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 - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE)
97V209000FORD MOTOR COMPANYfrom 03/01/1993 to 10/28/1997V (Vehicle)6400001/19/1998MFRFORD MOTOR COMPANY11/13/199711/20/1997
Defect SummaryVehicle description: motor home chassis. hot exhaust gasses can leak from the exhaust gas return (egr) tube on the engine. a hole can develop in the flexible section of the tube. heat damage to the passenger compartment floor and floor covering can occur.
Consequence SummaryDepending on the materials used in the construction of the completed vehicle, ignition of these materials could occur resulting in a vehicle fire.
Corrective SummaryDealers will replace the egr tube.
NotesOwner notification began january 19, 1998. owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact ford motorhome customer service at 1-800-444-3311.also contact the national highway traffic safety administration's auto safety hotline at 1-800-424-9393.

Bulletins

BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY
96B9509/01/199650885Owner notification program 96b95 - engine cooling system radiator replacementon certain 1997 f super duty motorhome stripped chassis. *tw06/17/1997
ENGINE AND ENGINE COOLING - ENGINE
03214510/30/20030220410004856External oil leak diagnosis for 7.3l dit engines. various models including 2003 super duty f series. *tt01/12/2004
03212310/30/20039761810004834Low rpm, no start, runs poorly, stall. 7.3l dit engine. *tt01/09/2004
03212110/30/20039721610004832A high number of high pressure rexroth pumps and injection pressure regulators (ipr) are being replaced due to oil leaking, when all that is required is a new gasket or seal on either the pump or ipr. *tt01/09/2004
03212010/30/200397214100048317.3l dit glow plug start-up on-time during cold temperature - service tip. *tt01/09/2004
0321110/30/200394231510004812Loss of power and malfunction indicator lamp may also illuminate with diagnostic trouble codes 128 and 845 or p0236 and p0238 stored in memory. *tt01/08/2004
1669703/01/200310001943Exhaust air rush noise and lower power. *tt *jb07/28/2003
9761803/17/199752000Low rpm- 7.3l dit engine fails to start- code 340 stored in memory and/or engine fails to achieve rated speed for 2-3 minutes after extended cold soak- f-series built through 2/9/96 and all econolines. *jd07/17/1997
9721601/20/199751404Leak - oil leakat engine valley pan and/or high pressure oil pump - vehicles equipped with 7.3l diesel engine. *tw06/27/1997
ENGINE AND ENGINE COOLING - ENGINE - DIESEL
BC313097022102/21/199751716Diesel exhaust smell in passenger cabin may be due to poor connection at the inlet or outlet to/from the turbo. *tw06/27/1997
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
98518511/01/1998613316Cold start engine noise01/29/2001
461608/01/1998615154Brief information vehicles exhibiting hard start / no start condition. *tt01/02/2001
462508/01/1998615162Brief information on vehicles exhibiting a stall on deceleration condition. *tt01/02/2001
462908/01/1998615165Brief information concern vehicles exhbiting external oil leaks. *tt01/02/2001
461708/01/1998615155Brief information on vehicles exhibiting lack of power condition. *tt01/02/2001
98-472609/01/1998607139Repeat message, no change: hard start/ no start. *ak11/02/2000
9981605/03/1999606420Ford motor company now recommends sae 5w-30 viscosity grade for servicing any ford gasoline-powered vehicle regardless of model year. *tt08/19/1999
BC025697020101/02/199751092A running change for the 7.3l to allow better definition on cylinder contribution tests in process. *jd06/27/1997
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS
98231411/23/1998603761Premature wear of the belt tensioner may occur on some vehicles. *yc03/04/1999
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER
0321310/30/20039561310004814A no-start or reduced power condition may occur intermittently. *tt01/08/2004
98-473409/01/1998607148Lack of power due to failure of engine turbo boost11/02/2000
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
98201010/12/1998603695Experiencing a buzzing or rattling noise from the exhaust system. *yc03/02/1999
986403/30/1998601312Information on a buzzing or rattle noise from the exhaust system. *tt07/21/1998
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
98231011/23/1998603724Mass air flow (maf)- sensor contamination- service tip. *ak03/03/1999
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
9815608/03/1998609536Exhaust leak at exhaust manifolds--vehicle equipped with 7.0l 0r 7.5l engine. *ak01/29/2001
BC324197021002/10/199751863Exhaust leaks or noise at the joint between the y-pipe and the exhaust manifold. *tw07/17/1997
96221310/21/199650952Exhaust - exhaust leak at exhaust manifolds - vehicles equipped with 7.0l or 7.5l engine. *tw06/17/1997

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.
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK 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
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK 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 - 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.
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK 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 datemilesoccurencesPurchase date
ENGINE AND ENGINE COOLING - ENGINE
08/25/200026420403/01/1997
 The brakes failed while driving. the consumer found the brakes reservoir empty, then inspected the brake lines and saw a hole in the rear brake line. *nm consumer lost control of vehicle when brakes went out and went over a curb, over parking lots, into a parking lot, and caused fuel tank and strap damage, front end and rear tad axle out of the alignment. consumer found wear hole in rear brake line, egr tube corroded, burnt engine cover, and carpet. *sb *nm
ENGINE AND ENGINE COOLING - ENGINE - DIESEL
03/26/2008287000202/26/2007
 Tl*- the contact owns a1997 ford f super duty. he received a recall notice on the camshaft position sensor, which can cause engine stalling. he had been experiencing that problem whenever he approached lower speeds in his vehicle. he took the vehicle to the dealership they replaced the sensor with a newer and non-defected sensor. after they replaced the sensor the vehicle would not start. they tried several sensors and none of them would start the engine. the mechanic then placed the old sensor back into the vehicle and the engine was able to turn on. the mechanic told him to bring the vehicle back in the following day. when he took the vehicle back in the next day, they replaced the sensor once again and the vehicle would not start. they placed the older sensor back into the vehicle and he was able to drive away. minutes after driving away the check engine light started to come on and off randomly in the vehicle, which is a problem not previously experienced. he took the vehicle back into the dealership and they were not able to repair the problem. the current and failure mileage was 287,000. updated 04/23/08 *bf
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
09/01/1997105/01/1997
 Fuel vapor canister hose failed. yh

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