Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||||
| 0361 | 03/31/2003 | 10001855 | Malfunction indicator lamp on with or without rough running, lack of power, surge or poor fuel economy with diagnostic trouble codes p0401, p0402, p1400, p1401. *tt *jb | 07/23/2003 | |
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| 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 |
| 02177 | 09/02/2002 | 10008581 | Cooling system-motorcraft premium gold engine coolant-serivce tips. *mj | 08/05/2004 | |
| 16416 | 11/01/2002 | 10008345 | No/hard start in cold ambients / new two-piece block heater cord released. *mj | 07/28/2004 | |
| 02221 | 11/11/2002 | 10008304 | Engine-gear driven synchronizers-incorrect installation-camshaft position synchronizer (cmp) installation tool correct application. *mj | 07/27/2004 | |
| 02227 | 11/11/2002 | 10008310 | Engine-cylinder head deck leak-4.6 and 5.4l engines-new service-only gasket and cylinder head kits availability. *mj | 07/27/2004 | |
| 16393 | 11/01/2002 | 10008327 | Rolling idle/poor fuel economy. *mj | 07/27/2004 | |
| 03256 | 12/22/2003 | 10008278 | Engine-romeo built 4.6l 2v-tick noise from engine-engines built before 9/17/2003. *mj | 07/26/2004 | |
| 17259 | 10/01/2003 | 10004913 | Rough idle and/or misfire with diagnostic trouble code p0316 after an overnight soak in extreme cold and high humidity conditions. *tt | 01/20/2004 | |
| 03206 | 10/13/2003 | 10004889 | Some dedicated cng vehicles may exhibit various driveability conditions due to a loss of injector performance, resulting from fuel quality. loss of power at heavy load, diagnostic trouble codes (dtcs) for lean fuel, rough idle, hard start, | 01/14/2004 | |
| 03207 | 10/13/2003 | 03910 | 10004890 | A vibration and/or rattle condition when the engine is at idle in gear or when accelerating from a slow speed 32 km/h (20 mph). *tt | 01/14/2004 |
| 17104 | 09/01/2003 | 10004045 | Ticking/tapping noise with the engine warmed up and the transmission in gear at idle. 2003 e150 included. *tt | 11/17/2003 | |
| 03144 | 07/21/2003 | 10003744 | Engine misfire or rough running condition with coil on plug (cop) ignition systems may be more accurately diagnosed using the optional worldwide diagnostic system (wds) coil on plug (cop) kit. 2003 super duty f series included. *tt | 10/29/2003 | |
| 03164 | 08/18/2003 | 10003118 | Some vehicles, equipped with the 4.6l 2v engine, with an engine build date prior to 8/29/03 may exhibit an engine tick noise that is present at all temperatures during idle. 2004 models included. *tt | 10/08/2003 | |
| 03910 | 05/12/2003 | 10002782 | Vibration and/or rattle condition when the engine is at idle in gear or when accelerating from a slow speed (20 mph, 32 km/h). *tt | 09/17/2003 | |
| 03103 | 05/26/2003 | 10002767 | Vehicles without the coolant lock-off may exhibit a no start condition. *tt | 09/16/2003 | |
| 16899 | 06/01/2003 | 10002610 | Rolling idle after shifting to park or neutral, from drive or reverse, when the engine temperature is 100 - 140 degrees f. *tt | 09/08/2003 | |
| 0322 | 02/03/2003 | 10002472 | Streamlined diagnostic procedure for vehicles with malfunction indicator lamp (mil) on and diagnostic trouble codes (dtcs) p0401, p0402, p1400 or p1401, or runs rough, lacks power, surge, poor fuel economy, and the above listed dtcs without | 09/03/2003 | |
| 870197 | 10/22/2002 | 10000592 | Incorrectly installed gear driven camshaft position (cmp) sensor synchronizer assemblies causing surge, lost of power, malfunction indicator lamp on and diagnostic trouble codes p1336, p1309 and p0340. *tt | 03/25/2003 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||||
| 15932 | 05/01/2002 | 637836 | Some vehicles equipped with 4.2l, 4.6l and 5.4l engine may exhibit a lack of power condition. *tt | 12/06/2002 | |
| 021003 | 05/01/2002 | 637864 | Some bi-fuel cng vehicles may exhibit a crank no start condition while operating in alternate fuel mode with the alt fuel light on. *tt | 12/06/2002 | |
| 15913 | 05/01/2002 | 637809 | Some vehicles equipped with 5.4l v8 engine may exhibit air induction system conditions as well as engine hesitation / surge and / or a malfunction indicator lamp illuminated. *tt | 12/06/2002 | |
| 15817 | 04/01/2002 | 637550 | Some vehicles equipped with bi-fuel (cng/lpg) alternate fuel engines may exhibit hard / no start, runs rough or misses after starting, and or hesitation on acceleration when operated in the bi-fuel mode. *tt | 12/02/2002 | |
| 15758 | 03/01/2002 | 636406 | Snow packing of the air filter when driving in severe snow conditions may exhibit loss of power and / or the malfunction indicator lamp illuminating. *tt | 11/08/2002 | |
| 02105 | 05/27/2002 | 636076 | Some bi-fuel cang and lpg vehicles may exhibit a no start condition. *tt | 11/05/2002 | |
| 02108 | 05/27/2002 | 636083 | Some vehicles equipped with the 5.4l 2v engine may exhibit a whistling noise fromthe formed nylon tube inthe idle-air bypass flow circuit. *tt | 11/05/2002 | |
| 02103 | 05/27/2002 | 636072 | Some bi-fuel cng vehicles may exhibit a crank no start condition while operating in alternate fuel mode, with the alt fuel light on. *tt | 11/05/2002 | |
| 02104 | 05/27/2002 | 636074 | Some bi-fuel lpg vehicles may exhibit a no start, rolling idle, surging idle and / or surge at cruise condition in lpg mode with alt fuel green light on. *tt | 11/05/2002 | |
| 01246 | 12/10/2001 | 630515 | Engine oil system priming procedures, service tips for reports of premature engine failure. *tt | 04/18/2002 | |
| 15431 | 11/01/2001 | 630452 | Exhibiting lack of power condition when vehicle is operated in ambient temperatures. *tt | 04/17/2002 | |
| 0214 | 01/21/2002 | 630001 | Some engine assemblies with aluminum cylinder heads repaired in-vehile have been found to leak coolant and/or oil from the cylinder head gasket area. *tt | 04/11/2002 | |
| 01205 | 10/15/2001 | 627927 | Some vehicles may exhibit vacuum or air leaks in the intake manifold and / or engine system causing diagnostic trouble codes p0171 and or p0174. *tt | 02/26/2002 | |
| 15259 | 09/01/2001 | 625807 | Concerns with the lower power in high ambient temepratures. *tt | 12/03/2001 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||||
| 17655 | 03/01/2004 | 10007419 | Evidence of oil in the air intake system. *tt | 06/22/2004 | |
| 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 | |
| 17320 | 11/01/2003 | 10008169 | Broken exhaust manifold studs. *tt | 07/22/2004 | |
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 | ||||||
