Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| 17406 | 09/01/2004 | 18147 | 10008288 | Low power, poor fuel economy, fuel gelling cold, excessive white smoke cold, or hard start. *mj this oasis updates previous oasis dated 12/01/03. *tt | 07/26/2004 |
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 | ||||||
| EA06012 | FORD MOTOR COMPANY | 06/22/2006 | 12/07/2007 | ENGINE STALLING | 07V553000 | |
| In a december 3, 2007 letter, ford advised nhtsa that it will conduct a safety recall to replace the cam position sensor (cps) in approximately 1.2 million subject vehicles to address reports of engine stalling.a new design cps with improved performance and durability will be installed as a remedy.owner notifications will begin in december 2007. the subject vehicles are durable, full-sized, medium duty trucks commonly used for commercial purposes, rescue/emergency response, and commercial or recreational towing.cps failure is comparable to unexpectedly turning the key off since the signal it produces is vital to the electronic engine control system.cps signal loss terminates fuel injection resulting in an engine stall.once stalled, the engine may restart right away, or may restart after a delay (typically 5 to 10 minutes), or may not restart at all.in addition to exposing the driver and other motorists to crash risk due to loss of motive power or vehicle disablement, engine stalling also effects the power assisted steering and braking. through consumer interviews, odi determined that cps failures occurred without any form of warning, at any vehicle speed (50% at highway speeds), and under any driving condition, such as accelerating.consumers reported that about a third of the vehicles failed to restart, with another third reporting delayed restarting.half the vehicles that did restart experienced another stall on the same or a subsequent drive cycle (before cps replacement) re-exposing those consumers to the risks associated with a stalling event.in their voq reports, half of the odi complainants described difficulty controlling the vehicle due to lose of power assist systems, especially those who were towing at the time of the incident. the one alleged injury incident occurred in an intersection when a subject vehicle stalled while turning across oncoming lanes of traffic.although unsubstantiated, the complainant alleged an injury to a child occupant during odi's interview.the other crash allegations mostly involved low speed, loss of control incidents often caused by lack of power assist; no injuries are reported in these incidents, and property damage, if any, was minimal.consumers also reported other incidents with significant safety risks, such as disablement in a lane or on a shoulder of a high-speed roadway or interstate, or extended disablement in remote areas during severe weather conditions. the population above is ford's estimate of the 1.4 million subject vehicles produced that are currently registered.the ford complaint and warranty counts noted above are current as of ford's last submission dated june 21, 2007; they do not include f-450, f-550, or econoline counts as these products were not formally within scope of the investigation when failure information was requested.warranty data analysis indicates that about half the claims involved a stall while driving event ( ford's assessment) and that poor cps durability was a longstanding concern.ford reported that the new cps design should meet or exceed their 10 year, 150k mile life expectancy design requirement. | ||||||
| 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 | ||||||
| EA06012 | FORD MOTOR COMPANY | 06/22/2006 | 12/07/2007 | ENGINE STALLING | 07V553000 | |
| In a december 3, 2007 letter, ford advised nhtsa that it will conduct a safety recall to replace the cam position sensor (cps) in approximately 1.2 million subject vehicles to address reports of engine stalling.a new design cps with improved performance and durability will be installed as a remedy.owner notifications will begin in december 2007. the subject vehicles are durable, full-sized, medium duty trucks commonly used for commercial purposes, rescue/emergency response, and commercial or recreational towing.cps failure is comparable to unexpectedly turning the key off since the signal it produces is vital to the electronic engine control system.cps signal loss terminates fuel injection resulting in an engine stall.once stalled, the engine may restart right away, or may restart after a delay (typically 5 to 10 minutes), or may not restart at all.in addition to exposing the driver and other motorists to crash risk due to loss of motive power or vehicle disablement, engine stalling also effects the