Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||||
| 0361 | 03/31/2003 | 10001855 | Malfunction 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 *jb | 07/23/2003 | |
| ENGINE AND ENGINE COOLING - COOLING SYSTEM - HOSE | |||||
| 17198 | 09/01/2003 | 10004069 | Wear-through condition on the abrasion sleeve of the upper radiator hose near the air conditioning accumulator or transmission fluid dipstick. *tt | 11/17/2003 | |
| ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY | |||||
| 15835 | 04/01/2002 | 637584 | Running change for the upper radiator sight shield. *tt | 12/03/2002 | |
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| 020801 | 08/09/2004 | 04154 | 10011150 | Rattle noise from primary chain drive area 2000-3000 rpm - 4.0l sohc engine. *tt | 01/04/2005 |
| 17544 | 02/01/2004 | 10008115 | Generator noise in cold ambient temperatures. *mj | 07/22/2004 | |
| 17379 | 11/01/2003 | 10008191 | Rough idle, hesitation on cold engine tip-in and/or hesitation during a 5-3 downshift. *tt | 07/22/2004 | |
| 17378 | 11/01/2003 | 10008190 | Intermittent engine driveability issues. vehcles with automatic transmission built between 03/04/2002 and 12/01/2002. *tt | 07/22/2004 | |
| 17376 | 11/01/2003 | 10008189 | Lacks power/runs rough/black smoke condition. *tt | 07/22/2004 | |
| 17167 | 09/01/2003 | 10004060 | Multiple vehicles with 3.0l or 4.0l engines lacks power/runs rough/black smoke. 2004 sport trac included. *tt | 11/17/2003 | |
| 17055 | 08/01/2003 | 10003165 | Lacks power / black smoke / runs rough, usually with no malfunction indicator lamp on or diagnostic trouble codes. *tt | 10/09/2003 | |
| 16810 | 04/01/2003 | 10002675 | Rough idle and/or check engine lamp due to closure hose which becomes loose or disconnected at the right hand cam cover. *tt | 09/10/2003 | |
| 0335 | 02/17/2003 | 10002482 | Idle air control (iac) valve diagnostic service tips. *tt | 09/03/2003 | |
| 0322 | 02/03/2003 | 10002472 | Streamlined 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 without | 09/03/2003 | |
| 16610 | 02/01/2003 | 10002495 | No start, no communication with power train control module (pcm) using wds/ngs or a miss/buck/jerk while driving. *tt | 09/03/2003 | |
| 870197 | 10/22/2002 | 10000592 | Incorrectly 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. *tt | 03/25/2003 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||||
| 0281 | 04/29/2002 | 637920 | Some vehicles equipped with the 4.0 sohc (single over-head cam) engine may exhibit a primary timing chain rattle noise. *tt | 12/09/2002 | |
| 15936 | 05/01/2002 | 637843 | Some 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. *tt | 12/06/2002 | |
| 15898 | 05/01/2002 | 637781 | Some vehicles may exhibit a hard start / no start condition due to fuel pressure bleed down. *tt | 12/06/2002 | |
| 15754 | 03/01/2002 | 636395 | Some 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. *tt | 11/08/2002 | |
| 16124 | 08/01/2002 | 636147 | Some vehicles built on or after 3/4/2002 may exhibit intermittent engine driveability issues. engineer is investigating. *tt | 11/06/2002 | |
| 0276 | 04/15/2002 | 636013 | Information on diagnosing engine rattle noise from primary chain drive area between 2000-3000 rpm on cold engine operation only. *tt | 11/04/2002 | |
| 15644 | 02/01/2002 | 630693 | Some vehicles may exhbit a hard start/no start condition when trying to start the vehicle. *tt | 04/19/2002 | |
| 01246 | 12/10/2001 | 630515 | Engine oil system priming procedures, service tips for reports of premature engine failure. *tt | 04/18/2002 | |
| 15378 | 11/01/2001 | 630388 | Some vehicles with the 4.0l engine may exhibit an engine flutter noise. *tt | 04/16/2002 | |
| 15358 | 10/01/2001 | 630276 | Concerns with engine quitting during deceleration. *tt | 04/16/2002 | |
| 15381 | 11/01/2001 | 630391 | Some vehicles with a manual transmission may exhibit an engine loss or reduction in power condition on deceleration, but will immediately restart. *tt | 04/16/2002 | |
| 15531 | 01/01/2002 | 630061 | Subject regarding engine quitting on deceleration/stopping.*yd | 04/12/2002 | |