| 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 - 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 | |||
| 07/11/2011 | 200000 | ||
| Tl- the contact owns a 2002 ford f150. the contact stated while the vehicle was parked he heard a loud noise and noticed the vehicle was on fire. the fire department stated the fire initiated in the engine. there was no mention of a fire report being filed. the vin information was not available. the failure and current miles was 200,000. rvk | |||
| 07/11/2011 | 200000 | ||
| Tl-the contact owns a 2002 ford f150. the contact stated while the vehicle was parked the contact heard a loud noise and found the vehicle on fire. the fire department advised that the fire initiated at the engine. the vin information was not available. the failure and the current miles was 200,000. li | |||
| 08/24/2010 | 95800 | ||
| Tl-the contact owns a 2002 ford f-150. while driving at approximately 3 mph he heard a pop noise and the vehicle began to lose power as he heard noise coming from the engine. the vehicle was pulled over and towed to an authorized dealer where he was informed a spark plug blew out of the engine and ripped an engine coil off. the vehicle was in the process of being repaired. the failure and current mileages were 95,800. the vin was unavailable. sm. | |||
| 04/13/2010 | 178764 | 1 | |
| Auto fire: resident heard car horn sounding, came out and saw 2002 ford f-150 smoking. opened door and air entering vehicle started flames to grow. neighbor extinguished with dry chemical. appears to have been smoldering for sometime, due to heavy smoked glass in cab interior and melted dash compartment. resident had last driven vehicle at 7pm, monday night. truck dash is extensively damaged. fire originated in the middle of the dashboard. vin # has no recalls. reported to fire department. *tr | |||
| 03/24/2010 | 100645 | ||
| I was driving my 2002 ford f150 with a 4.6l triton v8 at 65 miles per hour, when all of a sudden my motor made a loud bang and the was banging non stop. i was unable to pull over imediatly because i was on the pa turnpike at a narrow point. i pulled over a little down the road and after a exspensive tow i learned that the #3 spark plug blew out of the cylinder head. the mechanic first tried to repair it with a self tapping sparkplug repalcemen thread but the damage was to extensive. now he is going to try a heli coil if that doesn't work i'm told i will need a new head. | |||
| 01/18/2010 | 98000 | 1 | |
| 2002 ford f-150 5.4 v8 - spark plug blew out of cylinder no. 3 under normal driving use. vehicle has 98,000 original miles on the engine. i have ford extended service plan on the vehicle, although the local dealer said this is not covered under the warranty, and wants to charge me $4500.00 to repair. when i called the salesman to inquire about the esp, he said that the 5.4 is known to have those problems with the spark plug, so why will ford not stand up and accept responsibility! *tr | |||
| 12/02/2009 | 79 | 1 | |
| I own a 2002 f-150 4x4 it has 79k miles and had the original ford plugs in it. i was stranded a long distance from home when the truck spit a spark plug out destroying the coil. smoke and fuel came out from the engine compartment and not knowing what went wrong i thought the truck was on fire. i had the truck towed to a ford dealership where they said yes that's a bummer. they fixed it with an insert and said there is no guarantee it wont happen again to that cylinder or the other ones!! not feeling comfortable leaving town in my truck now, i find out this spark plug issue is so common that there are shops in my little area that fix one to two of these problems a week! i'm sure ford don't even know about these vehicles. so i contacted ford directly and was told the same thing everyone else is being told across the country sorry cant help you!! but we have great incentives on new vehicles!! i was told the preventable fix for this problem is to replace the spark plugs more often although due to the cylinder head design this is only a possible bandage not a permanent fix and it could still happen. ford and chevrolet represent history. i know times are bad but stand up for your product be american!! *tr | |||
| 12/09/2009 | 78000 | 1 | |
| 2002 ford f-150 5.4 v8 - original factory spark plug blew out of cylinder no. 3 under normal driving use. vehicle has 78,000 original miles on the engine and plugs and ford does not recommend changing the spark plugs in this engine for the first 100,000 miles. service manager at the ford dealership where truck is being repaired indicated that this is a common issue with this motor, however the repair is not covered by ford. *tr | |||
| 10/25/2009 | 1 | ||
| 02' ford f150 triton v8 5.4 1. loud tapping noise from motor. 2. & 3. spark plug blown out of the head. so far this has happened twice. new spark plug, new coil pack, healy-coil pack, 4 hrs of my time working on this p.o.f.s... there should be a recall on this because it seems to be happening on all the ford trucks out there. only ford. *tr | |||
| 08/31/2009 | 82000 | 1 | |
| My 2002 ford f-150 has in the past two months experienced three blown/ejected spark plugs causing the damage and necessary replacement of coils. this posed a possible safety hazard, and i am very unhappy at the time and cost i have incurred since the initial onset of this problem, that apparently ford has been aware of all of this time. *tr | |||
| 05/22/2009 | 69756 | 1 | |
| Driving along a river road at 35 miles per hour, after a short highway drive of about 70mph, a spark plug blew out of the #3 cylinder. we were going camping with our 2 young boys, so decided to drive the truck home. during the drive the smell of gasoline vapor was overpowering. we had only a 45 mile drive to home. on getting the truck home i popped the hood and to my horror the ejected plug was still firing on top of the valve cover. this is an extreme fire hazard! *tr | |||
| 05/08/2009 | 138000 | 1 | |
| Vehicle was in the drive way and caught on fire burned completely up and blew out tires. there is a report with the fire department. *tr | |||
| 01/01/2008 | 70000 | ||
