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
03/14/200525000
 Tl- the contact owns a 2003 ford f-350 sd diesel. the contact stated the vehicle experienced a blown head gasket. the dealer replaced the motor but the failure recurred. the manufacturer was notified of the failure but denied any assistance with repairs to the vehicle. the vehicle was not repaired. the failure mileage was 25,000 and the current mileage was 150,000. kmj
03/14/200525000
 Tl- the contact owns a 2003 ford f-350 sd, diesel engine. the contact stated the the vehicle had a blown head gasket. the dealer replaced the motor, but the failure recurred. the manufacturer was notified, but denied any assistance with repair to the failure. the vehicle was not repaired. the failure mileage was 25,000 and the current mileage was 150,000. nw
12/10/2008580001
 I'm sure i have the same problem. i heard a ticking noise also, then my truck started to miss under load. unable to determine which cylinder is the problem, sounds like all my be bad at some time. ford has to be aware of this problem, not taking the blame is an example of how they run their business. ooohhhh wait they are getting ready to go under. wonder why???? *tr
10/06/2008389421
 I have a 2003 ford f350 king ranch with a 6.0l diesel motor. the truck has had a variety of software failures with respect to the pcm for the motor which has resulted in the motor completely and instantaneously shutting down or catastrophic failure of the turbocharger resulting in the turbo over boosting and blowing up the intercooler or no psi out of the turbo leaving me and my family stranded twice in the mountains pulling a full two horse trailer (6,500 pounds). vehicle has been into bakersfield ford, visalia ford, rancho ford for service. pcm system was always reflashed and repairs made under warranty until the most recent turbocharger failure 09-28-2008. the vehicle was 5 months out of warranty and this failure cost me $2,700. today 10-6-2008 the pcm lost all its memory and i again lost power on the freeway and was nearly hit by multiple vehicles trying to get to the side of the road and off the freeway. this was five days after getting the truck back from ford. a process was went through at ford to re-learn the turbo strategy and the truck was returned to me working fine. *tr
ENGINE AND ENGINE COOLING - COOLING SYSTEM
02/04/2009953001
 I smelled hint of raw fuel when the engine was warm for 1-2 months prior to the obvious problem. 3-4 weeks prior to professional inspection there was white smoke out of the exhaust for 1-2 minutes. this smoke was associated with rough idling that when away completely until the next cold start up. the precipitating event for professional inspection was raw fuel spraying onto the trailer that was being pulled. inspection revealed raw fuel pooled on the horizontal engine surfaces and raw fuel in the cooling system. this was verified by manufacturer's dealer service department and found to be a leaking fuel injector cup. it will require changing all the fuel injector cups. the dealer service agent reported that this same problem has been several times in these particular models. it is usually a warranty item. this has not been repaired yet as this vehicle's warranty has expired by time limit but not mileage. the manufacturer has denied any obligation to help restore the vehicle to safe operation given that it seems to run unimpaired from a performance standpoint. *tr
ENGINE AND ENGINE COOLING - ENGINE
07/01/2003250001
 Vehicle stalls - surges - runs rough - problem has existed since new - have taken to ford garage and they have never fixed to last. *tr
09/07/2009630001
 We were using our ford f350 diesel (6.0 motor) with 63,000. we were going 70 mph on the interstate pulling a loaded 5 horse trailer when the truck would not accelerate, 15 seconds later engine cut off. we were in the left lane and had no power to steer off the road and could not come to a fast stop because of the weight of the of horse trailer. we had to coast approximately 100 yards and pull off on the left side because traffic was too heavy and going to fast to let us over to the right side. truck would not start again. had to be towed off the interstate and home. took it to the repair shop and was told the engine locked up and needs to be replaced at a cost of $7500 to $10000. i checked on warranty and because it is a 2003 it is expired. called ford and was told there was no recalls. it was extremely dangerous situation and can not believe that were is not some type of defect in the engine. *tr
07/22/200861800
 Tl*the contact owns a 2003 ford f-350 sd. while the contact was examining his vehicle, he noticed oil spots on the floor of the garage. the vehicle was taken to a local mechanic and they discovered that the oil pan was extremely rusted and the vehicle was serviced for the failure. the vehicle has not been diagnosed by the dealer. the current and failure mileages were 61,800.
04/15/2008580001
 I recently experienced severe surging at idle, making the vehicle jump forward, rough acceleration, and complete stalling at various speeds. took vehicle to dealer for repair. they replaced the icp sensor, and the icp wiring harness (which was burnt and shorting out), and cleaned injectors = $1348.00 this is the same issue that ford recall no. 05s34 addresses on the same truck, same engine (6.0), but one year newer. ford did not return old parts to me and i failed to ask for them. i am convinced that the shorting out of the icp harness, like the problem in #05s34, caused the sensor to fail. *tr
ENGINE AND ENGINE COOLING - ENGINE - DIESEL
05/01/2009207/01/2003
 2003 ford f350 has problems with the fuel injectors, transmission and an oil leak. *nj the consumer stated the vehicle lost power and white smoke emitted from the tailpipe. he also noticed a delay of engagement from drive to reverse and the fuel gauge was stuck. the number 8 injector had failed, the transmission needed a new part and the fuel gauge needed a new sensor. in the fall of 2008, the vehicle developed an oil leak. it was discovered that the icp sensor (injector control pressure) was the problem. in march 2009, while towing a tractor, the truck lost power and again it emitted smoke and there was a harsh jerk. it was determined that the engine failed again. the number 1 and number 3 injector had failed and there was a new oil leak. *jb

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