Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING
034303/03/200310001896Crank no start when the cht (cylinder head temperature) at ambient temperature. *tt *jb07/24/2003
ENGINE AND ENGINE COOLING - ENGINE
03140408/23/20040416110011162Engine 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
0217709/02/200210008581Cooling system-motorcraft premium gold engine coolant-serivce tips. *mj08/05/2004
1641611/01/200210008345No/hard start in cold ambients / new two-piece block heater cord released. *mj07/28/2004
0222711/11/200210008310Engine-cylinder head deck leak-4.6 and 5.4l engines-new service-only gasket and cylinder head kits availability. *mj07/27/2004
0222111/11/200210008304Engine-gear driven synchronizers-incorrect installation-camshaft position synchronizer (cmp) installation tool correct application. *mj07/27/2004
0325612/22/200310008278Engine-romeo built 4.6l 2v-tick noise from engine-engines built before 9/17/2003. *mj07/26/2004
1725910/01/200310004913Rough idle and/or misfire with diagnostic trouble code p0316 after an overnight soak in extreme cold and high humidity conditions. *tt01/20/2004
0320610/13/200310004889Some 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
1710409/01/200310004045Ticking/tapping noise with the engine warmed up and the transmission in gear at idle. 2003 e150 included. *tt11/17/2003
0314407/21/200310003744Engine 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. *tt10/29/2003
0316408/18/200310003118Some 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. *tt10/08/2003
0310305/26/200310002767Vehicles without the coolant lock-off may exhibit a no start condition. *tt09/16/2003
1689906/01/200310002610Rolling idle after shifting to park or neutral, from drive or reverse, when the engine temperature is 100 - 140 degrees f. *tt09/08/2003
03B0403/01/200310001349Customer satisfaction program - cold start calibration product enhancement. *tt04/30/2003
87019710/22/200210000592Incorrectly 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. *tt03/25/2003
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
1765503/01/200410007419Evidence of oil in the air intake system. *tt06/22/2004
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE)
0541703/07/200510014666Intermittent rough idle - non-commanded egr (exhaust gas recirculation valve) flow. *tt05/05/2005
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
055403/21/200510014685Use of stainless steel exhaust studs in service for 5.4l 2v engine. *tt05/05/2005
1732011/01/200310008169Broken exhaust manifold studs. *tt07/22/2004

Investigations


NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
ENGINE AND ENGINE COOLING
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK 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
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK 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
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK 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 datemilesoccurencesPurchase date
ENGINE AND ENGINE COOLING
01/04/201193000
 I recently purchased a 2003 ford f 150, triton v8 from a local reputable dealer. it is in for repairs due to engine concerns. in researching the triton v8 i find that i am not alone and there is a concern with blowing spark plugs out of the engine head. i want to document my problem at this point so if the need to legally seek repairs i have a paper trail. at this point i am told that the repair will be $550.00, but in reading other consumer complaints i see that most began the same way.
11/06/2010135000
 I have a 2003 f150 that has 135k miles. i have had the truck serviced regularly and have had no major issues until today. i am in the navy and was driving into work for duty when my spark plug was ejected from my engine. the explosion was so great that it broke the coil pack in three pieces and when i pulled over in investigate the noise i turned on the engine with the hood open to see the spark coil across the port where the plug had been and it was sparking (it's a wonder that it didn't catch the vapors on fire fron the cylinder) the plug also severed one of the vaccuume hoses in the engine compartment. i contacted the ford dealership in town and the mechaninc told me that was normal for trucks over 100k miles, and that they would 'start popping out like popcorn'. this seems outragous! i tried to fix it myself but now am having to concede to letting ford do the work since they have the replacement kit ( because this always happens - their own words). there is a potential that this could cause an engine fire! please force ford to do a recall.
