Recalls
| Campaign | Manufacturer | Manufacturing date | Type | # of units affected | Date Owner notified Mfg | Recall Initiated by | Manufacturers of recalled vehicles/products | Report Recieved Date | Record Creation Date | Regulation Part Number | FMVSS Number | |||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | ||||||||||||||||
| 07V553000 | FORD MOTOR COMPANY | V (Vehicle) | 1176000 | 12/29/2007 | ODI | FORD MOTOR COMPANY | 12/05/2007 | 12/05/2007 | ||||||||
| Defect Summary | On certain heavy duty trucks equipped with 7.3l diesel engines, the camshaft position sensor located on the engine of the vehicle may function intermittently, possibly resulting in an engine stall. | |||||||||||||||
| Consequence Summary | In the event of an engine stall, a crash could result without warning. | |||||||||||||||
| Corrective Summary | Dealers will inspect the sensor and replace it with an improved camshaft position sensor free of charge. the recall began on december 29, 2007. owners may contact ford at 1-866-436-7332. | |||||||||||||||
| Notes | Ford recall no. 07s57.customers may also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov. | |||||||||||||||
Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||||
| 19728 | 04/01/2007 | 10022243 | Lack of power due to low fuel pressure - fuel tank liner seperation. *kb | 07/23/2007 | |
| ENGINE AND ENGINE COOLING - ENGINE - OTHER FUEL TYPES - TURBO-CHARGER | |||||
| 20228 | 04/01/2008 | 10024865 | 1999-2008 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. *nj | 06/03/2008 | |
Investigations
| NHTSA ID | Manufacturer | Date open | Date close | Subject | Recall campaign | |
|---|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | ||||||
| EA06012 | FORD MOTOR COMPANY | 06/22/2006 | 12/07/2007 | ENGINE STALLING | 07V553000 | |
| In a december 3, 2007 letter, ford advised nhtsa that it will conduct a safety recall to replace the cam position sensor (cps) in approximately 1.2 million subject vehicles to address reports of engine stalling.a new design cps with improved performance and durability will be installed as a remedy.owner notifications will begin in december 2007. the subject vehicles are durable, full-sized, medium duty trucks commonly used for commercial purposes, rescue/emergency response, and commercial or recreational towing.cps failure is comparable to unexpectedly turning the key off since the signal it produces is vital to the electronic engine control system.cps signal loss terminates fuel injection resulting in an engine stall.once stalled, the engine may restart right away, or may restart after a delay (typically 5 to 10 minutes), or may not restart at all.in addition to exposing the driver and other motorists to crash risk due to loss of motive power or vehicle disablement, engine stalling also effects the power assisted steering and braking. through consumer interviews, odi determined that cps failures occurred without any form of warning, at any vehicle speed (50% at highway speeds), and under any driving condition, such as accelerating.consumers reported that about a third of the vehicles failed to restart, with another third reporting delayed restarting.half the vehicles that did restart experienced another stall on the same or a subsequent drive cycle (before cps replacement) re-exposing those consumers to the risks associated with a stalling event.in their voq reports, half of the odi complainants described difficulty controlling the vehicle due to lose of power assist systems, especially those who were towing at the time of the incident. the one alleged injury incident occurred in an intersection when a subject vehicle stalled while turning across oncoming lanes of traffic.although unsubstantiated, the complainant alleged an injury to a child occupant during odi's interview.the other crash allegations mostly involved low speed, loss of control incidents often caused by lack of power assist; no injuries are reported in these incidents, and property damage, if any, was minimal.consumers also reported other incidents with significant safety risks, such as disablement in a lane or on a shoulder of a high-speed roadway or interstate, or extended disablement in remote areas during severe weather conditions. the population above is ford's estimate of the 1.4 million subject vehicles produced that are currently registered.the ford complaint and warranty counts noted above are current as of ford's last submission dated june 21, 2007; they do not include f-450, f-550, or econoline counts as these products were not formally within scope of the investigation when failure information was requested.warranty data analysis indicates that about half the claims involved a stall while driving event ( ford's assessment) and that poor cps durability was a longstanding concern.ford reported that the new cps design should meet or exceed their 10 year, 150k mile life expectancy design requirement. | ||||||
