Bulletins

BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ELECTRICAL SYSTEM
1757102/01/200410008134Malfunction indicator lamp (mil) on with diagnostic trouble codes p0603 (powertrain control module keep alive memory error) or p0605 ( powertrain control module read only memory error). *tt07/22/2004
461508/01/1998615152Information on vehicles exhibiting 4x4 lights on / 4x4 inoperative / multiple gem codes. *tt01/02/2001
98502411/01/1998613055Some vehicles may exhibit abs codes of b2141 or b2477 and / or speedometer errors following replacement of a gem module. *tt06/16/2000
991303008/01/1999609032Some vehicles equipped with either the trailer towing package or chassis cab may exhibit various trailer related electrical conditions such as: backup lights inoperative, trailer battery feed inoperative or electric brake power inoperative12/07/1999
99674708/01/1999608458Some vehicles equipped with either the trailer towing package or chassis cab may exhibit various trailer related electrical conditions. instructions on installing the trailer towing relays and fuses are provided in the trailer towing kit.12/02/1999
98B2905/01/1999607309Owner notification for gem module replacement. *tt09/20/1999
ELECTRICAL SYSTEM - FUSES AND CIRCUIT BREAKERS
1376601/01/2000612795Some vehicles without over cab lights may exhibit a number 8 fuse open in the power distribution box and/or not parking lamps. *mjs06/12/2000

Investigations

NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
ELECTRICAL SYSTEM
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES06V286000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES08V025000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES07V078000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES05V388000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES07V488000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES07V347000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES07V336000
 Ea05-005 is closed with ford
ELECTRICAL SYSTEM - WIRING - FRONT UNDERHOOD
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES07V336000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES07V347000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES08V025000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES07V488000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES06V286000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES07V078000
 Ea05-005 is closed with ford
EA05005FORD MOTOR COMPANY03/22/200508/02/2006ENGINE COMPARTMENT FIRES05V388000
 Ea05-005 is closed with ford