11/17/2009930001
 I had been driving my truck for about ten minutes and as i was driving on the freeway the engine spark plug blew. i got my truck to start up and drove a short distance before this occurred again. this repeated until i managed to get to my home which was about two miles away when the problem first occurred. then i called venus, a towing and repair shop, to have my truck towed from my house to their shop. the towing service cost $80.00. when the problem was diagnosed they called me and told me what happened. they fixed my truck and charged $250.00. *tr
08/20/2009156461
 I have a 2003 f150 v8 5.4 l and i was driving down the road and i heard a pop, and i checked my engine and noticed the ignition coil was loose and the spark plug was attached to the ignition coil, so now the threads in the head are stripped and i cannot drive my vehicle!! this is a huge problem and i am very disappointed that because not enough people have complained that this is not recall issue it should be!!! *tr
07/05/2009901231
 While traveling @ 65 miles per hour down a highway, the number 3 spark plug & coil blew out from the head causing damage to the coil & spark plug itself. our 2003 ford f150 supercrew lariot pick-up truck, which is in excellent condition, had to be towed. this is the first time this has happened to our vehicle. the local ford dealership recommended a quick fix of a spark plug insert after the plug hole was retapped while stating several times that there was no guarantee that this would work. another option was to replace the heads costing approximately $2500. the dealership also advised us that they were aware of this problem & has seen it happen on a variety of ford vehicles. we're extremely lucky that our vehicle didn't catch fire, as the coil that blew hit the fuel rail, which is held in place by two 8mm bolts. this experience is extremely frustrating & concerning to us as if we spend money going the route of the insert, it may last for one trip down the road & give out. it's disappointing that ford isn't standing by their product & fixing it appropriately. this is a well known problem that brings with it severe safety issues. we will not be purchasing a ford vehicle in the future.
11/28/200630000207/25/2004
 This is the second occurance that i have had a oil seal or gasket on the engine after driving 80 +mile per hour. i had my truck less than three years. i have also noticed it vibrate when reaching the speed mentioned. *nm
07/12/200407/12/2003
 I purchased an 2003 f-150 stx 4x4 in july of 2003. less than 1 year later the air conditioner had to be replaced. stopped working with no noticable problems. in the next 12 months the gear box has been replaced twice, i called our local dealer and told them the transmission was shifting harder than usual. took it in and they couldn't duplicate or correct the problem. it continued, and less than 6 months goes by and i am sitting at a red light downtown louisville ky and the light turns green i pushed the accelerator and the truck goes backwards! thank god no one was behind me! after 15 minutes i finally get the truck to the side of the street and call ford roadside asstistance. that was a joke in itself. finally 4 hours later the truck is towed to our local dealer and they call the next day and say it is the transmission. duh! i told them that months ago. they fix it and it still is not right. i have even taken it to another dealer and i have contacted ford. the second dealer could not find a problem, so far all i get is, yes, it does shift really hard but we can't get a code to see what is wrong with it! i am still paying for the truck and it is now under the extended warranty this is completely wrong! no one should pay $36000 for a truck and have this much go wrong with it! any help would be appreciated.
05/09/200511181112/27/2002
 Dt: own a 2003 ford f150 with 11,000 miles. there is a heat shield over the muffler that was falling down. took vehicle to the dealer, and as instructed by ford, was to remove the heat shield entirely. feels this is dangerous without the heat shield which is not on the vehicle right now. dealer ordered a new heat shield because the old one was deteriorating. ford ordered not to replace the heat shield as per engineering since it was no longer needed. *ak leaking rear seal, pan and gasket were also replaced. *tt *nm
10/19/20042
 While driving,the vehicle stalled. the consumer was able to restart the vehicle and drove it to the dealer for inspection. the mechanic informed the consumer that the problem could not be duplicated. *jb
ENGINE AND ENGINE COOLING - ENGINE
05/29/2009420001
 The spark plug on my 2003 ford f-150 was ejected from the engine. the truck has 42,000 miles on it. there was a huge bang from the engine, and the gas vapors flooded the cab. luckily i was able to navigate to the side of the road and my family was not injured. this problem appears to be well-documented online, and i will be following up to see where the nhtsa is on this issue. *tr
12/06/20081150001
 My 2003 ford f-150 with 5.4 triton engine spit out the number 3 spark plug. this is the second time this has happened to the same plug. ford customer relations refused to even discuss the matter with me, saying there was no problem with its product! *tr
07/27/200771976201/27/2006
 In between oil changes, the sender assembly in my ford f150 failed to send a message to the gauge that the engine was overheating. because of that failure, both head gaskets were blown allowing water to go inside the engine. the sender assembly was not working so it did not send a signal to the oil gauge that the pressure was low. this caused a complete engine failure. cost to replace the engine was $5,405.12 + 20 days of a rent car $672. all of this out of my pocket and ford refuses to reimburse me as does the dealership who did the repair. *tr
03/22/20071
 Engine light turns on, intake mnanifold gasket needs to be replaced on a 2003 v6 4.2l engine in a ford f150. *ak
03/13/20072
 I purchased a used 2003 f-150 with 38,000 miles on it aproximately 6 months ago. i started noticing an oil leak in december but could not locate where it came from. after trying to add stop leak to seal it, i finally brought it to the dealer. with 49,000 miles on it, the front gasket and left head gasket were bad. this seems a little premature for a failure of this type.