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | ||||||
| EA06012 | FORD MOTOR COMPANY | 06/22/2006 | 12/07/2007 | ENGINE STALLING | 07V553000 | |
| In a december 3, 2007 letter, ford advised nhtsa that it will conduct a safety recall to replace the cam position sensor (cps) in approximately 1.2 million subject vehicles to address reports of engine stalling.a new design cps with improved performance and durability will be installed as a remedy.owner notifications will begin in december 2007. the subject vehicles are durable, full-sized, medium duty trucks commonly used for commercial purposes, rescue/emergency response, and commercial or recreational towing.cps failure is comparable to unexpectedly turning the key off since the signal it produces is vital to the electronic engine control system.cps signal loss terminates fuel injection resulting in an engine stall.once stalled, the engine may restart right away, or may restart after a delay (typically 5 to 10 minutes), or may not restart at all.in addition to exposing the driver and other motorists to crash risk due to loss of motive power or vehicle disablement, engine stalling also effects the power assisted steering and braking. through consumer interviews, odi determined that cps failures occurred without any form of warning, at any vehicle speed (50% at highway speeds), and under any driving condition, such as accelerating.consumers reported that about a third of the vehicles failed to restart, with another third reporting delayed restarting.half the vehicles that did restart experienced another stall on the same or a subsequent drive cycle (before cps replacement) re-exposing those consumers to the risks associated with a stalling event.in their voq reports, half of the odi complainants described difficulty controlling the vehicle due to lose of power assist systems, especially those who were towing at the time of the incident. the one alleged injury incident occurred in an intersection when a subject vehicle stalled while turning across oncoming lanes of traffic.although unsubstantiated, the complainant alleged an injury to a child occupant during odi's interview.the other crash allegations mostly involved low speed, loss of control incidents often caused by lack of power assist; no injuries are reported in these incidents, and property damage, if any, was minimal.consumers also reported other incidents with significant safety risks, such as disablement in a lane or on a shoulder of a high-speed roadway or interstate, or extended disablement in remote areas during severe weather conditions. the population above is ford's estimate of the 1.4 million subject vehicles produced that are currently registered.the ford complaint and warranty counts noted above are current as of ford's last submission dated june 21, 2007; they do not include f-450, f-550, or econoline counts as these products were not formally within scope of the investigation when failure information was requested.warranty data analysis indicates that about half the claims involved a stall while driving event ( ford's assessment) and that poor cps durability was a longstanding concern.ford reported that the new cps design should meet or exceed their 10 year, 150k mile life expectancy design requirement. | ||||||
Consumer Complaints
| Fail date | miles | occurences | Purchase date |
|---|---|---|---|
| ENGINE | |||
| 07/28/2012 | 150000 | ||
| While driving i began to hear a loud popping noise coming from the engine. after stopping and checking the engine i notice i had a blown out spark plug and busted ignition coil. i have a 2002 ford f 250 sd. i have attempted to put in a new plug but it will not screw into the hole. damage estimates are from $150.00 on labor fees and $75-100 on a temp. fix helicoil or head replacement for $2500.00. ford mech. said it happens all the time, due to poor design. *js | |||
| 07/28/2012 | 150000 | ||
| While driving i began to hear a loud popping noise coming from the engine. after stopping and checking the engine i notice i had a blown out spark plug and busted ignition coil. i have a 2002 ford f 250 sd. i have attempted to put in a new plug but it will not screw into the hole. damage estimates are from $150.00 on labor fees and $75-100 on a temp. fix helicoil or head replacement for $2500.00. ford mech. said it happens all the time, due to poor design. | |||