power assisted steering and braking. through consumer interviews, odi determined that cps failures occurred without any form of warning, at any vehicle speed (50% at highway speeds), and under any driving condition, such as accelerating.consumers reported that about a third of the vehicles failed to restart, with another third reporting delayed restarting.half the vehicles that did restart experienced another stall on the same or a subsequent drive cycle (before cps replacement) re-exposing those consumers to the risks associated with a stalling event.in their voq reports, half of the odi complainants described difficulty controlling the vehicle due to lose of power assist systems, especially those who were towing at the time of the incident. the one alleged injury incident occurred in an intersection when a subject vehicle stalled while turning across oncoming lanes of traffic.although unsubstantiated, the complainant alleged an injury to a child occupant during odi's interview.the other crash allegations mostly involved low speed, loss of control incidents often caused by lack of power assist; no injuries are reported in these incidents, and property damage, if any, was minimal.consumers also reported other incidents with significant safety risks, such as disablement in a lane or on a shoulder of a high-speed roadway or interstate, or extended disablement in remote areas during severe weather conditions. the population above is ford's estimate of the 1.4 million subject vehicles produced that are currently registered.the ford complaint and warranty counts noted above are current as of ford's last submission dated june 21, 2007; they do not include f-450, f-550, or econoline counts as these products were not formally within scope of the investigation when failure information was requested.warranty data analysis indicates that about half the claims involved a stall while driving event ( ford's assessment) and that poor cps durability was a longstanding concern.ford reported that the new cps design should meet or exceed their 10 year, 150k mile life expectancy design requirement. | ||||||
| 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 | |||
| 04/04/2011 | 106390 | ||
| There was no event leading up to this failure it just happend the spark plug and coil blew out of the cyl head of the engine causing a loud noise and severe lost of power. the truck had to be towed to the repair shop to repair the head and rethread the spark plug hole. looking on the internet for this same problem and found hundreds of complaints with the same problem | |||
| 05/01/2010 | 64000 | ||
| Tl* the contact owns a 2002 ford f-250 super duty. the contact was driving at approximate speeds of 10 mph with a boat hitched to the rear trailer. he proceeded to drive downhill, shifted into second gear and activated the vehicle overdriven. when the overdriven was activated, the instrument panel immediately went blank and the vehicle went idle. the vehicle was towed to a local dealer where the contact was informed that a fuse had blown in the vehicle and the dealer serviced the vehicle accordingly. the failure recurred on a separate occasion while towing a camper downhill under similar conditions as the first failure. the vehicle was taken to an authorized dealer to be serviced. the failure mileage was 64,000 and the current mileage was 64,100. | |||
| 07/08/2008 | 70142 | ||
| Tl*the contact owns a 2002 ford f-250 super duty. while driving at 50 mph, the contact heard a hissing noise and the vehicle suddenly lost power. the contact pulled over and noticed a spark plug had fallen out of the vehicle. the vehicle was towed to an authorized dealership where it was repaired. the failure mileage was 70,142. the current mileage was approximately 79,000. | |||
| 09/24/2009 | 170000 | 1 | |
| I have a 2002 ford f250 3/4 ton 4-door long box truck. it was a wyoming highway department truck. i got it in january and it was running great with 170,000 miles on it, then the # 3 spark plug was spit out of the engine on startup, after it sat for a half hour in september. the coil pack also was spit out and was dangling out on the valve cover. *tr | |||
| 03/10/2008 | 110000 | 1 | |
| Two spark plug so far have been ejected. *tr | |||
| 07/22/2009 | 165769 | 1 | |
| The number three spark plug blew out and caused a small fire that was extinguished with a large slurpee. *tr | |||
| 10/20/2008 | 75000 | 1 | |
