Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING - COOLING SYSTEM
1406204/01/2000613705Some vehicles may exhibit a cooling system leak due to a broken constant tension clamp. **mr07/27/2000
853404/01/2000613665Some vehicles may exhibit a cooling system leak due to a broken constant tension clamp. **mr07/26/2000
ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY
1461701/01/2001617995Subject pertaining to broken thermostat. *jb04/03/2001
1458301/01/2001617968Concerns with broken thermostats on engines. *jb04/02/2001
ENGINE AND ENGINE COOLING - ENGINE
02080108/09/20040415410011150Rattle noise from primary chain drive area 2000-3000 rpm - 4.0l sohc engine. *tt01/04/2005
0319909/29/200310004038Rattle/buzz sound from under the vehicle on 4.0l single overhead cam (sohc) engines. *tt11/14/2003
1695207/01/200310003839Postal fleet vehicles equipped with 4.0l fe engine may exhibit a low oil pressure gauge reading, check engine light on and sometimes upper or lower engine noise. *tt11/04/2003
033502/17/200310002482Idle air control (iac) valve diagnostic service tips. *tt09/03/2003
87019710/22/200210000592Incorrectly installed gear driven camshaft position (cmp) sensor synchronizer assemblies causing surge, lost of power, malfunction indicator lamp on and diagnostic trouble codes p1336, p1309 and p0340. *tt03/25/2003
1529010/01/2001630190Some 4.0l sohc may exhibit an engine oil leak condition, coming from the oil pan or ladder frame area. *tt04/15/2002
00M1211/01/2000616507Ford motor company is providing additional coverage for the 4.0l sohc camshaft chain tensioner and lower intake manifold gasket. *tt03/01/2001
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
028104/29/2002637920Some vehicles equipped with the 4.0 sohc (single over-head cam) engine may exhibit a primary timing chain rattle noise. *tt12/09/2002
027604/15/2002636013Information on diagnosing engine rattle noise from primary chain drive area between 2000-3000 rpm on cold engine operation only. *tt11/04/2002
0124612/10/2001630515Engine oil system priming procedures, service tips for reports of premature engine failure. *tt04/18/2002
1549612/01/2001630605Some vehicles built before april 23, 2001 may exhibit a hard start/long crank after sitting for an hour or more due to fuel system contamination. *tt04/18/2002
1547012/01/2001630576Concerns with spark knock noise or chain rattle noise between 2000-3000 rpm, during cold engine operation only. *tt04/18/2002
1542211/01/2001630442Some vehicles may exhibit a hard start/long crank condition after sitting for an hour or more. *tt04/17/2002
1556701/01/2002630105Some vehicles built before april 23, 2001 may exhibit a hard start/long crank after sitting for an hour or more. *tt04/12/2002
021401/21/2002630001Some engine assemblies with aluminum cylinder heads repaired in-vehile have been found to leak coolant and/or oil from the cylinder head gasket area. *tt04/11/2002
0120510/15/2001627927Some vehicles may exhibit vacuum or air leaks in the intake manifold and / or engine system causing diagnostic trouble codes p0171 and or p0174. *tt02/26/2002
1482304/01/2001619317Some vehicles equipped with the 4.0 sohc engine may exhibit a primary chain rattle noise between 2000 - 3000 rpm (sometimes described as a spark knock-type noise). *tt05/23/2001
1486804/01/2001619337Some vehicles equipped with the 4.0 sohc engine may exhibit a primary chain rattle noise (sometimes described as a spark knock-type noise). *tt05/23/2001
1455501/01/2001617932Concerns with engine ticking sound/noise. *jb04/02/2001
1458401/01/2001617878Subject regarding flex fuel vechicle oil and fuel recommendations. *jb04/02/2001
1409004/01/2000613716Some vehicles may exhibit a hard start / no start condition when attempting to start the vehicle. *tt08/07/2000
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
0221610/28/200210013064Excessive sulfur smell from exhaust. *eh04/07/2005
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR
CSP-08B0105/16/200810026389Ford: certain 1999-2001 model year vehicles up to 6000 lb gvwr registered in new york and certain 2001 vehicles up to 6000 lb gvwr registered in the state of maine, certified for sale in california-federal emission warranty refund. *pe10/23/2008

Investigations


NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
ENGINE AND ENGINE COOLING
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK PLUG EJECTION FROM CYLINDER HEAD
 On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi
ENGINE AND ENGINE COOLING - ENGINE
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK PLUG EJECTION FROM CYLINDER HEAD
 On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK PLUG EJECTION FROM CYLINDER HEAD
 On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi

Consumer Complaints


Fail datemilesoccurencesPurchase date
ENGINE AND ENGINE COOLING
08/05/20125
 Cpsc#i12a0111a. 2001 ford explorer. consumer stated that a day after she brought the car it broke down. *ln the consumer stated there was a problem with the engine, as well as a hole in gas tank, which had rusted out, the bearings needed to be replaced, the tire were dry rotted, as they kept going flat, the driver's door did not lock, the rear doors did not open from the inside, the rear driver's door did not open at all, the outside handle was broke, the rear hatch would not close, and most of the time it had to be slammed shut.
