Bulletins

BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING
04160111/14/20050522810018745Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running. *tt01/12/2006
05171310/07/20050524910018062Coolant degas bottle overflow. *tt12/14/2005
0510206/07/20050518910017935Malfunction indicator lamp (mil) on and/or various driveability conditions - 5.4l 3-valve engine - vehicles built before 4/20/2005. *tt12/07/2005
1888410/01/200510017810Hard start, no start and/or other symptoms caused by a high pressure oil system leak - service tip. *tt12/01/2005
0518910/03/20050519110017802Mil on-various driveability conditions-5.4l 3-valve engine-vehicles built before 4/20/2005. *tt11/30/2005
0521510/31/200510017806Buck/jerk or surge - 6.0l vehicles built before 8/22/2005. *tt11/30/2005
0422106/07/200505101510013393Malfunction indicator lamp on with misfire dtc's spark knock piston scuffing. *eh vehicles built through 4/25/2005 - 5.4l 3v engine. *tt04/18/2005
ENGINE AND ENGINE COOLING - ENGINE
TSB-08-18-206/01/200910029205Ford/mercury/lincoln: vehicles may exhibit one or more of the following symptoms: drive away hesitation, loss of rpm on deceleration, difficulty starting, and/or idle rpm less than desired. the f53 motorhome chassis is included. *06/26/2009
0721210/01/200710023943Some 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. *pe02/20/2008
0615210021048Spark plug removal instructions - 5.4 3v. *kb02/27/2007
06191210020792Diagnostic trouble codes (dtc) p0340, p0344, p0345, p0349. are found. *kb01/16/2007
05101501/01/200505255100189355.4l 3v with p030x and/or p0316 accompanied by spark knock. *tt01/25/2006
0513201/01/20050518310016845Diagnostic trouble code (dtc) p0340 and or p0344-5.4 3v engine. *sc10/12/2005
03140408/23/20040416110011162Engine 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
ENGINE AND ENGINE COOLING - ENGINE - OTHER FUEL TYPES - TURBO-CHARGER
2022804/01/2008100248651999-2008 7.3l/6.0l/6.4l/4.5l diesel f-super duty - clean the charge air cooler (cac) system after certain turbo or engine failures - service tip. *nj06/03/2008

Consumer Complaints

Fail datemilesoccurencesPurchase date
ENGINE AND ENGINE COOLING
04/13/201294000
 Tl-the contact owns a 2005 ford f-150. the contact stated that while driving approximately 55 mph he noticed that the engine misfired. the vehicle was taken to an independent mechanic and the mechanic stated that the engine heads welded themselves to the spark plugs. the mechanic performed a tune up and replaced the spark plugs. the manufacturer was notified and they offered no assistance. the failure mileage was approximately 94,000. the vin was unavailable. sm.
04/13/201294000
 Tl-the contact owns a 2005 ford f-150. the contact stated that while driving approximately 55 mph he noticed that the vehicle would misfire. the vehicle was taken to an independent mechanic and they advised him that the heads had welded themselves to the spark plugs. the vehicle was repaired for a tune up and pulling the heads out to replace the spark plugs. the manufacturer was contacted and they offered no assistance. the failure mileage was approximately 94,000. the vin was unavailable. tb
02/27/201278000
 Tl* the contact owns a 2005 ford f-150. the contact stated that while the vehicle was parked, a loud pop noise was heard and the vehicle erupted into flames. the vehicle caused extensive damages to a commercial building in which it was parked near. the police were contacted and a police report was filed. the fire department did not determine the cause of the fire. the manufacturer was not contacted. the failure mileage was approximately 78,000. the vin was unavailable.
02/27/201278000
 Tl-the contact owns a 2005 ford f-150. the contact stated that while the vehicle was parked, a loud pop noise was heard and the vehicle erupted into flames. the vehicle caused extensive damages to a commercial building in which it was parked near. the police were contacted and a police report was filed. the fire department did not determine the cause of the fire. the manufacturer was not contacted. the failure mileage was approximately 78,000. the vin was unavailable. kmj
02/27/201278000
 Tl-the contact owns a 2005 ford f-150. the contact stated while the vehicle was parked the owner heard a loud pop and the vehicle engulfed into flames. due to the fire it caused damages to a commercial building that it was parked in front of. the police were contacted and a report was available. the fire department did not mention to the onwer what caused fire. the manufacturer was not contacted. the failure mileage was approximately 78,000. the vin was unavailable. tb
11/16/201181231
 The problem started in 2010, it now has happen three times this year my 2005 ford f-150 supercab has without any warning, either lost all power or the engine was reduced to idle rpm at highway speeds. a total of five times this has happen since i bought the truck. its happen in all typs of driving, highway speeds, city driving, acceleration and at a steady speed. i have had to maneuver across busy freeway lanes while coasting. in three of the incidents in which the engine stalled, i had to accomplish this without power steering or brakes. in another incident, the engine was idling so p/s and p/b were functioning, but there was no response to throttle inputs for acceleration. the check engine and wrench warning lights were illuminated on the dashboard. after turning off the ignition switch, the vehicle re-started and i was able to continue, the wrench light went off after restart, but the check engine light remained illuminated untill i have it reset. i been very fortunate that i have not been in an accident. this problem is intermittent and comes with absolutely no warning, it is clearly a safety issue. i now will not let my family drive the truck.
03/01/201087000
 Tl* the contact owns a 2005 ford f150. the contact stated that while driving 60 mph, a loud noise was emitted from the engine compartment. the contact mentioned that the failure recurred twice. the vehicle was taken to the dealer who diagnosed that the spark plugs were not torqued correctly, causing the spark plugs to be spewed from the engine block. the manufacturer was made aware of the failure who did not offer any assistance since the vehicle was not included in any recalls. the vehicle was repaired. the failure mileage was 87,000 and the current mileage was 120,000.
03/01/201087000
 Tl - the contact owns a 2005 ford f150. the contact stated that while driving 60 mph, a loud noise was emitted from the engine compartment. the contact mentioned that the failure recurred twice. the vehicle was taken to the dealer who diagnosed that the spark plugs were not torqued correctly, causing the spark plugs to be spewed from the engine block. the manufacturer was made aware of the failure who did not offer any assistance since the vehicle was not included in any recalls. the vehicle was repaired. the failure mileage was 87,000 and the current mileage was 120,000. kmj
03/01/201087000
 Tl - the contact owns a 2005 ford f150. the contact stated that while driving 60 mph a loud noise was emitted from the engine compartment. the contact mentioned that the failure occurred on two different occasions. the vehicle was taken to the dealer who diagnosed that due to improper torque of the spark plugs blew out of the engine and needed to be replaced. the manufacturer was made aware of the failure who did not offer any assistance since the vehicle was not included on any recall. the vehicle was repaired. the failure mileage was 87,000 and the current mileage was 120,000. pm
03/12/201087000
 While driving to work #5 sparkplug blew out of the block. with the engine still running fumes or gas vapors from the sparkplug hole and the spark from the coil pack can cause the engine to catch fire or even explode!!!! causing bodily injury or death to the occupant of the vehicle.