| I purchased an f250 2002 triton v8 super duty mid year 2007. less than a year after the purchase a spark plug blew out of the manifold. this all happened under normal highway driving conditions. the dealer put in an insert, rethreaded it and replaced spark plug. almost a year to the day it happened again. so now #2 & #4 have blown out. on 5/30/09 a third one blew out. all on the left side (passenger side) of the manifold. so now #2, #3 and #4 have blown out. i researched the incident online and have found 500 other cases. i'm curious how many are really out there that weren't reported. i've been fortunate because in some cases the spark plug blew through the hood or damaged the manifold. i do however wonder what damage is occurring each time it happens. how many reports or how many vehicles does it take before there's a recall? even though i have extended warranty i've been charged a deductible each time and now face a third if my warranty is still good. i have one more plug on that side that hasn't blown yet and since this one was only 7 months since the last one i suspect i'll be paying again. i saw online where it was suggested as a piston problem. *tr | |||
| 06/11/2008 | 83000 | 1 | |
| High pressure oil pump o-ring failure. (1) o-ring failed at 08/30/04 with 30,000 miles. dealer repaired with updated o-ring kit as specified by ford bulletin. covered under warranty (2)o-ring failed again at 08/16/07 with 70,826 miles. ford dealer repaired with updated 0-ring kit as specified by ford bulletin. this time i had to pay $100.00 deductible. (3)o-ring failed again on 06/11/08 with 83,000 miles. repaired again in 10 month since last repair. i had to pay the full price of repair of 561.82. same part has failed three times on my 2002 f250 crewcab 4 door 7.3 diesel. when o-ring fails the oil is leaking while engine is running. this is not a slow leak but a steady stream as the line is under high pressure. i had to shut down the engine while driving because of low oil pressure and you have no control of brakes or the power steering on vehicle. *tr | |||
| 06/14/2007 | 47000 | 1 | |
| My ford f-250 pickup blew a spark plug out of the head. the dealer charged me 5,200.00 to replace the head. at the time of this, the truck had only 47,000 miles on it. it's a 2002 ford f-250 super duty, 5.4 ltr engine. *tr | |||
| 04/26/2007 | 100000 | 1 | |
| Recently four goshen vans and / or buses have caught fire and completely burned up. in three cases the buses / vans were parked and either just shut off or parked and idling when smoke was discovered and then the fire started. in each case the vehicle burned up in minutes (7 minutes in one case). some of these vehicles are used to transport disabled clients so these are very serious incidents which could lead to death or injury. *tr | |||
| 02/12/2005 | 42000 | 5 | 10/31/2002 |
| I am on my fifth sparkplug blowout,the first one blew out with 42000 miles and ford would not cover it, it cost me $482.00, & now i'm up to $2,410.00.my mechanic said when the back plugs blow it will cost more......he also said that the heli coil would last about 1-2 yrs. *tr | |||
| 09/23/2007 | 57452 | 1 | |
| My 2002 ford f-250 superduty (7.3 diesel) truck broke down while coming back from the mountains. check engine light....harsh banging in the drive train (almost like hitting a huge pot hole at highway speeds) and then the truck died. my truck and trailer had to be towed to eagle colorado (the nearest dealership). sure enough, as i suspected and have seen from about ten other owners of these trucks, it was the camshaft position sensor. the repair was $237.56. i only write today, because msn reports that ford is finally recalling these vehicles due to the cps. how nice of them to do it after most of us have already broken down on the side of the road with this exact problem...i know i am only one guy and i only know 12 other people with this engine, but i think it is funny that everyone i know with over 60k miles has had this happen. my truck only has 58k on the odometer. several of us carry a spare cps and the tools to replace it with us in the truck at all times. in case anyone wants to know, they seem to fail more regularly after they have been replaced. *tr | |||
| 07/08/2006 | 82116 | 1 | 03/08/2002 |
| The cps (camshaft position sensor) failed on my 2002 f250 ford powerstroke while driving. this resulted in very hard steering and very poor braking ability. if i had been towing my fifth wheel the situation could have been very serious. i later found that the failure of the cps is very common on ford powerstrokes from 1999 through 2003. *nm | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 03/10/2010 | 79000 | ||
| I had a spark plug blow out of my cylinder head of my ford f250 2002 with 79,000 miles on it. | |||
| 01/11/2010 | 146332 | 1 | |
