Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ELECTRICAL SYSTEM
0221510/28/200210013063Heavy static or signal loss on two way radio communication . bi fuel lpg vehicle only. *eh04/07/2005
048305/03/200410008544Splicing new wire(s) into existing electrical harness. service procedure. *tt08/04/2004
0411106/14/2004043110008252Streamlined diagnostic procedure for vehicles with malfunction indicator lamp (mil) on and diagnostic trouble codes (dtcs) p0401, p0402, p1400 or p1401. additional symptoms may include runs rough, lacks power, surge, poor fuel economy.07/23/2004
0322301/26/2004043110007360Streamlined diagnostic procedure for vehicles with malfunction indicator lamp on and diagnostic trouble codes (dtcs) p0401, p0402, p1400 or p1401. additional symptoms may include runs rough, lacks power, surge, poor fuel economy. *tt06/16/2004
1706308/01/200310003171Malfunction indicator lamp (mil) on with diagnostic trouble codes (dtc) p0171, or p0174. f150 lighting and f150 harley davidson supercrew. *tt10/09/2003
1700908/01/200310003149Malfunction indicator lamp (mil) illumination with no hard fault. *tt10/09/2003
1692806/01/200310002639Various intermittent electrical concerns including but not limited to some accessories remaining powered up with the key out of the ignition, multiple system warning lights with short to power or low battery voltage diagnostic trouble codes09/09/2003
ELECTRICAL SYSTEM - BATTERY
024503/04/2002636065Information regarding discharged battery charging service tips and guidelines. *tt11/05/2002
ELECTRICAL SYSTEM - IGNITION - MODULE
1525509/01/2001625800Concerns with diagnostic trouble codes p1516, p1518, p1519, and p1520. *tt12/03/2001
ELECTRICAL SYSTEM - IGNITION - SWITCH
01211310/29/2001627774Some ignition switch lock cylinder assemblies may exhibit rougness and / or excess effort in turning, key does not fully return from start, a malfunction indicator lamp may illuminate with p0500, p1502 and u1039 stored in powertrian control02/22/2002

Investigations


NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
ELECTRICAL SYSTEM
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES06V286000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES05V388000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES07V336000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES07V078000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES07V488000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES07V347000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES08V025000
 Ea05-005 is closed with ford
ELECTRICAL SYSTEM - WIRING - FRONT UNDERHOOD
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES07V336000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES07V347000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES07V488000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES06V286000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES05V388000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES07V078000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES08V025000
 Ea05-005 is closed with ford

Consumer Complaints


Fail datemilesoccurencesPurchase date
ELECTRICAL SYSTEM
07/05/2007800001
 The windshield of my f150 ford king ranch leaks and has done damage to the fuse box and rust is occurring in locations not easily accessed by water. *tr
09/23/2008900001
 Intermittent starting problem caused by the anti theft unit in that it won't allow the truck to start. if allowed to sit for an hour or so it usually starts. ford dealerships say that they have to have it when the problem is occurring. well, now the problem seems permanent, as it won't start at all. when asked if system can be turned off they say no, it is a safety issue their safety issue has put me in peril on more than one occasion. one being on a boat ramp with rising water and a vehicle that won't start. how safe is that? the vehicle is at the dealer now, and they tell me they must duplicate the not starting so they can see what's wrong, in fact it is not starting. *tr
03/20/20081000001
 I have had the 02' f150 since december 07' and have had major problems with the windshield leaking. i have found that this is a common problem with in the 97' to 03' f150 models via ford forums and other internet sites as well as the local ford dealer repair shop who worked on my truck. this leak shorts out the fuse panel in the cab that causes the loss of power to equipment including the windshield wipers which is a safety issue when driving in inclement weather. the leak also tends to short out the instrument panel causing the computer to be unable to read what gear the truck is in. this causes the truck to not start and even shut down while driving which again is a safety issue while driving in any condition. this leak cost me $1500 dollars in repairs due to damage to the starter, relay, alternator, computer, fuse panel, and having to replacing the windshield. i was told by ford that this leak was not a safety issue and have only issued a special service bulletin! i can not understand how the windshield leak is not a safety issue yet a recall can be issued for fading paint? *tr
06/01/2006102000
 Tl*the contact owns a 2002 ford f-150. while driving 25 mph, he heard a loud banging noise coming from the engine. upon inspection he noticed the spark plugs were loose and the coil had blown off. the dealer stated that there was a defect within the engine that caused the failure. they replaced the coils and the spark plugs. approximately three months later the failure occurred again. the dealer stated that a defect within the engine caused the failure. they replaced the coils and spark plugs. the failure mileage was 102,000 and current mileage 113,000.
