Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| 02177 | 09/02/2002 | 10008581 | Cooling system-motorcraft premium gold engine coolant-serivce tips. *mj | 08/05/2004 | |
| 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 | |
| 15904 | 05/01/2002 | 637792 | Some vehicle equipped with a 4.6l engine without air conditioning may exhibit a no start condition. *tt | 12/06/2002 | |
| 15311 | 10/01/2001 | 630218 | Some 4x4 vehicles may exhibit a crank no start condition. *tt | 04/15/2002 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS | |||||
| 16291 | 10/01/2002 | 10013071 | Loud squealing noise from the engine area when the engine fan clutch is under load while operated in hot dusty climates. vehicles equipped with a 7.3l engine. *tt | 04/07/2005 | |
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 | |||
| 09/19/2008 | 115174 | 1 | |
| 2002 ford f-250 pickup with a 5.4 litre engine. spark plugs keep blowing out of the engine. the ford service department tells me they see this often and then present me with a $400.00 bill each time a spark plug blows loose. i've recently learned that this can also result in an engine fire because the compressed gas and air mixture are being blown through the spark plug hole, while the loose plug continues to fire nearby. *tr | |||
| 01/01/1901 | 3 | ||
| Ford f250 truck customer states that ford is not standing behind the problem with the spark plugs blowing out**cc the consumer stated the spark plug blew out of the motor, which required replacement of the engine. *jb | |||
| 09/01/2006 | 99600 | 1 | 11/01/2005 |
| Dt*: the contact stated at various speeds, without warning, the vehicle stalled. the vehicle restarted occasionally. when the vehicle would not restart, a new camshaft position sensor was installed. the vehicle has not been inspected by a mechanic and the problem persists. | |||
| 07/01/2004 | 4 | ||
| Complaint regarding problems with ford v-10 engine. *mr the consumer started a petition with other ford consumers who have experienced problems as well. additional problems the consumer experienced were: brief tapping noise and a pop, then a loud noise like a manifold leak, the mechanic observed a spark plug had been blown out of the cylinder and the cylinder head had broken. the consumer's cell# 845 0 438-3527. *sc *jb | |||
| 01/10/2003 | |||
| Consumer stated the clamps are to lose and causes anti freeze to leak from the vehicle. dealer notified. ph | |||
| 10/26/2002 | 1 | ||
| While the consumer was backing the vehicle down the driveway, the engine stalled and due to the increased ability to steer or brake, the vehicle rolled into the kingpin of the fifth wheel and damaged the upper left rear fender. the consumer requested reimbursement or refund. *yh *scc | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 12/05/2008 | 160000 | 1 | |
| Tl*the contact owns a 2002 ford f250. the contact stated that the spark plugs blew out of the hole, which caused oil to spray onto the top of the engine. the failure could cause an engine fire. he called the dealer and they stated that there was no recall for the failure. they further stated that the vehicle was out of warranty; therefore, the contact would have to pay for the repair. the failure mileage was 160,000. updated 2/2/09 *cn updated 02/04/09. *jb | |||
| 02/02/2005 | 100000 | 2 | 10/16/2001 |
| Tl*- the contact stated that while driving the 2002 ford f250 with 100,000 failure mileage at 55 mph the contact heard a loud popping noise, the vehicle was riding rough and it started to shake. the vehicle was taken to a dealer, and they stated that the spark plug blew out of the aluminum head. the contact was concerned that this was a serious safety problem. the current mileage was 140,000. *ak the vehicle would lose power when the spark plug failed. update 4/25/07 *tr | |||
| 12/10/2006 | 61399 | 1 | 01/10/2002 |
| Dt*: the contact stated while driving 70 mph under normal road conditions, the vehicle lost compression and speed. also, there was smoke coming out from the exhaust. the vehicle was taken to the service dealer, who replaced the engine head. | |||
| 08/21/2005 | 56000 | 1 | 08/24/2001 |
| 2002 ford f-250 ,5.4 litre triton motor. original dealer installed spark plug blown out of aluminum head becuase of a lack of thread engagment. cost of repair $3,200 | |||