Consumer Complaints

Fail datemilesoccurencesPurchase date
ELECTRICAL SYSTEM
01/07/201169000
 I have a 1999 ford f-250, super duty pick-up, with a 5.4 v8 engine, with only 69,000 miles. i was traveling through town at 35 mph when i heard a loud pop (gun shot sound), followed by pop pop pop pop pop. when i pulled over i discovered that one of my micro-coils over my spark plug had broken of the plastic housing. when i removed the coil i found the platinum spark plug in the coil boot. spark plug blow out! nice!...ford wants $550 to repair one spark plug and coil, and also check the rest of the plugs for tighness. help!
10/17/2009122903
 Purchased a 1999 ford f250 super duty february,2009. in september 2009, recieved a letter from ford informing of a recall to the speed control (05s28). on october 6,2009, took the truck to nearest ford dealer which had performed the necessary part to prevent the truck from igniting a fire. on october 17,2009 while the truck was parked in our driveway, it caught fire. we learned from a neighbor: they pulled in their house and seen smoke coming from the truck under the hood. they ran over and grabbed the water hose and tried to open the door, it was locked. they called the local fire dept. and the fire started.the truck's engine started up, the headlights camer on and the wipers started going back and forth. my neighbor looked in the window and seen there was no keys in the ignition. the firemen arrived and force and forced the hood up and put out the fire.it was a total loss. we contacted the local dealership where the recalled part was replaced and told us to contact ford motor company. we did, they sent us a letter of needed information from us. when submitted all information and in december 2009 got a reply they were unable to associate with us on our damage.
04/27/20091500001
 Truck sputtered and shut down at highway speeds. starts sometimes, other times doesn't. previous owner had replaced item 1 month before i got the truck. *tr
11/13/20081800001
 I have a 1999 f250 super duty pickup 7.3 diesel. as i was driving it one evening i smelled smoke and saw smoke coming from under the dash and up in the defroster area at the windshield. it then began to flame up from those areas and i slowed the vehicle down and jumped out,fearing i was going to get burned. it was late at night on a country road at 2 am. and the truck burned for almost a half hour before anyone drove by me to call 911. by the time the f.d. got there the vehicle was totaled destroyed and totaled engulfed in flames. i had a small one gallon gas/oil mixture container( for my chain saw on the floor of the vehicle) which had less than half a gallon in it. i told my insurance co. of that fact. the insurance co. now wants me to be deposed under oath. i have nothing to hide and will allow that. however i received information from an anonymous source that the insurance co is trying to deny my claim and even possibly try to charge me with arson and fraud. the engine compartment was melted and the entire truck had burned to bare metal. i had smelled the odor of burning electrical wires on several prior occasions but i never did find the source of the odor. i even had a ford mechanic check it and he didn't find what the smell was from. i believe the culprit was the cruise control switch as i have researched the internet and saw several recalls for such imminent fires from a faulty device. please advise if my veh. had that control that is suspect on these latest recalls. *tr
10/13/20081872871
 Powerstroke engine code po 344 cam shaft pos sensor, had to replace. *tr
05/08/200345000103/14/2002
 While driving in traffic and the truck began to buck and shutter than shut off with no warning. would not start was very happy i had not just pulled into traffic! ford wanted 600$ to fix it when its a 100$ part and takes 15 minetes to fix!. *ak
06/07/200715500005/02/2007
 On the 7.3 powerstroke ford truck i think it is a safety hazord if the camshaft position sensor were to fail approaching an intersection and you wouldnt have power brakes if the engin shuts off and you may not be able to stop fast enough to avoid an accident. i think there should be a recall on the cps because it seems that my life may be endangered every day on the way to work with the common problem.
02/12/2003100000102/13/2002
 I was driving on the freeway at 65 mph when the truck suddenly shut down and then turned back on almost instantly. the amount of traffic and freeway speeds made this a very dangerous situation. i got off the freeway and my truck proceeded to shut off two more times before i arrived at home. i called the ford dealer and described what had happened and the first thing the service advisor stated its the cps we see it all of the time. i replaced the cps and sure enough it ran great again. the cost of the new cps was $180.00. *tr
06/21/2006110000102/08/2004
 Vehicle seemed to be running fine. parked in my driveway and 70 minutes later my wife came home and found the truck on fire. heavy fire was ensuing from the driver side wheel well as well as out the front driver side grill. *jb
03/12/200691000209/11/2004
 First day-accessories stay on while ignition switch is turned off & key is removed. second day-batteries goes dead, wipers turn on by themselves, speedometer quits, transmission will not shift, 2 different buzzing noise from under dash, dome lights flashing on & off, abs brake lights come on. we have had no recent mechanical work done. no single source causes all these problems at one time. *jb
08/15/20051380691
 Daughter was driving truck on highway 101 and engine died. no power, no power brakes or steering. she pulled to side and tried to restart truck - nothing. called tow truck and vehicle started but died again. vehicle was towed to ford dealer. they said it was the cam positioning sensor. when it is broken the truck thinks the engine is not running and kills the power. they did not recommend she drive the truck without making the repair as it would die again. the repair cost $500 and only the dealer could do the repair as they had the computer to read the error. they said there were numerous service bulletins on this problem but no recall. *nm
12/21/200461000111/04/1998
 Spark plug blow-out on my 1999 ford f-250 super duty v-10. *nm
04/11/20051200001
 The vehicle was parked for twenty minutes. there was a loud noise, the consumer went to see what caused the noise, and discovered, the vehicle engine was on fire. the fire department responded to put the fire out. *nm
10/01/2004680001
 Spark plug was blown from the head. subsequent damage to the cylinder head and cylinder wall created enough material and labor costs to justify replacing the entire engine.*ak
09/28/200470000105/10/1999
 I was merging into the right lane of the freeway to exit the freeway and there was a loud bang and my truck decelerated and caused the person behind me to swerve to avoid running into the back of me. i took my truck to my local ase certified mechanic and was told the third spark plug on the pasenger side had blown out of the aluminium cylinder head. the cylinder plug opening was bored out and tapped. an insert was then put into place and the spark plug replaced. the total cost of this was ~$450. after much research i have discovered that this is a very common occurence on the ford triton engines and that ford is doing everything they can to avoid taking any responsibility for this apparent design defect. this stinks!!!*ak
07/13/2004105198110/15/2002