| Tl*the contact owns a 2002 ford f150. while driving approximately 60 mph, the driver suddenly heard a loud noise coming from the engine compartment. she initially thought that the muffler failed. the vehicle did not stall or overheat. she drove the vehicle to a mechanic, who stated that a spark plug blew out due to the aluminum head on the engine. the mechanic performed a healie core and replaced the plug. the vehicle drove normally for over a year before the failure recurred. while driving 65 mph, the contact heard a popping noise coming from the engine. she drove approximately one mile and then had the vehicle towed to the ford dealer. the mechanic stated that the vehicle had a defective cylinder, which caused it to blow out the spark plugs. the mechanic further stated that it was a very common issue and no recall was available. the contact is waiting for a call back from a ford supervisor. she believes that ford should be responsible for the repair. the vehicle has not yet been repaired. the failure mileage was 70,000 and current mileage was 98,000. | |||
| 02/20/2009 | 55000 | 1 | |
| 2002 ford f-150 w/ 5.4 l v-8 engine----spark plugs keep blowing out of engine. *tr | |||
| 08/17/2008 | 51581 | 1 | |
| I have a '02 ford f150 with 51,581 miles on it. yesterday, cylinder #3 decided to blow the spark plug right out of the cylinder head. fortunately, i was able to stop the vehicle immediately. after reading many other frustrated customers with the same issue, i found out that i was quite lucky that the engine didn't immediately erupt in flames. ford refuses to acknowledge there is any issue with this design even though it's well documented. ford expects it's customer to replace the head to resolve the problem at the customer's expense. mine $3,322.96. now the better part. because it appears the design has not changed, even by replacing the head there is no guarantee that this will not happen again. *tr | |||
| 08/10/2008 | 42009 | 1 | |
| My 2002 ford f150 5.4 spark plug blow out of the motor with only 42000. miles on it. $ 890.00 to repair. *tr | |||
| 05/20/2008 | 50000 | 1 | |
| Tl*the contact owns a 2002 ford f150. the contact stated that the sparks plugs were loosening and stripping off the treads. the spark plugs were also detaching from the vehicle. he notified the ford dealer and they stated that there was nothing wrong with the spark plugs flying off the vehicle. when the spark plugs detach, sparks fly. the failure occurs whenever the vehicle is started and before moving. the failure always occurs with the number three cylinder. the failure mileage was 50,000. updated 07/29/08. *lj updated 08/05/08. *jb | |||
| 05/31/2007 | 143000 | ||
| Tl*the contact owns a 2002 ford f150 harley davidson. on january 3, 2008, a spark plug blew out. on may 31, 2008, while at a car wash, the contact heard a loud noise. the vehicle was turned off and towed to the dealer. the dealer stated that the same spark plug from the solenoid had blown again, which also blew the engine head. the repair is expected to cost between $2,200, and $5,000. also, in december of 2007, the sunroof motor shorted and no longer works. she was informed that the repair would cost $1,000, and has not used the sunroof since. the current and failure mileages were 143,000. | |||
| 03/03/2008 | 102000 | 1 | |
| Plug blown out of head!!!!!!! cost 250 dollars to fix.......... *tr | |||
| 04/02/2008 | 68500 | 2 | 07/20/2003 |
| The #4 spark plug blew out of my 2002 ford f150. it happened twice within 2 weeks of each other. *tr | |||
| 07/12/2005 | 78443 | 1 | 04/01/2002 |
| I currently own a 2002 ford f-150. at about 70,000 miles a spark blew out on the drivers side. this was the original plug. had to have helicoil installed. prior to this incident, my 2001 expedition had the same problem. this was also the original plugs, but this motor only had 60,000 miles. unfortunately, the ford dealer i had it towed to would not perform helicoil, so i had to replace the head. they said ford did not recommend helicoil. so i have owned 2 fords within 1 year of each other and both have had the exact same problem with plugs. it's apparent that ford has a design flaw. i heard from a ford dealer that the newer body style of f-150 has had a correction in the thread design in the heads. *tr | |||
| 02/23/2007 | 69000 | 1 | 08/01/2002 |
| My wife was driving in the car pool lane during rush hour traffic when the number three spark plug was ejected from the head of my 2002 ford f150 lightning. my wife loss power. it was a very dangerous situation to be in the car pool lane when losing power. i am a mechanic and a spark plug should not just eject itself. luckily my wife was able to maneuver the truck over and off the freeway. ford was contacted. they said they know of this issue with the spark plugs, but at this time it is the consumers responsibility to pay for the repairs. i feel it should be a recall. there has been thousand of complaints regarding this same issue and nothing has been done. *jb | |||
| 05/20/2006 | 1 | ||
| I was driving down the road about 45 mph, when i heard a loud noise so i pulled over , found the pass side rear plug was shot out of the motor and laying on the top of the engine. the coil pack is cracked and the mounting bracket snapped off. i have done nothing to fix this yet!yes i have old parts. *jb | |||
| 03/10/2006 | 110200 | 1 | 09/20/2004 |
| The 2002 f150 lariet was running great, had not had any problems leading up to this incident. the number 7 spark plug ejected from the head, caused loss of power of the engine, taken to a ford dealer and they are telling us they can replace the head for $3300.00 our cost. i feel this is a defect in the head and ford should be responsible to replace. *jb | |||
| 09/24/2005 | 95500 | 3 | |
| I was driving my 2002 ford f-150 when the spark plug (3rd one on passenger side blew out of the head on the engine. the engine is a 4.6 liter triton engine. it made a large bang then a thumping noise and loss of power to engine so i hurried and pulled over and shut the engine off. tried to put spark plug back in. it stayed in for a few days and blew out again. it will not stay in. the cost of repairs could reach $2000.00 easily. if someone was near the engine when it went off it might of killed them. very dangerous situation. i looked up on the internet to find a way to fix the problem and found out hundreds if not thousands of people have had the same problem with these engines. *jb | |||
| 09/30/2005 | 46337 | 1 | 08/11/2002 |