| ENGINE AND ENGINE COOLING | |||
| 11/20/2011 | 142000 | ||
| Tl-the contact owns a 2002 ford f250 sd. while driving approximately 50 mph, the contact heard a loud noise outside of the vehicle and suddenly there was a reduction in the engine power. the contact maneuvered to the side of the road and then resumed cautiously to the residence. upon reaching the destination the vehicle was inspected. the contact detected one of the spark plugs exploded from the head. the vehicle had not been repaired. the manufacturer was made aware of the problem. the approximate failure mileage was 142,000. kmj | |||
| 11/20/2011 | 142000 | ||
| Tl-the contact owns a 2002 ford f250. while driving approximately 50 mph, the contact heard a loud noise outside of the vehicle and suddenly there was a reduction in the engine power. the contact maneuvered to the side of the road and then resumed cautiously to the residence. upon reaching the destination the vehicle was inspected. the contact detected one of the spark plugs exploded from the head. the vehicle had not been repaired. the manufacturer was made aware of the problem. the approximate failure mileage was 142,000. js | |||
| 10/10/2011 | 183595 | ||
| Spark plug in the #8 cylinder was blown out breaking the coil pack and messing the threads up inside the head on the triton 5.4 v8 | |||
| 11/22/2010 | 86000 | ||
| Tl-the contact owns a 2002 ford f250 super duty. while the contact was driving approximately 35 mph, the vehicle began to shake with a vibration. the vehicle was taken to a local independent mechanic where they informed that one of the spark plugs ejected from the engine. the vehicle was in the process of being towed to a different mechanic for repair. the failure mileage was 86,000. js | |||
| 05/10/2010 | 60560 | ||
| Ford f-250 spark plug came out of head, broke off coil pack, cant get new plug back in. this should not be able to happen.i guess i am going to try hillicoil,it happened on the 3rd cyl back from the front on right side so its kind of under the windshield all ready, not much room for drill. | |||
| 04/07/2010 | 48000 | ||
| Spark plug blowout while driving on 5.4 liter triton motor with 48,000 miles factory installed spark plugs. ford motor dealer contacted. refused to accept responsibility. mechanic made shop repair by pulling intake and installing insert to number 3 cylinder. $1000.00 dollar repair, potential fuel ignition from motor, escaping fuel mix combined with coil spark present during failure | |||
| 08/15/2009 | 145000 | 1 | |
| Ford f250 v-10 spit spark plug, caused small fire under the hood. broke the cop. if a spark plug blows out and could injure a person working on the vehicle, why is that different from this that is classified as a safety recall? (engine cooling fan blades that break unexpectedly causing injury to persons working on a vehicle). *tr | |||
| 02/03/2010 | 121000 | 1 | |
| Ford f-250 2002 engine blew out a spark plug. *tr | |||
| 04/15/2008 | 80000 | 1 | |
| Ford f-250 5.4 l while driving low speed, heard loud pop in engine compartment, spark plug ejected from head. discovered that this is a common occurrence with aluminum head engines, esp ford 1989 through 2005 4.6 and 5.4 liter engines. problem is the result of 5 thread depth in head instead on new spec of 7. preventive measures, remove plugs, clean carbon from threads, reinstall plug, torque to required foot pounds. why ford or dealer doesn't tell you this is criminal. that's why i now drive a toyota. *tr | |||
| 07/31/2009 | 89000 | ||
| Tl*the contact owns a 2002 ford f-250 sd. while driving approximately 15 mph, the contact heard a loud popping noise outside of the vehicle. suddenly, there was reduced engine power. the driver pulled over to the side of the road and turned off the engine. the engine was restarted after a few minutes and the contact heard an extremely loud noise. the vehicle is in the process of being towed to an independent mechanic. the cause of the failure has not been determined. the vin was unknown. the failure and current mileages were 89,000. updated 09/01/09 *bf | |||
| 04/08/2009 | 160000 | 1 | |
| I was driving when a loud pop and what sounded like a large exhaust leak came from under the hood. opened hood and found coil pack and spark plug laying on top of the valve cover. vehicle stalled and didn't want to start. took to repair facility where the retapped spark plug cylinder added heli coil new spark plug and coil pack two weeks later the engine started making a loud gurgling noise which has yet to be diagnosed. *tr | |||
| 03/19/2009 | 1 | ||