 A spark plug blew out of the engine which is due to a design flaw that ford motor co. is well aware of. this can happen when the engine is new or it has many thousands or, in my case, hundreds of thousands, of miles on it. ford is well aware of the problem, and they have been forced to make the necessary repairs on vehicles that are still under warranty. for those vehicles, like mine, that are no longer under warranty, the full cost of the repair is left up to the consumer. the average repair cost for this major malfunction is $2,500.00-$3,500.00. this is an unacceptable situation for the basic fact that ford is well aware of this problem and they are on the public record stating that they will not issue a recall for these engines because of the significant expense for them to fix them all, because this particular engine is the one that ford installs in most of it's high end trucks and suvs. this position by ford is just not fair business and it certainly is not fair to the consumer who should be able to expect a better product when paying $25,000.00-$40,000.00 for said product, especially when the defect is one known by the manufacturer and their engineering team who finally redesigned the engine in the 2002 model year to avoid this specific problem. *jb
05/15/2004105000110/08/1999
 My truck had 105000 miles and the spark plug blew out of the head stipping.he threds.the head had to be pulled to get the coil in. $2000.*ak
02/25/20042
 Intermittently doors won't lock. also, while driving between 15 to 20 dome light stayed on. dealer indicated it was an electrical problem. *ak
07/10/200305/25/2002
 Ford f-250 5.4 l v8 blown spark plug from cylinder head. there are not enough threads to keep the spark plug from eventually being blown from the head. have had several instances myself with this problem in two different vehicles. ford needs to recognize the problem and warranty the parts. we still have an extended warranty, but they can't guarantee it will be covered. even though it says right in the paperwork that this part is covered. *nlm
2
 Consumer states that spark plugs blewout of the cylinder, stripping the threads out of the cylinder heads, resulting in engine failure. this has occurred twice since vehicle purchased. 1st occurrence at 3900 miles, 2nd occurrence at 56000 miles. *ak
04/12/200349738011/11/2001
 My truck has 49,000 miles on it and a spark plug blew out of the top of the cylinder head and broke the coil pack. the truck has never been tuned up. this is a result of a bad design for the spark plug hole in the cylinder head. it only has 5 threads to hold the spark plug in an aluminum head. *nlm
ELECTRICAL SYSTEM - IGNITION
12/15/200672860108/18/2004
 1999 f250 super duty 7.3l diesel. cps sensor failed and caused the engine to stall while driving 65 mph on freeway. there was no power steering or brakes. vehicle very hard to control. i replaced the cps sensor(f7tz-12k073-a- synchronizer) and repaired the problem. very similar to the thick film ignition issues from the past. the old part is available to the nhtsa. *nm
01/15/200645000305/21/2001
 1999 f250 with a v-10. spark plugs have blown out twice and where repaired by dealer. expensive! one of the repaired plugs blew out again. had to have head removed and taken to a machine shop. i have contacted ford on each occasion and they claim they never heard of this problem before. it ruins an expensive coil pack each time. *jb
03/16/200067000306/01/1999
 Cps(camp position sensor has failed on a 1999 ford super duty 7.3l psd a total of 3 times. first time, son and i were turning into a walmart parking lot, and vehicle shut down and refused to restart. 13k miles on it. dealer fixed cps. second time traveling down interstate 95, and suddenly vehicle shut down again, while doing 75 mph. fortunately the truck is a manual transmission, or we would have ended up in the trees, or into the side of the semi that was passing on the left. third time we were towing our travel trailer, and truck died on a 8% grade, there was no time to get out of the lane we were in to the shoulder before we slowed too much and caused a wreck behind us the truck now has 77k miles on it. we feel the cps failing 3x in 77k miles is exxx... the last two sensors were not under warranty and cost $250~ we have researched on the internet and found out that the cps is a very common problem, and has shown up in mileage instances ranging from 100 miles on odo. all the way to not showing up until 200k miles. we, (along with apparently thousands of other truck owners) feel that the vehicle shutting down, and losing 90% of our steering and likely 85% of brakes (on diesels you do not get a reserve brake boost, unlike on gas engines with vacuum), as the brake system is powered by the hydraulic pressure provided by the power steering pump!!!! we know there is no way around the brake system. however, in two of our cases. it was very scary and a very dangerous situation when the truck died. we now have a spare cps inside of the glove box inside of vehicle and proper tools to replace it ourselves should it happen again. we have heard of other people driving said trucks with 7.3l psd engines ( do not know if the 6.0l is having the same problem with the cps) of the trucks being totaled and people being seriously injured because of the cps failing. we feel that a recall, should be made... thank you and good day....*jb
11/18/200392000112/18/2001
 First we started to hear a ticking sound from engine. dealer said it was something to do either with the fuel system or the y-collector on the exhaust. they advised to change y-collector with something less performance oriented, sounded incorrect so i obivously declined. soon after while traveling down in baja mexico we were climbing a mello grade when bamm!!! we lost most of our power and it sounded as though we were riding a large lawn mower without a muffler. since we were in mexico with no cell service, we crawled all the way home after midnight. upon inspection, rear passanger spark plug had blown through the threads and took the coil with it. replaced with cold-fusion coil, but still sounds as though main bearings aren't going to make it much longer!!!!*ak
ELECTRICAL SYSTEM - IGNITION - MODULE
07/15/20051285003010/20/2003
 Random truck failure of the engine at no particular time. problem diagnosed as camshaft sensor by ford technicians. $185.00 part that seems to be failing a lot according to ford techs. ford states they are currently not having problems with the sensors but out of 5 guys i personally know, all 5 have had problems with their 7.3l diesel camshaft sensors. extremely dangerous because of engine failure. ford only offers a 1 month warranty on the item and offers an average of 6 months on any other electronic device on the truck. seems they know the failures are occuring as well but doing nothing about it.
ELECTRICAL SYSTEM - WIRING
04/10/2003113000505/06/1999
 Truck wanders on road and pulls when brakes applied, dealer was told of this problem since viehicle was purchased they never could find the problem. i have owned this viehicle for 3 years and have replaced brake pads 3 times and have had to replace the hubs twice myself at my expence out of warranty now. there was almost a fatality when i applied the brakes my truck pulled me into the ditch sliding and rocking from drivers side to passenger side up on two wheels. my airbag light flashes on and off. who knows if they even work. my overdrive switch has been replaced 4 times and is broke again. door ajar lite on constantly. but quality ford cant find or offer me some kind of solution. they need to be investigated.
ELECTRICAL SYSTEM - WIRING - FRONT UNDERHOOD
04/11/200486000111/06/2003
 Vehicle was parked for the night (ignition was off). vehicle burned due to fire from under the hood caused by electrical failure. total loss (repairs to exceed value). vehicle is still in my possession. i was recently made aware of a ford recall for cruise control components causing underhood fires of similar nature and consequence on similar vehicles.*ak

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