Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||||
| 15397 | 11/01/2001 | 630412 | Some vehicles may exhibit a condition of oil contamination in cooling system. *tt | 04/17/2002 | |
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| TB-08-258 | 12/29/2008 | 10029029 | Jerr-dan: anti stall feature for ford f series light duty chassis with v10 gas engine and an engine drive clutch pump. model years unknown. *pe | 06/12/2009 | |
| 11675 | 10/30/2003 | 10004874 | Rough idle, miss and various other driveability concerns on vehicles with 7.3l dit engine. this may be related to injector bore scuffing caused by fuel quality issues. *tt | 01/13/2004 | |
| 16683 | 03/01/2003 | 10001937 | False failure of the vapor management valve (vmv). *tt *jb | 07/28/2003 | |
| 13846 | 03/01/2001 | 620275 | Some vehicles built 7/1998 to 6/1999 equipped with a 4.6 / 5.4l winsor built engines may exhibit an oil leak from the cylinder heat gasket area. *tt | 07/23/2001 | |
| 14821 | 04/01/2001 | 619315 | Some vehicles equipped with 4.6l romeo engine may exhibit an oil leak from the cylinder head gasket area. *tt | 05/23/2001 | |
| 14864 | 04/01/2001 | 619335 | Subject regarding certain vehicles with 4.6l romeo engines exhibiting an oil leak from the cylinder head gasket area. *tt | 05/23/2001 | |
| 13846 | 02/01/2000 | 612444 | Some vehicles built 7/1998 to 6/1999 equipped with a 4.6 / 5.4l windsor built engines may exhibit an oil leak from the cylinder head gasket area. *tt | 06/08/2000 | |
| 8093 | 02/01/2000 | 612291 | Some vehicles built 7/1998 to 6/1999 equipped with a 4.6 / 5.4l windsor built engine may exhibit an oil leak from the cylinder head gasket area. *tt | 06/07/2000 | |
| 6585 | 07/01/1999 | 610701 | Some vehicles equipped with 7.3l dit diesel engines may develop a cracked flexplate. *tt | 05/11/2000 | |
| 13180 | 09/01/1999 | 6090538 | Information regarding camshaft position (cmp) sensor alignment tool chart. *mjs | 03/21/2000 | |
| 6997 | 09/01/1999 | 6090310 | Some service manuals may list the incorrect camshaft position sensor alignment tool for vehicles with various engine sizes. *tt | 03/14/2000 | |
| 980307 | 04/01/1998 | 602160 | Conditions with pressure being higher/lower than expected. *yc | 09/23/1998 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||||
| 15851 | 05/01/2002 | 637696 | Some 5.4l windsor power improved engines may exhibit a slight oil leak or weep at the cylinder head to block joint. *tt | 12/04/2002 | |
| 15761 | 03/01/2002 | 636408 | Some dedicated cng vehicles may exhibit driveability conditions of hard start / no start / rough running. *tt | 11/08/2002 | |
| 4711 | 08/01/1998 | 615250 | Some super duty trucks equipped with the 7.3l dit engine may exhibit a lack of power and / or a whistle noise coming from the engine compartment. *tt | 01/10/2001 | |
| 11776 | 08/01/1998 | 615276 | Some vehicles with 7.3l dit engines may exhibit a no start / hard start and / or long crank time. *tt | 01/10/2001 | |
| 12798 | 05/01/1999 | 607112 | Some vehicles equipped with engines produced by windsor engine plant may exhibit an engine knock at initial cold startup. *tt | 01/05/2001 | |
| 4658 | 08/01/1998 | 615194 | Some vehicles with 7.3l dit engine may exhibit a no start / hard start and / or long crank time. *tt | 01/03/2001 | |
| 13331 | 10/01/1999 | 6092152 | Some vehicles equipped with engines produced by windsor engine plant may exhibit an engine knock at initial cold startup. *tt | 11/27/2000 | |
| 12174 | 11/01/1998 | 613224 | Some vehicles may exhibit a hard start/long crank, cold start stall, cold rough idle concern. *mjs | 06/19/2000 | |
| 985072 | 11/01/1998 | 613203 | Some vehicles with 7.3l dit engine may exhibit a no start / hard start and / or long crank time. *tt | 06/19/2000 | |
| 13870 | 02/01/2000 | 612476 | Concerns with a no start condition after installation of a new 6.8l engine assembly. *tt | 06/08/2000 | |
| 8138 | 02/01/2000 | 612327 | Some vehicles may exhibit a no start condition after installation of a new 6.8l engine assembly. *tt | 06/07/2000 | |
| 6350 | 07/01/1999 | 610653 | Some vehicles equipped with engines produced by windsor engine plant may exhibit an engine knock at initial cold startup. *tt | 05/10/2000 | |
