Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING - ENGINE
03214010/30/20030025410004851Engine buck, surge or jerk (also known as hitching/hesitation) while the speed control is active through all engine temperatures. *tt01/12/2004
03212010/30/200397214100048317.3l dit glow plug start-up on-time during cold temperature - service tip. *tt01/09/2004
03212310/30/20039761810004834Low rpm, no start, runs poorly, stall. 7.3l dit engine. *tt01/09/2004
03212110/30/20039721610004832A high number of high pressure rexroth pumps and injection pressure regulators (ipr) are being replaced due to oil leaking, when all that is required is a new gasket or seal on either the pump or ipr. *tt01/09/2004
03211910/30/20039711310004830An engine vibration and/or moaning noise at 2600-3000 rpm. *tt01/09/2004
1445511/01/2000616551Oil leak from the front or rear cylinder head oil supply rail end plugs. *tt03/02/2001
98032504/01/1998603518Cold engine upper knock/tick. *yc07/18/2000
98505811/01/1998613195Subject regarding external oil leaks - repeat message. *tt06/19/2000
98330102/04/1998607462This bulletin provides procedures on neutralizing the exhaust, transmission and engine mounts. *tt09/23/1999
97600707/01/1997605786Brief information regarding cylinder head temperature (cht) and fail safe cooling. *tt07/26/1999
98274004/01/1998603593Concerns with high pressure oil pumps are not serviceable. *yc02/25/1999
9761803/17/199752000Low rpm- 7.3l dit engine fails to start- code 340 stored in memory and/or engine fails to achieve rated speed for 2-3 minutes after extended cold soak- f-series built through 2/9/96 and all econolines. *jd07/17/1997
9711301/02/199751368An engine vibration and/or moaning noise at 2600-3000 rpm may occur on some vehicles. *jd06/27/1997
BC031597020101/02/199751114Fead belt squeal, cold only. revised belt released. *jd06/27/1997
BC032597230101/23/199751435Some 5.4l front end serpetntine belts may make some noise between temperatures fo 30 f-50 f. *jd06/27/1997
BC309097022502/25/199751690Vehicles with a rough running/miss symptom with a misfire dtc on a particular cylinder where normal diagnosis does not pinpoint a cause - check for damage to camshaft. *tw06/27/1997
9721601/20/199751404Leak - oil leakat engine valley pan and/or high pressure oil pump - vehicles equipped with 7.3l diesel engine. *tw06/27/1997
ENGINE AND ENGINE COOLING - ENGINE - DIESEL
9762903/17/199752014Transmission- e4od- harsh/delayed 2-3 upshifts- vehicles with 7.3l diesel and 49-state calibration- f-series built through 2/3/97 and all 1996 e-350. *jd07/17/1997
BC313097022102/21/199751716Diesel exhaust smell in passenger cabin may be due to poor connection at the inlet or outlet to/from the turbo. *tw06/27/1997
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
0124612/10/2001630515Engine oil system priming procedures, service tips for reports of premature engine failure. *tt04/18/2002
98030701/01/1998607708Vehicle stalls/quits while driving. *ak02/06/2001
525412/01/1998615371Information on super duty 7.3 dit diesel engine vehicles exhibiti lack of power. *tt01/13/2001
463808/01/1998615176Malfunction indicator lamp on, with p0300 - p0308 misfire diagnostic trouble codes with a 4.6l engine. *tt01/03/2001
462508/01/1998615162Brief information on vehicles exhibiting a stall on deceleration condition. *tt01/02/2001
461608/01/1998615154Brief information vehicles exhibiting hard start / no start condition. *tt01/02/2001
461708/01/1998615155Brief information on vehicles exhibiting lack of power condition. *tt01/02/2001
462908/01/1998615165Brief information concern vehicles exhbiting external oil leaks. *tt01/02/2001
98-473809/01/1998607152Cold engine knock 5.4l action. *ak11/03/2000
98-472609/01/1998607139Repeat message, no change: hard start/ no start. *ak11/02/2000
98031204/01/1998603506Excessive white smoke. verify glow plug operation by performing glow plug system operation check on the hard start/no start diagnostic sheet. *tt07/14/2000
504711/01/1999613141Repeat message regarding a hard start / no start condition. *tt06/19/2000
504611/01/1998613103Repeat message regarding vehicles exhibiting a lack of power. *tt06/16/2000
98504211/01/1998613086Repeat message regarding vehicles exhibiting rough idle / miss condition. *tt06/16/2000
98357001/01/1998607838Some engines may exhibit oil leakage. *tt10/13/1999
981133509/24/1999607505Exhibiting a vibration, noise or ground out condition when turning or under load. *tt09/24/1999
981134602/01/1998607516Some vehicles may experience an intermittent stall condition after a long deceleration when using the m1 or m2 gear on the e40d or when using a lower gear with the m50d for engine braking. *tt09/24/1999
99603405/01/1999606947Experiencing a engine knock at cold start-up. *tt09/08/1999
97601111/01/1997605811Customer may complain of intermittent stall / bucks / jerks while driving. *tt07/26/1999
98231311/23/1998603760Some vehicles with a 7.3l direct injection (di) turbo diesel engine, one or more of the following concerns may be present: rough idle, stalling, hesitation/ stumble, loss / lack of power, poor fuel economy, and excessive oil consumption.03/04/1999
98211011/01/1998603673During high idle speeds throttle sticks after steady state driving in cold ambient temperatures. *yc03/01/1999
98032304/01/1998603516Concerns with external oil leaks. *yc02/23/1999
98031704/01/1998603510Symptoms regarding p0300-p0308 misfire dtcs with 4.6l engines. *yc02/23/1999
BC025697020101/02/199751092A running change for the 7.3l to allow better definition on cylinder contribution tests in process. *jd06/27/1997
BC078296101410/14/199650408Concerns of check engine light 'on'. *tt04/24/1997
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS
98231411/23/1998603761Premature wear of the belt tensioner may occur on some vehicles. *yc03/04/1999
BC005697230101/23/199751407Some vehicles with air conditioning can exhibit a cold start accessory drive belt noise (chirp) concern. *jd06/27/1997
BC031596110111/01/199650723Fead belt squeal, cold only. *tw06/17/1997