11/04/2011127000
 Auto ran great,fuel milage real good,then sparkplug blew out without any advance indication of a problem.
03/12/201087000
 While driving to work #5 sparkplug blew out of the block. with the engine still running fumes or gas vapors from the sparkplug hole and the spark from the coil pack can cause the engine to catch fire or even explode!!!! causing bodily injury or death to the occupant of the vehicle.
11/04/2011127000
 Auto ran great,fuel milage real good,then sparkplug blew out without any advance indication of a problem.
09/20/2011150000
 Vehicle misfired on acceleration on highway. was aware of spark plug ejections w/ my particular year and model after going through camshaft phaser repairs. (2005 f-150 w/ 5.4l triton engine). mechanic suggested replacing all factory spark plugs w/ new designed spark plug kit to eliminate ejection problem. i did so at a cost of $831.52. costs to date $4729.25 within the last 2 months on a 2005 vehicle. unacceptable. researched on internet anfd found this to be a very well known problem. no mention of it from the dealer upon purchase. ford has turned their back on this (and the camshaft phaser defect). i am a small contractor whose livelihood depends on this vehicle. the purchase price of $35,890.00 plus tax and license was a huge investment for me (i paid cash and drained my savings so i would not have monthly payment). so these additional costs to an almost new vehicle have drained my account again.
08/05/2011148000
 Camshaft phasers failed so engine would not idle, causing a very dangerous situation at stop signs having to constantly rev engine to keep running. repair cost $3,897.73 through internet investigation have found my particular year and engine (5.4l triton) has a history of this failure. told that a non-motorcraft oil filter can release debris that clogs a lubrivation port in the cam phasers which in turn destroys them. no info. of this sort was ever relayed to me on purchase of vehicle. i have no reason to believe i have ever used anything but a motorcraft oil filter. a 2005 vehicle w/ a $3900.00 mechanical repair is unacceptable. have contacted ford until i have exhausted my attempts. they finally told me this was the end of our communications.
09/20/2011150000
 Vehicle misfired on acceleration on highway. was aware of spark plug ejections w/ my particular year and model after going through camshaft phaser repairs. (2005 f-150 w/ 5.4l triton engine). mechanic suggested replacing all factory spark plugs w/ new designed spark plug kit to eliminate ejection problem. i did so at a cost of $831.52. costs to date $4729.25 within the last 2 months on a 2005 vehicle. unacceptable. researched on internet anfd found this to be a very well known problem. no mention of it from the dealer upon purchase. ford has turned their back on this (and the camshaft phaser defect). i am a small contractor whose livelihood depends on this vehicle. the purchase price of $35,890.00 plus tax and license was a huge investment for me (i paid cash and drained my savings so i would not have monthly payment). so these additional costs to an almost new vehicle have drained my account again.
08/05/2011148000
 Camshaft phasers failed so engine would not idle, causing a very dangerous situation at stop signs having to constantly rev engine to keep running. repair cost $3,897.73 through internet investigation have found my particular year and engine (5.4l triton) has a history of this failure. told that a non-motorcraft oil filter can release debris that clogs a lubrivation port in the cam phasers which in turn destroys them. no info. of this sort was ever relayed to me on purchase of vehicle. i have no reason to believe i have ever used anything but a motorcraft oil filter. a 2005 vehicle w/ a $3900.00 mechanical repair is unacceptable. have contacted ford until i have exhausted my attempts. they finally told me this was the end of our communications.
09/20/2011150000
 Vehicle misfired on acceleration on highway. was aware of spark plug ejections w/ my particular year and model after going through camshaft phaser repairs. (2005 f-150 w/ 5.4l triton engine). mechanic suggested replacing all factory spark plugs w/ new designed spark plug kit to eliminate ejection problem. i did so at a cost of $831.52. costs to date $4729.25 within the last 2 months on a 2005 vehicle. unacceptable. researched on internet anfd found this to be a very well known problem. no mention of it from the dealer upon purchase. ford has turned their back on this (and the camshaft phaser defect). i am a small contractor whose livelihood depends on this vehicle. the purchase price of $35,890.00 plus tax and license was a huge investment for me (i paid cash and drained my savings so i would not have monthly payment). so these additional costs to an almost new vehicle have drained my account again.
08/05/2011148000
 Camshaft phasers failed so engine would not idle, causing a very dangerous situation at stop signs having to constantly rev engine to keep running. repair cost $3,897.73 through internet investigation have found my particular year and engine (5.4l triton) has a history of this failure. told that a non-motorcraft oil filter can release debris that clogs a lubrivation port in the cam phasers which in turn destroys them. no info. of this sort was ever relayed to me on purchase of vehicle. i have no reason to believe i have ever used anything but a motorcraft oil filter. a 2005 vehicle w/ a $3900.00 mechanical repair is unacceptable. have contacted ford until i have exhausted my attempts. they finally told me this was the end of our communications.
09/20/2011150000
 Vehicle misfired on acceleration on highway. was aware of spark plug ejections w/ my particular year and model after going through camshaft phaser repairs. (2005 f-150 w/ 5.4l triton engine). mechanic suggested replacing all factory spark plugs w/ new designed spark plug kit to eliminate ejection problem. i did so at a cost of $831.52. costs to date $4729.25 within the last 2 months on a 2005 vehicle. unacceptable. researched on internet anfd found this to be a very well known problem. no mention of it from the dealer upon purchase. ford has turned their back on this (and the camshaft phaser defect). i am a small contractor whose livelihood depends on this vehicle. the purchase price of $35,890.00 plus tax and license was a huge investment for me (i paid cash and drained my savings so i would not have monthly payment). so these additional costs to an almost new vehicle have drained my account again.
08/05/2011148000
 Camshaft phasers failed so engine would not idle, causing a very dangerous situation at stop signs having to constantly rev engine to keep running. repair cost $3,897.73 through internet investigation have found my particular year and engine (5.4l triton) has a history of this failure. told that a non-motorcraft oil filter can release debris that clogs a lubrivation port in the cam phasers which in turn destroys them. no info. of this sort was ever relayed to me on purchase of vehicle. i have no reason to believe i have ever used anything but a motorcraft oil filter. a 2005 vehicle w/ a $3900.00 mechanical repair is unacceptable. have contacted ford until i have exhausted my attempts. they finally told me this was the end of our communications.