| Driving in my car and i heard a thump and some smoke appeared from hood. when i raised the hood of the car i noticed a spark plug hanging in which this is a ford f250 2002. took it to the shop and they told me that all ford trucks has been doing this. not fair that there is no class action lawsuit against them this could have happened to me while i was on the express way and caused some major problems. what can i do because it is bound to happen again. *tr | |||
| 08/03/2002 | 80841 | 1 | |
| Driving my 2002 ford f-250 w/a 5.4l triton engine with 80k miles, #3 cylinder spit out its spark plug and strips threads . vehicle stalled, brought to ford dealer and incurred $3,800.00 engine repair. this is absolute bs!, ford is well aware of thousands of these defective cylinder heads, as they profit from this very expensive repair ($3,800.00). my complaint is that there ought to be a recall as there are thousands of victims of this defective ford product. it's a safety issue, i stalled on a major highway and the sparkplug is right under my fuel rail. please don't tell me this is another ineffective/costly government agency, surely the nhtsa is doing something about this well known defect. *tr | |||
| 06/19/2008 | 64856 | 1 | |
| After stopping at a stop sign i stepped on the gas pedal and heard a loud bang. as i was only 100 yards from home , i went home and called my mechanic. he said i blew out a spark plug and damaged the coil for that plug. i had to put in a helicoil and replace the coil. after reading many reports of this i felt the need to file this complaint. i feel ford should do something about this problem. i am going to replace my truck , most likely with a different brand. *tr | |||
| 07/14/2007 | 1 | 01/01/2007 | |
| I just bought a ford f250 it has a 5.4l. and the spark plugs eject from the engine why i was driving. no warning what so ever the truck seemed to be running fine. spark plug ejection is dangerous because fuel vapor starts coming out the spark plug hole, which is clearly a serious safety issue. the fuel vapor can be ignited by the loose spark plug . so i took it in and the mechanic said he has seen this happen in ford trucks to many times. he tried to fix it with a helicoil kit . that worked for about 2 weeks then it blew out again. then i had the heads replaced. to make a long story short to this day i am still having a problem . since the heads were replaced its been in the shop at least 6 times because of this. and spent more then $3,000 i just think this is not only a safety problem but it should not be my problem. *tr | |||
| 02/15/2008 | 115000 | 3 | |
| Ford f250 v10 blown spark plugs. 3 in under two months. *tr | |||
| 11/14/2007 | 97440 | 1 | |
| Cam shaft sensor failed while 7.3 powerstroke was a dealer for scheduled maintenance. *tr | |||
| 10/14/2007 | 64000 | 2 | |
| Several cam position sensor failures . *tr | |||
| 05/07/2007 | 20000 | 5 | 11/23/2001 |
| I have a ford f-250 7.3 liter diesel truck that has stranded me, my wife and family too many times due to ford p/n f7tz-12k073-a sensor-camshaft failure. i had to purchase five of the sensors at $100 plus, and had only 59,000 miles on my truck. i just ordered two p/n f7tz-12k073-b sensor-camshaft because the current sensor failed. *ak | |||
| 04/25/2004 | 4 | 11/23/2001 | |
| #3 spark plug blew out of the head. first happened in 2004 ford service acted like he never saw it before and didn't know a solution . i had a heli coil installed, it happened 3 more times before the last time, i had all plugs heli coiled .well when #3 blew out again on 4-14-07 and could not be repaired again. i was told the entire engine should replaced as previous problems had caused excessive cylinder wear. it was being done today. total out of pocket $ 7,000 plus 16 lost days of work rental fees.*ak | |||
| 07/24/2006 | 69500 | 06/15/2002 | |
| Dt: the contact stated while driving 15-20 mph, there was a loud popping sound. the vehicle was taken to the dealer who determined the head, spark plug and ignition coil on the spark plugs needed to be replaced. while searching the internet for information related to the defect on the vehicle, a case action suit in california was observed against the manufacturer. | |||
| 04/23/2006 | 42000 | 2 | 06/15/2004 |
