Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING
062130622310019380White smoke, lacks power, exhaust odor, surges, runs rough, or no start - 6.0l. *tt03/13/2006
1852504/01/200510017875Buck/jerk, lacks power, black smoke, rolling idle, surge, mil on, and diagnostic trouble codes p2263, p0299, or p0401. *tt12/06/2005
ENGINE AND ENGINE COOLING - COOLING SYSTEM
05262301/01/2006063810019385Coolant degas bottle overflow - 6.0l. *tt03/13/2006
ENGINE AND ENGINE COOLING - ENGINE
0624610022295Dtc's p006a or p132b - lacks power, surge, or flutter after field service action 06e17. *kb07/25/2007
05262501/01/2006069710020069Misfire, lack of power, buck/jerk, excessive smoke or crank/no start. *tt07/18/2006
1836201/01/200510013307Lack of power or runs rough condition, and/or the malfunction indicator light on with egr related diagnostic trouble codes (p0401, p0402, p0403, p0404, p0405, or p0406). *tt04/14/2005
1634311/01/200210008315Hard start, hesitation with malfunction indicator lamp (mil) light on diagnostic trouble code (dtc) p0340/p0344 - contact request. *tt07/27/2004
1740609/01/20041814710008288Low power, poor fuel economy, fuel gelling cold, excessive white smoke cold, or hard start. *mj this oasis updates previous oasis dated 12/01/03. *tt07/26/2004
1786906/01/200410008263Air induction system appears to be warped and/or not sealing. *tt07/23/2004
1768304/01/200410008208Engine oil leaks at lower crankcase. *tt07/23/2004
1753001/01/200410007355Moan/drone noise and tactile vibration between 1500-2000 rpm. *tt06/14/2004
03215003/08/2004044410004861High pressure oil pump leak on vehicles equipped with 7.3l diesel engine. *tt01/12/2004
03B0604/01/200310002181Cold operation calibration product enhancement for reduced cold weather engine performance and rough idle due to powertrain calibration concerns. customer satisfaction program. *tt08/14/2003
031004/01/200310002171Ramp-rate from base engine idle (625 rpm) to 1200 rpm target is higher than prior 7.3l diesel engine. this may be too rapid for smooth engagement of transmission-mounted pto serving high-inertia pto system start-ups, typical of direct-driv08/14/2003
ENGINE AND ENGINE COOLING - ENGINE - DIESEL
0513901/01/200510016842Diesel exhaust smell in cab-6.0l engine. *sc10/12/2005
1650601/01/200310005086Vehicles with a 6.0l diesel engine - possible oil overfill after delivery. this includes 2003 super duty f-series. oasis. *tt01/29/2004
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS
1771604/01/200410008221Belt noise. *tt07/23/2004
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER
1869406/01/200510017873Lack of power and/or dtc p2263 or p0299 after turbocharger replacement - service tip. *tt12/06/2005
1788506/01/200410008269Lack of power and/or diagnostic trouble code (dtc) p2263 after turbocharger replacement. *tt07/23/2004
1756602/01/200410008129Turbo moan/drone noise and tactile vibration between 1500-2000 rpm. *tt07/22/2004
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
061704/01/200610019945Voluntary emission recall 06e17 supplement #1: control module recalibration. corrosion may exist at the electrode surface on the exhaust pressure (ep) sensor; fuel delivery timing during cold weather may not be optimal; and/or exhaust gas05/17/2006
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE)
1756802/01/200410008131Normal egr (exhaust gas recirculation) operation - service tip. *tt07/22/2004
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
1732011/01/200310008169Broken exhaust manifold studs. *tt07/22/2004

Investigations


NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
ENGINE AND ENGINE COOLING
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK 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
EA06012FORD MOTOR COMPANY06/22/200612/07/2007ENGINE STALLING07V553000
 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.