| Spark plug blow out on my 2002 f150, 5.4l,v8, ford pickup. mileage at time of the incident,46337. while turning right after stopping at a stop sign, i heard a loud pop. the engine lost power and continued to pop very loud. i pulled to the side of the road and called a tow truck. i knew what the problem was, because my brothers 2001, f150, 5.4l, v8, ford pickup, mileage aprox.103000 had the same problem. ford knows about the problem and has a new head with 8 threads instead of 4, but claim no responsibility for the failure. my truck is a the dealership that i purchased it from. i have an extended warranty that is covering the replacement of one head. i am paying for the replacement of the other head. i think it is totally wrong to replace only one head when they both have the same defect!!*jb | |||
| 01/06/2003 | 1 | ||
| Vehicle experienced sudden stalling at various speeds. took vehicle to dealer for checkup, but the cause was undetermined.*ak | |||
| 01/14/2004 | 306 | 4 | |
| 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 | |||
| 01/28/2003 | 17000 | 1 | 03/12/2002 |
| Spark plug self launching from ford f150 5.4 l engine | |||
| ENGINE AND ENGINE COOLING - COOLING SYSTEM - FAN | |||
| 09/29/2003 | 2 | ||
| I have a 2002 ford f150 that has headlights going off while driving. i have had it repaired only for it to reoccur. this is not a minor problem to me and the dealership that i purchased it from is unable to make a service appointment for a week. i have another vehicle but not everyone has that privelege and i have decided to service it at another location. maybe my vehicle is the only one and it is just something that happened. but i am concerned for my safety. thank you for allowing me to voice my concern. llc | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 09/28/2010 | 99149 | ||
| On september 28th 2010 i was driving from indianapolis, in to louisville, ky on a very busy i-65 interstate. at approximately 4pm i heard a very loud pop and lost all power. i could hear a very loud banging noise and at first i thought i blew a tire. i immediately tried to get from the fast lane to the emergency lane but with as many cars on the road this was difficult. i finally made it to the emergency lane and turned my flashers on. when i got out of my vehicle i checked for a flat tire but that was not the issue. i restarted the truck and lifted the hood of my engine. i noticed that one of my coil power packs was at a weird angle. when i went to check if it was still attached the compression of my number 2 cylinder blew the spark plug the rest of the way out of the engine and hit my hood very narrowly missing my head. the coil was also destroyed by the force of the spark plug coming out of the cylinder. my truck is a 2002 ford f-150 with less than 100k miles. this is a very dangerous issue that needs to be corrected | |||
| 06/20/2008 | 160000 | ||
| 2002 f-150ford 4.6 v-8 spark plug ejection. first time happened on june 20 2008 in the number 3 cylinder truck showing 160,000 kms. i removed the head sent it to machine shop to be repaired. 11 months later(182000) the heli-coil that was installed came out with the spark plug. removed the head and installed reman head (on right side) during the spring of 2010 i started to loose compression on all cylinders, ranging from 0-90 lbs and the best cylinder at 120 lbs) brought it to a ford dealer, and results showed leaking was around spark plugs. ford declared i need a new engine. i am lucky enough to be able to do my own repairs. i purchased a used engine from a wrecker and installed @ 190000kms in july 2010. i have spent over $4000.00 on this problem, and i am not dumb enough to change spark plugs when the engine is hot, i use anti-seize when installing, and torque as ford recommends! ford needs to fess up to this issue and offer some sort of recall program. i'm sure that my repair bills would have been double if i had to pay for labor. | |||
| 08/19/2010 | 100000 | ||
| Starting from a stoplight, i heard a sudden pop and smelled gas. loud clicking or popping noise caused me to turn around and head straight to the dealer. they said a spark plug blew out, damaging the coil. initial estimate of $500 grew to $3600 as they said then that the head would need to be replaced due to damage there as well. researching this problem, it appears that there are quite a few (many many many) ford owners with this problem! why is there no recall? immediate safety or not, this is an obvious defect. | |||
| 06/20/2008 | 160000 | ||
| 2002 f-150ford 4.6 v-8 spark plug ejection. first time happened on june 20 2008 in the number 3 cylinder truck showing 160,000 kms. i removed the head sent it to machine shop to be repaired. 11 months later(182000) the heli-coil that was installed came out with the spark plug. removed the head and installed reman head (on right side) during the spring of 2010 i started to loose compression on all cylinders, ranging from 0-90 lbs and the best cylinder at 120 lbs) brought it to a ford dealer, and results showed leaking was around spark plugs. ford declared i need a new engine. i am lucky enough to be able to do my own repairs. i purchased a used engine from a wrecker and installed @ 190000kms in july 2010. i have spent over $4000.00 on this problem, and i am not dumb enough to change spark plugs when the engine is hot, i use anti-seize when installing, and torque as ford recommends! ford needs to fess up to this issue and offer some sort of recall program. i'm sure that my repair bills would have been double if i had to pay for labor. | |||
| 08/19/2010 | 100000 | ||
| Starting from a stoplight, i heard a sudden pop and smelled gas. loud clicking or popping noise caused me to turn around and head straight to the dealer. they said a spark plug blew out, damaging the coil. initial estimate of $500 grew to $3600 as they said then that the head would need to be replaced due to damage there as well. researching this problem, it appears that there are quite a few (many many many) ford owners with this problem! why is there no recall? immediate safety or not, this is an obvious defect. | |||
| 06/20/2008 | 160000 | ||
| 2002 f-150ford 4.6 v-8 spark plug ejection. first time happened on june 20 2008 in the number 3 cylinder truck showing 160,000 kms. i removed the head sent it to machine shop to be repaired. 11 months later(182000) the heli-coil that was installed came out with the spark plug. removed the head and installed reman head (on right side) during the spring of 2010 i started to loose compression on all cylinders, ranging from 0-90 lbs and the best cylinder at 120 lbs) brought it to a ford dealer, and results showed leaking was around spark plugs. ford declared i need a new engine. i am lucky enough to be able to do my own repairs. i purchased a used engine from a wrecker and installed @ 190000kms in july 2010. i have spent over $4000.00 on this problem, and i am not dumb enough to change spark plugs when the engine is hot, i use anti-seize when installing, and torque as ford recommends! ford needs to fess up to this issue and offer some sort of recall program. i'm sure that my repair bills would have been double if i had to pay for labor. | |||
