Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||||
| 041601 | 11/14/2005 | 05228 | 10018745 | Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running. *tt | 01/12/2006 |
| ENGINE AND ENGINE COOLING - COOLING SYSTEM - HOSE | |||||
| 12507 | 03/01/1999 | 605274 | Subject regarding upper radiator hose production change. *tt | 06/07/1999 | |
| ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY | |||||
| 16921 | 06/01/2003 | 10002632 | Coolant leak due to broken radiator hose clamp. 1999-2003 models. *tt | 09/09/2003 | |
| 16597 | 02/01/2003 | 10002486 | Coolant leak due to a broken lower radiator hose clamp. *tt | 09/03/2003 | |
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| 07212 | 10/01/2007 | 10023943 | Some 1997-2008 vehicles equipped with a 4.6l 2v, 5.4l 2v, or 6.8l 2v engine--spark plug thread repair procedure--not covered under new vehicle limited warranty. *nj this includes f-53 motorhome chassis. updated 2/23/10. *pe | 02/20/2008 | |
| 031404 | 08/23/2004 | 04161 | 10011162 | Engine misfire or running - coil on plug (cop) ignition systems - wds cop kit diagnostic tips. to include various 2005 models. * ar this article 04161 supersedes tsb 03-14-04. | 01/06/2005 |
| 032140 | 10/30/2003 | 00254 | 10004851 | Engine buck, surge or jerk (also known as hitching/hesitation) while the speed control is active through all engine temperatures. *tt | 01/12/2004 |
| 032151 | 10/18/2004 | 04202 | 10004862 | Some 7.3l diesel turbocharger pedestals may leak oil around the exhaust back pressure actuator (ebp). *tt this article supersedes tsb 03-21-51 dated 10/30/2003. *tt | 01/12/2004 |
| 16697 | 03/01/2003 | 10001943 | Exhaust air rush noise and lower power. *tt *jb | 07/28/2003 | |
| 5052 | 11/01/1998 | 613187 | Subject regarding loss of power. *tt | 06/19/2000 | |
| 9913142 | 08/01/1999 | 609056 | Information on all vehicles built after 5/19/99 equipped with the 7.3l dit with a engine serial # greater than 1039780 now have a filter screen added to the high pressure oil reservoir. *tt | 12/07/1999 | |
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||||
| 03192 | 09/29/2003 | 031410 | 10004032 | Leak oil around the exhaust backpressure actuator (ebp) - 7.3l diesel turbocharger pedestals. *tt | 11/14/2003 |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||||
| 14434 | 01/01/2000 | 620447 | Some vehicles may exhibit a buck or jerk (also known as hitching) during highway driving at speeds 40 mph or greater with the cruise control engaged. *tt | 08/08/2001 | |
| 14184 | 01/01/2000 | 620373 | Some vehicles equipped with 7.3l dit engine may exhibit an engine that runs rough, misses, buck / jerk, hesitate / stumble, surge, lacks power, various idle symptoms, malfunction indicator lamp on. *tt | 08/07/2001 | |
| 985185 | 11/01/1998 | 613316 | Cold start engine noise | 01/29/2001 | |
| 12277 | 12/01/1998 | 615530 | Some vehicles with 7.3l / 4r100 transmission may exhibit an increase in engine rpm of 200 - 300 rpm between shifts (shift flare). *tt | 01/18/2001 | |
| 5263 | 12/01/1998 | 615384 | Brief information on vehicles exhibiting loss of power. *tt | 01/16/2001 | |
| 5270 | 12/01/1998 | 615391 | Subject regarding hard start or no start condition. *tt | 01/16/2001 | |
| 11819 | 08/01/1998 | 615316 | Some 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 | 01/13/2001 | |
| 98-4729 | 09/01/1998 | 607140 | Rough idle. *ak | 11/02/2000 | |
| 996889 | 12/06/1999 | 608900 | Information on 7.3l dit vehicles exhibiting an intermittent engine knock which may be perceived as a rod knock. *tt | 12/06/1999 | |
| 982722 | 04/01/1998 | 603586 | Some vehicles equipped with 5.4l or 6.8l engines may display a lack of power on acceleration. *yc | 02/25/1999 | |
| 9878 | 04/13/1998 | 601363 | Significant changes have been made to the 7.3l dit engine effective with the 1998 and 1999 model years. *yc | 07/27/1998 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER | |||||
| 13327 | 10/01/1999 | 609614 | Some super duty f series 250 - 550 vehicles may exhibit tubocharger noise, exhaust noise, or oil / soot presence on the rear of engine or turbocharger. *tt | 04/04/2000 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR | |||||
| CSP-08B05 | 10/13/2008 | 10027988 | Ford/lincoln/mercury: program of affected vehicles registered in ca (8500 gvwr), ma (6000 gvwr), or vt (6000 gvwr) and who previously paid to have repairs performed that are now covered under federal emissions warranty. 1999-2001 model year | 02/25/2009 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE) | |||||
| 05417 | 03/07/2005 | 10014666 | Intermittent rough idle - non-commanded egr (exhaust gas recirculation valve) flow. *tt | 05/05/2005 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||||
| 0554 | 03/21/2005 | 10014685 | Use of stainless steel exhaust studs in service for 5.4l 2v engine. *tt | 05/05/2005 | |
Investigations
| NHTSA ID | Manufacturer | Date open | Date close | Subject | Recall campaign | |
|---|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | ||||||
| EA06012 | FORD MOTOR COMPANY | 06/22/2006 | 12/07/2007 | ENGINE STALLING | 07V553000 | |
| 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. | ||||||
| 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 - DIESEL | ||||||
| EA06012 | FORD MOTOR COMPANY | 06/22/2006 | 12/07/2007 | ENGINE STALLING | 07V553000 | |
| 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. | ||||||
| PE06011 | FORD MOTOR COMPANY | 02/27/2006 | 06/23/2006 | ENGINE STALLING | ||