| 13322 | 10/01/1999 | 609613 | Some vehicles may exhibit an engine knock at initial cold startup. *tt | 04/04/2000 | |
| 7155 | 10/01/1999 | 6090791 | Vehicles equipped with windsor engines only may exhibit an engine knock at initial cold startup. *tt | 03/30/2000 | |
| 13285 | 09/01/1999 | 6090709 | Experiencing engine knock at initial cold startup. *tt | 03/23/2000 | |
| 983316 | 02/03/1998 | 607481 | Some customer may complain of a ticking noise on initial cold start-up in park position and neutral position. *tt | 09/23/1999 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER | |||||
| 11672 | 10/30/2003 | 10004873 | 7.3l dit turbocharger replacement under warranty. ford special service message. *tt | 01/12/2004 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL | |||||
| 982310 | 11/23/1998 | 603724 | Mass air flow (maf)- sensor contamination- service tip. *ak | 03/03/1999 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR | |||||
| CSP-08B01 | 05/16/2008 | 10026389 | Ford: certain 1999-2001 model year vehicles up to 6000 lb gvwr registered in new york and certain 2001 vehicles up to 6000 lb gvwr registered in the state of maine, certified for sale in california-federal emission warranty refund. *pe | 10/23/2008 | |
Investigations
| NHTSA ID | Manufacturer | Date open | Date close | Subject | Recall campaign | |
|---|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK PLUG EJECTION FROM CYLINDER HEAD | ||
| On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi | ||||||
| ENGINE AND ENGINE COOLING - ENGINE | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK PLUG EJECTION FROM CYLINDER HEAD | ||
| On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi | ||||||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK PLUG EJECTION FROM CYLINDER HEAD | ||
| On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi | ||||||
Consumer Complaints
| Fail date | miles | occurences | Purchase date |
|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||
| 11/28/2009 | 100988 | ||
| I had just got off work and was leaving the parking area and blew out the number 4 sparkplug on the right side head. i shut off the my truck and parked it. i called a friend that lives close for a ride home. the next morning i drove back to the plant and took my truck to the local ford dealership. they said that i should replace the head or install a helicoil and also replace the spark plug and coil pack. so i had them install the helicoil and replace the damaged parts. less then a month later i was driving to work on the i 90 and i blow out the number 5 cylinder spark plug and this time it took out the plasic sheild and ripped the spark plug and the coil pack off he truck. i have not done any thing but contact ford motor company about this at this time. there suggestion was to replace the heads my self at a cost of 6,000 dollars | |||
| 12/18/2007 | 172000 | 3 | |
| Blew out sparkplugs and broke bracket on the side of coil packs. don't like paying $85 a pop for ford's poor design. plus the healy coils or maybe that's the motive. this happened three different times. *tr | |||
| 04/01/2004 | 65000 | 2 | 08/01/2003 |
| 1999 ford expedition first blew out a spark plug in 2003 due to too few threads in cylinder head. mechanic was able to repair for around $500. the problem occurred again on another spark plug in 2004 which destroyed the whole engine. i contacted ford and was told they could do nothing about it. the refurbished jasper engine ended up being around $5400. the old engine was turned in to avoid a core charge. i have all of the paperwork from the mechanic stating the problem. *nm | |||
| 03/25/2005 | 60000 | 1 | 02/27/2004 |
| 1999 f-150 head gasket leaking on right back side on exhaust and catalytic convert smell and see smoke affraid of fire while driving or parked .*ak | |||
| 09/15/2003 | 100000 | ||
| 6.8 litre v-10 engine and one spark plug from each cylinder head came out. one cyl head had threads destoyed thereby making a replacement nessesary and the other one was suspect. the dealer suggested a rebuilt engine as costs would be very close between repairs and a genuine ford rebuilt engine and it would come with a warrenty. my complaint is that the plugs came out because the cyl heads were a poor design with only 3/8" threads in an aluminum casting and i shouldn't be paying for poor engineering and designs. there has been an update in 2001 that now has a cyl head with 9/16" threads and plugs to suit. i want ford to install a new updated engine at their cost. | |||