03/18/2008105/12/2003
 2002 f150 supercrew leaky windshield causing electrical parts to go on and off. i wish ford would fix this problem im afraid to take the family in it in fear of an electrical fire. *tr
02/06/20080808/06/2002
 I have a 2002 ford f-150 supercrew, about 6 months ago my electrical panel started having a mind of its own everytime it rains. my radio, windshield wipers, blinkers, tail lights and interior lights go off and on. i have almost been in several accidents due to this problem not being able to see because of windshield wipers not working and also because of blinkers not working. the problem is getting worse and i believe ford should fix this since it is definitely several large safety issues. *tr
09/10/200792000106/15/2007
 Possible windshield leakage causing extreme random electrical failure. truck won't start if raining. truck shuts off during operation. particularly hazardous during highway operation. electrical operations occur without warning, with or without keys in ignition. *jb
08/10/200754000104/02/2005
 My f-150 pickup just started smoking then with in seconds was fully engulfed in flames resulting in me jumping out to save own life. thankfully no one else was with me. *jb
11/19/200679000110/22/2005
 Drove my 2002 f 150 approximately 25 miles home and parked it. the truck has never given me any problems and wasn't making any noise. about 30 minutes later i noticed a orange fire ball realizing it was my truck. the truck was fully involved within minutes. the entire front end of the truck melted away. the drivers side wheel, hood, and everything connected to the engine block is non existent. this is in addition to the cab which there is nothing left either. i am the second owner of this truck, never received a recall notice in the mail. im not sure what caused the fire. fire marshall said it started in the engine compartment. *jb
11/15/20066300025
 Wipers and radio work only when in park. lights remain on even when in off position. vehicle will sporadically not start. problem started in the fall of 05 and persisted until summer 06, at which time all symptoms disappeared. now in the fall of 06, all symptoms have returned. *jb
10/25/200567500104/14/2002
 Electrical system failed due to water leaking from faulty windshield installation. *jb
09/11/200534000306/09/2005
 After raining 4x4 indicator light flashes , windshield wipers and radio shut on and off while driving. *nm
09/23/2004109/23/2002
 2002 ford f150 caught on fire while parked in the driveway. *mr the vehicle was parked then approximately thirty minutes later, the horn began to hunk and the consumer had come outside and found the vehicle engulfed in flames in the cab portion of the vehicle. *sc *jb
06/04/2005330001
 Spark plug blew out of head on my 2002 ford f150 (5.4l triton v8) pickup on the passenger side of motor. no warning, everything was working properly then it just blew while driving. lost power & coasted to the side of the road. truck had to be towed to the local ford dealer. head is being replaced, truck is still under warranty. time to get it back will be about a week & a half.
