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 - 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 | |
| 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 | |||||
| 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 | |
| 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 | |
| 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 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER | |||||
| 14348 | 09/01/2000 | 618621 | Concerns with a turbo hoot condition. *jb | 04/18/2001 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||||
| 0113 | 01/22/2001 | 618067 | Some vehicles equipped with 5.4l or 6.8l engine built through 9/10/2000 may exhibit a miss sound from the exhaust. this may be cuased by the design of the exhaust y-pipe which can cause a miss like sound known as impingement. * | 04/03/2001 | |
| 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 | |||
| 09/10/2012 | 128000 | 3 | |
| The 5.4l engine has blown 3 spark plugs now , cylinders 7,6,and 4. *tr | |||
| 09/10/2012 | 128000 | ||
| The 5.4l engine has blown 3 spark plugs now , cylinders 7,6,and 4. | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 06/20/2010 | 83000 | ||
| Engine on my 2000 ford f-250 v10 started missing intermittently about 1 week ago. yesterday, the service engine soon light came on. about 10 miles down the road, the engine ejected a spark plug out of the cylinder head while towing at 50 mph. vehicle is at ford dealership now for assessment and repair. | |||
| 08/01/2009 | 90000 | 1 | |
| Spark plug blown out of ford v10. it was the factory plug to the best of my knowledge. installed heli coil and been good since. *tr | |||
| 02/24/2007 | 41000 | 8 | 12/04/1999 |
| 2000 ford super duty crewcab with a service engine soon light that will not stay off. obd code reads gross vapor leak. after 8 attempts to correct, dealer is unable to find problem. all parts of the vapor system have been replaced including the on board computer. personal research indicates that other ford truck owners are experiencing the same problem. *nm | |||
| 12/27/2005 | 68000 | 1 | 08/08/2000 |
| I was driving down the road, heard a loud pop and lost power and control to the vehicle. pulled onto the shoulder and found the engine had blown a spark plug out of the cylinder head. had to take to dealership to replace the aluminum, poorly engineered cylinder head. many, many, many people have reported this same issue and nothing is being done. this has the potential of causing engine fires as the fuel rail can be damaged and ruptured when the plug is ejected out of the head. this needs to be recalled. see how many people are reporting this at: http://www.consumeraffairs.com/automotive/ford_spark.html . *nm | |||
| 11/13/2006 | 108900 | 1 | 06/18/2005 |
| Spark plug blown out of cylinder head. *nm | |||
| 06/28/2001 | 6 | 06/01/2000 | |
| Valve stems became loose and allowed air pressure to go to zero. *ak | |||
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||
| 06/15/2002 | 35000 | 3 | 06/14/2000 |
| 2000 ford excursion with 7.3 power stroke diesel. sudden stall of engine while driving. no warning, just quit while driving causing loss of power steering and power brakes which are necessary for adequate control of a vehicle of this size. replacement of the camshaft position solved the problem. to date, and 260,000 miles on the vehicle, this sensor has failed three times. i now carry a spare sensor, and know how to replace it. *tr | |||
| 08/01/2006 | 135000 | 1 | 10/15/2001 |
| Cam position sensor failed without warning truck shut-off and would not restart on busy residential street. vehicle had to be towed. *nm | |||
| 04/20/2006 | 97800 | 1 | 10/12/1999 |
| Truck engine quit running. can happen at any engine speed has happened in park and while driving. troubleshoot problem. bad cam position sensor. ford f250 with 7.3 diesel. *nm | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| 12/27/2005 | 128000 | 2 | 03/20/2000 |
| Second spark plug in my 2000 ford v10 has blown out of cylinder head in last three months. last plug came out tuesday after christmas. dealer now says it needs to do $3475 head replacement for both heads. *jb | |||
| 09/13/2005 | 85000 | 2 | 08/12/2003 |
| My vehicle has blown out a spark plug on two separate occasions while on the freeway almost causing a accident on both incidents. i know that this is a major problem do to what i have found on-line. there is even a company that makes a repair kit and it is only a matter of time before someone is stranded in a remote area which will be very dangerous. *nm | |||
| 02/07/2004 | 62000 | 1 | 06/20/2001 |
| I have a 2000 f-250 with 62,000 mi. and had one of the spark plugs back out and strip out the last few threads. i spoke to a mechanic who told me that the 5.4 engine is known for this and that fords only fix to it was to replace the head at @ $1500.00 per head. he referred me to another mechanic that devised a cheaper fix of retapping the plug hole. this mechanic said that he personally has done 5 to include my truck.*ak | |||
| 09/02/2000 | 1 | 03/01/2000 | |
| This is my second ford truck in a year 1/2 and my forth motor i am experiencing a loud engine knock on cold start up. the knock gets louder and longer. ford has replaced lifters on my 2000, that did not take care of the knock. i have talked to different people that own the 5.4 engine and they expereince the same noise. i have found most people do not notice the noise because of the radio,as well as the bell noise when you first start the truck. i have also had a spark plug ejected from the cylinder head of my 1999. the ford dealer want to replace my 2000 5.4 engine with a new one . how much should a consumer take. here i go again with engine replacement in a new truck less than a year old. please help!!!! thank you!!!*ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||
| 07/25/2005 | 52400 | 1 | 06/08/2001 |
| Bolts rusted to my manifolds ( on both ) sides. had to have both manifolds replaced and the heads bored out. if i did not realize the noise and had it fixed it would have cracked my heads.*jb | |||