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||
| 02/12/2003 | 48665 | 0 | 06/14/1999 |
| Engine comes up to temperature heater works normal heat goes out. engine temp risies quickly to overheat condition. this condition continues to repeat itself. it is a major driving distracton because you are focused on the heater not driving. the potential for an accident axists due to the distraction! failures started occurring | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 02/04/2010 | 154000 | 1 | |
| I was driving my 1999 ford f150 4x4 with 5.4l engine home from work and stopped at traffic light. the light turned green and i proceeded to go and then pow the truck began to make a loud popping noise and lost all engine power. i was in the middle of the intersection and somehow managed to keep it running long enough to get through the intersection and on a side road. i hesitated to open the hood because of the strong gasoline smell but it wasn't on fire yet so i opened it and found one of my ignition coils (coil packs) loose on top of the intake manifold. upon further inspection i realized the spark plug had blown out of the aluminum cylinder head. i was able to catch a ride to the auto parts store with coil and plug in hand. the salesman at the store immediately knew what had happened and even knew the engine was a 5.4l before being told. he said that if i was lucky i would probably just have to install a helicoil or threaded insert in it. the other option was to replace the cylinder head. i purchased new coil and plug then drove back to my truck. i tried to clean the threads with a spark plug thread chaser but there were no threads left to clean. i searched the web and found numerous complaints of the same issue. some people said they had multiple spark plugs blow out or spit out on the same vehicle. why doesn't ford have a recall on this? the gasoline smell was due to the fuel injector still spraying while the plug was blown out of the head. what if it had caught on fire? i haven't repaired it yet but will try the repair kit that was handed to me when i bought the coil and plug. i think ford should recall all the 5.4l engines that have this problem and install the helicoil or insert to prevent a customer breakdown or a potential vehicle fire. *tr | |||
| 07/23/2003 | 75348 | 1 | 01/28/2002 |
| My family and i were 25 miles from home in our 1999 ford f-250 when a spark plug blew out of the head. i had the truck towed to the ford dealership and was told that even though the truck had less than 75,000 miles. i had to pay for the repair. this repair cost us over $3,000. *jb | |||
| 12/14/2004 | 80000 | 1 | |
| I blew a plug on my ford f150. engine has had proper maintenance. it has about 80,000 miles on it. 5.4 v8 year is 1999. called ford and they will no acknowledge a problem and will do nothing to reimburse any of the repair costs. i think it is a faulty head on the triton engines. | |||
| 12/10/2002 | 47000 | 1 | 07/05/1999 |
| There is a common problem with the right side head gasket in 5.4l v8 engines in vehicles from 1999. this problem results in a blown head gasket that requires repair at great expense. in addition the repair that is approved by ford is not permanent, so the vehicle many times has the same problem multiple times. i personally have a vehicle with this problem and have several friends with the same problem. i believe that ford needs to issue a recall for this problem and fix it right so that recurrences do not happen. *jb | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| 03/08/2004 | 89000 | 1 | |
| On the day listed below my 1999 ford f150 with a triton 5.4l v8 engine ejected a spark plug from the cylinder head. upon inspection by a mechanic it was determined that the threads in the cylinder head failed. the compression in the cylinder then ejected the spark plug. after the spark plug was ejected and before i could get stopped there was a strong smell of gas in the cab of the truck. which i assume was caused by the open cylinder and fuel being expressed through the spark plug opening. *ak | |||