| Spark plug blew out after stopping for red light. shut off engine, popped the hood and there was a small fire under the hood. i was able to put the fire out quickly with my shirt. cop was damaged, tried to re-install plug, but the threads in the head were stripped. i was able to just snug the plug down enough to get me home. about .5 mi. i was stopped in the middle of the road with traffic going around me both directions. *tr | |||
| 11/16/2009 | 79000 | 1 | |
| 5:30 monday morning i started my 2002 ford f250 superduty pickup, as soon as my truck started there was a huge explosion and a big fire ball flash from under my hood followed by smoke and the odor of plastic burning and gas fumes. i immediately shut the truck off and opened the hood, after some investigation i was amazed to see that a spark plug had completely blown out of the head of my engine. i was happy to see that the fire was minimal but i was completely amazed that a plug blew out of my engine. about seven or so days ago my engine started to make a tapping noise under the hood, i knew that it could be a lifter because of the over head cam but now i guess i know what that noise was, just the gases pushing through the threads of the plug. no one was hurt and my truck didn't burn to the ground, but i did have to borrow my wife's truck all week and work out rides while mine was in the shop. i am a carpenter and need my truck every day so when this happened i knew i had to find information on this problem. i was amazed to find that there were many people i know that this happened to, so i looked into it more and found that there are many people talking about it on the computer with the exact same experience as me some with more damage and some say it happened several times in the same engine. there are many repair kit options available for this problem in the ford engines, it seams quite obvious to me that this is a huge problem that ford must be responsible for, i know i'm not i take care of my truck and have always maintained it at high level. ford says that the plugs are blowing out because of improper torquing well i guess they must have done that wrong in the plant when the truck was built because they were never changed or touched by anyone else. after looking into this problem i cant understand why there has not been a recall to fix this problem instead ford just makes money off consumers on it by selling them new heads for the engines and the labor $1500. *tr | |||
| 10/10/2008 | 80000 | 1 | |
| Vehicle stalls intermittently. occurs often in intersections when taking off. creates a very dangerous situation. the same year, make, model number and engine type have been recalled, however, our vin was not included so ford will not honor. *tr | |||
| 10/10/2008 | 95000 | ||
| Tl*the contact owns a 2002 ford f250 super duty. while driving less than 70 mph, the contact heard a thumping noise under the hood. he noticed that the spark plug wires were loose and the number 3 cylinder spark plug was detached. this was the second time the failure occurred. the vehicle was taken to an independent mechanic, who stated that ford was experiencing issues with aluminum heads causing the spark plugs to fail. the vin was unknown. the failure and current mileages were less than 95,000. | |||
| 10/21/2007 | 101000 | 1 | 03/27/2002 |
| I own a 2002 ford f-250 w/ 5.4 triton v8. on this past sunday, while driving at 30 mph, a large bang was heard form my engine. the engine began to lose power and slow. after being towed to my local ford dealer to be checked out, it was discovered that a spark plug had blown out of the cylinder head on the right side of the engine. the service manager at the ford garage stated it ruined the cylinder head and needs replacement. this service will require a large amount of work and new parts to complete. the cost will be $3400.00. *jb | |||
| 12/05/2006 | 89740 | 1 | 05/27/2002 |
| Failure of engine heli-coil in 2002 ford f-250 triton 5.4l gasoline engine. failure occurred at 89,000 miles. failure occurred upon startup. vehicle towed to dealer and heli-coil rethreaded for $1,000. subsequent research on the web indicates this problem is extremely common in this engine and due to manufacturing/design flaw. *nm | |||
| 06/20/2006 | 71800 | 1 | 02/01/2003 |
| I was making a left turn when i heard a pop,pop, pop. i blew out #3 spark plug in my 2002 f250. it has 72,000 miles on it. i chose to have it repaired rather than replacing the head(600$ as opposed to 3000$). the ford dealership in wausau wi. would not repair it,they would only replace the head, and would not admit that this was a recurring problem. *jb | |||
| 01/25/2006 | 1 | ||
| When driving at 25 mph the # 3 spark plug blew out of the cylinder head. *ak | |||
| 10/16/2005 | 1 | ||
| Cam position sensor failure. loss of power. no steering. no brakes. replaced sensor. *nm | |||