| I have a ford 2002 f-250 super duty that the spark plug blew out f the cylinder head. this caused a very significant power loss causing the truck to slow very quickly much like applying the brakes but not using them. this caused a very near accident on a highway traveling at 50 mph and the slowing without brake lights nearly caused an accident. after approximately 1 min of researching the problem about the accident i realized that this problem is huge !!!! to say the least. there have been countless reports of spark plugs blowing and either people being stranded to near collisions. also i am a firefighters paramedic and my nose is no hydrocarbon meter but the levels of gasoline vapors that accumulate in a very short time. my question to that is how much vapor collects in the cab compartment and can it cause a compartment fire before the driver can safely get the vehicle to a safe area to exit the vehicle? i bring this to your attention because of my research i do not believe any letters or calling ford motor as just a vehicle owner can make ford motor company more aware of this problem. thank you! *jb | |||
| 01/11/2006 | 77200 | 3 | |
| Camshaft position sensor (cps) has failed 3 times since i've had the vehicle. my truck has only 77,000 miles on it. when this sensor fails the truck dies instantly and will not restart. i was lucky all 3 times to not be pulling a trailer in heavy traffic. *jb | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 05/15/2010 | 78000 | ||
| Leaking head gaskets on 2002 ford f250 truck with 5.4l engine allows oil to leak onto starter and exhaust manifold creating safety hazzard. this is a known problem with this type engine. | |||
| 03/11/2010 | 97625 | 5 | |
| I have a 2002 ford f250 with a triton v* engine. to this date, it has blown out 5 spark plugs! so far, the repairs have run over $1000 to fix this, and with three more to go, i can foresee at least another $750, which i can ill afford. *tr | |||
| 01/15/2010 | 84000 | 1 | |
| I own a 2002 f250 v10 with approx 84,000 miles. i was just driving along and the spark plug from the # 8 cylinder blew out. i had to retap it and put a helicoil in it. the spark plugs were the original spark plugs and have never been replaced. i have seen numerous complaints of the same problem on kline. it is definitely a manufacturing defect. also i need to replace the exhaust manifold bolts on the same cylinder heads. this is another problem i have found numerous complaints about online. *tr | |||
| 08/22/2008 | 168000 | ||
| Tl* the contact owns a 2002 ford f-250. he noticed flames emerging from the engine compartment. the fire department extinguished the fire. the vehicle has not been inspected to determine the cause of the failure. the current and failure mileages were 168000. | |||
| 08/27/2009 | 99000 | 1 | |
| 2002 ford f250 with a triton v8 5.4l engine had the spark plug blown out of the cylinder head and destroyed the ignition coil. apparently this is an extremely common problem and ford is unwilling to do anything. cost of repair is $1100.00. could potentially start a fire as fuel air mixture escape the cylinder the coil was sparking against the engine and this could have started a fire. the original factory plugs were installed in the engine, and the engine has never been serviced by anyone except the ford dealership. *tr | |||
| 08/05/2009 | 152000 | 1 | |
| While driving at 35 mph, a spark plug was ejected from my 2002 ford f-250 5.4l v8 pickup truck, causing the engine to stall and resulting in a loss of power for steering and braking. i'm told by my mechanic today, who identified the problem even before i told him why i was there, that this is due to a known defect with many ford engines, but that no recall was ever issued. given the danger of fuel vapors escaping from the spark plug hole and risk of fire, perhaps the nhtsa should press ford on the issue if it really is a common problem. *tr | |||
| 06/30/2009 | 104000 | ||
| Tl*the contact owns a 2002 ford f-250 sd. while driving 60 mph, the contact heard a popping sound coming from the engine. she examined the vehicle and noticed that a spark plug ejected out of the engine. the vehicle has not been diagnosed by the dealer. the failure recurred on three different occasions. the current and failure mileages were 104,000. | |||
| 11/20/2008 | 121000 | ||
| Tl*the contact owns a 2002 ford f-250 sd. while driving less than 65 mph, the contact smelled burning oil. he then noticed smoke underneath the hood and oil dripping from the exhaust. the vehicle was taken to the dealer and they stated that the head gasket was leaking. they would need to disassemble the engine and replace the head gasket at the estimated cost of $2,800-$4,000. the manufacturer was notified and could not assist because there were no recalls. the failure mileage was 121,000 and current mileage was 122,000. | |||
| 08/03/2002 | 80841 | 1 | |
