Bulletins

BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING
036103/31/200310001855Malfunction indicator lamp on with or without rough running, lack of power, surge or poor fuel economy with diagnostic trouble codes p0401, p0402, p1400, p1401. *tt *jb07/23/2003
ENGINE AND ENGINE COOLING - COOLING SYSTEM - HOSE
1719809/01/200310004069Wear-through condition on the abrasion sleeve of the upper radiator hose near the air conditioning accumulator or transmission fluid dipstick. *tt11/17/2003
ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY
1583504/01/2002637584Running change for the upper radiator sight shield. *tt12/03/2002
ENGINE AND ENGINE COOLING - ENGINE
02080108/09/20040415410011150Rattle noise from primary chain drive area 2000-3000 rpm - 4.0l sohc engine. *tt01/04/2005
1737611/01/200310008189Lacks power/runs rough/black smoke condition. *tt07/22/2004
1737911/01/200310008191Rough idle, hesitation on cold engine tip-in and/or hesitation during a 5-3 downshift. *tt07/22/2004
1737811/01/200310008190Intermittent engine driveability issues. vehcles with automatic transmission built between 03/04/2002 and 12/01/2002. *tt07/22/2004
1754402/01/200410008115Generator noise in cold ambient temperatures. *mj07/22/2004
1716709/01/200310004060Multiple vehicles with 3.0l or 4.0l engines lacks power/runs rough/black smoke. 2004 sport trac included. *tt11/17/2003
1705508/01/200310003165Lacks power / black smoke / runs rough, usually with no malfunction indicator lamp on or diagnostic trouble codes. *tt10/09/2003
1681004/01/200310002675Rough idle and/or check engine lamp due to closure hose which becomes loose or disconnected at the right hand cam cover. *tt09/10/2003
033502/17/200310002482Idle air control (iac) valve diagnostic service tips. *tt09/03/2003
032202/03/200310002472Streamlined diagnostic procedure for vehicles with malfunction indicator lamp (mil) on and diagnostic trouble codes (dtcs) p0401, p0402, p1400 or p1401, or runs rough, lacks power, surge, poor fuel economy, and the above listed dtcs without09/03/2003
1661002/01/200310002495No start, no communication with power train control module (pcm) using wds/ngs or a miss/buck/jerk while driving. *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
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
1593605/01/2002637843Some vehicles equpped with 4.0l engine and automatic transmission may exhibit a rough idle, low speed engine quit, hesitation on cold engine tip-in and / or hesitation during a 5-3 donwshift. *tt12/06/2002
1589805/01/2002637781Some vehicles may exhibit a hard start / no start condition due to fuel pressure bleed down. *tt12/06/2002
1575403/01/2002636395Some vehicles equipped with 4.0l engine and manual transmission may exhibit an intermittent stumble during deceleration and / or at stops when the clutch pedal is depressed. *tt11/08/2002
1612408/01/2002636147Some vehicles built on or after 3/4/2002 may exhibit intermittent engine driveability issues. engineer is investigating. *tt11/06/2002
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
1564402/01/2002630693Some vehicles may exhbit a hard start/no start condition when trying to start the vehicle. *tt04/19/2002
0124612/10/2001630515Engine oil system priming procedures, service tips for reports of premature engine failure. *tt04/18/2002
1537811/01/2001630388Some vehicles with the 4.0l engine may exhibit an engine flutter noise. *tt04/16/2002
1535810/01/2001630276Concerns with engine quitting during deceleration. *tt04/16/2002
1538111/01/2001630391Some vehicles with a manual transmission may exhibit an engine loss or reduction in power condition on deceleration, but will immediately restart. *tt04/16/2002
1553101/01/2002630061Subject regarding engine quitting on deceleration/stopping.*yd04/12/2002
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
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
0221610/28/200210013064Excessive sulfur smell from exhaust. *eh04/07/2005
1565502/01/2002630714Concerns with excessive sulphur smell from the exhaust when operating under certain drive modes. *tt04/19/2002
1547112/01/2001630579Some 4.0l sohc engines may exhibit excessive sulphur smell from the exhaust system while operating under certain drive modes. *tt04/18/2002
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE)
02M0106/01/200402M0110007207Customer satisfaction program 02m01 supplement #4. certain ford 2000 through 2003 vehicles equipped with a tube-mounted egr pressure sensor - additional egr pressure sensor warranty coverage. *tt supplement #3. *mj supplement #606/03/2004

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
03/02/20091
 Check engine light accelerating when braking rotating tire axle idle issues. *tr
ENGINE AND ENGINE COOLING - COOLING SYSTEM - HOSE
08/16/2003110/11/2002
 I have been smelling anti-freeze. i just noticed that my radiator hose has been rubbing on the oil fill and made a nice big hole on that side as well as on the other side from another mechanism under the hood. nice assembly. i owned my truck for 8 months now.*ak
ENGINE AND ENGINE COOLING - ENGINE
08/25/200256001
 Intermittently the vehicle misfired, idled rough and then vibrated. *jb
06/15/200225001
 The engine stalled without warning.*jb
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
11/02/2002209/01/2002
 My father-in-law has the same problem. he bought his 5 days after me, his stalled 5 times to this date. remember the news, (fog and major pile up with numerous deaths) what was the reason ? i don't want this to be our accident waiting to happen. intermittent , couldn't reproduce the problem. not good enough to keep my family safe. please help. dt
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
12/22/20081
 Riding in a car in cold weather...all we can figure at this time is that there is some kind of exhaust leak..in the ford explorer....the passenger shared with the drive the symptoms of carbon monoxide poisoning...the driver larger in stature was getting drowsy and not thought much about since it was after midnight, but the other person ended up getting in another car traveling with them and ended up stopping three or more times due to the symptoms.... *tr

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