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||
| 02/01/2007 | 52000 | 3 | |
| Repeated failure of camshaft position sensor. *tr | |||
| 12/10/2006 | 67000 | 1 | 09/17/2002 |
| Cam position sensor failure on 2002 ford f250 powerstroke diesel. 70 mph on interstate. loss of power brakes and power steering.*ak | |||
| 05/16/2007 | 52000 | 2 | 06/28/2002 |
| I had 2 occurrences of this problem. both times camshaft position sensor failed , causing loss of control.(engine died in traffic. 2002 ford f-250 7.3l diesel. extreme safety hazard , especially since these trucks were for heavy towing which i did from time to time. seemed to be widespread problem needing to be addressed.*ak | |||
| 04/24/2007 | 74467 | 5 | 10/10/2004 |
| I have a 2002 ford f250 power stroke diesel truck. the diesel engine just shutdown as i was driving on a major road in memphis tn. i lost power steering and brakes but was able to avoid an accident because i muscled the steering wheel and the brakes to get my truck off the road into a parking lot. fortunately i was in the outside lane and not traveling at 65 mph or the accident could have been very serious. i am told that the problem is the cps although i just found that out today. the truck has been stalling intermittently at stop lights and sputtering on the interstate so i had a hard time diagnosing the problem. *tr | |||
| 04/24/2007 | 4 | 12/17/2001 | |
| I have my truck at the dealership today and after diagnostic they find out that my problem is caused by the cam sensor. my problem start about two weeks a go when my truck just with no alerts/lights just shut off on the middle of the road but on tuesday 24th of 2007 i was driving on an small road i'm pulling a 6x12 cargo trailer when my truck did it again but this time because my trailer on the back was very difficult to drive with no power steering and no brakes. i did a search just now and found out that is a problem that ford is aware off and they just don't want to admit please advice me to what i need to do. dealer estimate to fix the problem is about $500.00 labor and parts. *jb | |||
| 08/13/2006 | 42000 | 10 | 11/14/2002 |
| Engine stalling truck shuts down, all power is lost. *jb | |||
| 11/30/2006 | 90000 | 2 | 10/01/2002 |
| 2002 ford f250 diesel truck on interstate 25 in denver. proceeding at 70 mph in middle lane in heavy fast traffic and suddenly everything shut down. no power, no electrical, no brakes, no steering, very dangerous situation in rush hour traffic. had it towed. this is the second time the cam sensor has just quit within 1.5 years at $500 cost to replace each time. but, i could have been seriously injured. i believe this justifies a recall to prevent someone from being seriously hurt. cam sensor!!! *jb | |||
| 10/16/2006 | 75000 | 30 | 12/15/2001 |
| Truck (2002 ford f-250 powerstroke) engine randomly quits during braking or low/no acceleration. this causes loss of power brakes and steering. braking and low acceleration occur in intersections frequently i have discovered. truck will restart and problem may or may not return immediately. i took it to a dealership who said they could not duplicate the event and the codes set by the pcm were unrelated. i took it to the dealer a total of three times for this problem. i read on the internet (www.dieselstop.com) that this symptom was frequently caused by a bad cps sensor. i went to an international engine (maker of the ford powerstroke) dealer and bought a new cps which resolved the problem. i have the old part for inspection if needed. this problem is dangerous. if pulling my trailer, loss of assisted brakes and steering could quickly become catastrophic. *nm | |||
| 04/08/2006 | 29000 | 1 | |
| Dt*: the contact stated while driving at any speed, the vehicle stalled without prior warning. the engine had to remain in the off position for 15 minutes before it would restart. the vehicle was taken to the dealer for inspection. | |||
| 03/12/2006 | 83000 | 1 | 01/18/2002 |
| I have a 2002 ford f-250 power stroke diesel. i was on my way to work and all of a sudden the engine just shut off as if i had turned the key off. it picked right back up almost immediately and continued to run for about a mile. then it shut off again and did not pick back up. this was on a 4 lane highway at 55-60 mph with no power steering and no power brakes on a 7000# truck. i managed to coast into a turn lane and got it to re-fire and moved it into a parking lot. checked all of my electrical connections under the hood and restarted the truck. it idled fine for a while so i thought maybe a connector was loose and i had fixed the problem. i decided to continue on my way to work. i pulled back out onto the highway and no problems. i had to make a u-turn on the 4 lane highway and right in the middle of it, the truck decides to die again. luckily, i was able to get it into neutral and re-fired before i got hit in the side by oncoming traffic. had heard of the cps failures being a problem on the 7.3 power stroke engines so i had it towed home and replaced the cam position sensor. no problems since. i started looking on web sites to find out how many people had been having this same type failure and it seems to be a very common problem. several web sites are recommending that the power stroke owners that have had this problem notify you all so maybe we can get the problem solved. *jb | |||