| 01205 | 10/15/2001 | 627927 | Some vehicles may exhibit vacuum or air leaks in the intake manifold and / or engine system causing diagnostic trouble codes p0171 and or p0174. *tt | 02/26/2002 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||||
| 02216 | 10/28/2002 | 10013064 | Excessive sulfur smell from exhaust. *eh | 04/07/2005 | |
| 15655 | 02/01/2002 | 630714 | Concerns with excessive sulphur smell from the exhaust when operating under certain drive modes. *tt | 04/19/2002 | |
| 15471 | 12/01/2001 | 630579 | Some 4.0l sohc engines may exhibit excessive sulphur smell from the exhaust system while operating under certain drive modes. *tt | 04/18/2002 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL | |||||
| 0305 | 01/01/2004 | 10007144 | Emissions recall 03e05: evaporative emissions canister fresh air inlet hose connector replacement.*mr | 06/02/2004 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE) | |||||
| 02M01 | 06/01/2004 | 02M01 | 10007207 | Customer 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 #6 | 06/03/2004 |
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 AND ENGINE COOLING | |||
| 08/14/2012 | 91000 | 1 | |
| The body mounts on the vehicle are desintegrating. i touched it with my hand and it fell apart. body mounts should last much longer. *tr | |||
| 02/01/2011 | 161673 | ||
| Tl-the contact owns a 2002 ford explorer sport trac. the contact stated that the vehicle was taken to an automotive repair shop where a mechanic performed a diagnostic test and detected a malfunction in the emissions control system. the manufacturer had issued a voluntary recall for the emissions control system however, the contact | |||
| 02/01/2011 | 161673 | ||
| Tl-the contact owns a 2002 ford explorer sport trac. the contact stated the vehicle was taken to an auto shop where the mechanic performed a diagnostic test which detected a malfunction in the emissions control system.the contact experienced the same failure as mentioned in the recall defect. there was a voluntary recall issued by the manufacturer regarding the emissions control system; the vin was ineligible under the recall. the vehicle had not been repaired. the manufacturer was notified of the problem. the approximate failure mileage was 161,673. js | |||
| 06/03/2006 | 40000 | ||
| Tl*the contact owns a 2002 ford explorer sport trac. while driving 40 mph, the oxygen sensor caused the check engine light to illuminate and the cruise control failed at 40,000 miles. the dealer promised over the phone to repair both the recall and the engine light, but later denied service because the vehicle was 24,000 miles over the limit to repair the oxygen sensor. the technician disconnected the cruise control switch to prevent a fire from occurring until the parts for the recall were available. a year has passed and the dealer still does not have the parts for the repair. the recall number was unknown. the current mileage was 56,000 and failure mileage was 40,000. | |||
| 09/29/2004 | 33000 | 3 | |
| While driving vehicle stalled. the consumer pulled over and restarted the vehicle. dealership was notified, but did not resolve the problem. *ak | |||
| 09/01/2004 | 1 | 08/10/2002 | |
| Problems with vehicle engine stalling while driving. *mr this was an intermittent problem. there would be no warning. *sc *jb | |||
| 01/06/2003 | 500 | 15 | 12/23/2002 |
| I purchased a ford explorer sport trac in dec. 2002. i have been in and out of the service department a number of times. the following is a list of items that i've had repaired under warranty: 1.) front brakes: a loud rubbing/griding sound became increasingly louder. the first time the service dept. folks said that it was normal. the next time i brought the car in, they could deny the noise and they subsequently replace one rotor and resurfaced the other. 2.) rear axle: a broken seal allowed hydroulic fluid to cover inside of the rear wheel causing difficulty in braking. the service dept. repaired under warranty 3.) the transfer case for the 4-wheel drive was leaking fluid. the service dept. repaired under warranty. 