03/02/20051
 While driving approximately 60 mph consumer heard a loud pop coming from the engine. took vehicle to dealer for service, and it was determined that a spark plug blew out. *ak
01/04/2005270001
 While parked in a work yard vehicle caught on fire. the cause has yet to be determined. *ak
01/14/20043064
 Electrical: at 306 miles the solenoids had to be replaced. upon shutting the vehicle off; the dash board would still illuminate. also, upon shutting the vehicle off it would continue to run. this has happened a total of four times. the transmission completely failed with no warning. the consumer took the vehicle to the dealer, and was told the windshield had a leak which corroded the electrical system. the electrical problems started at 44000 miles. the gasket had to be replaced, and the harness wiring had to be replaced also. upon trying to start the vehicle again the battery would be completely dead. please provide any further information. *jb
12/08/2004680001
 Vehicle blew out a spark plug, resulting in fuel going into the cylinder unburned. then it washes down, pass the rings into the crank case, which could cause a fire or an explosion . provide further details. *ak
10/01/20041
 While driving vehicle stalled. consumer noticed that all the electrically compliences failed. to come on its own. consumer had the vehicle towed to the dealer for inspection, and mechanic stated that the problem could not duplicated. *ak
08/27/200445000106/15/2002
 Spark plug blew out of the head. i hear this has happened to many times to mention. i have a 2002 hd - f-150 with 45,000 miles on it.*ak
05/02/200453379105/21/2002
 Windshield seal leaked (rain) along roofline causing multiple electrical problems. vehicle has multiple system warning lights visible on dash. short circuit sounds coming from behind dashboard. warning lights, blower motor and head lights operate without key in the ignition causing battery to be drained. wipers cut off without warning. door windows stop working without warning. vehicle shifts into four-wheel drive without warning. engine races while parked (revs to 4000 rpm and returns to normal). sales man informed that ford will not cover the problem because the truck is out of warranty and to bring truck to dealer (5/3/04). truck would not start until 5/8/04. seal to windshield separated from vehicle on left side while driving to dealership (5/10/04). the truck now has excessive wind noise. truck will no longer start (5/11/04). i called fords customer and requested that a representative from ford inspect the truck. customer service asked that the truck be towed to a ford dealer. truck was towed to local dealer. dealer did not want to help me contact ford after i informed them that the truck has a defective windshield seal. dealership informs me on 5/13/04 that the zone supervisor from ford said that there was nothing that could be done about the problem. in addition, dealer refuses to put statement in writing. the dealer also informed me that for a fee, they could seal the windshield and diagnosis the problem but the dealership where the truck was purchased from should do the repairs. *ak
03/30/200440180111/10/2002
 Sparkplugs blew out of the head at 65 mph on svt lightning. service manager indicated ford is aware of this happening but they are not issuing a recall. he stated they put out a what to do if a vehicle comes in with this problem. unfortunately, that does not help us consumers who have to fork the bill.*ak
07/10/20031
 Electrical system fails intermittently, causing headlights and other electronic components to blink. *ak
08/02/2003
 Hello, i'm writing to complain about my friends 2002 ford lightning which launched a spark plug through the head. i've heard that this problem has been happening to many of these trucks, and i think the problem needs to be resolved. how about a recall. *nlm
109/01/2002
 The rear door locks will not open unless the lock is manually unlocked. the front doors will unlock and open by using the inside door handle. the rear doors will not do this. you must first unlock the rear door manually (for with the power locks), then open the door with the inside door handle. i feel that this condition is a safety issue because if there is an instance where someone is riding in the rear seat and the person must exit the vehicle in a hurry, they may become disoriented and forget to first unlock the rear door manually. they will get panicky then until they realize, if they do, what is happening. this is especially true in the case of older children who are old enough to operate a car door by themselves.**** dims 11 ivoq entry posted after 12/12/02 cut-over to artemis****769311. *ak *jb
ELECTRICAL SYSTEM - ALTERNATOR/GENERATOR/REGULATOR
3
 Problems with vehicle passenger door, and paint defect on driver side of vehicle. *mr the consumer was told that the only problems were with the torque converter which was replaced and the alternator. the consumer was concerned that the vehicle was previously involved in an accident, as there was a paint defect on the door handle which didn't fully shut at times. the consumer was willing to give back the vehicle in return of all the monies (payment(s)/down payment). *scc *jb
ELECTRICAL SYSTEM - BATTERY - CABLES
10/28/20042
 While driving vehicle stalled. consumer was unable to restart vehicle, and had it towed to the dealer for inspection. mechanic determined that the battery an battery cable needed to be replaced. *ak
ELECTRICAL SYSTEM - FUSES AND CIRCUIT BREAKERS