| 12/10/2004 | 56496 | 3 | 11/15/2001 |
| I own a ford f250,2002, diesel. on three different occasions, while driving down the road the engine has simply quit. on two of those instances, i was very lucky not to have had a terrible accident. the first time, it was under warranty and they fixed it no problem, the last two times, it has been rather expensive to have it fixed. ford does pay for the part and it is the same part each time, a cam sensor, but i have to pay for the towing and the deductible. this is extremely dangerous, and it is the same part that is failing. according to the tow truck drivers who have picked up the vehicle, they say it is a common problem. it has also happened to my brother-in-law and he has a 1999 model, but only once. i only have 57,000 miles on the truck, and as i said, it is extremely dangerous, as when it goes, there is no warning, it simply dies. the first time i was doing 70 mph and was just about wiped out by a semi behind me. *jb | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| 09/28/2007 | 120000 | 1 | 11/24/2001 |
| I own a 2002 f-250 sd truck which has the 5.4 triton engine in it. on september 28,2007, i was driving down the road and the # 3 spark plug ejected out of the cylinder head in which stripped all the threads in the cylinder head and the spark plug. i have the spark plug. i am having the problem repaired by an independent auto shop. i have done some research on this situation and found this has happened alot from 1998 to 2003. the plugs are tapered and the plugs have 12 threads , but only 4 threads are the cylinder head which means that the spark plug is only held by 4 threads. i believe ford motor company has an engineering flaw and should be held responsible for the cost of the repairs. *tr updated 02-13-08 *bf updated 02/13/08 *tr | |||
| 01/04/2007 | 98000 | 1 | 08/05/2002 |
| No warning , the spark plug just blew out of the cylinder head with a loud bang while driving down the road. ford motor company denied responsibility and placed the blame on one of it's dealers who previously had replace an ignition coil on a different cylinder. neither party wanted to accept responsibility for the repair cost. this vehicle is used for business purpose and it gets expensive when it is not in service. after a week of phone calls and correspondence between the dealer and ford and getting no where i had a local mechanic repair the vehicle a my cost. *jb | |||
| 01/05/2005 | 61717 | 1 | 08/12/2002 |
| 2002 ford f-250 super cab spark plug blew out of cylinder head. just driving down the street and all at once there was a loud bang like a big hole blew out of the muffler. shut the engine off, pulled over and tried to determine cause. drove truck another couple of miles to repair shop. the repair bill was over $2,000. the repair shop states they have had at least 6 of these situations in the last 2 months. we believe this is a defect in this truck - the truck has 61,700 miles on it and it is too early to experience this kind of difficulty. *jb | |||
| 07/09/2004 | 63000 | 1 | 09/12/2001 |
| I have a 2002 ford f-250 super duty pickup truck with a v-10 engine. it has approx. 63,000 miles and is subsequently 'out of warranty' (3/36,000). on july 9, 2004 i heard a brief tapping noise and a pop then a loud noise like an exhaust manifold leak. immediately upon hearing this noise i shut off the engine and called a tow truck, as i am not a mechanic and did not want to create further damage. when the mechanic arrived to tow my truck he observed that a spark plug had been blown out of the cylinder. i informed him to tow it to his lot until i could decide what to do. the next dy i had the tow truck company bring my truck to the ford dealership i purchased it from. today after the dealership's mechanic inspected my truck they informed me that the cylinder head was broken and i would be liable for the $3,700.00 repair. what i find distubing is my scheduled spark plug replacement service interval: ford recommends 100,000 miles before replacement. how