08/13/2011150000
 Tl- the contact owns a 2001 ford explorer. while the vehicle was stopped, the contact noticed smoke coming from under the vehicle. the vehicle was destroyed as a result of the fire. there was not a police or fire report filed. the dealer was not notified of the failure since the vehicle was purchased from a private seller. the manufacturer was made aware of the failure however, did not offer any assistance. the current and failure mileages were 150,000. the vin was unavailable. kmj
02/20/20101040001
 As with so many explorers i have read about, my o/d light comes on and flashes. i lose all power during initial acceleration and then the truck shoots off like a rocket. if i turn the ignition off, the light resets and the vehicle is ok for a while until the light comes on again. i had the codes read and it came up a solenoid problem. i had them replaced and ten miles from the lot, the light came on again. i have read that this is a known issue from ford, but they have yet to act on this issue. *tr
03/10/20091465441
 2001 ford explorer timing chain rattle and failure. on 4.0l sohc. there are many people with this problem on forums. ford needs to have a recall of this potentially dangerous motor issue or reimburse people that need to have this repaired. *tr
06/10/20081100001
 Wife parked explorer in garage, 20 min later heard a loud noise then noticed the vehicle was engulfed in flames. luckily, we were able to save our home and everyone is alright. car is completely totaled and our garage is a disaster. *tr
12/28/20036500012/20/2002
 Vehicle began stalling when it was around 30 degrees or lower in the winter and would have to restart the vehicle 3 or 4 times to get it to stay started, now vehicle does this every morning and even when its warm out. took vehicle to dealer, dealer put seal on intake platton. vehicle does it every time you start it now.
11/01/20045
 Driver seat recliner bolt, the seat back/recline/forward broke, replaced several times. *bf the oil filter had come with a hole too large, the driver's side seat handle broke, the tires blewout and caused an accident that totaled the vehicle. *sc
11/21/20022
 There were repeated problems with the idle air control motor on 2001 ford explorer. *mr upon starting the vehicle, the engine immediately stalled. *sc
10/15/200376500
 I purchased this car on october 8,2003. three days after i bought it the check engine light came on. i brought the car back four times back to back. the first time they said nothing was wrong. the second and third time the same thing. on the fourth attempt, they had me take it to one of "their" mechanics. he said it was a bad switch in the system. not even a whole week later, the check guage light came on. the car lot where i bought it from said they were not going to look at my car because out of the kindness of their heart they've already looked at it. so i took it to a ford dealership, they fixed it and said it was a problem with transmission, and the steering wheel. they car lot said it was not their problem. i had to pay out of my pocket for some problems that are still under warranty. then the first time the check engine light came on i later found out that a sales person who was not certified mechanic, tried to fix the car when they said they were sending it to a mechanic. i'm still having problems and it seems like there just getting worse!
