Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||||
| 17288 | 10/01/2003 | 10004931 | Lack of power and/or low boost pressure condition. this includes 2003-2004 super duty f-series. *tt | 01/20/2004 | |
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| 18397 | 02/01/2005 | 10012958 | Lack of power, surge, and/or diagnostic trouble codes p2263 or p0299. *tt | 04/05/2005 | |
| 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 | |
| 04115 | 06/14/2004 | 04186 | 10008255 | No start or constant engine misfire - fuel injection control module (ficm) diagnosis - 6.0l diesel. *tt | 07/23/2004 |
| 17554 | 02/01/2004 | 10008119 | Oil/dust film at cac connections. *mj | 07/22/2004 | |
| 17667 | 03/01/2004 | 10007424 | Oil leak from front or rear of engine. *tt | 06/22/2004 | |
| 17460 | 01/01/2004 | 10007317 | Oil leak that seems to be coming from head gasket area. including ford f450/550 my2003. *tt | 06/10/2004 | |
| 17266 | 10/01/2003 | 10004917 | Low base engine oil pressure caused by high pressure oil system leak. *tt | 01/20/2004 | |
| 17252 | 10/01/2003 | 10004906 | Oil leak at, or near, the rear main seal. this includes 2003-2004 super duty f-series. *tt | 01/14/2004 | |
| 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 | |||||
| 17472 | 01/01/2004 | 10007321 | Low power condition and/or diagnostic trouble code (dtc) p2263. 6.0l diesel engine. also includes my2003 ford f450/550. *tt | 06/10/2004 | |
| 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 - TURBO-CHARGER | |||||
| 18069 | 08/01/2004 | 10011181 | Low power and/or diagnostic trouble code p0299 or p2263 - turbocharger diagnostic service tip. *tt | 01/07/2005 | |
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 - DIESEL | ||||||
| PE04070 | FORD MOTOR COMPANY | 10/07/2004 | 02/15/2005 | ENGINE STALLING | ||
| Twenty five of the odi failure reports are duplicative of ford complaints.twenty odi reports do not contain a vin (and may or may not be duplicative of ford reports).the 14 alleged crashes and 2 alleged injuries were all minor.submitted during preliminary evaluation (pe) 04-070, ford's response to odi's information request (ir) letter contained about 5,000 consumer reports (mors) and 8,700 field reports (cqis).ford reviewed the complaints and categorized them.the manufacturer reports shown above represent a count of unique vehicles that ford categorized as allegedly stalling due to a subject engine component ('a' category, see ford's ir response letter for further detail); some of these vehicles received multiple reports.odi has not yet confirmed ford's categorization of these reports, nor has odi confirmed ford's categorization of the remaining reports (which ford states do not pertain to the alleged defect).ford submitted nearly 19,000 warranty claims, many of which involved claims for a technical service bulletin (tsb 04-13-08) and field service action (fsa 03b05) which ford identified as potential remedies for stalling complaints.odi has not confirmed that either of these are a remedy for engine stalling complaints.several other dealer communications related to engine stall were also submitted as well as over 50 product modifications, 15 of which involve revisions to the software for the electronic engine control unit.further investigation is required and odi is upgrading pe04-070 to an engineering analysis (ea).during the ea, odi will establish and update manufacturer failure report counts, further investigate the frequency and trend of stalling complaints, and determine the scope and safety implication of stalling events.odi will also investigate ford's remedies, their effectiveness, and whether further action is required. | ||||||
| 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 | |||
| 07/06/2004 | 24289 | ||
| I just entered a safety complaint regarding brake rotors rusting (( 10328142 ) on my 2003 ford f250 7.3 l diesel. this complaint regards rusting out radiator hose brackets. on july 6 th 2007 a radiator hose clamp rusted out , and i rapidly lost cooling, while on interstate 68 in md traveling at 65 mph towing a travel trailer. i managed to stop the vehicle and trailer safely but had to be towed to a dealer for repairs. this was on a 4 year old truck.( just recently in conjunction with the rotor problem a wireing clamp rusted out under the body leaving loose dangling wires. at the time i thought it was a single rusting issue. now that i am experiencing multiple failures i know the problems are more extensive. | |||