| Driving my 2002 ford f-250 w/a 5.4l triton engine with 80k miles, #3 cylinder spit out its spark plug and strips threads . vehicle stalled, brought to ford dealer and incurred $3,800.00 engine repair. this is absolute bs!, ford is well aware of thousands of these defective cylinder heads, as they profit from this very expensive repair ($3,800.00). my complaint is that there ought to be a recall as there are thousands of victims of this defective ford product. it's a safety issue, i stalled on a major highway and the sparkplug is right under my fuel rail. please don't tell me this is another ineffective/costly government agency, surely the nhtsa is doing something about this well known defect. *tr | |||
| 07/21/2008 | 91573 | 1 | |
| 2002 ford f250 crew cab 4x4 short box, 5.4l v-8 gasoline engine just under 92000 miles. on 7/21/2008 merging on the expressway under heavy acceleration, a loud bang with spring popping sound was heard from the engine followed by the distinct odor of exhaust and unburned gasoline. verified throttle control and continued to drive with loud noise coming from engine. drove 4 miles to work to safely inspect the problem. noted that the exhaust y-pipe was separated from the drivers side exhaust manifold. assuming that it was just a failed manifold bolt, drove ~20 miles to the dealership to have it looked at. received the call that the number 6 spark plug was ejected from the head. upon the dealerships inspection, found that the threads were stripped out of the head. the spark plug then arrested in the ignition coil which was separated from the head due to failure of its mounting flange. the ignition wire held the coil and plug on the engine. there was zero gap noted on the spark plug electrode with anti-seize compound on only about .5 of the spark plug thread. thus suggested that only .5 of thread engagement was present from the factory original plugs (i.e. the spark plugs were not replaced since the recommended replacement interval is 10 years 100000 miles). advised that at a minimum a head needed to be replaced, but that an engine may be a better economical choice so that both heads are replaced and this design issue could be overcome (the newly remanufactured engine is supposed to have larger thread engagement at approximately .75). engine replaced to insure that this failure would not occur on one of the other cylinders in the head that would not be replaced. *tr | |||
| 06/21/2007 | 120000 | 1 | |
| 2002 ford f-250 5.4l spark plug loosened and blew out of cylinder head. 3rd plug from the front on passenger side. strong smell of gasoline. broke the coil over plug, could have broken the fuel rail and resulted in fire. repair cost not yet available - will attempt to fix myself as out of warranty. cruise control also not working but this truck not included in past recall - concerned about fire hazard in cruise control also. | |||
| 07/11/2005 | 54630 | 1 | 12/07/2001 |
| #2 spark plug blown out of head while driving. spark plug threads in head stripped out causing plug to blow out and damage coil. truck was taken to dealer for diagnosis, dealer had to install a helicoil in head at location #2. *nm | |||
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||
| 01/01/2013 | 1 | ||
| 2002 ford f250 superduty. consumer writes in regards to a strong diesel fuel odor and finding fuel on the passenger side of the engine compartment in the cab of the vehicle. the dealer informed the consumer, the diesel engine was designed with copper sleeves or cups around the fuel injectors. the purpose of the cups were to separate the engine cooling system from the pressurized fuel system. over a period of time, the engine coolant reacted with the copper cups and created small pin holes or cracks in the injector cups. since the fuel system was pressurized it injected diesel fuel into the coolant circulating in the engine. eventually the diesel fuel came out of the radiator overflow and all over the passenger side of the engine compartment. since there was no way to tell, which injector cup was bad, all of them would have to be replaced along with the coolant hoses and the radiator would need to be flushed. the engine would have to be taken apart, the heads would have to be removed and the injector cups replace. | |||
| 07/11/2007 | 133450 | 4 | 05/20/2003 |
| Cam position sensor failed on 2002 ford f250 w. 7.3l diesel. when this sensor fails you loose all power assist and the steering becomes very hard and breaks are at best no existent. i was able to get the truck to the side of the highway and not become a hazard. replace sensor with spare i had with me due to multiple failures over the years made me aware to keep an extra with me at all times. *tr | |||
| 08/30/2007 | 103000 | 10 | 06/30/2002 |