09/20/2011150000
 Vehicle misfired on acceleration on highway. was aware of spark plug ejections w/ my particular year and model after going through camshaft phaser repairs. (2005 f-150 w/ 5.4l triton engine). mechanic suggested replacing all factory spark plugs w/ new designed spark plug kit to eliminate ejection problem. i did so at a cost of $831.52. costs to date $4729.25 within the last 2 months on a 2005 vehicle. unacceptable. researched on internet anfd found this to be a very well known problem. no mention of it from the dealer upon purchase. ford has turned their back on this (and the camshaft phaser defect). i am a small contractor whose livelihood depends on this vehicle. the purchase price of $35,890.00 plus tax and license was a huge investment for me (i paid cash and drained my savings so i would not have monthly payment). so these additional costs to an almost new vehicle have drained my account again.
08/05/2011148000
 Camshaft phasers failed so engine would not idle, causing a very dangerous situation at stop signs having to constantly rev engine to keep running. repair cost $3,897.73 through internet investigation have found my particular year and engine (5.4l triton) has a history of this failure. told that a non-motorcraft oil filter can release debris that clogs a lubrivation port in the cam phasers which in turn destroys them. no info. of this sort was ever relayed to me on purchase of vehicle. i have no reason to believe i have ever used anything but a motorcraft oil filter. a 2005 vehicle w/ a $3900.00 mechanical repair is unacceptable. have contacted ford until i have exhausted my attempts. they finally told me this was the end of our communications.
03/01/200939000
 Tl* the contact owns a 2005 ford f-150. while stopped, the contact heard a ticking sound coming from the engine. the vehicle was taken to the dealer for diagnostic testing where the technician stated that the cam phaser and the tentioners would have to be replaced. the vehicle was not repaired. the approximate failure mileage was 39,000.
03/01/200939000
 Tl- the contact owns a 2005 ford f-150. while stopped, the contact heard a ticking sound coming from the engine. the vehicle was taken to the dealer for diagnostic testing where the technician stated that the cam phaser and the tentioners would have to be replaced. the vehicle was not repaired. the approximate failure mileage was 39,000. kmj
03/01/200939000
 Tl- the contact owns a 2005 ford f-150.while stopped the contact heard a ticking sound coming from the engine. the vehicle was taken to the dealer for diagnostic. the technician stated the cam phaser and the tentioners would have to be replaced. the vehicle was not repaired. the approximate failure mileage was 39,000. ds
05/30/200729546
 Truck continues accelerating after foot is removed from accelerator pedal. almost impossible to stop with brake pedal. had to take out of gear to stop truck. restarted truck and it operates properly. it has happened three more times since this original occurrence. ford dealer could find no problem in 2007. am taking it back again as it has happened twice in the past year.
09/01/200820000
 Tl- the contact owns a 2005 ford f-150. the contact stated that the vehicle would intermittently shift into four wheel drive unexpectedly. the failure occurred when driving 30 mph and above. the vehicle was taken to an authorized dealer and the contact was informed that water was penetrating the actuator. various repairs were performed, but the failure continued. the manufacturer was made aware of the failure, but offered no assistance. the failure mileage was 20,000. kmj
05/30/200729546
 Truck continues accelerating after foot is removed from accelerator pedal. almost impossible to stop with brake pedal. had to take out of gear to stop truck. restarted truck and it operates properly. it has happened three more times since this original occurrence. ford dealer could find no problem in 2007. am taking it back again as it has happened twice in the past year.
09/01/200820000
 Tl- the contact owns a 2005 ford f-150. the contact stated that the vehicle would intermittently shift into four wheel drive unexpectedly. the failure occurred when driving 30 mph and above. the vehicle was taken to an authorized dealer and the contact was informed that water was penetrating the actuator. various repairs were performed, but the failure continued. the manufacturer was made aware of the failure, but offered no assistance. the failure mileage was 20,000. kmj
05/30/200729546
 Truck continues accelerating after foot is removed from accelerator pedal. almost impossible to stop with brake pedal. had to take out of gear to stop truck. restarted truck and it operates properly. it has happened three more times since this original occurrence. ford dealer could find no problem in 2007. am taking it back again as it has happened twice in the past year.
09/16/201161000
 Tl* the contact owns a 2005 ford f-150. the contact stated that the vehicle was idle and in park when it exhibited an abnormally loud popping sound. the vehicle was taken to the local dealer who diagnosed that four cylinders were defective and needed replacement. the vehicle was not repaired. the dealer and the manufacturer were notified of the failure but denied any assistance with repairs. the failure and current mileage was 61,000.
09/16/201161000
 Tl- the contact owns a 2005 ford f-150. the contact stated that the vehicle was idle and in park when it exhibited an abnormally loud popping sound. the vehicle was taken to the local dealer who diagnosed that four cylinders were defective and needed replacement. the vehicle was not repaired. the dealer and the manufacturer were notified of the failure but denied any assistance with repairs. the failure and current mileage was 61,000. kmj
09/16/201161000
 Tl- the contact owns a 2005 ford f-150. while the vehicle was idole and in park, the contact stated that the vehicle made a loud popping noise. a local dealer diagnosed that four cylinders were defective and needed repair. the vehicle was not repaired. the dealer and manufacturer were notified, but denied any assistance with repair to the failure. the failure and current mileage was 61,000. nw
09/03/201164800
 Proceeded to drive out of home driveway onto road, which is gravel and travels immediately downhill. i heard a pop and what sounded like exhaust/compression popping and experienced the engine skipping with slight loss of power. i turned around, as soon as it was safe to do so, and drove back to my own driveway. i contacted a local mechanic which i use regulary and explained my situation. the mechanic was only able to check it out thursday 8, september, 2011. he then diagnosed the problem as a blown sparkplug and suggested i contact ford for some relief as the problem is widespread. i did and was denied. the problem, as i understand it, could have resulted in having raw gasoline spraying out of the spark plug hole, onto a hot manifold and possibly causing a fire.
05/02/2011131000
 Tl*the contact owns a 2005 ford f150. the contact stated that the motor was faulty due to the design, causing a carbon build up that blocks the spark plugs. the vehicle was towed to the dealer; however, the dealer was unable to remove the spark plugs. the manufacturer referred the contact to nhtsa to file a complaint. no repairs were performed. the current and failure mileage was 131,000.
05/02/2011131000
 Tl- the contact owns a 2005 ford f150. the contact stated that the motor was faulty due to the design, causing a carbon build up that blocks the spark plugs. the vehicle was towed to the dealer;however, the dealer was unable to remove the spark plugs. the manufacturer referred the contact to nhtsa to file a complaint. no repairs were performed. the current and failure mileage was 131,000. bw
04/11/201190000
 Tl* the contact owns a 2005 ford f150. the contact was driving at relatively low speeds when the brakes were applied and the vehicle stalled. the vehicle was taken to the dealer where the contact was advised that the engine mass air flow sensor failed. the vehicle was not repaired. the failure and the current mileage was 90,000.