| 08/19/2010 | 100000 | ||
| Starting from a stoplight, i heard a sudden pop and smelled gas. loud clicking or popping noise caused me to turn around and head straight to the dealer. they said a spark plug blew out, damaging the coil. initial estimate of $500 grew to $3600 as they said then that the head would need to be replaced due to damage there as well. researching this problem, it appears that there are quite a few (many many many) ford owners with this problem! why is there no recall? immediate safety or not, this is an obvious defect. | |||
| 11/29/2009 | 86000 | 1 | |
| Well the events leading up to the failure....there were none we were driving back home when all of a sudden pop and there goes my #3 spark plug. well i was stranded for two hours or more until i got my truck towed to my house. the estimated price on a repair for that is $1700 to take the cylinder head apart and install an insert and that price is just for labor no charge on parts yet. this is a common problem that if you look online you will see that many people have the same problem. we need to make ford stand up for their mistake before someone looses their life do to an open spark and fuel being present and exposed when the spark plug blows out. *tr | |||
| 05/16/2009 | 220000 | 1 | |
| Fordf150 2002 model was driving down hwy 11w approximately 45 mile an hour and heard loud bang the #5 spark plug had blown out of engine spitting fuel the engine is 5.4 trition v8 it broke the coil pack and busted the fuel rail on pick up truck is the a recall ? or needs to be recalled any suggestions as to how to fix this issue? *tr | |||
| 02/03/2009 | 81300 | 1 | |
| While driving at 45 mph on level surface the #5 spark plug was ejected from it's hole damaging the coil over plug causing arcing from the coil to the engine. the vehicle immediately slowed dramatically and the smell of gasoline was apparent. luckily there was very light traffic and i was able to pull to the side of the road and shutdown the engine. i identified the problem and having some mechanical training knew enough to disconnect the fuel injector wire for the #5 cylinder. this was the only way i could safely move the vehicle. had i not known what to do, an engine compartment explosion would have easily resulted. *tr | |||
| 05/20/2008 | 91250 | 1 | |
| Normal driving conditions on the freeway - spark plug discharged out of the motor. vehicle towed to nearest auto repair shop. to repair, the hole for the spark plug in the aluminum head was rethreaded using a standard helicoil kit. two spark plug holes have been replaced at a cost of $1100 per hole for parts and labor. *tr | |||
| 08/11/2008 | 85000 | 1 | |
| While being 250 miles away from home, the spark plug blew out of the engine of my 2002 f-150 truck. i was able to buy tools and perform a temporary repair in order to get my truck home. i then hired a mechanic to repair the engine using a heli-coil. unfortunately i don't trust the truck now as i bought it to pull my camper and am concerned over being stranded. i was told by my mechanic that it is a common problem with the 5.4 triton engine. i am not sure why ford has not performed a recall on it. *tr | |||
| 09/17/2008 | 62000 | 1 | |
| Truck maintained according to manufacturer specs. while driving daughter to school, heard loud pop. was able to make it to local repair shop. blown spark plug out of #2 cylinder. with the use of helicoil repairs came to approx. $700. less than 6 weeks later #4 cylinder blew spark plug while driving 65 miles per hour on the freeway. this time (after much research of similar complaints) installed longer thread spark plugs suggested by ford parts department. this time repair costs were $800.00. if ford has made a special kit and new longer spark plugs for this problem isn't that a subtle admission or guilt/responsibility. what ever happened to doing the right thing...admit your mistakes and take care of these repairs. built ford tough my eye!! my next truck will be a toyota... *tr | |||
| 04/13/2007 | 66000 | 1 | 09/01/2004 |
| I have a 2002 ford f-150 with 65,000 miles on it. it is the 4.2 liter v-6 that has always been taken care of. the motor threw a rod and needed to be replaced and stopped with a loud banging and the cost was 5,000 for a new long block by local ford dealership. i have looked on the internet and seen hundreds of folks having to have their same v-6 engine go out prematurely. from 40,000 to 100,000 miles. the plastic intake gaskets are faulty and it gets coolant on the spark plug in cylinder and motor goes out by throwing a rod. ford does not accept any responsibility for this lemon engine that seems to have many design flaws starting from 1997 when they started putting it in their vehicles. *tr updated 09/19/07 *tr | |||
| 07/12/2007 | 104231 | 1 | |
| In the middle of july of 07, my wife, granddaughter and i were coming home from vacation in idaho, by york, ne. the truck was all of a sudden running rough. i was unable to find a mechanic to let me know what was wrong. i had to drive the vehicle home. i called my son in idaho, who is a mechanic and he listened to the vehicle over the phone. he told me that it sounded like a spark plug had blown out. i looked and saw the plug on top of the engine. i called around and found out it was going to cost over 2000.00 for the job. then i found out that ford had made a kit for it. in over 40 years of driving i have never heard of such a thing. if ford made a kit for it, then it seems to me that they should either fix the problem or inform customers about it. *tr | |||
| 07/14/2007 | 104000 | 1 | 11/01/2002 |
| Tl*the contact owns a 2002 ford f150. the contact stated that the spark plug injection on the number three cylinder is defective. the vehicle began spilling raw fuel into the engine compartment. he has taken his vehicle to the dealer and they stated that this is something that just happens and the vehicle is not covered under warranty. currently, the vehicle is at the dealer, where it has been for eleven days. the current and failure mileages were 104,000. the consumer provided for repairs and a letter from ford motor company referencing the defect. updated 08/07/07 *tr | |||