06/20/20031
 While driving the engine light was flashing , suddenly the vehicle lost power. dealer stated, spring broke over the third valve. consumer indicated that the vehicle was not any longer under warranty so she had to pay. *ak
01/22/2003290004
 While driving and without warning timing chain was making a lot of noise. dealer was notified and repaired the problem. vehicle still experienced problems. *ak
03/05/2002108/26/2000
 Temperature indicator light flashed, afterwards engine stalled. dealer has replaced thermostat.*akthe service engine light illuminated, vehicle started to smoke while in motion at a speed of 65 mph. vehicle was taken to dealer where he was informed he had a blown head gasket. consumers insurance company did a test where it was determined out that a faulty thermostat was the cause. *jg
ENGINE AND ENGINE COOLING - COOLING SYSTEM
06/17/2005110/27/2001
 Defective intake manifold on 2001 ford explorer xlt. *nm
ENGINE AND ENGINE COOLING - COOLING SYSTEM - HOSE
08/24/2001112/01/2000
 The heater/coolant hose in the left side engine compartment is rubbing against the dipstick, wearing through the hose and potentially spraying very hot coolant under the hood.*ak
ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY
03/05/2002108/26/2000
 Temperature indicator light flashed, afterwards engine stalled. dealer has replaced thermostat.*akthe service engine light illuminated, vehicle started to smoke while in motion at a speed of 65 mph. vehicle was taken to dealer where he was informed he had a blown head gasket. consumers insurance company did a test where it was determined out that a faulty thermostat was the cause. *jg
03/11/2002105/01/2001
 Mfg installation or design defect--- upper radiator hose lays on the upper part of engine. it lays against the heater core inlet hose. the heater core inlet hose has a clamp that cuts into the upper radiator hose., normal engine vibrations are enough to cut through the hose. note: the hose has a nylon netting which is abraided. this results in a loss of engine coolant. the offending clamp is of poor design and placement. it is made from stamped sheet metal and has obvious sharp edges, hence cutting into the radiator hose. this could have been avoided at design with a different hose clamp or at assembly by turning the offending clamp aprox 90 degrees.*ak
ENGINE AND ENGINE COOLING - ENGINE
01/09/2009135000
 Tl*the contact owns a 2001 ford explorer. the contact heard rattling noises in the engine and the vehicle shut off. the vehicle was taken to a body shop and the mechanic stated that she needed a new transmission. the contact got a second opinion and was informed that a new engine was needed. a third repair shop stated that the timing chain and camshaft were the causes of the failure. the contact was informed that the parts were modified and were defective; therefore, entirely new parts were needed. the vehicle has not been repaired. the dealer diagnosed the issue as having engine failure. the failure and current mileages were 135,000.
11/01/200654184111/15/2002
 Tl*the contact owns a 2001 ford explorer. while driving 35 mph, the vehicle began to ride roughly and backfired when the contact attempted to accelerate. the contact attempted to replace the spark plugs, however, the hex nut snapped when it was removed. approximately one week later, the dealer inspected the vehicle and stated that the threaded part of the spark plug had failed inside the head. the dealer recommended that a machine shop remove the spark plug. as of july 3, 2007, the vehicle has not been repaired. the current and failure mileages were 54,184.
12/04/200562500108/15/2004
 After having my 2001 lmtd edition explorer parked for over 45 minutes, the vehicle caught on fire and was consumed. it was a total loss, melted down to the frame of the vehicle. the fire marshal was unable to determine the cause of the fire as the damage was so severe, but i was referred to several articles regarding similar ford explorer fires. *jb
10/27/200335502103/29/2002
 While driving at any speed, the vehicle lost total power. *ak when the new motor was placed in the vehicle, it would just die while in motion at any speed. it had taken the dealer three attempts when they told the consumer that there wasn't a running code, so it could not be fixed. *scc *jb
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
 Consumer notice when depressing the accelerator pedal to gain speed from a stop, vehicle stalls without any indication dealer has been contacted. please provide further information. mr
09/25/2001609/16/2001
 The vehicle stalled and was repaired six times by the dealer. the problem was getting worse and the consumer was concerned about safety and wants the manufacturer to replace or repurchase the vehicle. *yh
10/11/2001508/29/2001
 Vehicle hesitates upon acceleration and has also stalled on 5 occasions, the dealer has repaired/replaced various componets on the vehicle, however consumer still experiences the same problems.*jb
10/01/200109/01/2001