| 05/01/2004 | 46000 | 2 | 10/02/2001 |
| The ignition shut off unexpectedly. the vehicle was towed to a service dealer and they were unable to resolve the problem. *ak there was no code for the check engine at the early stages of the problem. the engine died and the consumer's vehicle drifted into the other lane. the service dealer found that the cam sensor was bad and the exhaust sensor was replaced. *sc *jb | |||
| 06/01/2002 | 7800 | 5 | 02/09/2002 |
| The vehicle stalled on 5 different occasions, numerous parts was replaced, however the vehicle continued to stall, also a faulty brake relay switch was replaced.*jb | |||
| 02/15/2002 | 3000 | 10 | 11/23/2001 |
| The vehicle would stall intermittently when coming to a stop. ph dealership recalibrated the pcm and installed a flight recorder. however dealership had no knowledge of how to read the flight recorder and problem still existed. manufacturer not willing to do anything. consumer has retained an attorney. *tt *jb | |||
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||
| 04/28/2006 | 51390 | 1 | |
| (1) failed during driving at highway speed on narrow road without shoulder. caused complete and immediate engine shutdown, loss of power steering and substantial challenge in steering out of corner. (2) failure of part: camshaft position sensor on ford 2002 7.3l power stroke diesel engine in f-250 sd pickup. (3) dealer replaced sensor and also synchronizer assembly under warranty. cost was $100 deductible and $96.87 tow bill. old parts not available. *jb | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| 02/15/2002 | |||
| Intermently stlawing when slowing down in heavy traffic. ph | |||
| 10/21/2002 | 0 | ||
| Consumer states her truck 's engine keep racing even though her foot is on the brakes, it keeps raving as if wants to go, and if you lighten up on the brakes just a little it jumps forward. ts | |||
| 06/27/2002 | 2 | ||
| Consumer had the brakes changed two different times, but problem still persists.dealer has been notified.*ak the vehicle dies while driving due to cam sensor failure. the gas gauge reads 1/2 full after driving 40 miles due to fuel sending unit failure. *yh | |||
| 08/01/2002 | 24 | 07/01/2002 | |
| The vehicle will lose power with the engine light coming on, cause unknown. the ford dealership has had the vehicle for three days, stating that vehicle was getting some sort of resistance. the vehicle was again failing with the same problem. *ak the consumer states that he had taken the vehicle to another ford dealer and they seemed to have remedied the problem-linkage accelerator. the windshield was leaking-resealed-still leaking. the vehicle has been okay since the last repair. now the windshield is leaking water, and is running behind the dashboard. the consumer has also experienced the following: when stopping the vehicle feels like the drivline shifts forward-loud bang,when starting off, the vehicle shifts backwards, the connector is not fully seated(pcm module), and the injector harness intermittenly opens-repair loose left valve cover injector harness connector causing high resistance cleared. *scc | |||
| 07/15/2002 | 12 | ||
| Vehicle has stalled 12 times at various speed. vehicle was taken to dealer twice, could not find cause of problem.*ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||
| 07/16/2009 | 95000 | 1 | |
| Rust out of oil pan, 2002 ford f250 diesel causing major oil leakage onto exhaust. ford indicated this is a cosmetic problem but issued a service bulletin to dealers. vehicle has been serviced by dealer since new. ford indicates there is not a problem as it is cosmetic. it cost over $1400.00 to fix this cosmetic problem which resulted in totally oil covered exhaust system. repair was not done by dealer that indicated the problem was a pan gasket. a second opinion showed a large hole in the pan from rusting. could have been a major fire. *tr | |||
| 05/01/2004 | 46000 | 2 | 10/02/2001 |
| The ignition shut off unexpectedly. the vehicle was towed to a service dealer and they were unable to resolve the problem. *ak there was no code for the check engine at the early stages of the problem. the engine died and the consumer's vehicle drifted into the other lane. the service dealer found that the cam sensor was bad and the exhaust sensor was replaced. *sc *jb | |||