| 10/10/2006 | 74000 | 1 | 07/01/2002 |
| Vehicle was always maintained correctly, while driving at approximately 25-30 miles per hour, there was a sudden popping noise, vehicle lost power which startled the driver and caused the vehicle to crash off the road. vehicle was returned to the road and brought to a parking lot. next day the vehicle was towed to mechanic and it was discovered that the spark plug was blown from the aluminum head. mechanic tapped the head and owner was forced to spend $600 dollars, or replace entire head for $3500. minor vehicle damage due to accident, if this occurred at higher speed unknown what could have happened. pregnant woman in the vehicle who was extremely scared due to noises and exhaust blowing into cabin of 02 f150 v8. *nm | |||
| 06/29/2006 | 31262 | 1 | |
| Ford f-150 blew out a spark plug from the head, this is a known problem and has happened to thousands of people and ford refuses to do anything about it. average cost of repair to the customer is 3500. *jb | |||
| 04/28/2006 | 44000 | 1 | 03/07/2006 |
| My 2002 ford f150 svt lightning ejected the very back passenger side spark plug. i was idling at a red light, a loud pop, and somehow drove the truck to the nearest ford dealer. (joe sartain ford, decatur, al) *nm | |||
| 12/29/2005 | 57365 | 1 | 04/01/2002 |
| On 12-29-2005 heard tapping noise coming from engine of 2002 ford f-150 harley davidson. after accelerating from intersection near home, i heard a large bang and truck lost power. immediately pulled truck over and had it aaa towed to local ford dealership. ford diagnosed the truck and according to the ford service advisor, #6 spark plug blew, causing damage to left cylinder head. approximate damage repair $3800.00. truck only had 57,000 miles. *jb | |||
| 12/15/2005 | 44210 | 1 | 06/29/2005 |
| Engine spark plug blown from aluminum cylinder head. vehicle disabled by damage. repair cost $2481.38 to owner. information commonly available shows this to be recurring problem that ford will cover only with vehicle under warranty. problem not restricted to age of engine. *jb | |||
| 12/08/2005 | 45000 | 1 | 06/08/2002 |
| Dt: the contact stated while driving the clutch would not disengage. he took the vehicle to a certified repair shop for diagnosis. the engine lost a cylinder and fluid leaked out into the engine. the vehicle is being repaired at the contact's expense. *ak | |||
| 12/01/2005 | 30121 | 1 | 04/17/2004 |
| 2002 ford f150 svt lightning 5.4l engine with only 30,121 miles on it blew up on dyno meter on 12-1-05 at only 3300 rpm's. local ford dealership where i bought it says it is out of warranty and too bad. estimate for new engine is $5300 plus tax, etc, installation adds up to a total of $9,300 which i don't have. i am still making payments on this truck too. i have read 32 complaints on this site tonight regarding the spark plugs ejecting and causing engine damage (a rod was thrown in this case). thank goodness i wasn't on the freeway with it. this is a serious safety issue. how many complaints does nhtsa need to get before they make ford recall and fix these engines that only have 4 threads on the spark plugs??? hopefully before anyone is killed as a result. maybe more people should join the california law firm's lawsuit on behalf of 9 people that you list on your defect investigations page. *jb | |||
| 11/29/2005 | 56000 | 1 | 05/30/2002 |
| 2002 f-150, 5.4l - 56,000 miles on truck. spark plug ejected from cylinder head. heard loud pop - experienced loss of power - pulled over - got towed to dealer. dealer diagnosed problem - said cylinder head would have to be replaced - engine would have to be removed for fix - estimate of over $3,000 - would not do any kind of insert (helicoil) fix. called and complained with ford customer service - dealer agreed to give me 10% discount - still cost me over $3,100 plus towing and rental vehicle. plugs were original from factory - had never been touched. had been hearing a slight ticking noise for a few days prior to incident. internet research has revealed several other complaints of this type for f-150, f-250, expedition from 1999-2002. cylinder heads reported to have only 4 threads for plug. apparently ford changed cylinder head in 2003 to an 8-thread plug design.*jb | |||
| 11/15/2005 | 59000 | 1 | 02/03/2002 |
| Right before the failure i was sitting at a stop sign. as i began pulling a way i heard a single loud popping sound followed by a complete loss of power and popping and ticking. i stopped the truck immediately -- i never made it out onto the cross street. the plug blew out of the head --blown plug. ford has offered to replace the head for a cost of $3900.00. *jb | |||
| 10/31/2005 | 45354 | 1 | 11/22/2003 |
| Spark plug blew out of #2 cylinder on right side head. 45000 miles with original plugs still in from factory. dealer said it's a factory defect but ford is not covering it. 3200 dollar repair. truck is a 2002 ford f-150 with 5.4l tritin v-8. *nm | |||
| 11/02/2005 | 81500 | 2 | 03/15/2004 |
| April 2005 2002 f-150 ford truck engine failure at highway speeds. #3 cylinder spark plug blew out of cylinder causing emergency exit from fast lane on hwy 81. second incident same cylinder november 2. after researching ford forums on the internet found this is a common occurrence with the ford triton 5.4 liter v8 motors. ford consumer affairs was contacted - no assistance. this is a manufacturing defect affecting thousands of vehicles as well as lives. ford has refused to recognize the issue and will lend no consumer assistance. a forced recall should be initiated. failure is due to insufficient threading of machined aluminum head on all triton 5.4 liter v8s. estimated repairs in excess of $300 each occurrence. this is unacceptable and ford should be held accountable. this is not a wear/tear component of any vehicle. it is an integral part and should be covered by ford at any cost. *nm | |||
| 09/29/2005 | 48000 | 1 | |
| Spark plug blown out of cylinder head. *nm | |||
| 09/02/2005 | 60000 | 2 | 08/01/2002 |
