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 | |
| 15172 | 08/01/2001 | 624688 | Some vehicles may exhibita coolant leak from the water pump weep hole. *yh | 11/08/2001 | |
| 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 | |
| 16683 | 03/01/2003 | 10001937 | False failure of the vapor management valve (vmv). *tt *jb | 07/28/2003 | |
| 15121 | 08/01/2001 | 624615 | Some vehicles may exhibit a miss or popping through the intake or exhaust. *slc | 11/08/2001 | |
| 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 | |
| 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 | |
| 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 | |
| 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 | |
| 02E19 | 02/01/2002 | 630640 | Subject regarding emissions recall 02e19 regarding catalytic converter replacement. *tt | 04/19/2002 | |
| 01V04 | 05/02/2001 | 619650 | Field action for vehicles built with incorrect exhaust system catalysts. *tt | 06/23/2001 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE) | |||||
| 02M01 | 06/01/2004 | 02M01 | 10007207 | Customer satisfaction program 02m01 supplement #4. certain ford 2000 through 2003 vehicles equipped with a tube-mounted egr pressure sensor - additional egr pressure sensor warranty coverage. *tt supplement #3. *mj supplement #6 | 06/03/2004 |
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 | |||
| 09/16/2009 | 47000 | 1 | |
| 2001 ford f150 caught fire in the middle of the night and was completely destroyed. vehicle had not cranked in over 24 hrs., and no keys were in the ignition. *tr | |||
| 01/04/2009 | 100000 | 1 | |
| On multiple occasions i have been driving and heard a loud bang and felt the motor starting to shake and loss of power to the vehicle. upon inspection, i have noticed the coil pack of my 2001 ford f-150 sitting on top of the motor. i have replaced two coil packs twice each. it is getting costly to repair as it costs $50 per coil pack. i have retapped the holes but the problem keeps occurring. i am a divorced father of a 2 year old son. i can't afford to keep repairing the problem. *tr | |||
| 07/14/2008 | 83577 | 1 | |
| #3 spark blew out of engine head and broke spark plug coil in the process. this was an original factory installed spark plug. *tr | |||
| 06/03/2008 | 19 | 1 | |
| We own a motor home, built on a ford incomplete vehicle chassis, powered by a ford v-10 triton engine. the first engine began to spit out spark plugs after reaching 75,000 miles on the odometer. this occurred on friday, january 27, 2006, about forty miles east of kingman, arizona. after spending money to get the problem diagnosed at a goodyear dealership in kingman, arizona, we had to order a special repair kit from baril engine rebuilding company in green bay, wisconsin, paying for the shipping both ways. a mechanic resleeved the cylinder. as i had to make a speaking engagement, we had to drive for close to 1,000 miles with wretched fumes and horrid noise. the second spark plug was spit out on friday, feburary 10, 2007. as i had another speaking engagement, which is how i make my living, we had to drive to pensacola, florida, and thence lafayette, louisiana, before another repair kit was rented to be used by yet another mechanic. the third spark plug was spit out two weeks later, on monday, february 26, 2007, as we were driving from pensacola to lafayette. we rented the tool kit from baril engine rebuilding company once again. this original ford v-10 triton engine died on thursday, april 19, 2007, on interstate 80/94 just east of mile marker 160. two cylinders had lost compression entirely. no one at terry ford lincoln mercury in peotone, illinois, could explain why this had happened. we had to raise $9,000 to pay for a new engine and its installation. the engine had been well maintained. the replacement engine has also been maintained well. despite this fact, however, the engine spit out its first spark plug, just 19,000 miles and thirteen months, eight days after its installation, an incident that occurred this afternoon, wednesday, june 3, 2008, at exit 22 of the new york state thruway in selkirk, new york. *tr | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 01/04/2009 | 100000 | 1 | |
| On multiple occasions i have been driving and heard a loud bang and felt the motor starting to shake and loss of power to the vehicle. upon inspection, i have noticed the coil pack of my 2001 ford f-150 sitting on top of the motor. i have replaced two coil packs twice each. it is getting costly to repair as it costs $50 per coil pack. i have retapped the holes but the problem keeps occurring. i am a divorced father of a 2 year old son. i can't afford to keep repairing the problem. *tr | |||
| 04/29/2008 | 112000 | 1 | |
| 4 months ago spark plug #3 unexpectedly left the engine destroyed the coil-on-plug and stripped the cyl. head. ~2500 miles later #6 plug and coil....same thing. *tr | |||