| 05/11/2007 | 1 | ||
| Cam shaft position sensor ( cps ) failure, truck engine stops running. ford dealership replaced it at cost of $388.*ak | |||
| 05/02/2003 | 5810 | 14 | 02/27/2003 |
| Vin # 1fmsu41px3ec31720 5/3/03 recall 03b06 6/4/03 air conditioner failure 6/17/04 air conditioner failure , ac blend door binding ,plenum defective,had to remove dashboard to repair 6/18/03 4x4 failed to engage, faulty gem module 6/18/03 oil leaking at rear of motor, rear main seal failure, still leaking to date 11/6/03 water seperator failure, perform recall 03e04, perform recall 03l12 1/14/04 rear heater leaking , rear heater core failure, replace fuel manifold,because fuel seperator light still warning 2/27/04 rear main seal leaking/ no repair offered 3/11/04 rear main leaking / no repair offered 5/17/04 air conditioner failure,faulty line conection/rear main still leaking 6/10/04 rear main still leaking /no repair offered 8/5/04 recall 04s15 peformed/ turbo failure, unrelated to recall 8/13/04 rear main still leaking/ no repair offered 9/15/04 rear main still leaking / no repair offered/power loss since turbo replacement | |||
| 08/17/2004 | 289 | 6 | 04/03/2003 |
| When taking off from either a stop sign or light vehicle failed to accelerate forward properly. this caused the vehicle to stall at an inopportune time. its was an ongoing problem. consumer took vehicle to dealership 6 times in 1 1/2 years, and was informed by dealer that problem was low rpm power, which was poor torque, and an improper gear ratio in transmission.*ak the consumers foot contacts the accelerator pedal hanger when attemptingto depress the pedal to the floor. the engine runs rough at idle 750 rpm causing the vehicle to vivrate. at speeds between 750 and 1000 rpm the engine will not maintain a constant speed. speed fluctuates up and down rapidly. the engine produces very little power at low rpm's below 1500. other problems with the vehicle are as follows: defective fuel injectors'; return true; onmouseout=window.status=''; return true;>fuel injectors'; return true; onmouseout=window.status=''; return true;>fuel injectors, leaking rear main seal, leaking brake line junction block, leaking gaskets on rear transmission housing, and broken fasterner on the metal line. *tc | |||
| 06/01/2004 | 4 | ||
| While driving at 60 mph vehicle shut down. vehicle will not start right up again. one hour into driving the problem started. engine made a whistling sound. other then that there were no warnings. consumer has taken the vehicle in for the same problem a total of four times. *ak power steering and brakes shut down as a result of loss of engine power. *tc | |||
| 06/25/2004 | 19000 | 3 | |
| While driving 50 mph engine stalled. as a result, consumer was able to move the vehicle off the road. dealer stated that the oil sensor system malfunctioned, causing oil to leak. *ak | |||
| 03/25/2004 | 15600 | 1 | |
| When the vehicle was idling, it vibrated heavily. *jb | |||
| 07/05/2003 | 1 | ||
| Consumer states that while driving and no warning the vehicle will stall and it will be hard for the consumer to control the vehicle. dealer notified. *ak | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 03/12/2011 | 152000 | ||
| Have a 2003 ford f-250 with the 5.4l triton engine i have owned the truck approx. 6months and in a matter of 1000 miles i have blown 2 spark plugs and inserts out, this repair has cost me $300 each time and $150 in towing fees,i am waiting to see when the other ones will blow, this problem is well known by all mechanics and make the repairs often, if this problem is so well known maybe ford should address this issue and demand a recall of all vehicles with this well known issue, this problem also causes other issues, like engine fires due to the fuel fumes escaping from where the spark plug should be, when i try to research this problem i see that there is a website dedicated to this truck and problem so apparently ford is waiting for an engine blowup to kill someone before they take this seriously | |||