04/11/201190000
 Tl-the contact owns a 2005 ford f150. the contact stated nhtsa campaign id number 11v107000 air bags frontal driver side inflater module was performed on the vehicle april, 11 2010 and after the repair while driving at low speed when he attempted to slow the vehicle down it stalled. the vehicle was taken back to the dealer test drove the vehicle and advised the failure was not related to the recall repair, the engine mass air flow sensor failed. the vehicle was not repaired. the failure and the current miles were 90,000. li
03/03/2011130000
 My 2005 ford f150 quit while driving down the highway with my 12 yr old son. engine began to spit and sputter and stranded us on the highway. after towing to my local ford dealer. the dealer discovered the timing chain had slipped causing the truck to jump time and ruining the engine. the truck has 130,000 highway miles. now they want $7,500 for a new engine. the other issue is my rear driver side window just fell into the door. they want between 200 and 300 dollars to repair.
03/14/2011100800
 Tl- the contact owns a 2005 ford f150. while driving approximately 20 mph the check engine light illuminated on the dash board. the vehicle was taken to an independent mechanic where the mechanic informed the contact the spark plug was broken in the head of cylinder five. the manufacturer was contacted and stated there was no recall and suggested the contact keep his receipts for reimbursement if repairs were made and there was a recall in the future. the vehicle was not repaired. the vin was not available. the approximate failure mileage was 100,800. ds
02/01/200740000
 Tl* the contact owns a 2005 ford f150. while driving approximately 35 mph, the vehicle stalled without warning. the contact was able to maneuver off the roadway and shifted into park. he was able to restart the vehicle after several minutes. the failure recurred approximately five times and the vehicle was taken to both an authorized dealer and an independent mechanic who were both unable to diagnose the failure. the vehicle was not repaired. the approximate failure mileage was 40,000.
09/15/2010105000
 Tl* the contact owns a 2005 ford f150. the contact stated that the vehicle exhibited an abnormal grinding noise from the engine whether the vehicle was parked or in motion. the vehicle was taken to the dealer but the mechanic was unable to diagnose the failure. the vehicle was not repaired. the approximate failure mileage was 105,000.
09/15/2010105000
 Tl- the contact owns a 2005 ford f150. while parked the contact heard a grinding noise coming from the engine. the contact stated the noise could also be heard while driving at various speeds or when the vehicle was stopped. the vehicle was taken to the dealer where it was purchased but the mechanic could not diagnose the failure. the vehicle was not taken into a ford dealer for diagnostics. the vehicle was not repaired. the approximate failure mileage was 105,000. ds
07/12/201071000
 Tl- the contact owns a 2005 f-150. the contact stated the vehicle looses and stalls without warning. the failure occurs randomly under all types of conditions. the contact explained the failure to the manufacturer and they set up an appointment to have the vehicle inspected. the failure has occurred four times and there has never been a warning light or any other notice of a failure. the failure mileage was 71000 and the current mileage was unknown.rl
09/03/201058020
 Tl- the contact owns a 2005 ford f150. while driving at any speed the vehicle stalls the dash board light illuminated indicating the throttle body while the failure occurred. the contact placed the gear in neutral turn the vehicle off was able to restart the vehicle. the dealer advised the vehicle didn't have a recall. the vehicle wasn't repaired. the vin information wasn't available. the manufacturer will be contacted the failure mileage was 58,020, and the current mileage was 58,040. li
08/29/201075000
 Tl-the contact owns a 2005 ford f150 truck. while driving 35-40 mph the the vehicle was later towed to a local mechanic. he stated the vehicle was skipping and jumping. the vehicle was towed to a local mechanic and the local mechanic had to remove the engine head to get to the spark plug. the mechanic could not get all of the spark plugs out and referred him back to the dealer. the local mechanic repaired the vehicle for $900. the dealer wanted to charge $2800 to repair the vehicle. the contact stated because of the design of the vehicle the spark plugs are difficult to get to. the failure mileage was 75,000 and the current mileage was 80,000. vwb
05/25/201080000
 Tl* the contact owns a 2005 ford f-150. while driving at speeds of 55 mph, the spark plugs disbursed from the engine and the vehicle lost power and stalled. the dealer was contacted informed the contact that repairs would be at her liability. the vehicle was not repaired. the failure and current mileages were 80,000.
02/23/2010590001
 At just over 59k miles on my 2005 f-150 5.4l triton v8 driving at 30 mph i noticed a ticking sound that increased/decreased with rpms. traveling about 2 miles further the noise increased in volume so i pulled over and raised the hood. the noise was coming form the passenger side of the motor and the motor was shaking as if miss firing or running iraticly. i had no engine warning light or any other notifications on the dash prior. i went directly to my mechanic. when my mechanic came out to see what was happening he knew right away what was going on. he has repaired this problem several times before. he said that i had blownout a least one spark plug. this is a known flaw with the triton v8 motors or rather the spark plug design that was put in the engine from the factory. the spark plug is a three piece design the is crimped together and ultimately cracks and separates over a period of time leading to literally blowing up. in some cases the threads in the motor where the spark plug screws in can be torn out. this requires re-tapping new threads or a heliocoil pack. this issue was not pointed out to me by ford prior so i could prevent possible damage and very expensive repair costs as i know they are aware of this problem and that is very wrong. the manual provided by ford with the truck says the spark plugs don't need to be changed until 100k. after further investigation online i found hundreds of others experiencing the same problem prior to 100k. i will be sending the bill to repair my truck to ford through my attorney as this is negligent behavior and a faulty design flaw that i could not have prevented. ford is sending owners of this motor down a path of guaranteed financial and potential physical harm. ford needs to stand up and own this mistake. *tr
01/28/2010495001
 While at ~45mph, i eased off the accelerator to go into a left hand turn. my f150 then lost all power and shut off (no power steering, etc), and there were 2 tracker trailers coming in the opposite direction from me. i was barely able to complete the turn with the momentum that i had before the truck died. the truck re-started without any issue. this had happened before 2 other times with large gaps of time in between (once in november 09 and the other time a week before this latest incident). the other 2 occurrences were similar (highway speeds of 60mph), and restarting without any issue or error codes. an error code was generated (finally) with the incident described at the top of this complaint, and i brought the truck to the dealership. they diagnosed a faulty throttle sensor which was replaced. at less than 50,000 miles i did not expect to see an issue with this sensor, and certainly i would expect the truck to default into the limp home mode described in the manual, which it did not. there were several other similar complaints for this on some forums and i felt it might need some attention. *tr
11/17/2009435671