| Re: nhtsa action #: pe06011 i am currently experiencing these problems related to cps failures and would like to add my support for a recall request. * updated 12/12/07 *bf updated 12/12/07 *tr | |||
| 04/16/2007 | 160000 | 20 | 10/11/2004 |
| My 2002 ford f-250 supercab diesel 7.3 started with a miss as i drove down the highway and has gotten progressively worse. now it dies out at low speeds in town driving leaving me with no brakes or steering. i have been told this is a common problem with this truck caused by the camshaft positioning sensor but ford assumes no responsibility. this is a very dangerous problem especially when the vehicle is pulling a load. *tr | |||
| 06/02/2007 | 85450 | 3 | 09/27/2004 |
| Vehicle has quit running on several occasions, engine just dies, has been happening for about 6 months periodically. on june 2 2007 engine quit 3 times in a half hour time period,replaced camshaft sensor at my expense warranty expired on jan 1 2007. i have read of several complaints about these sensors on the internet and would like to share mine also. *tr | |||
| 05/22/2003 | 60000 | 2 | 12/27/2001 |
| Vehicle is a 2002 ford f-250 w/ 7.3l diesel engine. the cam position sensor (cps) failed. when it fails, the engine stalls. this means that a nearly 7400 pound vehicle suddenly has no power, including loss of power steering & brakes. the reported incident date is the date of the first failure (happened at a stop light). the second failure happened about 1 year later (while driving). when purchasing a replacement cps, the parts guy said they sell a lot of these (as in they fail often). *jb | |||
| 05/15/2005 | 63400 | 2 | 04/15/2003 |
| Truck started cutting off randomly. truck finally quit running on major street was able to get it off the road coasting. cps was replaced and problem was corrected. old part may still be available. *tr | |||
| 10/05/2005 | 45000 | 2 | 01/14/2002 |
| Cam position sensor failure. *jb | |||
| 10/20/2006 | 123575 | 1 | 10/25/2005 |
| I own a 2002 ford f250 7.3l power stroke diesel. on 10-20-06 the cps failed in a rainstorm. my wife (7 months pregnant) was driving and was nearly involved in a crash because when the failure occurred all electronics died as did the motor. this rendered the power steering and power brakes useless. this problem could have caused a fatality if not to my wife but other drivers as well. the truck stranded my wife on the side of a country road for 2 hrs. waiting for a tow service. the vehicle had to be towed and the cps replaced before the truck would restart. *jb | |||
| 11/25/2005 | 45000 | 1 | 03/08/2005 |
| Truck sat all night, started truck waited approx 10 min , drove approx 2 miles, truck stalled/died in the middle of intersection, brakes did not have power assist. coasted down hill approx .5 miles before i could stop the truck. truck cooled and restarted then died approx 2 min later. truck was towed to local ford. cps replaced as bad. *jb | |||
| 03/06/2006 | 80000 | 5 | 07/20/2002 |
| Truck stops running with no warning during normal operation. *nm | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| 02/25/2007 | 59456 | 1 | 03/16/2002 |
| I was driving down the highway at approx 65 mph when all of a sudden i heard a pop and lost engine power. i pulled over and looked under the hood of the truck and observed a sparkplug lying in the engine compartment and the wireharness for it was torn loose. it was clear that a sparkplug had rotated loose causing it to come out of engine which caused sudden engine failure at highway speeds. the sparkplug which rotated loose, tore out the last 3 threads of the sparkplug hole in the cylinder head and destroyed the sparkplug wire harness. the truck was brought to the dealership on a flat bed truck. the cylinder head had to be removed and a helicoil put in to replaced the torn out thread for the failed sparkplug hole. all sparkplugs had to be replaced with new ones. a new sparkplug wireharness was installed. i observed that the ceramic portion of the sparkplug rotated independantly of the treaded part of the sparkplug body which would allow rotation of the sparkplug body independant of the ceramic portion. i do not have the sparkplug that rotated loose. | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||
| 05/02/2010 | 160000 | ||
| Well guess what, it's me again with f250 4x4 with the triton motor. got in it made it about 1/10 of a mile, it started shimmimg and running rough again and it died. i'm afraid to start it because of the spark plug ejecting already once and i'm afraid it's gonna do it again and catch fire. ford if this keeps up u will have a lawsuit and you can bring in your big lawyers but i guarantee you will not win. | |||