4.) the vehicle stalls a numerous amounts of times (10-15 times) since i've owned it. it stalls while i'm driving at 35 miles per hour, in reverse, day or night. when i go for an errand and park, the vehicle will not start. an hour later, when the tow truck is there, the vehicle start. it drives me crazy!! the service dept. says they cannot do anything because nothing registers on the computer and they cannot simulate the problem. the last time it happened (08-04-04) merging on to the freeway it stalled. upon start-up, black smoke poured out of the exhaust and idling was extremely rough. i had it towed to a ford dealership. the service dept replaced a mass airflow meter under warrenty. the vehicle runs...i'll cross my fingers!! my current problem is that the front tires are severly cupping and the front end viberates at 60 mph and over. the vehicle has 25k miles and the tires have been rotated 5 times about every 5k miles. i had the wheels checked for alignment and balance and it is to specifications. the service dept says its normal and to continue with the rotations. the tires are wearing unevenly and prematurely. the tire shop recommends that the shocks and struts be replaced. the service dept does not.*ak | |||
| 05/26/2004 | 22288 | 1 | |
| While driving at any speed, the vehicle stalled without warning. the cause has yet to be determined. please provide additional information. *la | |||
| 10/15/2003 | 12023 | 1 | |
| All four tires were slightly cupping, and the brakes made a thumping noise when they were depressed. dealership replaced the pads, lubed the front caliper slide pin, and replaced rotors. *ak vehicle experiencing problems with tires cupping. the following repairs were performed on the vehicle: engine replaced, brakes, replaced, alignment, battery wiring assembly repaired, dpfe sensor replaced. consumer asked dealer for a full refund on vehicle.*mr | |||
| 10/19/2003 | 10812 | 2 | 01/05/2003 |
| While merging onto a freeway, couldn't get over 2,000 rpm and thus couldn't get enough speed to merge on at over 25mph. vehicle stalled several times while trying to get off the freeway. new vehicle has 10812 miles. ford maintenance dept stated they couldn't find anything wrong, it ran fine for them. my husband went to pick up the vehicle and in drive it ran, in neutral couldn't get more than 2,000 rpm, mechanic said it was the governor, needless to say, my husband said fix the car. they still have my truck.*ak | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 07/01/2004 | 32000 | 1 | 04/20/2002 |
| My 2002 ford explorer sport trac stalls when going down the road. it's like you're taking your foot off the gas and back on it again except that isn't what i'm doing. today it did that and then went dead while driving down the road. i took it to the ford place but they said with no lights on it wouldn't do any good to hook it up to a machine. they said it could be anything from electronics, fuel pump, etc. my warranty runs out in about 4,500 miles. this has been going on for about a year with the stalling out but this was the first time it actually went dead while driving down the road. i would estimate that over the past year that it has stalled at least 25 separate occasions but only 1 time so far did it go dead. *nm | |||
| 19900 | 2 | ||
| Consumer complained about a stalling problem. vehicle was taken to dealer. however, the problem had not been corrected. also, right rear door locks malfunctioned, and door couldn't be opened except from the outside. *ak | |||
| 01/09/2004 | 2500 | 1 | |
| While driving at any speed vehicle intermittently stalled. consumer made contact with the dealership. the cause of failure was not identified at this time. however, floor manager suggested that for another $125.00 consumer could have a nice and decent new car. *ak | |||
| 10/07/2002 | 4683 | 1 | 08/03/2002 |
| Engine stalled at 4683 miles on the odometer. date: 7 october 2002. i noted that it now idles at 600 rpm. i don't know what that means. *jb | |||
| 09/01/2002 | 4372 | 2 | 08/03/2002 |
| 4405 miles, 9:05 a.m., september 1, 2002, car stalled again. *jb | |||