09/27/200775000111/01/2002
 Ford motor company does not install the fuse necessary to operate the towing harness lamps on the 2002 f150. local ford dealer installed a fuse and then discovered that the pin beneath the fuse box was bent. the fuse box had to be removed in order to straighten out the pin and then re-installed. ford refused to cover the cost ($200.00) saying the vehicle was out of warranty. contention is that this either came from the factory this way or the dealer bent the pin when they installed the fuse. neither ford motor company or the local ford dealer will accept responsibility. the bent pin made the parking lamps inoperable which would be hazardous for towing anything at night. *tr
03/13/200460000210/13/2002
 Dt: the contact stated windshield leaked in the lower passenger side. the fuse box was damaged due to the leaking, and replaced. the windshield was replaced at contact's expense. the manufacturer was notified. they did not offer any free remedy. *ak
ELECTRICAL SYSTEM - IGNITION
09/08/200646000111/11/2005
 Truck makes noise and will not start the key pad will not let me in my truck and the truck acts like it wants to start but anti theft system won't let it start. are there any recalls on this problem. *nm
06/16/2005171000202/01/2002
 Spark plug blown out/striped out of cylnider head
02/25/20045
 Ignition coils had to be replaced 5 times within the last year. when taken to get serviced, they could not determine the problem. *nm
09/04/2001330005
 The ignition coil went out continuously, which caused the vehicle to loose power. the dealer has replaced the ignition coil four times and the vehicle is being repaired again for the coil. *jb
11/21/200435000306/22/2002
 My 2002 f150 supercrew (1ftrw076x2kb58773) is getting the 3rd ignition coil replaced. 1st time @ 26,000 miles, 2nd @ 46,000 miles, and now @ 59,000. each time tomball ford has repaired the vehicle and the last two times i have had to pay for the repairs. i would like ford to recall the ignition coil on this model and pay for my repairs. *jb
03/01/20043000111/15/2001
 Ignition coil misfiring, vehicle exhibited occasional miss fire. upon cold start after sitting for several days plume of blue smoke from tail pipe was noticed. dealer could not duplicate event but determined #1 ignition coil was firing at reduced capacity. unit was replaced and incident of blue smoke at cold start has been reduced. *la
30000
 Consumer can hear a clicking noise coming from ignition when the key is not in ignition. consumer stated vehicle was parked in first gear when it inadvertently started and hit the house. *ak
01/28/200317000103/12/2002
 Spark plug self launching from ford f150 5.4 l engine
ELECTRICAL SYSTEM - IGNITION - ANTI-THEFT CONTROLLER
05/15/200533377203/10/2003
 Water leak from the windshield into the dash board damaging electronic components for the amount over $800.00, the vehicle is a 2002 ford 150, it had a the time of the incident only 33,000 miles but it was out of warranty for about 5 weeks. therefore they wouldn't fix it without a charge.
ELECTRICAL SYSTEM - IGNITION - MODULE
05/15/200533377203/10/2003
 Water leak from the windshield into the dash board damaging electronic components for the amount over $800.00, the vehicle is a 2002 ford 150, it had a the time of the incident only 33,000 miles but it was out of warranty for about 5 weeks. therefore they wouldn't fix it without a charge.
12/30/200420000102/28/2002
 (1) truck's bed spreading apart and ignition/wiring shortage (2) the bed of my truck has spread apart for no reason at all. i cannot even shut my tailgate. my truck's battery continues to run down. when i turn on my truck, the starter doesn't want to stop. a light displays, door opened! the windshield wipers stopped working. the music goes on and off. (3) i took my truck to the dealer to get the bed fixed. they set me an appointment. i made another trip over an hour one way to get fixed and then they didn't fix. my warranty has just recently ran out. i am having several problems and don't know what is the matter. i haven't had no luck with talking with a ford mechanic. the wires in the steering column looks too tight or loose. there is a constant buzzing sound. my clock and mileage readings erases. my windows stop working. this only happens when i place the truck in drive. most of the time everything starts working once placed in park. i only have close to 70,000 miles. this has been going on for months.*ak
ELECTRICAL SYSTEM - STARTER ASSEMBLY
08/20/200615400012/31/2001
 The truck was driven back from the store, a distance of a few miles, then parked in my driveway. apprximately 30 minutes later i head what sounded like a compressor running out in the street. went out into the driveway and found the starter was turning over the engine. the truck had been turned off when parked and the key was removed. went back inside got the key, and turned the ignition switch to the run position. truck started and ran. turned off ignition and removed key, but the starter continued to turn engine. did this several times before letting the engine run for approximately 5 minutes, then finally was able to turn off ignition and starter did not crank the engine. next morning truck would not start. truck was towed and had to have starter replaced because it had burned out. the truck has only 15,000 miles. called local ford service department where truck was purchased and they said they were unaware of any problems with starters. obviously there is a problem with starter engaging by itself.