| 03/20/2008 | 120000 | 1 | |
| My 2003 ford f250 triton v10 blew a spark plug out of the head while i was traveling in traffic. *tr | |||
| 01/20/2003 | 20 | ||
| While driving at any speed vehicle stalled. consumer restarted the vehicle, and drove it to the dealer for inspection numerous times. however, mechanic could not duplicate the problem. *ak | |||
| 04/09/2003 | 2600 | 1 | |
| The engine stalled without warning. *jb | |||
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||
| 06/26/2003 | 11000 | 200 | 06/02/2003 |
| Tl*the contact owns a 2003 ford f250. whenever the vehicle is at a stop light, stop sign, or idling, it surges forward. the contact has taken the vehicle to a dealer over 25 times, but the failure has not been diagnosed. the current mileage was 55,000 and failure mileage was 11,000. | |||
| 03/01/2008 | 35000 | 50 | 11/11/2003 |
| When in a slow acceleration the motor rpm will race and you have to quickly apply the brake in order to avoid a mishap. the next thing that is a safety hazard is the cab fills with diesels fumes. making everyone nauseas. acceleration from stop vehicle billows white smoke and is sluggish. *tr | |||
| 09/01/2004 | 1 | 05/30/2003 | |
| Vehicle was running rough. there was a problem with the cruise control. when the cruise was set, it would kick off with the brake or come to a complete stop and the cruise would re-engage. the re-engaging would occur intermittently. *sc the engine lost power. *jb | |||
| 03/02/2003 | 2500 | 0 | 02/01/2003 |
| 2003 6.0 diesel on cold starts the vehicle discharges black and blue smoke for a few seconds, and i have had it back to the dealer several times for surging problems and rough running, the ipc sensor has been replaced twice, and still have various rough running and slight surging problems, dealer is now saying that ford motor company has stated that this is normal and acceptable for the all new best in class diesel. *jb | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||
| 12/30/2003 | 7700 | 1 | 08/01/2003 |
| When the heater or air conditioner was engaged the exhaust fumes seeped through the ventilation. *ak it took one week to have this repaired because the exhaust pipe was on national back order. *nm | |||
| 10/28/2003 | 10000 | 1 | 04/11/2003 |
| While driving at various speeds, the consumer smelled strong exhaust fumes. the dealer inspected the vehicle and could not duplicate or correct the problem, however they suggested turning the air conditioner on max to neutralize the exhaust fumes. *ak the consumer stated the fumes were noticeable even when the heat was on. the consumer was told this was a common problem. *jb | |||
| 03/17/2003 | 14200 | ||
| The vehicles exhaust was coming through the vents into the vehicle. the dealer was notified. *nlm | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL | |||
| 03/11/2004 | 11600 | 6 | |
| While driving consumer smelled gas fumes coming from inside the vehicle. dealership tried to repair the problem, but did not resolve it. *ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR | |||
| 07/09/2004 | 48 | 1 | 01/10/2003 |
| Vibration when under acceleration from stop, ford has replaced catayltic converter 3 times. problem still exists. savere air leak drivers window, i was told it was an enginering defect and nothing could be done.rough idle and skipping , i was told i was buying cheep gas chenged brand still same problem. *ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||
| 11/01/2006 | 13500 | 1 | 01/10/2003 |
| Tl*- the contact stated that on 11/01/06 he could hear the exhaust system and he could smell fumes coming from the vehicle. the contact stated the 2003 ford f250 was taken to several dealerships, and he was informed that the manifold bolts broke. the contact stated that they would have to replace the manifold bolts, and this was only a temporary repair. he has been informed by the dealership that this was an ongoing problem. the contact stated that the only way to resolve this problem was to take the heads off the engine and drill the exhaust manifold holds and reassemble with larger bolts. the failure mileage was 13500, and the current mileage was 15800.*ak updated 03/30/07. *jb | |||