Recalls

CampaignManufacturerManufacturing dateType# of units affectedDate Owner notified MfgRecall Initiated byManufacturers of recalled vehicles/productsReport Recieved DateRecord Creation DateRegulation Part NumberFMVSS Number
ENGINE AND ENGINE COOLING - ENGINE - DIESEL
07V553000FORD MOTOR COMPANY V (Vehicle)117600012/29/2007ODIFORD MOTOR COMPANY12/05/200712/05/2007
Defect SummaryOn 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 SummaryIn the event of an engine stall, a crash could result without warning.
Corrective SummaryDealers 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.
NotesFord 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

BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING
05171310/07/20050524910018062Coolant degas bottle overflow. *tt12/14/2005
ENGINE AND ENGINE COOLING - COOLING SYSTEM
0524901/01/200505262310018939Coolant degas bottle overflow. *tt01/25/2006
ENGINE AND ENGINE COOLING - COOLING SYSTEM - FAN
071410021236Lack of cooling fan operation. *kb03/23/2007
ENGINE AND ENGINE COOLING - ENGINE
062401100222936.0l diesel engine - oil leak or boost pressure leak at hot side charge air cooler duct. *kb07/25/2007
1961402/01/200710021619Air filter water ingestion / snow packing with codes p0103. *kb06/12/2007
075410021462Cold start driveability - white smoke, lacks power, exhaust odor, surges, runs, rough, or no start. *kb04/27/2007
07515100214646.0l oil seep or boost pressure leak at hot side charge air cooler duct. *kb04/27/2007
1937509/01/200610021229Watch for oil flow from the base engine oil pump. vehicles equipped with a 6.0l diesel engine. *kb03/23/2007
1924706/01/200610021173Oil flow from the base engine oil pump. *kb03/19/2007
1935609/01/200610021174Driveability issues and/or dtc p132b, p006a immediately after reprogramming. *kb03/19/2007
ENGINE AND ENGINE COOLING - ENGINE - DIESEL
1972804/01/200710022243Lack of power due to low fuel pressure - fuel tank liner seperation. *kb07/23/2007
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
08-2-1103/01/200808-4-7100243256.0l turbocharger carbon deposit diagnostics and service tips. *nj updated 5/29/08. *nj04/04/2008
0617106183100212326.0l turbocharger carbon deposit diagnostics and service tips - lack of power, white or black smoke, surge, p0238, p0299, p0404, p2262, and/or p2263. *kb03/23/2007
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE)
0721910/01/2007100238556.0l--mil on--p0401, p0402, p0404, p1335--lack of power or surge with some 2003-2007 f-super duty, 2003-2005 excursion and 2004-2008 e-series vehicles. *nj02/06/2008

Investigations

NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
ENGINE AND ENGINE COOLING
EA06012FORD MOTOR COMPANY06/22/200612/07/2007ENGINE STALLING07V553000
 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
EA06012FORD MOTOR COMPANY06/22/200612/07/2007ENGINE STALLING07V553000
 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 datemilesoccurencesPurchase date
ENGINE AND ENGINE COOLING
09/17/2011108000
 Tl* the contact owns a 2003 ford f-250 superduty. the contact was driving 40 mph when the vehicle stalled and failed to restart. the vehicle was towed to the dealer but was not repaired. the manufacturer was not made aware of the failure. the vehicle was not repaired. the failure and current mileages were 108,000.
09/17/2011108000
 Tl- the contact owns a 2003 ford f-250 superduty. the contact was driving 40 mph when the vehicle stalled and failed to restart. the vehicle was towed to the dealer but was not repaired. the manufacturer was not made aware of the failure. the vehicle was not repaired. the failure and current mileages were 108,000. kmj
09/17/2011108000
 Tl- the contact owns a 2003 ford f-250 super duty. the contact was driving 40mph when the engine stalled, and failed to restart. the vehicle was towed to the dealer, but the manufacturer was not contacted. the vehicle was not repaired. the failure and current mileages were 108,00 . rds
05/09/2010130000
 My 2003 ford f 250 shoy a spark plug out - mechanic looked inside and said all the threads had been ripped out and has had this issue with several other ford pickups in recent months. obviously a problem as this is a small town and not that many ford pickups around. 2 optionjs to fix replace the heads or retap.
03/13/2008171700010/27/2007
 I was checking my transmission fluid on my truck, my spark plug blew out nearly hitting me in the face. i fell off my step stool, and hurt my wrist because of the big noise and it scared the heck out of me!!this could have been a much worse of day for me if it hit me. this is also the second time the plug has blown out!! *tr
ENGINE AND ENGINE COOLING - COOLING SYSTEM
06/23/200775000305/12/2004
 Failed three times in the last 24 months - fuel regulator, oxygen sensor. water pump failed 06/23/07. *ak
ENGINE AND ENGINE COOLING - ENGINE
09/25/201059885
 I started to hear a ticking noise in my truck. so i t had it looked at by my maechanic. he could not tell where the noise was coming from. so about a week later i was getting ready to go to work, i started up my truck and a loud pop!!! and black smoke from underneath my hood. i shut the truck down and pop the hood and thats when i saw the mangled coil pack. so there i was was assed out of a day of work cause i had to fix this problem, which took me all day to fix. off to pepboys i went to buy another coilpack as well as all 8 spark plugs. might aswell right? so $120.00 later the problem was fixed until now!!! here we go again..... same freakin noise and its getting louder. since i can't tell which sparkplug it is i really don't know how to fix this prob before another coilpak blows again. i really hate this engine. it has only been ^ months from the first time i fixed the or at least thought i fixed the problem. i didn't save any of the old parts.
03/24/201072340
 I was driving my 2003 ford f-250 when a spark plug blew out of the cylinder head breaking the coil, and causing the truck to run on 7 cylinders. my truck has only 72340 miles on it and those are the original spark plugs from the factory.
07/27/2009790001
 Traveling at 52mph spark plug blew out. 2003 ford f250 5.4l. *tr
07/18/200660000109/01/2002
 Dt*: the contact stated while driving 70 mph on the freeway, the contact heard a loud popping noise. upon inspection of the engine, the spark plug was lying on the intake manifold. the vehicle was towed to a local dealership.
ENGINE AND ENGINE COOLING - ENGINE - DIESEL
04/12/200667000111/01/2003
 Failed cps (cam position sensor). *jb
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
04/05/200853197102/15/2003
 I was driving on hwy 59 south to home when a spark plug blew out of my 2003 f-250 with 5.4 motor. number 3 passenger spark plug blew out, truck only has 53,000 miles on it. truck was towed to dealership and they acted like they never heard of such but that they had a kit to fix it. cost to fix was $454.36, then the told me no warranty on the fix. plus tow bill of $149.00 ford motor company knows of this defect and refuses to do anything! *tr
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER
11/01/200435000607/01/2003
 Dt*: the contact stated when the turbo started to flutter and the truck either stalled or almost stalled. the vehicle stalled 6 times and on two of the occasions it would not start. this first incident occurred in november 2004 and the most recent occurrence was august 4 2006. this incident occurred only while accelerating. the vehicle has been taken to the dealer 4 times however they were unable to repair the vehicle.
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
03/06/2010980001
 This the second time my 2003 ford f-250 v/10 has ejected a spark-plug. *tr
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
06/23/200775000305/12/2004
 Failed three times in the last 24 months - fuel regulator, oxygen sensor. water pump failed 06/23/07. *ak

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