| Spark plugs blown out of cylinder head while driving through the desert. the front and rear spark plug on the driver's side of the engine blew out within a 24 hour period. i was diving to oregon early friday morning when the rear spark plug on the drivers side of the engine blew out. i was stuck in the desert for 9 hours. called aaa and was towed back to winnemucca on friday night before labor day weekend. no repair facilities available but the tow yard guy had some jb weld. i put some on the threads of the spark plug and screwed it back into what little threads remained in the cylinder head. i was supposed to be at work the following saturday morning. i let the jb weld set for 5 hours. when i left winnemucca it was 1:30 am saturday. i drove from winnemucca nevada to auburn california , nearly 270 miles when i blew another spark plug this time the front one on the drivers side. then i had to be towed to san jose california. obviously i missed work that saturday, but my boss was kind enough to reschedule the work for sunday. the fact that the spark plug that had not been repaired (the front plug) blew out while the repaired one did not blow out tells me that all of my spark plugs are probably hanging on by a thread. if i did not have a cellular phone with service when the first plug blew out, i don't think i would have made it out of that desert 70 miles north of winnemucca on i-80. there is nothing out there. nothing. no phone, no water, no people, except for the big trucks that blow by every once in a while at 90 mph while your trying to fix your p-o-s broken down 2002 ford f-150 lightning on the side of a 2 lane highway. *nm | |||
| 08/03/2005 | 26400 | 1 | 08/27/2002 |
| I was driving in germany road back home when suddenly a hard bang under the hood and then there was a noise like the hole muffler was gone and i lost power, i barly could park my truck on the side of the road on a very dangerous place with a lot of traffic. i had to be towed away, it took 4 hours, next day a garage owner from a bosh workshop put in a replacement insertcoil with a new spark plug. it cost over the 450 euro's to pay in advance whit no waranty. *jb | |||
| 08/01/2005 | 1 | 09/01/2002 | |
| 2002 ford f150 caught on fire in the inside of the passenger cabin while parked.*mr *jb | |||
| 07/19/2005 | 49000 | 1 | 12/08/2001 |
| Replaced spark plugs, drove normally for 8 or 9,000 miles, went to ohio and back .then drove to work on the 19th, heard a pop and the truck started to run rough. when i got of work i looked at the truck and found the number three plug was ejected out of the cylinder head. | |||
| 07/10/2005 | 1 | 10/01/2003 | |
| Dt: contact states her vehicle is stalling while driving at any speed. the only thing that signals that the vehicle is stalling is that the vehicle will jerk and rpms drop. this happens with the vehicle stalling everyday. the service dealer can not determine what is wrong with the vehicle because the service engine light is not illuminated. the contact is taking the vehicle to the service dealer today. *nm | |||
| 05/02/2005 | 51000 | 1 | 12/01/2001 |
| 2002 ford pick up truck engine ejected a spark plug while driving.*mr the consumer stated the vehicle suddenly slowed down as if he applied the brakes. the mechanic told the consumer the threads had been stripped from the head when the plug was ejected. *jb the consumer no longer owns the vehicle. | |||
| 01/27/2005 | 75000 | 1 | 11/16/2004 |
| While accelerating from a stop, a loud pop came from the engine compartment and the engine started shaking violently. pulled over to check under hood and discovered a spark plug was blown out of the engine head. head needs replacement.*ak | |||
| 10/27/2004 | 130000 | 1 | |
| Spark plug blown out of head . new head needed $2500 repair. *jb | |||
| 8000 | 1 | ||
| While driving the vehicle stalled without warning. the dealer could not determine the cause of the problem. *ak | |||
| 10/18/2001 | 50245 | 1 | 02/22/2002 |
| I have 2 spark plugs that will not stay tight. because of the problem with these motor blowing plugs out i have to stay on top of them. i tighten then about every 3 weeks. *la | |||
| 11/17/2000 | 21000 | 1 | |
| Known failure to cylinder heads. failure involves the launching of spark plugs while engine is running resulting in severe engine damage. *la | |||
| 01/22/2003 | 341 | 5 | 01/28/2002 |
| Engine misfires in cold weather while driving causing serious loss of power first started at 341 miles and continues to date.*jb | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| 01/06/2007 | 58000 | 1 | |
| Driving at 60 mph, pop, loss of power, noisy motor, stopped, opened hood to find blown #3 plug. blew coil from mount and damaged insulator. *jb | |||
| 07/14/2006 | 76483 | 3 | 08/14/2002 |
| My 2002 ford f150 harley davidson pickup truck ejected a spark plug while driving on the highway . this is the third incident of failure and am concerned for my safety as the truck looses power while at highway speeds and could cause an accident . in addition the failing plug this time was one right under the fuel rail and the coil was prevented from continuing to pull out by the fuel rail adding concern that it could puncture and cause an engine fire .when contacting ford they basically took my information and offered no assistance . *nm | |||
| 11/21/2005 | 66234 | 1 | 10/26/2003 |
| 2002 ford f-150 5.4 liter engine 66,xxx miles driving on city street, approximately 35 mph, 3rd spark plug on passenger side blew out towed to repair shop, heli coil insert installed no old part available. *nm | |||
| 09/27/2005 | 88000 | 1 | |
| Engine on my 2002 ford f150 with 88,000 miles blew a spark plug while driving at approximately 45 mph. causing approximately $2,900 worth of damage. vehicle was pulled over immediately and towed to the closest repair facility. mechanic said this is a common problem with the ford f150 triton v8 engines that ford won't acknowledge.*jb | |||
| 05/20/2005 | 55000 | 2 | 08/22/2002 |
| On two seperate occasions while driving my 2002 ford f150 harley-davidson pickup there was a loud bang from under the hood then vehicle would barely run.turns out that i blew a spark plug out of the cylinder head each of the two times.both times were the right side head and the were the rear two plugs.seems like a lot of other people are experiencing the same problem but ford will not acknowledge it.this is a safety issue as it happens whether on the highway or streets. | |||
| 03/12/2005 | 45123 | 1 | 05/25/2003 |
| Spark plug blown.i had the # 3 cylinder coil and fuel injector replaced earlier.dealer thought it odd both were gone on the same cylinder. i was driving at less than 15 mph when it happened.ford has a problem with blown spark plugs,they shoud be liable for any repairs.*ak | |||
| 02/12/2005 | 31912 | 1 | 01/29/2002 |