 While traveling through a tunnel at approx.55 mph the engine on my 2005 f-150 with a 5.4 liter engine quit running at full speed and went into what ford calls limp mode. luckily there was no other vehicle behind me or i would not be here to write this. the truck has since this incident quit running all together several different times. i took the vehicle back to where it was purchased and was charged $75 to diagnose the problem. they said that the throttle body was not functioning properly and it would cost $450 to replace. ford knows of this problem and will do nothing to repair the defective parts on their own. the dealer that is doing the repairs said that there are 397 of these parts on back order, that should tell them something! this could be a life threatening defect that the ford motor co. will not take responsibility for. *tr
11/28/2009704001
 Spark plug breaking off in engine. *tr
04/10/2009400001
 Ventilation fin got stuck on a piece of foam. the motor controller then failed. this resulted in inability to switch air flow direction in the vehicle. *tr
11/17/2009710001
 There were no warnings or events leading up to the incident. no warning lights, no noises. we had been driving earlier, but only about 5 miles and then we ate dinner, so the car rested. we came home and my son was about to take his young daughter home. my son was in drivers seat, i was putting granddaughter in back seat child safety seat . then i leaned into the passenger side front cab to grab a coke from the cupholder. my son turned on the truck, ford f150 pickup, and we heard a boom. it was so loud the neighbors all came out.-it sounded like a bomb! i was lacerated on the hand. my son was in pain, my granddaughter was screaming, and i went to rear cab from outside, unstrapped her and carried her out onto the sidewalk far away, fearing fire or explosion. my son was lacerated on his chest, stomach and was deaf in left ear for more than 2 hrs. the inside lights went on, and the car was running until we were brave enough to take out the keys about 10 mins. we had to wash dust off of ourselves, the smoke filled the cab. we called police and made report and called ins. carrier and made report. today we had it towed to ford dealer. i know this is a ford f150 defect. if my son had been driving, he would have had a terrible accident with my 4 yr old granddaughter in the truck. i am going to force ford to fix this and we are all hearing humming in our ears. the adjuster came out, gave us an estimate, we had the truck towed to ford dealer. i called ford customer service,, they took the complaint, and said wait 15 days for response. they asked me what do you expect to be the outcome of this call? ah what? i said that i expect them to pay the 1000.00 deduct and the cost. the rep told me to have a happy thanksgiving! its not her place to tell me that i should be grateful. i told her we were. i want ford to pay for this, the adjuster said they should. i bet they wont! *tr
11/15/2009320001
 2005 f150 5.4l v8. engine dies while driving. no warning, no indication. only connection seems to be that it happens during the first time the truck is driven in the morning. all electrical is still working during stall. go to hit the accelerator pedal and nothing. it is completely random. it has happened 3 times in the last 2 weeks with random days in between. turn the key off, turn it on and all works fine. others have had this issue in complaints, it can not be a coincidence with so many others having the same problem. this could pose a safety issue to f-150 drivers or other vehicles around an f150 if this stall happens. the incident date is just the most recent. taking my truck to the shop this week to get it checked out. i want answers from ford! i am the original owner of this truck with only 32000 miles on it. never driven hard, used for towing or heavy payloads. *tr
04/17/200745000
 Tl*the contact owns a 2005 ford f-150. while driving the vehicle began to stall and shut off. he made several attempts to restart the vehicle and was able to resume normal operation. the vehicle was taken to the dealer and a technician concluded that it would cost $600.00 to repair the vehicle. no repairs were made. the failure mileage was 45,000 and the current mileage was 70,447.
05/12/2009695001
 Regarding: 2005 ford f 150 truck purchased new from dealer, has been having problems with stalling. it has stalled in reverse and while driving on freeway. it is very dangerous. i almost got into an accident today on the freeway, which is why i am taking the time to look into this matter. i also know a few people with the same problem and have also seen many postings online for this issue. many people have been injured in accidents and many trucks have caught on fire. all have started with these same problems. ford recognized this problem until the made year of 2004. i do believe it also a problem with 2005, and maybe with other years. this really needs to be checked into. i have had my truck looked at by a mechanic, and he is not sure of the problem. i see a lot of problems with ford and fuel injectors and cruise control with my year of truck, but no recalls. this is a serious matter and i would appreciate that it be handled responsibly. *tr
04/17/2009860001
 I have a 2005 ford f-150 (4.6l v8) and i recently had a spark plug blow out of the engine, for the second time. the first time it cost me $556.50 to repair it. this time it happened in a different cylinder. this time i had my 2year old daughter with me and was stranded along interstate 70 for over an hour. i didn't report it the first time, because i thought it was an isolated incident. now after some research, i have found that this happening around the nation. i am not sure why there hasn't been a recall. not only can this be a fire hazard, but in my case, my daughter and i were stranded along side a very busy highway. *tr
04/12/2009450001
 My truck is a 2005 ford f-150 with 45,000 miles no prior problems serviced as per the ford recommendations as well as regular oil changes. while on vacation getting off the freeway off ramp in reno nevada and coming to a stop at a red light my car started to shake and sputter as if it was going to turn off and the check engine light was on. after the light turned green i proceeded through the green light and parked the truck in a safe spot off the street. i turned off the engine and lifted the hood and there was a small odder of gas fumes. seeing that i needed to get to a safe area i slowly drove the truck to a hotel. the next day on monday at a slow speed no more than 25 miles per hr. i drove the truck to the ford dealership where i spoke with a ford service advisor. the ford service advisor told me that there was a (fuel injector notice) for this year make and model ford truck. he also said that there could be a possibility that other engine problems could incur as a result of the bad fuel injector. he said that there could be a possibility that my motor could (hydrolock) and cause other problems in the engine and that there was also a possibility that my catalytic converter could be damaged. after receiving this info i left the dealership they shuttled me back to my hotel. later that day they diagnosed the problem. this is the explanation of what the dealership said was wrong with my truck: (1)bad fuel injector. (2)bent rod. (3)bent valve spring (4)scored valve head (5)possible bad catalytic converter estimated damage $4,300 and if catalytic converter was damaged $5,100. *tr
12/18/200882000
 Tl*the contact owns a 2005 ford f-150. while driving approximately 45 mph, the contact noticed that the temperature warning indicator was illuminated on the instrument panel, which meant that the vehicle was overheating. he also noticed smoke and water emanating from the vehicle. if the vehicle would have stalled while driving, he could have been seriously injured in a crash. the vehicle was towed to a local dealer and they replaced the water pump at the cost of $300. immediately after the repair, he noticed that the vehicle idled roughly. he took the vehicle back to the dealer and they stated that the engine needed to be replaced at the cost of $5,000. the vehicle has not been repaired. the failure and current mileages were 82,000.