| The cam position sensor (cps) provides a critical signal to the subject vehicle (sv) engine management system, the loss of which results in an engine stall.during pe06-011, ford stated in their response to odi that it is continuing to investigate allegations of cps related engine stall and further advised that an update will be provided upon completion of the investigation.ford data shows that 20% of the 716,000 svs are equipped with manual transmissions which are capable of back-driving the engine when a stall occurs; power assisted steering and braking are not lost during engine back-drive.ford data also indicates that back-drive occurs in automatic transmission vehicles above certain road speeds.the manufacturer reports noted reference 755 unique vehicles; 2 are duplicative of odi reports.in its review of customer and field reports, ford identified some 800 reports alleging one or more engine stalls potentially related to a cps failure in these 755 vehicles (ford | ||||||
| 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 | |||
| 06/02/2012 | 165000 | ||
| I bought the truck new in 1999, and never had a problem until 2005 when the first spark plug blow. it cost me $520.00 to have it towed and repaired. the second time the plug blow (2007), it cost me $620.00 to have it towed and repaired. yesterday (06/02/2012), it cost me $740.00 to have it towed and repaired. since i have owned the truck i have been extremly happy with the proformance, i have only replaced the alternator, which is great for most car & trucks. but! to have as much trouble with this engine and from what i have heard about the v10 & other ford turck engines ford should correct the problem & pay atleast half the cost! i love my truck, but if this continue (with the other seven plugs), i will have to look at gm. come on ford.... don't lose me!! | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 05/20/2011 | 110128 | ||
| 5.4l ford triton engine spark plugs were changed at 84,000, at 110,128 spark plug on #7 cylinder came loose and blew out. fuel air mixture comes out the spark plug hole which is dangerous(has been known to start engine fires). there is a design defect in the aluminum heads not having enough threads to keep the spark plug tight. this is an expensive repair that ford is not paying for when it is a poor design with the potential of it continuing to happen again on another cylinder. | |||
| 01/23/2011 | 232000 | ||
| While driving on the highway, crossing an intersection, or idle in traffic, the diesel engine in my1999 ford f250 dies, leaving me stranded in dangerous situations. i have replaced 2 in the last 6 mos. at my cost. | |||
| 09/13/2003 | 110000 | 1 | 06/25/1999 |
| Spark plug blew out of engine, causing $3000.00 damage to engine. *jb | |||
| 01/01/2001 | 1 | 03/01/1999 | |
| Blown head gasket on right head leaking oil onto right exhaust manifold fumes comming into cab creating health hazard and oil leaking onto engine and transmission housing then onto the ground also creating an enviromental hazard plus waste of precious oil supplies. *ak | |||
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||
| 01/01/2005 | 55000 | 12 | 03/01/2000 |
| At about 55,000 mile the engine began to randomly stop. it would start right back up. this usually happened when accelerating from a stop. after a while it began to happen more often and not restart right away. after having the truck looked at, i replaced the camshaft position sensor (cps). i am unsure if the old part is still available. *tr | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| 12/27/2003 | 51707 | 1 | 06/30/1998 |
| At low speed, spark plug blew out of engine, causing loud exhaust noise and gasoline fumes were immediately smelled inside passenger compartment. if this were to happen at high speed with engine under load when immediate engine shutdown was not safe or possible, this condition would cause large amounts gasoline/air mixture to be exposed to hot exhaust components, causing fire hazard. if this occurred when power was critical (passing or turning in front of traffic), the loss of power could also cause an accident. if this occurred when driving on slick road conditions, it could contribute to loss of control of vehicle. this is considered a heavy duty engine, but does not use a hardened threaded insert in the cylinder heads to strengthen the threads that the spark plugs screw into. searching on the internet for (triton blew sparkplug) reveals that this is not an isolated incident. also, the manufacturers torque specification for the spark plugs is quite low - probably due to the aluminum threads in the head. this could be a cause for the spark plugs loosening. *ak | |||
| 02/26/2002 | |||
| Ongoing problem with the vehicle hesitating during acceleration and intermittently stalling. vehicle been to dealer shop on several occasions, and problem still reoccurring. feel free to provide any further information.*ak | |||
| 12/20/1999 | 4 | 07/01/1999 | |
| Engine completely lost power, due to rain water ingested into air breather. *ak | |||
| 09/19/2000 | 1 | 07/01/1999 | |
| No summary listed for above vehicle. *ak (tiresize: 24570r19.5)( dot number: tire size: 24570r19.5 ) | |||
| 01/15/2001 | 1 | 02/01/1999 | |
| No summary listed for above vehicle. *ak | |||
| 07/15/1999 | 1 | 08/01/1998 | |
| While driving at 55/60 mph the engine quit. with total loss of power steering and power brakes. this failure needs to be added to the open action item # ea00017.. this failure has only happened once and was almost a fatality.*ak | |||