would i ever know that the speark plug was not installed properly at the factory prior to the scheduled service? additionally, had it not blown out on its own, who knows what other damages would have gone unchecked. i have researched this particular defect on the web and have found not less than 100 people thus far with the exact same complaint. additionally , i have found numerous people that this has happened to more than once on the same engine. i stopped researching because i feel this is suffucient supporting documentation of my complaint. if necessary, i will be happy to furnish this documentation for you. i have found this problem to be inherent in all v10 ford engines since 1999. i have also found that ford is aware of this problem and has issued a technical service bulletin to all of their dealerships describing this particular repair procedure. *ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||
| 03/11/2010 | 150000 | ||
| Sparkplug ejected out of motor on right side and another sparkplug on the left side keeps missing out because of oil in it. i can't keep fighting repairs i'm still paying on it. from what i'm hearing there is several motors doing this. i would like to see this problem solved please or ford can pay my tow bills. my cruise control quit working. i have a rumble in rear end when turning corners. i have had it looked at, different things fixed and no repair facility can figure it out. i work 60 minutes away and i can't keep getting stranded in it and i'm very tired of it. | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL | |||
| 04/27/2004 | 0 | 1 | 04/17/2001 |
| Diesel emissions entering into passenger compartment of 2001 ford f250 super duty v8-7.30. is there anyone out there that has experienced difficult breathing conditions and or in general, sick, after prolonged exposure the ultra fine particulate matter contained in the emissions of diesel engine. *ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CRANKCASE (PCV) | |||
| 07/28/2006 | 92000 | 3 | 10/10/2005 |
| Two times it died while driving the third i was idling talking to a friend and it just died and would not restart. *nm | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||
| 02/08/2008 | 90210 | 1 | 08/27/2002 |
| I heard a sound coming from my exhaust and after looking over the exhaust i notice that i had some exhaust manifold studs and nuts that hold the exhaust manifolds to the engine heads had either broken or snapped off causing the exhaust leak i heard. after seeing that i had an issue with the exhaust studs i took my 2002 ford f-250 super duty with 6.8 liter engine to the dealership were i have my service work done and had 1 of the service technicians look at the issue. i was told at the dealership that ford motor company knew of the problem with the studs and nuts that was used when my truck was manufactured and knew of that problem since 1997 through 2005. yet ford motor company will not do anything to resolve this issue. from 1997-2005 ford motor company used steel studs and nuts for attaching the exhaust manifolds to the enines on there 5.4 liter and 6.8 liter engines. that's a period of 9 years of using parts that were faulty for use in manufacture. the failure of these exhaust studs and bolts can and will cause the exhaust manifolds to warp thus the consumer having to replace the exhaust manifolds as well. also with the failure of the faulty exhaust studs and nuts could cause engine problems like warped valves, or head damage, which could cause engine to blow or lock-up. i have notified ford motor company on 3 occasions and have met with the same response that they will do nothing to amend the issue at hand. they have a technical service bulletin that they have available which requires that the use of stainless steel studs and nuts in service for the 5.4 liter and 6.8 liter engine. as well as replacing the exhaust manifold on the affected bank(s), exhaust manifold gaskets. ford motor company failed to notify the consumer while the vehicle was under warranty so repairs could be made. *tr | |||
| 06/05/2006 | 54000 | 1 | 05/08/2002 |
| 2002 ford f-250, exhaust leak developed just after 50,000 miles. right side manifold had split. ford refused to warranty it, even though it was only 4 1/2 years into a 5 yr/ 50,000 mile emissions warranty. there is a recall on the mounting studs that changes them to stainless steel. they have a problem with the factory studs rotting out. they also have made improvements to the holes in the manifold. they were enlarged to resist cracking. both manifolds had to be replaced along with the broken studs. all old parts are in my possession. otherwise the truck is in like new condition. *jb | |||