03/19/2009539001
 While driving, the vacuum solenoid for the 4 wheel drive tries to engage the 4 wheel drive - even at highway speeds- resulting in a horrible sound. the sound was like i had run over a shopping cart or hit something in the road and was dragging it under the truck. this happened 5 times in two days in less than 30 miles of total driving. the noise is so loud and alarming that it made me immediately apply the brakes and pull to the side of the road because i thought i had hit something/someone. at first i wondered if my muffler or drive shaft or some other part had fallen off of the truck. this false engagement of the 4 wheel drive happens without any warning in all kids of driving conditions (slow, fast, breaking or accelerating). a new, redesigned (now has a cover on it to keep moisture out- which was causing the failure) vacuum solenoid was installed on truck - a $27.00 part. dealership kept old part. tech. at dealer told me that this part will go bad at some point and need replacing on all the trucks with the part. he said not if but when. ford knew about the problem - hence the redesigned part. ford has not notified owners of this part and it's impending failure. *tr
01/21/2009579581
 Engine shut down while driving 30 mph this happened twice dealer scanned for code and found code p2104 idle air control valve stuck closed replaced body and motor assembly 6036 wp94 no charge under warranty recall replace switch 6306 wp94 and vacuum tebe 6l3z*9w431*a. *tr
11/10/2008464751
 5.4l, supercrew-- engine was replaced by ford at 38,000 miles (after complaint to ford cust svc) due to injector failure and cylinder hydra-lock. now at 46,000 miles, complete transmission failure. only used for daily driver, no towing, never off-road. transmission failed on initial start on 60 degree morning, no pre-failure indicators. paid $2800 for transmission rebuild. i have noticed a fairly large number of problems reported on sub-standard factory transmission and engine parts on ford trucks. *tr
09/18/200718000
 Tl*the contact owns a 2005 ford f-150. while driving 55 mph, the vehicle stalled when the brake pedal was depressed. when the failure occurred, the check engine indicator illuminated on the instrument panel. the dealer repaired the failure and they stated that the sensors failed; however, the failure still persists. the vehicle was taken to the dealer approximately two times. the ford manufacturer issued a recall for the power booster line. the vehicle has not been taken in to have the recall repaired. the failure mileage was 18,000 and current mileage was 35,820.
11/25/2008220001
 Slowing to a stop at light. was gong about 25. almost at complete stop, when engine went to almost full throttle. i pushed brake harder but still drove into the parked car in front of me. no damage done, just a very hard bump. turned key off, put in park. car in front of me drove ahead and parked to side of road. i started the engine and it immediately went to very high throttle. turned key off, waited 20 seconds, tried again. and it was ok. i pulled ahead and off to side to talk to other person involved. after 15 mins i calmed down and went home. *tr
11/13/200852700
 Tl*the contact owns a 2005 ford f-150. on two separate occasions, the vehicle misfires and loses power, but does not have to be restarted. the dealer stated that the spark plugs may need to be changed; however, they may break off in the process. the current mileage was 52,838 and failure mileage was 52,700.
10/06/20081
 I bought a truck at selinsgrove ford about a month ago. the night i got it home i noticed it sounded like a diesel.. that was fine then when you get up to about 55mph its has a bad shimmy and i had it back a couple of different time and they say they don't know what to do about it now. it had to be wrecked or something because there was a crease on the bumper and the drivers side door needed adjusted. *tr
11/06/2008630001
 I have a 2005 ford with the 5.4 lt. engine. at the 63,000 mile mark i decided to replace the spark plugs due to slight idle problem. after spending $102.00 on a new set of spark plugs i ran into the problem of the spark plug's lower half breaking inside the cylinder head, it took me two days to complete the replacement due to a faulty design of the spark plugs. the spark plug steel shell is made of two parts a top half that has the threads made onto it and the lower half that has the hood were the gap is made between the electrode and itself allowing for a spark to happen. the problem being in that these two parts are only crimped together, the crimping is not strong enough and the lower half due to the carbon build up maintains itself jammed in the cylinder head while the top part slips at the crimping area turns and is threaded out causing the separation, i was going to weld the two parts together so that the next time i had to change the spark plugs the lower half would turn with the top half of allowing it to break itself free from the carbon build up and not break in the cylinder head but decided not to go with it too much trouble i'll get rid of the truck before the spark plug need replacing. well what i hope to get out of this is that ford revamps it's spark plug design by either welding these two parts together or making the spark plug shell a 1 piece so that i don't have this problem again if i do decide to buy another ford product after the hell i had to go though changing these spark plugs. *tr
10/28/20081
 2004-2007 f-150 truck say to change the spark plugs out at 100k. the dealers say $300 to change but if they snap of it could cost more? they almost always snap!!! ford has a spark plug that snaps in half when trying to change out do to carbon build up. bad design and then is about $88 hr for a tech to fix. almost all dealerships break them and cost the owner $1000 to $1800 for a spark plug change do to poor design? everyone is breaking and ford is making a ton of money on a problem that should be recalled!!!!! if you research this on the web need i say no more....i bought a $32,000 truck that i cant change the spark plugs.. something really needs to happen. thank you ken belk *tr
12/08/2007400001
 My truck has 56k on it bought it used with 35k on it when it starts runs with high idle and the top end ticks really bad the ticking does not go away at all speeds at a stop light it sounds like a diesel tic tic tic sounds like a lifter is stuck. i put lucas in it to try to make it go away then i changed the oil ran about two weeks with no difference and changed it again and no change called ford dealer they couldn't help they said i would have take it in and get charged $165. then i changed the spark plugs maybe a fouled plug that wasn't it there goes 120 bucks a couple of weeks ago my wife was driving on the freeway and the drivers side window falls the window regulator broke $140 replaced that already. the passenger seat belt locks up sometimes now to the front the steering wheel shakes really bad when you apply the brakes turned the rotors at napa $20 new brake pads $90 at kragens balanced tires free i work at a tire shop shaking went away for about three days 350 miles later the shaking is back with a vengeance checked the balancing on the tires they were good rotors are out of shape again still on there now and the shaking is getting worse i cant afford them right now so they will stay there hooked up the snap on ehtos computer to it and registers that two sensors have an open circuit but no explanation for top end noise injectors might be bad. *tr
04/24/20081
 At 2:.00 am the morning of april 24, 2008 we were awakened by our seriously agitated dog, to find our 2005 ford f150 engulfed by flames and to soon see our other two vehicles and our home destroyed by fire. a total of four investigators have concluded that the cause of the fire is the ford f150. the truck is presently under lock and key and the investigation continues to find the exact component. *tr
11/23/200735000507/05/2005
 Tl*the contact owns a 2005 ford f-150. when slowing down for a turn or approaching a stop, the accelerator pedal does not retract. on april 16, 2008, the vehicle completely shut off. on january 7, 2008, the dealer replaced the throttle position sensor, but the failure recurred two additional times. the contact has an appointment with the dealer on april 21, 2008 to take another look at the vehicle and attempt to identify the failure. the speed was unknown. the failure mileage was 35,000 and current mileage was 38,300. the consumer stated the problem occurred 5 times prior to january 7th 2008 and 2 times between january 7th and april 16th. updated 05/05/08 *tr
12/15/200755000107/15/2005
 The truck started cutting out and acting like it was not getting any fuel. we continued to drive the truck home and turned the truck off. the next day went out to start truck did not want to start had it towed to ford dealer. they said due to fuel injection malfunction the motor had to be replaced. *tr
05/01/2007500001009/20/2005
 Tl*the contact owns a 2005 ford f-150. the contact stated that the vehicle will shut off and the steering wheel will lock while driving. the failures occur without warning. the service engine light illuminated on the dashboard and displayed that the engine has malfunctioned. the dealer repaired the failure three times by replacing the spark plugs and the chassel body. the speed was unknown. the current mileage was 70,000 and failure mileage was 50,000.