| I was driving home from work in my 2002 ford f-150 truck when i heard a loud bang under the hood followed by a popping sound and a loss of power. i immediately pulled over at the next opportunity to inspect under the hood. seeing nothing evident i took the car home at an extremely reduced speed where i left the vehicle until i could take it to the dealer. the dealer informed me that a spark plug had come loose and the hot gases leaking by it ruined the coil and head and needed replaced. the vehicle had 31,800 miles on it and was 2 weeks out of warranty.*ak | |||
| 12/05/2004 | 28003 | 1 | 07/17/2002 |
| A spark plug blew out of the right side of my truck's engine. this was at low rpm and the truck only has 28,000 miles on it. have learned this has happened numerous times. dealer fixed because still under warranty, but frequency increases as more miles are accumulated. this is an expensive repair. *jb | |||
| 09/26/2004 | 36900 | 1 | 03/13/2002 |
| Spark plug blew out of cylinder on my triton 5.4l ford f150 lightning truck. 900 miles after warranty expired. ford dealer quoted $3,100 to replace cylinder head with a 50% goodwill discount. in my searches on the web this is a very common problem. very common on their v10 diesel engines ford does not acknowledge that a defect exists. | |||
| 05/10/2004 | 73733 | 1 | 04/26/2002 |
| Driving down the road about 55 mph and heard a terrible sound come from the engine. it sounded like a piston disconected from the connecting rod. i had the vehicle towed to the nearest dealer. their diagnosis is that the #3 sparkplug loosend up and damaged the plug hole. the said that the head needed to be replaced and the biil would range from $3500-4500. i did not have the money to get the vehicle repaired so the vehicle sat at the dealer for 5 months. when i called the dealer they said there was a repair that could be done but it wasn't recomended by ford. the repair was to remove the head and sleave the blown out spark plug hole. i had them repair it this way. the cost to me was $1796.00 and there was no waranty because it was not a ford recomended repair. my concern is that this seems to be a fairly common problem and could happen again at great expense to the consumer. not only is there great expense but, if this were to happen in heavy traffic it could cause a major accident.*ak | |||
| 11/15/2002 | |||
| While driving the vehicle in reverse, to park the vehicle suffered sudden acceleration when shifted from driver into reverse vehicle collided with another car causing damage to his vehicle and other car. dealer has been notified. please provide furrther information. ts | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER | |||
| 06/11/2004 | 33500 | 1 | 01/01/2002 |
| Blown spark plug out of 2002 ford lightning. had to replace right cynlinder head . *ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||
| 05/12/2008 | 84000 | 1 | |
| My 2002 ford f-150 extended cab 5.4litre pickup blew a spark plug out of the number 3 cylinder. i called the local dealer to inquire as to the price of replacing an exhaust gasket as this is what the noise sounded like. the service adviser after hearing the make model and size engine and year of the truck said, no you did not blow the exhaust gasket, you blew a spark plug out of the head. i was astounded as to how he could make a diagnosis of this type as i had never even heard of such an occurrence. the cost would be a minimum of $850.00. after going on the internet this seems to be a prevalent problem. *tr | |||
| 08/02/2006 | 45345 | 1 | 04/22/2004 |
| I own a 2002 ford f 150 lightning with 45, 234 miles on it. my vehicle experienced some engine failure due to a spark plug shooting out of engine head. i believe it was the 3rd cylinder that failed. i was climbing onto a off ramp and just starting to accelerate when i heard this popping sound coming from the engine. i was accelerating normally when just like that the spark plug shot out. i bought the truck pre owned with 27,000 miles so i never thought to buy additional engine coverage. the truck was in good enough condition for the dealer to grant me a 5 year loan though. anyway i checked underneath the hood and saw the broken spark plug coil and the spark plug with ripped threads. i had the lightning towed to my how where it still sits. at this point in time i am making $466.46 monthly payments on a vehicle that i am unable to drive. i called ford about my problem and got nowhere b/c they said i was beyond the 30,000 mile warranty or the 3 year warranty. ford gave me an estimate to fix the damaged head for 3,600 hundred and 5,400 to do both. now from what i understand the 2003 ford lightnings do not experience spark plug issues b/c the engine were built with updated heads. that right there says that ford realizes that these trucks are defective to some degree. i am very frustrated in this matter b/c i spent 29,000 out of pocket for this truck and i can't even drive it. now i have to spend almost 6,000 to get it to driving condition. like 29,000 isn't enough money already? i work very hard in life to buy this truck i cant just pull that kind of money out just like that. if i have to join a class action law suit so be it. but all i am asking for is my ford f-150 lightning back i missed my truck. | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL | |||
| 01/29/2004 | 1 | ||
| In cold weather, while driving at any speed, consumer heard a loud noise come from the engine. this caused serious loss of power. two different dealerships indicated that it was the air intake system, which was a common problem on the ford, f150 vehicles. *ak | |||
| 1 | |||
| Consumer noticed while traveling a natural gas smell coming through air vents, making consumer sick. manufacturer and dealer had been contacted. *ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE) | |||
| 08/01/2004 | 42000 | 30 | 11/01/2003 |
| Normal every day use. service engine soon light turns on dpfe sensor and or egr valve has failed. from what i've researched in forums it is a very common failure amongst fords. engines that suffer this idle very rough, at times so much that the engine stalls out when it comes to a stop. at first i changed the air and fuel filter thinking this might solve the problem. soon after i had my truck scanned for trouble codes(obd ii) and discovered the above mentioned problem. every shop i've taken my truck for estimates has told me this is a very common defect with fords. *jb | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||
| 01/01/2001 | 1 | 05/09/2002 | |
| Sparkplug / head blow-outs. *ak | |||