| 01/27/2003 | 1 | ||
| I have experienced the same problem with gas spewing out of tank when refueling. this is my second sport trac. ford bought back my first one because they couldn't fix ongoing engine problems that started off as a rough idle problem. they even replaced the engine, and surprisingly that made things worse. i have had my new vehicle since the end of july and have experienced similar rough idle problems recently.*jb | |||
| 10/15/2001 | |||
| Body mounts on left front of vehicle keep coming loose. vehicle taken to dealer numerous times, dealer will tighten the body mounts. ford is buying vehicle back.*ak | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| 02/24/2004 | 29700 | 10 | 02/20/2004 |
| I bought this truck on february 20th, 2004 with a little over 20,000 miles. on february 24th, 2004, after leaving the dealership my truck died on a busy street on two separate occasions. the salesman told me that the truck had flooded. on june 10th, august 12th, november 19th, and again on december 2nd, 2004 (the only ones i wrote down it does happen more often) my truck also died while driving down the road. these have all been very serious incidents where i felt lucky to not only be alive but that i hadnt hit anything or anyone else. the technicians from the dealership have looked at my truck on all these occasions and gave me little or no excuse for the truck to die. at this time ive asked for a reasonable refund with no success&&im at a loss&&&please help!!!!*ak | |||
| 09/09/2003 | 11000 | 1 | 08/26/2002 |
| I bought a ford explorer sport trac in aug. of 2002. ever since it was a year old i have had nothing but problems with it. i had it 6 times for the same issue, they replaced the same part 4 times, that did not help. they finally called the ford help line and found out they needed to replace the whole gas tank. my truck the first time lost all power while driving down the road, i shut it off and it restarted fine. i took into the dealership and they had to re-program the main computer chip. next, my truck wouldn't start unless holding down the gas pedal then finally it would start and there would be a black smoke cloud that would come out of the tail pipe each time. the new gas tank finally fixed this problem! now i have other issues with a noise in the engine and when i first start it up and back out of the garage or parking space it sputters then once in drive it is ok, also when shifting after 40mph it has a hard shift instead of a smooth one. still trying to get it fixed.*ak | |||
| 08/21/2002 | 07/01/2002 | ||
| No summary. dt | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||
| 03/01/2004 | 16240 | 2 | 09/01/2002 |
| While driving 65 and attempting to pass another vehicle consumer's vehicle failed to go into passing gear. engine stalled and consumer had to coast to the side of the highway. once off the road consumer restarted the vehicle and continued driving. *ak the vehicle was towed to the dealer but the technician couldn't find anything wrong. the vehicle was taken back tot he dealer where they replaced the fuel pump, gas tank and air flow sensor. so far the vehicle has been running as it should. the heat shield under the vehicle rattled. the dealer adjusted it. the multifunction switch would not lock in place when using the turn signals. *nm | |||
| 09/05/2003 | 1 | 08/11/2002 | |
| The vehicle must be driven with the windows down because chemical fumes enter into the passenger's compartment. the dealer inspected the vehicle several times, and could not duplicate or correct the problem. *ak the catalytic converter was replaced and reset but the problem remained the same. *scc *jb | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||
| 09/29/2003 | 16573 | 1 | 07/06/2002 |
| While driving at various speeds black smoke would came from the tail pipe. consumer could smell gas fumes inside the vehicle. .*ak drivers rear door will not open from the inside. drivers side seat molding is falling off. center duct loose on dash. drivers seat cushion lost its form. *ts | |||