08/04/200745831109/26/2005
 Experienced sudden loss of power steering and power brakes while normal and routine driving on highway. no warning of any kind that failure was about to occur. engine ran rough, engine light warning came on after brake and steering failure and then engine shut off. narrowly avoided rear end collision and driving off the highway and into steep ravine. was able to bring vehicle under control with a lot of effort to steer and emergency brake. could have been injuries and/or fatal. towed vehicle to ford dealer. dealer performed eec test and received codes p0171 and p0174. dealer found vacuum hose from intake manifold to ebrake booster broken. dealer removed intake manifold, replaced vacuum hose and intake gaskets, and reinstalled intake manifold and cleared codes. i have old parts. *tr
01/04/2006107001503/19/2005
 Dt*: the contact stated while sitting inside the vehicle there was an odor of gasoline. the vehicle was inspected by the local dealership, and they replaced 7 fuel injectors, 8 spark plugs, and ordered a fuel rail. these attempts to solve the problem have been unsuccessful. *ak updated 01/25/06. *jb
ENGINE AND ENGINE COOLING - COOLING SYSTEM
03/20/201074000
 Ford motor company-there was a service bulletinput out show there was a problemwith the cam phasers and cam chain tensioner causing the engine to make noises and then engine faiure there has been lots of complaintsto ford with nothingbeing done if you where driving onthe road and the egine blew couldcause a accident i contact ford and they have all most admitted to it that they new there was a problem i have found that there has been 1092 complaints over this problem and nothing done. i contacted ford and thats how i found out about you they keep saying there sending the complaint to a onther dept..but this is aproblem that could have been correct before the enginewas ruined
11/19/2009476401
 2005 ford f150 5.4l engine twice the fail safe came on while my wife driving and the engine shut down. once in october,2009( on the interstate, speed 65) and 11/19/09. this could have resulted in a serious accident she was able to get off the road. after a couple of minutes, engine started ok. with no check engine on ford dealer replaced throttle body and motor; reprogrammed pcm at a cost of $510.00. *tr
ENGINE AND ENGINE COOLING - ENGINE
03/19/2012799681
 #3 spark plug blew out while traveling away from home in another state. in driving two miles back to my son's house, i had two explosions from excess gasoline and spark plug firing. the spark plugs were original and blew out because of the fine threads and aluminum cylinder heads. this is a design defect and safety problem known to ford. towing and insert installation by a ford dealer was $950. the engine is a 4.6 v-8 updated 05/17/12 *bf
03/19/2012799681
 #3 spark plug blew out while traveling away from home in another state. in driving two miles back to my son's house, i had two explosions from excess gasoline and spark plug firing. the spark plugs were original and blew out because of the fine threads and aluminum cylinder heads. this is a design defect and safety problem known to ford. towing and insert installation by a ford dealer was $950. the engine is a 4.6 v-8
07/10/2011120000
 Tl - the contact owns a 2005 ford f-150. the contact stated that while driving he heard a really loud noise. he inspected the vehicle and noticed that the spark plug from cylinder block was ejected. the vehicle was taken to the dealer who verified the failure and stated that the block needed to be re-threaded. the manufacturer was made aware of the failure who did offered any assistance. the vehicle was not repaired. the failure and current mileage was 120,000. pm
06/06/201195000
 Tl-the contact owns a 2005 ford f-150. the contact stated that there were faulty spark plugs fracturing in the cylinder head. after fracturing, the remains became stuck in the engine block. the vehicle was taken to an authorized dealer, but was not repaired. the manufacturer was made aware of the failure, but offered no assistance. the failure mileage was 95,000. sm.
06/06/201195000
 Tl-the contact owns a 2005 ford f150. the contact stated there are faulty spark plugs breaking in the cylinder head and remains in the engine block. this causes the dealer to have to remove the sparks plugs which break easily causing a major problem to repair. the vehicle was taken to the dealer who stated it will cost $2,000 to repair these spark plugs. the manufacturer was contacted who stated there is no warranty or recalls for this failure. the contact should save his receipts in case there was a recall. the failure mileage was 95,000...mw
04/16/201197000
 2005 ford f-150 spark plugs fuse to engine and break very easily. the truck has less than 100,000 miles and was brought to the dealersip for a tune up. the dealership tried to remove the plugs and they broke. they are now forced to remove the header and replace the plugs. this is now going to cost $2600 for a known problem with the manufacture provided plugs.
06/12/200895000
 My 2005 ford f-150 lariat 5.4l sounds like a diesel, i was told this is a very common problem with f-150's within 2003-2006. this is a result of either cam phasers or bad lifters.
06/28/201087033
 In the 2005 ford f-150 with the 5.4 liter 3 valve there is a defect pertaining to the spark plugs. in the event that you try to remove the spark plugs they tend to break off in the head possibly damaging the threads of the spark plug hole. when this occurs, ford is charging an outstanding amount of money to repair it. this problem is all over the internet and doesnt just affect the 2005 model. it is a very serious defect costing people a lot of money that i think should be placed on the manufactures plate. it is almost as if they designed this problem on purpose to make people have to bring it to their repair shop and have it fixed reguardless of the price. i have personally experienced this problem along with many others and i think it is obvious that the customers are not happy with the way ford has handled the issue. spark plugs are considered to be part of preventive maintenance but this is sickening how they can get away with charging that much for a small problem. the problem was not discovered until ford had sold so many of them that it would probably take them years to correct every one. it is pretty much guaranteed that you are going to break off at least one of your plugs while trying to do this small task. as far as i know the only thing done to correct the problem was they invented a tool that will removed the broken part of the spark plug in the head, but if the threads get messed up in the process thats when it begins to start costing big bucks and it is totally the manufactures fault to begin with. please take this request for a recall seriously as i am not the only one who feels this way, just look online.