 Anytime you are stopped, (in drive, neutral or reverse), or stopped at a light, the engine skips. they call it a lean idol miss. a miss in any motor will eventually burn up the valves. it is not fixable. they will not even attempt to fix the problem. i have now taken the tags off and it sets in my driveway. i will not cause any further damage to this truck. i have talked with everyone, including the dealership, the ford feild service person, consumer affairs, ford customer service and also an executive from ford in michigan named mr. duncan. no one will budge. no one will help me and i don't have the money for an attorney. ford knows they have a flaw in the motor, but they excuse it by saying it doesn't hurt the motor. yes it does. mine is already blowing smoke. can someone please help us. the only other choice i have is to let the truck go back to the finance company. please help. this was my first brand new vehicle we paid 25,000.00 dollars for now it has turned into a nightmare.*ak
06/21/2001512/16/2000
 While driving engine check light will flash intermittently. dealer has been notified. *ak consumer states that when the light illuminates, the vehicle begins to drive sluggish, rough, and sometimes makes a screeching noise. dealer has replaced the pcm, vapor management valve, canister purge solenoid, tensioner assembly, vacuum hose twice, dpfe, and the fuel tank. *slc
5002/01/2001
 Pinging noise at 2500-3000 rpms when the engine is cold. the noise goes away when the engine warms up.*ak
5002/01/2001
 Pinging noise when the engine is cold. when the engine gets warmer the noise starts to go away. computer # jxv2. *ak
09/25/2001
 While driving vehicle hesitates and seems not to get gas. then, completely shutsdown. cause unknown. dealer cannot identify the problem. please give any further details.*ak
06/01/2001
 When air conditioning is on vehicle stalls without prior warning . dealership is aware of problem.*ak
05/04/2001204/01/2001
 This is not the only problem i have tried to return to be repaired on this vehicle. i have also been subjected to the most unethical behavior i've ever seen, from this dealership, in the purchase and repair procedures.no safety defect listed. *ak
03/26/2001101/01/2001
 Ihave lost controll of this vehicle several times due to the steering and overall handling ,my tires are also playing a roll in this i beleave this problem is much more pronounced in rain or snow . i feel this vehicle is very unsafe for myself and my children! i've already had the vehicle into auburn motor sales for 6 days for complaints of lack&surge of power,bad sulfer smell at idle rolling idle(up&down), extremely poor gas mileage. the dealership was unable to diognose problem. as of today i've lost 21 days of use ,on a vehicle i've only had about4 and a half months know they say i need an engine that i'm still waiting on. i told the dealership i didn't feel this vehicle was safe and wanted it replaced .i got know where, when they found out i got lemon law paperwork they told me ford would not do anything about it pursue it through the state. i don't see how they can tell you that you are stuck when you purchased a new vehicle and it has compromised your safety time&time again! my salesman told me to look at the bright side i was still here to talk about it!!! i don't find this very amusing ,i wonder if ford knows how he feels in my opinion he was telling me i could of been dead!!! brenda. *ak (tiresize: 255/70/16)( dot number: tire size: 255/70/16 )
01/15/2001201/01/2001
 World ford has done nothing but give me a run around and not fixing my truck right!!! i have nothing but agrevation with my truck and i dont feel that it's safe with driving my children in it! when advising the dealership of the trucks major complications they advise me to bring the vehicle back in 30-60 days to aviod the lemon law! no safety defect listed. *ak
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS
01/01/200786000101/24/2003
 I am experiencing the timing belt tensioner issue that resulted in the ford customer service satisfaction program #00m12. this extended the warranty to 6 years or 72,000 miles on that part. too late for me, as i began having trouble a few months a go. now, i am at 6 years/87,000 miles. my local ford dealer said they knew nothing and so i called ford directly. they told me to lodge a complaint with nhts. pretty bad situation for me and many others as i have been researching on the internet. *nm
05/09/2002
 While parking vehicle power steering failed. dealer determined that serpentine belt had broken.*ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
05/15/200214491
 I have several more invoices 7-29-03 replaced dust seals and forgot to put brakes back together lost whole front end and braking. had truck for 3-4 days they have replaced the water pump pulley and s belt 2-3 times. cruise control 10-16, 12/31/02 again squeling noise 02/28/03 defrost kills truck and chirping still. 2/10/03 steering wheel snaped part falls around inside,cruise control was fixed, bearing failure in belt tensioner again. today still having the same problem. come get the piece of !@!@#@#. i am sick of taking this truck in every month to fix something. it is a lemon
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR
4
 While driving 60mph vehicle vibrates. vehicle pulls to the right severly. steering wheel is crooked, pulls to the left. dealer contacted. *ak also, consumer states that there is very bad smell from catalytic converter which ford says it is normal. *yd
10/01/2001
 From the date of purchase there has been a smell, both inside and outside the vehicle. a burning smell, at times the smell of rotten eggs. this smell causes me to be nauseaous. the dealer checked this on the computer, stated everyhing is okay. the computer results verify that the exhaust system is functioning within ford standards. *ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
01/02/2002
 Engine manifold cracked and was leaking coolant from underneath vehicle.*ak