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER
0321310/30/20039561310004814A no-start or reduced power condition may occur intermittently. *tt01/08/2004
98-473409/01/1998607148Lack of power due to failure of engine turbo boost11/02/2000
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
986403/30/1998601312Information on a buzzing or rattle noise from the exhaust system. *tt07/21/1998
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
98231011/23/1998603724Mass air flow (maf)- sensor contamination- service tip. *ak03/03/1999
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE)
BC351097230101/23/199751494Check engine light on with dtc p0455 in continuous memory on 1997 5.4l vehicle applications. *jd06/27/1997
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
BC324197021002/10/199751863Exhaust leaks or noise at the joint between the y-pipe and the exhaust manifold. *tw07/17/1997
96221310/21/199650952Exhaust - exhaust leak at exhaust manifolds - vehicles equipped with 7.0l or 7.5l engine. *tw06/17/1997
BC088396100410/04/199650440Vehicles may exhibit an exhaust leak &/or noise due to warped exhaust manifolds. *tt04/24/1997

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
06/17/2006800001
 Attempting to pass on a two line highway when spark plug blew out of engine. vehicle is a 1997 ford f250 4wd 80k miles. repairs involve removing head. cost is $2800. vehicle worthless since don't know when another plug will blow! *jb
05/01/2001103000609/10/1996
 The brake pedal had to be pumped in order to get the vehicle to stop. the front and rear rotors have been replaced 5 times. the parking brake cable failed and was replaced. the radiator failed 3 times and the heater core failed. *ts *nlm
ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY
04/01/2001509/10/1996
 The radiator has been replaced 5 time due to leakage. the heater core has been replaced twice due to leakage. *ts *nlm
ENGINE AND ENGINE COOLING - ENGINE
11/01/200455000108/17/2002
 While driving, the seat reclined which left the driver laying completely down. *jb the seat base assembly had broken on the driver's side front seat. *sc the tie rods had to be replaced. the consumer was unable to shift gears, because the shifter bolts had broke loose from the dash mounts, the head gaskets failed and the check engine light never illuminated. the hub/axle seals were replaced. *jb
07/20/20011
 Natural gas vehicle. clamp in engine was rubbing onto flexible hose that was hooked to fuel injectors ,causing a hole in flexible hose, emitting natural gas. the dealer and manufacturer have been notified.*ak
07/20/2001111/30/1997
 Natural gas vehicle. clamp in the engine was rubbing onto flexible hose that was hooked to fuel injectors, causing a hole in flexible hose, and emitting natural gas. dealer and manufacturer have been notified.*ak
111/30/1997
 Natural gas vehicle. clamp in engine was rubbing onto the flexible hose that was hooked to fuel injectors, causing a hole in flexible hose, emitting natural gas. the dealer and manufacturer have been notified.*ak
10/01/1998103/03/1997
 Engine oil seals (gaskets) failed. *yc
ENGINE AND ENGINE COOLING - ENGINE - DIESEL
06/05/2001
 Strong odor of diesel was in vehicle. diesel was floating around in engine. diesel hand was going down. *ak
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
04/30/2005100000101/28/2005
 While driving along a spark plug was blown out of the cylinder with the insuing loud banging scaring the driver and almost causing an accident. ford dealer rethreaded spark plug hole and replaced spark plug.
 The vehicle stalls out and dies without warning. the dealer has been contacted.
10/06/1996
 While driving under wet or snowy road conditions the engine goes idle once taking foot off the gas pedal. comsumer also stated that has loss of control of the vehicle once trying and putting on the brakes. consumer contacted the dealer and was told that's how the engine was built into the fuel computer. *ak
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS
11/18/200353000107/01/1998
 While driving, the vehicle lost steering and braking power. *ak the assembly that tightened the belt drive around the steel shaft about one inch in diameter had broken off at the time where the truck had no brakes or steering. *scc *jb
06/17/1997
 Front end misalignment causing vehicle to vibrate and premature wear of tires. in addition, belt tensioner roller makes noise when vehicle is started, and popping noise from cab when driving over uneven surfaces due to cab mounting bolts to frame being loose. *ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
 Exhaust system is located in the front of rear wheels is causing discoloration of wheels and melting of tires. *ak
10/01/1997105/10/1997
 Upon activation of the brakes during trailor hauling(5th wheel), the exhaust developed a leak in the down line directly after the turbo.
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
06/09/1998105/01/1997
 Oxygen sensor failed. yh
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR
08/08/1998101/15/1997
 Engine failed due to overhead cam pulley catalatic converters being totally blocked. yh
11/20/19976
 A catalytic convertor was put on a diesel truck. this caused a back pressure to occur. a hole was created in bottom of turbo. carbon monoxide was escaping through heater vent, causing a hazardous problem for driver, who became nauseous & had a headache. manufacturer knows about problem, but is not doing anything. *ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
105/29/1998
 Consumers vehicle will not pass future vehicle inspections because exhaust pipe exits on the side (design).
10/19/199810/15/1996
 The exhaust pipe heat shield was in contact with the metal transmission fluid tube from the transmission to the radiator. over a period of time the shield wore a small hole in the tube, resulting in a pinhole, which caused the transmission fluid to be released under pressure directly onto the exhaust pipe.