02/28/20031102/22/2003
 Hollow knocking noise in the 5.4 engine most noticeable when cold. ford and the dealer tell me to put up with it because it is normal. something about piston clearances or slap. i did not pay $30,000.00 + for a new vehicle to listen to it knock in the mornings when i start it up. ford is aware of this noise in the 5.4 and i would like someone to look into this because they are not willing to do anything about it. *la
07/28/200324107/28/2003
 I have a 2003 f-150 supercrew 5.4l 2x4, from day one, a hollow knocking noise is heard at idle most noticeable when in gear at idle, or low rpm. i have had it into ford several times and nothing has been done. we even started another truck on the lot (same year, engine ect.) and the noise was not found on the other truck. the service manager states he does hear the noise but ford does not know what it is therefore they cannot fix it so no attempt has been made to find or repair it (my truck has not been on the rack even once). please advise as to what i can do to resolve this problem. *la
09/02/20033000106/15/2003
 I have many problems with my 2003 ford f150 from engine noises to transmission leaking and slipping. my vehicle has been in twice now and nobody at fords or their engineers seem to know what is wrong. fords does not know what to do. i would greatly appreciate if someone could look into this matter because no one should have this many problems with a brand new $30,000 vehicle.*ak
08/04/20036998105/06/2003
 I have a 2003 supercharged harley truck,the concern is that all eight spark plugs were dark red in color and vehicle was missing horribly under a load with the a/c on or off.there was no check engine light,and vehicle fuel economy dipped to 11mpg on highway.it almost felt like a torque converter going south.the vehicle gets sunoco ultra 94 only and is babied.the vehicle only has 7k on it.p.s iam also the foreman at a large ford dealer.i hae never seen this before,unless high octane additives were used.what caused this.no one at ford knows. i am very dissatisfied with my 44k truck*ak
204/11/2003
 A noise was heard under the hood of the vehicle. the vehicle was taken to the dealership which could not determine the problem at that time. the noise was heard again. the vehicle was taken to the dealership which replaced the timing belt tensioner and the oil pump. please provide details. *ak
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
11/21/2007120000110/30/2003
 Spark plug blew out stripping threads. *tr
10/20/200554000112/30/2002
 2003 f-150 with 5.4l triton engine. 54k miles, experiencing right cylinder head gasket leak. ford has tsb 02227 concerning this issue. truck had 36k warranty. the costly repairs are not covered by ford. i believe there should be a recall on this defect in which the parts and labor is covered. i have researched with other owners on the internet who have had the same problems with their vehicles. i also believe there maybe a safety issue since the leaking oil drips onto the exhaust manifolds and catalytic converters which may cause a fire. please look into this issue. thanks. *nm
06/01/200427000201/02/2003
 Pinging noise coming from engine, have taken vehicle in twice with no resolve. bought truck new in jan 03, have 29,000mi on it. first they replaced the maf still heard noise, then second try they reprogramed the computer. service manager stated it might be coming from fuel injectors. sound heard on acceleration at all speeds greater under load.*ak
04/18/2003111/01/2001
 On a cold start up vehicle knocks every morning. has been to ford dealer 5 times. they have told me numerous things, like use heavier weight oil, no problem, we hear it but not sure what it is, we hear it common engine noise. problem still exists. first time i took it in was 4/2003, and vehicle is at dealer now again. *cb
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS
204/11/2003
 A noise was heard under the hood of the vehicle. the vehicle was taken to the dealership which could not determine the problem at that time. the noise was heard again. the vehicle was taken to the dealership which replaced the timing belt tensioner and the oil pump. please provide details. *ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
