Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| 16403 | 11/01/2002 | 10008334 | Engine-light tick or rattle type noise from engine after cold start. *mj | 07/28/2004 | |
| 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 | |
| 17554 | 02/01/2004 | 10008119 | Oil/dust film at cac connections. *mj | 07/22/2004 | |
| 03911 | 05/12/2003 | 10002783 | Rough idle and/or hesitation when acclerating on certain super duty vehicles equipped with a 5.4l or 6.8l engine. *tt | 09/17/2003 | |
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||||
| 16589 | 01/01/2003 | 10005093 | Gradual loss of power at cruise. use fuel additive to prevent his condition. all super duty f-series 1999-2003 included. oasis *tt | 01/29/2004 | |
| 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 | |
| 15500 | 12/01/2001 | 630609 | Concerns with low power while in reverse. *tt | 04/18/2002 | |
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 | |||
| 10/19/2009 | 113000 | 1 | |
| The ford f250 truck (2001) was parked outside of heb grocery store for approximately 30 minutes when witnesses saw sparks shooting out from underneath the vehicle seconds before it caught fire. the entire engine compartment burned and began to consume the cab before the fire department put out the fire. the ford f250 cruise control was used the previous two days and was having intermittent problems during a trip (~900 miles). *tr | |||
| 05/30/2009 | 1 | ||
| My ford f-250 had been parked outside my sons home for approx 2 hrs. when a neighbor informed me that it was engulfed in flames. the fire dept. was called to extinguish it. there was nothing salvageable. *tr | |||
| 01/01/2003 | 60000 | 2 | 11/01/2001 |
| Tl*the contact owns a 2001 ford f250. the engine has a boil heater that will keep the oil heated in the vehicle. the contact has had to replace two of them within five years. it was discovered that the plug to the oil heater was defective and caught fire. the fire burned the front license plate of the vehicle and front bumper caught on fire. the vehicle is currently in his possession and he replaced the part himself. the current mileage was 170,000 and failure mileage was 60,000. updated 03/18/08. *lj updated 03/18/08 *tr | |||
| 09/01/2005 | 26000 | 1 | 09/01/2001 |
| Dt*: the contact stated the vehicle's exhaust manifold inner fender well cracked due to salt and weather and the bolts fractured off. the service dealer was unable to fix the issue. | |||
| 03/14/2006 | 104000 | 1 | 08/11/2005 |
| Faulty engineering on a 2001 ford expedition. spark plugs under pressure just pop right out of the head. the ford barely hit a 100,000 miles. ford boasts that tune ups are not necessary until a 100,000 miles. well anyways the spark plug shot out of the head and the end result is that it will cost me $2,000 dollars to replace the entire aluminum head. after talking with other owners and doing some internet homework with on consumer affairs, i noticed at least a hundred other people with the exact same model ford and that have had the same exact problem. *nm | |||
| 06/01/2005 | 27000 | 4 | 07/20/2002 |
| The consumer stated at 27,000 miles his 2001 ford f250 developed an engine vibration. *jb the consumer was told there was no fix for the problem. when the consumer applied the brakes, there was a vibration. the dealer machined the front rotors and replaced the pads that were cracked. there was a rattle noise coming from under the vehicle. the exhaust shields were loose, the hose clamp on the radiator was replaced and the power door lock was replaced. *jb *nm | |||
| 02/01/2005 | 1 | ||
| The consumer's 2001 ford f250 super duty caught on fire under the hood while parked in the consumer's barn. *nm the fire started under the front hood on the driver's side. *sc *jb | |||
| 04/22/2004 | 40000 | 1 | |
| While driving at 40 mph engine sputtered. consumer pulled over, and opened the hood, and noticed that the spark plugs separated from where it was connected to the engine. the spark plugs were laying on top of the engine. vehicle was towed to a dealership, and mechanic determined that this occurred because of a failure with the aluminum engine motor head.*ak | |||
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||
| 12/08/2003 | 28000 | 1 | |
| Consumer noticed coolant leaking coolant from the engine. dealer stated it was normal for this vehicle to leak antifreeze. *ak | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 02/15/2009 | 98012 | 1 | |
| Spark plug blow out on my 2001 ford f250 5.4 liter engine.*tr | |||
| 08/17/2006 | 63000 | 1 | 02/14/2001 |
| Dt*: the contact stated while the vehicle was idle, a fire erupted which was caused by a faulty electrical system. the fire originated from the engine compartment front underhood. there were no warning signals prior to the incident. upon inspection, the cruise control deactivation switch and wiring for the electrical system was observed to be completely burnt to the ground. a fire report was taken# 06-017205. also, the manufacturer was notified, but would not offer any resolution while this case was under investigation. | |||
| 08/28/2003 | 16500 | 2 | 06/15/2001 |
| The engine stalled while driving 10-15 mph. the dealer determined that the camshaft sensor had to be replaced. *nlm the camshaft sensor had given off false positive readings which resulted in the computer shutting down the engine. this was a common problem according to the service writer. *scc *jb | |||
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||
| 10/07/2006 | 50822 | 1 | 06/01/2001 |
| Dt*: the contact stated the vehicle lost power while making a turn. the engine stalled and the power steering stopped functioning. there was no warning signal prior to the incident. the vehicle was taken to a service dealer, who determined that the cam sensor had failed. the manufacturer was notified. the consumer stated that this is a very common issue with this type of vehicle and feels as though this is a major safety issue. updated 07/17/07 *tr | |||
| 12/18/2005 | 98000 | 1 | 11/01/2001 |
| Dt: the contact complained about an oil ring failure the engine while driving. the engine was making a fluttering sound, and the oil gauge indicated a rapid loss of oil pressure. he pulled the vehicle over to the side of the road. upon inspecting the vehicle, he discovered the oil ring had blown out of the engine. he added enough oil to the engine to be able to drive the vehicle into his certified repair shop. repairs were made to the vehicle at the contact's expense. *ak | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| 12/15/2006 | 1 | 01/01/2001 | |
| Tl* - the contact has a blown head gaske, and white smoke was coming from exhaust system. temperature gauge was up due to mixture of antifreeze in oil. the contact noticed smoke coming out while driving at normal speed and weather conditions. van has been serviced on several occasions and problem still exist. | |||
| 05/05/2002 | |||
| When the vehicle is at a complete stop and consumer will try to start moving vehicle will go into idle and not move for about 10-15 seconds before moving again. contacted dealer, and theyare aware of problem, but can't remedy it. *ak | |||
| 11/13/2001 | 1 | 05/23/2001 | |
| Upon entering the highway, the truck suddenly started having problems, the r.p.m. gauge started fluctuating from 1000 to 3000 r.p.m., it squealed and jerked into gear and a popping noise was coming from the right side of the front end. the dealer could not find any problem, but he suggested that it could have been the clutch fan slipping. consumer experienced again what he felt was transmission problems but the light never flashed on the overdrive column so taking note of what was happening and continued driving. then the light started flashing on the overdrive column, within seconds, consumer noticed a large puff of black smoke coming from under the truck, the r.p.m. gauge went to below 1000, the truck lost all power, and the cab started filling with smoke, fire was escalating under the truck and hood. possible engine failure. *yd *slc | |||
| 07/01/2001 | 8 | ||
| When coming to a stop engine acts like it wants to keep going, this has happened 8 times since july. vehicle taken to 2 dealers, neither could find the cause. please add further comments. *ak | |||