ELECTRICAL SYSTEM - WIRING
10/28/2010802701
 2002 ford f-150. consumer states a major wire harness burned on the r.h. exhaust manifold and the protective plastic sleeve was gone as well as the insulation. *tgw the consumer stated the check engine light illuminated and the overdrive light started flashing and it wouldn't shift past 2nd gear. *jb
03/08/200878000110/05/2005
 1. driving approximately 35-40 mph in town in vehicle. vehicle has approximately 75,000 miles. heard a loud explosion and truck immediately began to sputter. had to pull over. barely made it to auto shop a couple of miles down the road. 2. diagnosed as a blown spark plug which damaged the block, head and engine. the auto repair company told me that only ford dealer could repair this damage. estimated at $3500 to $4000 to repair. 3. have yet to decide what to do, as we still owe a substantial amount of money on this vehicle. *tr
04/15/200550000103/05/2002
 My vehicle is a 2002 f-150 and the cruise control malfunctioned. i took it in to be repaired and learned that the deactivation switch leaked break fluid into the servo causing it to short out. i also learned that ford has admitted they have this problem in vehicles from 1997 to 2003, but have only recalled 2000 and 2001 year models. the total cost of the repair was $380 and i think ford should be held accountable for this cost
ELECTRICAL SYSTEM - WIRING - FRONT UNDERHOOD
06/01/200535600105/26/2002
 Dt: in june while owner was sitting there was a honking noise. owner was unaware if the honking was from other cars or from the alarm. then ,he heard a loud pop. he went outside and saw the truck engulfed in flames. the truck had been driven about 14.5 miles for 20 minutes before being parked. the vehicle was sitting for about 15 minutes in driveway. when owner saw the fire the truck was already engulfed in flames. the fire was coming from the hood. it burned for about 15 minutes. the fire department put out the fire, it took about 5 minutes for them to extinguish the fire. there was no warning lights on in the vehicle nor any other type of warning that there was a problem. there were no problems with the electrical system, and owner didn't really use the cruise control. there were no other major problems with the vehicle. the owner was unaware of any recalls on the vehicle. the vehicle was totaled.. part of the garage burned as well. the fire report stated that the brake deactivating switch within the master cylinder caused the fire. the fire report is available for investigators to view. the fire report stated the fire was mostly concentrated in the left rear compartment of engine. there was a police report.*ak
05/12/2005136000110/01/2001
 Dt: 2002, f150, ford pick-up truck. vehicle caught fire which started under the hood, two firemen and a fire expert named bud stringer said that the fire started in the engine compartment on the front driver's side. consumer stated they had no previous problem with the vehicle. it caught flames around 25 minutes after it had been parked. fire caused smoke damage to inside and outside of consumer's home. *ak
ELECTRICAL SYSTEM - WIRING - INTERIOR/UNDER DASH
04/12/2005400005008/21/2002
 I purchased my 2002 ford f150 super crew in august of 2002. i have had ongoing problems since i purchased the vehicle, and have had no responses or assistance from any ford dealerships. the problems started out with my radio going on and off all on its own. i took my vehicle to the dealership at least 10 times alone for this problem. never any assistance. the problems escalated around 40,000 miles and my whole electrical system seemed to be shorting out. i have had fire under the dash, the headlights not work, the wipers would only work when the vehicle was in park, same thing with the heater, it would not turn off after you shut the vehicle off. now this week i had another fire which i was able to put out on my own. i took it to a different dealer and they identified the problem with the gem module and central junction box. apparently the vehicle was not put together correctly and these modules keep shorting out causing my vehicles problems. i have to wonder everyday whether or not my vehicle is going to catch fire and burn up. on a daily basis i can smell smoke coming from under the dash almost like burning plastic or wiring. none of the problems have been addressed and seem to be escalating. to me this is a safety issue. i would hate to think that i would be traveling with my family and the car catch fire while we are driving. the electrical system needs to be investigated and repaired. none of which has been done by the dealer i purchased the vehicle from. i even filed a complaint with the ford motor company and received no real concern.*ak
10/01/20021
 While driving the vehicle noticed a problem in the instrumental cluster dash board, dealer and manufacturer has been notified. (see odi#0814163). nlm