06/01/20043000612/29/2002
 I purchased my ford f150 on december 29, 2002 from sunrise ford in north hollywood, california. i returned it in march 2003 because there was an odd clunking, grinding and whining sound when it was driven. i was told that they could not find anything wrong with it. then i took it back one more time in april of 2003 and they still could not find anything wrong. in may 2003, i moved to arizona and on may 9, 2003 i took it to berge ford located mesa, arizona. they tested the vehicle and could not find anything wrong. even though they previously mentioned that it could be the rear end that has the problem. i took it in again on september 17, 2003 to berge ford and they found several items wrong with the truck. although they fixed the items listed on the service ticket, the truck is not fixed. this vehicle obviously has a problem. i would not waste my time leaving work to deal with such issues if the issues did not exist. it took four times to locate a problem and it is still not fixed. i took the car to berge ford on may 26, 2004 again. this time they replaced the air flow valve. i again took the vehicle in on june 1, 2004 and they couldn't find anything wrong again. i believe that this vehicle is truly a lemon and i am hoping that ford can work with me on these issues. i was told i do not qualify for the lemon law because of my mileage, but the problems started before i was over the mileage limit. it is frustrating to deal with these issues for over a year. if there were not any problems then why would i have returned the truck 3 months after i bought it? i would love to trade it in, but i do not want to lose again by being upside down. i spoke with a gentleman at berge ford and he said that there is a possibility that ford might be able to buy the truck back and that is exactly what i need them to do at this point. thank you for your immediate attention to this matter. *ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE)
12/02/20022694210/19/2002
 We purchased a 2003 ford f150 supercrew fx4 in october of 2002. on december 2,2002 this vehicle lost control of it's brakes and acceleration pedal. it was picked up that day and taken to the dealership to be fixed. it is still to this day at the dealership. we have not had possession of it since. they have repeatedly tried to fix it but we unable, until 01-22-03 when we were told it was fixed. but even so we are not given a guarantee by the dealership that it is. they do not feel safe with it on the road also. we are in the process of acting on the lemon law with ford. at first,we were told that the egr valve was the problem , it litteraly let moisture into the throttle body which formed ice, and they have pictures of this, which made the vehicle lose control of the brakes and the throttle to stick wide open. i have been told that there has been further complaints against moisture in throttle bodys of the same trucks but not to the extent of ours. also there is complaints of the gas pedal sticking but ford is telling people that it is thier floor mat creating the problem. i really feel this should be looked into before someone gets hurt or killed. it is not a good feeling when you are driving on icy curves and hills and the speed keeps increasing on its own and the brakes dont work! the only way i stopped it was by throwing it in park,thank god it was in 4 wheel drive, this probably ruined the transmission, but it was the least of my concerns at the moment. i had a car coming towards me and one following behind me, thank god no one was hurt. please check into this.
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
12/11/200563000101/31/2005
 Truck was parked overnight (no problems). next morning, i started the truck. it sounded like a lawnmower trying to start with a loud popping noise. smelt raw gas vapors coming from the top of the engine. took to ford to fix. they quoted me $3200 repair job by replacing a cylinder head. i refused and took to a (farther away) trustworthy mechanic to put a thread insert into spark plug hole and use a helicoi for approx $400. ford refused to do thread insert repair, and wanted to sell me same part that broke in the first place. *nm