02/23/2010640001
 2005 ford f150 v8 4.6l driving down the road, spark plug popped out of the head. 65,000 miles, original plugs. *tr
02/12/2010590001
 2005 ford f150, 5.4 v-8 engine, 59,000 miles incident 1) 02/7/10 - upon accelerating away from a stop light while turning left, the truck accelerator pedal became inactive. truck was moving at 25-30 mph. additional pressure applied to the pedal caused no acceleration. light traffic allowed me to coast to shoulder where i was able to put the truck in park. truck faulted into 'limp mode' that limits the accelerator pedal operation (per manual), this was indicated by the 'wrench' light on the dash, no check engine light appeared. turned the ignition off, waited a ~15 seconds and restarted. upon restart 'wrench' light cleared and accelerator functioned as prior, again no check engine light appeared. incident 2) 02/12/10 - while driving on a federal highway at 55 mph in right lane the same sequence as incident one above occurred ? the truck accelerator pedal became inactive. being in the right-most lane i was able to coast on to the shoulder and avoid a rear-end collision. same ?wrench? light was indicated on dash, same sequence was used to restart and drive off. this obviously could have been much worse had the situation been different, i.e. in high-speed lane or heavier traffic patterns. this is certainly a safety concern for driving public, both those in the f150 and on the road around them. almost identical instances can be seen on nhtsa site for exact make/model/year truck. administration should investigate and consider a safety recall to avoid future damage. *tr
09/28/200950000
 Tl*the contact owns a 2005 ford f150. during a routine inspection a technician concluded that five of the eight spark plugs separated from the engine head; however, no repairs were made. the manufacturer was notified and no assistance was provided. the failure and current mileages were 50,000.
05/26/20091151501
 I have a 2005 ford f-150 pick up with a 5.4 liter triton engine. while driving on the highway the number 1 sparkplug was spit out damaging the head. the vehicle immediately slowed down in the middle of traffic. ford said this is uncommon, yet there are thousands of complaints already filed about this particular engine through the nhtsa. i have to completely replace the engine. *tr
05/18/2009550001
 Spark plugs cannot be changed because of design of cylinder head. this is a spark plug breakage inside the head. this is a common occurrence on 5.4 liter ford motors as reported on forums and through word of mouth. 1998 to 2008 motors are notorious leading consumers to either pay huge repair bills or trade before they wish to trade. also, someone wishing to change his plugs for proper emissions or proper maintenance is just screwed. scared to death to have them changed even at a dealership. ford mechanics even have trouble.this is no few vehicles. this is widespread.
07/22/200890000
 Tl*the contact owns a 2005 ford f-150. while driving various speeds, the vehicle began to jerk, backfire, and run badly. in addition, the check engine light illuminated on the instrument panel. the vehicle had to be towed twice. the fuel injectors were cleaned twice and the dealer stated that the catalytic converter needed to be replaced. the vin was unknown. the current mileage was 100,000 and failure mileage was 90,000.
08/22/20081020001
 2005 ford f-150 5.4 liter engine; all service work was performed at the recommended service intervals on this vehicle. at 102,000 miles, i took the vehicle to the dealership to have spark plugs replaced. (ford recommended 100,000 mile tune-up) the first three spark plugs attempted to be removed by three different technicians broke off even when following the ford tsb proceedure. this tune up will cost me almost $2,000 due to the defective spark plug design. ford will not help with the repair. *tr
07/21/2008431431
 Advised that the 2005 f-150 5.4 triton engine has a history of spark plugs seizing in the engine and recommended that the plugs be replaced. ford says the plugs will last for 100,000 miles. tsb 08-7-6 issued by ford to address problem. had plugs replaced at 43,123 miles and had three frozen or seized costing over $300.00 in labor. ford knows of problem and has not issued a recall to correct design flaw. read many other similar stories on internet where citizens are paying thousands of dollars to get the plugs out and vehicle back in operation. *tr
05/09/2008989191
 Since jan. 08 there have been 3 dealers look at & supposedly fixed 5.4 liter ford engine. ford does not want to help with any expense & i have 3 other vehicles that have had same recurring problem. all the above started with recall and has gone downhill. *tr
02/01/200745000103/01/2005
 Known issue of spark plugs breaking off in the cylinders. ford is well aware of this issue, but refuses to issue a recall for it. due to the breakage, it has been known to cost well over $2,000 in repair costs; just for a spark plug change! *tr
03/17/200615420101/02/2006
 Dt*: the contact stated while the heater is engaged gas fumes are detected in the vehicle. in an attempt to remedy the problem the dealer replaced the fuel injectors, spark plugs, starter, fly wheel, transfer case, and catalytic converter with no success.
01/03/20066000107/01/2005
 Dt*: the contact stated there were noises that resembled the sound of breaking glass. after finding the source of the noise it was discovered the vehicle had caught on fire. the vehicle had been parked since the previous day. the fire spread to the contact's other vehicle and home. the fire marshal filed a report. the fire started in the engine compartment and completely melted. the vehicle is still being inspected. there were no previous problems with the vehicle.
06/24/200517000201/22/2005
 2004 f-150 super crew stalled after decelerating and at low speed turning left through oncoming traffic. was able to roll through intersection without power steering and re-start engine after coming to a stop and shifting to park. this is the second time the vehicle has stalled at a low speed or turning.
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
02/09/200853000112/21/2005
 My 2005 ford f-150 w/ 4.6 triton engine lost compression around the #3 spark plug from the passenger's side. the engine ran, but with loss of power and a popping noise. the truck has less than 55,000 miles. leaving me stranded and requiring towing. *tr
08/01/2005100107/22/2005
 Engine knocks. *jb
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
01/07/200880000
 2005 ford f-150 5.4l triton had 2 blown spark plugs. first one happened at 80,000 miles, second at 130,000. the first time it destroyed the exhaust manifold and cost $3000 to repair. the second time this happened it blew the left side exhaust and the coil pack. this cost about $1500 to repair.
10/10/2009570001
 Coil on plug keeps miss firing . they were changed twice. ford wants to do a valve job to fix the problem . the truck has only 57000 miles on it. *tr
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR
07/19/200735742
 Tl*the contact owns a 2005 ford f150. while driving at speeds over 20 mph, the vehicle would shake and vibrate violently. he also observed black smoke emitting from the exhaust pipe and a strong gasoline fuel odor from the vehicle interior. the vehicle was taken to the dealer where they replaced the fuel injectors (performed under ford customer satisfaction program 07m08, nhtsa service bulletin number : 07m08, fuel system, gasoline:fuel injection system:injectors) and made repairs to the brake booster (performed under nhtsa campaign id number: 08v208000: component: service brakes, hydraulic:power assist:vacuum:hoses, lines/piping, and fittings). immediately after the repairs, when putting the vehicle into the drive position, there was a rattling noise under the vehicle. the vehicle was taken back to the dealer who stated that the catalytic converter was damaged due to the fuel injector failure. the dealer was advised by the manufacturer that the catalytic converter would not be covered and they would take no liability for the failure. there were no repairs made to the catalytic converter, to date. the contact has all service records, if needed. the failure mileage was 35,742 and the current approximate mileage was 84,000.

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