| 08/19/2005 | 75000 | ||
| I had to replace exhaust manifold bolts at 75,000 miles and now i am replacing them again also. i have read all these complaints about the sparkplugs and the bolts burning into and i have had fords since i've been driving at age 16 which is over 30 years ago and i might be changing my brand because i am sick of the trouble. ford you need to step up to the plate, these are hard times for everyone but you need to take responsibity of these problems. | |||
| 10/06/2009 | 80000 | ||
| I have 2002 ford f250 with a 5.4l triton engine. the exhaust manifold studs are rusting and breaking off. i have contacted my dealer and have been told it is common problem. this is an $850 to $1000 fix. i am afraid that the exhaust gasses may start something burning in the engine compartment and that the leaking exhaust is not being cleaned by the catalytic converter. if this is a common problem, why isn't there a recall? the replacement studs are stainless steel and are bigger so ford must know of this problem. | |||
| 01/15/2010 | 84000 | 1 | |
| I own a 2002 f250 v10 with approx 84,000 miles. i was just driving along and the spark plug from the # 8 cylinder blew out. i had to retap it and put a helicoil in it. the spark plugs were the original spark plugs and have never been replaced. i have seen numerous complaints of the same problem on kline. it is definitely a manufacturing defect. also i need to replace the exhaust manifold bolts on the same cylinder heads. this is another problem i have found numerous complaints about online. *tr | |||
| 08/22/2009 | 82000 | 1 | |
| While driving my 2002 ford f250 super duty (5.4l v-8) i experienced a popping sound from under the hood which increased in volume very quickly. i pulled over (on a busy highway) and had to be towed to a shop where i learned that a spark plug had been ejected. the repair, which was about the most minimal that could be done, cost me over $600.00, with no guarantee that this will not happen again. my internet research on this indicates that there have been literally thousands of these incidents involving ford engines. ford clearly knows about this, but does not acknowledge it, does not assist with the costs, and will not recall the engines. this is not just a very costly inconvenience - it is a clear-cut safety issue that strands vehicles on busy highways and has resulted in numerous fires. *tr | |||
| 04/29/2009 | 102000 | 1 | |
| Approximately 5 days before the failure, i began to hear an exhaust leak. i kept driving my truck assuming it was just a small leak in the exhaust system. on april 29, the spark plug blew out of the head of my v10 taking the last few threads with it. the dealer says, best case scenario i need a helicoil repair, costing around $600, worse case scenario, the failure could cost me my engine. $1000's of dollars. *tr | |||
| 11/14/2002 | 66234 | 1 | |
| Spark plug ejected from #3 cylinder head. *tr | |||
| 09/15/2006 | 30000 | 3 | 04/24/2005 |
| Tl*the contact owns a 2002 ford f-250 super duty. the contact stated that the bolts on the exhaust manifold snapped off on three different occasions. the failure was brought to his attention by his mechanic during routine maintenance. the dealer and manufacturer have not been notified because the vehicle was no longer under warranty. the vehicle has not yet been repaired. the current mileage was approximately 79,000 and failure mileage was approximately 30,000. updated 10/20/08. *lj updated 10/20/08. *jb | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||
| 01/06/2007 | 1 | 06/08/2002 | |
| I have a 2002 ford sd with the 6.8 v10 with 42,000 miles on it. when i took in for a noise from the exhaust i was told that i had 4 manifold bolts rusted off and more where ready to break. i had the repair work completed at a cost of $3200 which i had to cover. i was told that this is a common problem but ford is not standing behind this problem. while they were working on the truck they found the power steering pump coming off and looking in to that it was found that a bolt was broken off in the frame. the repair shop told me that they have done many of them just like mine. i have owned 10 new ford products in the past 12 years and this will probably be the last. *tr | |||
| 04/10/2008 | 30000 | 4 | 12/23/2002 |
| Two manifold bolts snapped off each side of my 02 6.8 liter engine. the rest are horribly rusted. the truck has only 37000 mi on it. there has been a tsb concerning this, but it is a huge and common problem. there needs to be a recall for the people out of warranty,as it does concern emissions and the leaking of exhaust gases from before the cat. *tr | |||