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 | |||||
| 15398 | 11/01/2001 | 630414 | Some vehicles may exhibit a coolant leak due to a broken radiator hose clamp. *tt | 04/17/2002 | |
| 01185 | 09/09/2001 | 625695 | Subject regarding engine cooling system.*jb | 11/30/2001 | |
| 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 | |
| 15678 | 03/01/2002 | 636306 | Coolant leak due to a broken lower radiator hose clamp. *tt | 11/07/2002 | |
| 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 |
| 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 | |
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||||
| CSP-48B01 | 05/26/2008 | CSP-08B02-48B01 | 10026321 | Ford: vehicles mistakenly charged $100 powertrain warranty deductible for fuel injector repair or repairs. no model or model years provided. *pe econoline, excursion and f-series super duty vehicles, model years 2002-2005. updated | 10/17/2008 |
| 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 | |||||
| 15412 | 11/01/2001 | 630427 | Some vehicles may exhibit a crank/no start condition due to failure of fuel pump fuse #40 or an engine remains at idle condition with diagnostic trouble code p0211. *tt | 04/17/2002 | |
| 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 | ||||||
| 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 | ||||||
| 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. | ||||||
| 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. | ||||||
| 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 | |||
| 04/21/2012 | 112000 | ||
| Went to start my truck and thats when the spark plug blew out. | |||
| 12/24/2011 | 74000 | ||
| Injector drive module (idm), diesel 7.3 navistar engine. idm failed where the likely cause was water infiltration of the device with sudden catastrophic results which included a sudden significant loss of engine power, inability to maintain highway speed, inability to keep speed above 5 miles per hour, and demonstration of sever roughness during attempts to rev the engine or idle loads. due to the idm failure, three of eight fuel injectors were rendered nonfunctional and replaced; also the actual number of injectors that were online or offline during the idm failure to engine shut-down period was unknown. during the idm failure to engine shut-down period of ~3 miles, the vehicle's obdii system did not illuminate any dashboard indicators despite the engine's inability to function normally. idm was operated in manufacturer's oem configuration, without modifications, and under normal conditions. all parts sent directly from mechanic shop to suppliers under core replacement requirements. subsequent research on vehicle owner's forms and conversation with mechanic show failure of the idm due to water penetration / infiltration is known and ranges in indications from mine (sudden sever power loss) to complete power loss / engine stop. | |||
| 10/07/2011 | 83000 | ||
| Spark plug blowout | |||
| 08/27/2011 | 105000 | ||
| The #9 spark plug shot out 9000 miles after the ford dealership replaced all 10 plugs for $270. i was told by all private garages and mechanics locally that the ford dealership had to replace the plugs otherwise they would shoot out. (glad i used the ford dealership) when i contacted the ford dealership about the failure, they told me that they would have it towed in and be able to fix it for around $350.00. when i explained to them that i thought they should guarantee their work and fix it for free, i think i made them laugh. if and when i get this truck fixed and sold, i will never ever by a ford product again. | |||
| 03/27/2007 | 80000 | 1 | |
| Thrown spark plug from 2002 f-250. *tr | |||
| 12/01/2009 | 52000 | 1 | |
| I have a 2002 ford f250 that in the last year has blown out the sparkplugs 3 different times. i have bought the replacement kit for it each time and i am still having the problem. *tr | |||
| 05/06/2008 | 87500 | 1 | |
| Original spark plug was ejected from the engine thread on the head was destroyed. dealer said it is a known issue, but there is no recall issued. well, there should be one !!! *tr | |||
| 12/20/2004 | 70000 | 1 | 03/20/2002 |
| 2002 ford f250 superduty v10- engine. driving to work at about 15 mph. heard a loud bang from engine compartment, engine started to idle rough, exhaust smell and loud popping noise from engine, towed to dealer wayside ford marlborugh ma., verified spark plug blown out of head. truck has been dealer maintained. currently has about $70k miles. plugs are not scheduled to be changed until 100k miles. truck is not drivalbe, estimate about $300.00 to replce head and coil. waiting for response from ford for help. this is a commom problem per dealer and owners groups.*ak | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 09/09/2007 | 100000 | 1 | 03/06/2007 |
| 2002 f250 blowing out spark plugs. *tr | |||
| 09/17/2005 | 81000 | 1 | 07/08/2002 |
| 2002 ford f-250 5.4l motor. blew spark plug on drivers side 2nd one from front out of vehicle. *nm | |||