| 10/27/2006 | 80000 | 2 | 10/01/2004 |
| On october 27, 2006 i was driving my 2001 ford f-150 pickup down the highway at about 45 miles per hour. all of a sudden we heard a loud noise and pulled over. upon inspection my husband noticed that the number 3 spark plug and coil pack had been ejected from the cylinder head. he also noticed that it had caused a sizeable dent in the fuel injector rail. the rail/fuel line which provides fuel under pressure to the injectors is made of steel. the coil pack although the mounting point was broken off remained plugged in and functioning. the spark plug also remained in tact and appeared undamaged. the spark plug still resting in the spark plug boot managed to find a ground very near if not on the dented fuel rail. this was evident by the fact that it continued sparking as the motor sat and idled as we tried to determine the source of the problem. if there had been any sort of fuel leak or had it ran longer sparking against the fuel rail, i suspect a fire could have resulted. a rather serious fire considering the fuel in the rail is under pressure. admittedly this may be a very unlikely set of circumstances. however in checking on the internet the spark plug ejection seem to be common and the dented fuel rail not uncommon. the coil pack continuing to fire seems likely as the connection to the wiring harness seems quite secure. it also seems that the steel fuel rail is a very convenient ground. not only did this happen once no it happened again on january 19, 2007. ford refuses to recognize a problem with the cylinder head and charges $3000 to replace the head and all of it internal components every time it happens. ford blames this problem on the spark plug i can assure you the spark plug was completely in tact and sparking not in the combustion chamber mind you but against a steel fuel line. ford recommends that you change the spark plugs at 100,000 miles my truck was only at 80,000. *nm | |||
| 07/01/2006 | 217000 | 1 | |
| 2001 ford expedition eddie bauer, at about 30 mph, 3rd spark plug blew out stripping threads and ruining coil. we replaced the coil, but dealer will not rethread, the dealer says that if they were to rethread it would not hold and would probably blow again possibly doing more damage to motor. they said they will only replace the head which is 2000.00. when it blew i was on my way to the airport to pick up family with my newborn and four year old. i was stranded on the highway for an hour and a half in 98 degree heat. my family was stranded at the airport for two hours, not to mention the tow bill. i called ford, they acknowledge a problem, but take no responsibility. they said it was because of poor maintenance. but my vehicle has been 100 percent properly maintained. *nm | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| 12/04/2004 | 19000 | 1 | 05/10/2001 |
| Spark plug blew out of the head on the engine. *jb | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||
| 05/05/2007 | 113000 | 1 | 07/15/2006 |
| I exited on i-75 onto sr 200, traveled 100 feet approximately 20 mph, heard popping sound like baseball card in spokes of a bicycle wheel. happened saturday night while bringing my son home from college. cost $75 to tow home to unload the 2001 f150 5.4 liter v-8. $75 to tow to ford of ocala, belleview, who diagnosed blown #3 plug, charged $98, then $75 tow to ford of ocala in ocala told $4000 to replace head or $6000 to replace engine. this was a common occurrence with this faulty head and plug design. ford should be made to fix this problem since replacing either the head or engine with the same faulty ford product was not an option to me. estimated charges were outrageous even for a physician to pay. please see www.f150online.com forum for additional disgruntled f-150 owners whom have had same problem. this was a fraud alert. *ak | |||
| 04/16/2007 | 97000 | 1 | |
| Spark plug # 7 blew out of the ford f-150 truck with a v8 motor. the plug and coil stuck the fuel rail above this area , and took a chunk of the fuel rail out, almost crating a leak , vehicle could catch on fire. over 100,000 reports on the exact same spark plug along with # 3 plug doing the same thing with the fuel rail also. usually the other plug blew a few months after the first one blew out of the engine. repairs were to pull the header ,and drill hole in header to install a coil to replace threads torn on the head, and install a new plug due to blow out and coil. *ak | |||
| 08/15/2003 | 49000 | 1 | 08/17/2001 |
| Check engine light came on at 49000 diag reports erg/back flow/solenoid. replaced all and reset computer. next day light returned, diag reports erg/backflow/solenoid failure. telephone to ford states, several have this problem, excessive buildup of carbon in exhaust manifold. extended warranty covers repair (design flaw). *jb | |||