visit the dealer said all electronic checks were in spec and there was nothing wrong with the vehicle. said they would have to turn it over to ford engineer. we are waiting to hear from ford. the car idles rough and the mileage is poor. still no resolution to original problem. *ak | |||
| 11/16/2004 | 52 | 1 | 04/14/2004 |
| 2004 ford expedition. since delivery day the truck has a rough idle in any gear once the temperature gauge reaches the mid point between c and h. the truck has been returned to three different dealershi[s for this problem. two have changed different coil packs and spark plugs. one of them changed oil saying it displayed too much oil. the third dealership, which the truck was taken to twice said this was a charateristic of the 2004 4.6 engine. the truck now has 6,000 miles ane the rough idle continues after it warms up. no of these dealers have checked for a bad cooling sensor, bad head gasket, clogged or defective radiator or constricted cooling system.*ak | |||
| 11/01/2003 | 2 | ||
| Gas mileage 6 mpg city and 11 mpg highway. power windows make a loud scratching sound when operated.*ak | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| 03/15/2006 | 38000 | 1 | 01/02/2004 |
| My 2004 ford expedition's motor possibly needs to be replaced. i have only 38,000 miles on it. i was blamed saying i didn't change the oil saying they didn't have me on record coming to dealer to have it done. i changed my own oil and could only furnish a few receipts. the dealer and the inspector blamed each other for the denial saying there was sludge in the oil pan which was the cause. they have had my suv for 17 weeks given me no rental and it was taken apart and is not drivable and they want to charge me for it. they also won't put it back together without charging me so i can take it somewhere else. i also am an employee of ford motor at the norfolk assembly plant where the f-150 is built and was told it didn't matter that i worked for ford. *jb | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||
| 05/10/2004 | 1 | ||
| Consumer will describe the problem related with the exhaust intake manifold. dealer and manufacturer has been notified. *jb the leaf and twig litter would collect on the skid plate when driven off of the road. this was in close proximity to hot pipes which caused smoldering and a fire hazard. *sc *jb | |||