EA05003FORD MOTOR COMPANY02/15/200511/02/2005ENGINE STALLING05V270000
 In a june 7, 2005 letter, ford notified odi that it would be conducting a safety recall of approximately 180,000 ford f-super duty, excursion and e-series vehicles equipped with 6.0l diesel engines to correct two wiring related conditions that could result in engine stall (nhtsa recall no. 05v-270, ford no. 05s34).the affected vehicles were built between september 29, 2003 and may 31, 2004.according to ford, vehicles with the conditions may stall without warning and may or may not restart.ford will instruct owners of vehicles included in the recall to take their vehicles to a dealer to have the fuel injector control module wire harness upgraded or replaced and or have a new injection control pressure sensor connector installed.during a may 2005 presentation to odi, ford identified a number of potential failure mechanisms that could affect engine performance in various segments of the subject vehicle population, including the wiring conditions addressed by 05v-270.the wiring conditions, which both affect engine fueling, were the most likely conditions to result in engine stall.the recalled vehicles comprise approximately 43% of the subject vehicle population and account for 75 of the 113 odi reports that have a valid vin (66%).the voq complaint rate for the recall population is 45/100k while the rate for vehicles outside the recall population is 17/100k and their trend (by date of receipt) is declining.based on the analysis, odi believes ford
ENGINE AND ENGINE COOLING - ENGINE
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK 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
EA06012FORD MOTOR COMPANY06/22/200612/07/2007ENGINE STALLING07V553000
 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.
PE04070FORD MOTOR COMPANY10/07/200402/15/2005ENGINE 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.
EA05003FORD MOTOR COMPANY02/15/200511/02/2005ENGINE STALLING05V270000
 In a june 7, 2005 letter, ford notified odi that it would be conducting a safety recall of approximately 180,000 ford f-super duty, excursion and e-series vehicles equipped with 6.0l diesel engines to correct two wiring related conditions that could result in engine stall (nhtsa recall no. 05v-270, ford no. 05s34).the affected vehicles were built between september 29, 2003 and may 31, 2004.according to ford, vehicles with the conditions may stall without warning and may or may not restart.ford will instruct owners of vehicles included in the recall to take their vehicles to a dealer to have the fuel injector control module wire harness upgraded or replaced and or have a new injection control pressure sensor connector installed.during a may 2005 presentation to odi, ford identified a number of potential failure mechanisms that could affect engine performance in various segments of the subject vehicle population, including the wiring conditions addressed by 05v-270.the wiring conditions, which both affect engine fueling, were the most likely conditions to result in engine stall.the recalled vehicles comprise approximately 43% of the subject vehicle population and account for 75 of the 113 odi reports that have a valid vin (66%).the voq complaint rate for the recall population is 45/100k while the rate for vehicles outside the recall population is 17/100k and their trend (by date of receipt) is declining.based on the analysis, odi believes ford
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK 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 datemilesoccurencesPurchase date
ENGINE AND ENGINE COOLING
01/22/201177000
 Tl- the contact owns a 2003 ford f-250 super duty. the contact stated the rear right spark plug on the passenger side blew out of the engine. this failure caused the vehicle to stall. the contact took the vehicle to the dealer and was told that this is a known problem with that particular plug. the vehicle had not been repaired at the time of the complaint. the vin was unknown. the failure mileage and current mileages was 77,000.rl
12/03/2010141000
 I was at a stop sign on 12/3/2010 and when i stepped on the gas to go, i heard a extremely loud popping noise. i pulled off to the side of the road and discovered that one of my spark plugs and the coil was flopping around in my engine. i call a friend of mine who is a mechanic at a ford dealership and explained what had happened. he knew exactly what it was and which plug had blown out, without even looking at it. after getting my truck home and taking a closer look, it seems that these were the original spark plugs installed at the factory. this was not a case of over torquing or not tightening. this is a case of faulty design and poor quality by a company that apparently does not care if someone is hurt or killed by there poor design. what if this had caused a accident with my kids in the car??? what if this started my vehicle on fire????? after researching this problem it seems it is quite common on ford vehicles. when is enough enough???? i am currently unemployed and am barely able to keep up with my monthly obligations. i have no idea how i am going to pay for this repair now. please, it is time to hold ford motor company responsible for not fixing a known problem and potentially getting some one killed.
07/16/200361000
 I understand that there is a technical service bulletin on the 2003 ford f 250 2w/4w drive v-10 motor. was this motor [v10-6.8l vin s] recalled ? was ford to repair / or replace these defective motors? the vin # on the truck is 1ftnw21s33ed41612.
09/03/2009720001
 I have a 2003 ford f250 with 73k miles on it, and i too am another victim of a spark plug blowing out of my 4th cylinder on the passenger side of my truck. why is ford not doing anything about this. as much as we pay for these cars and trucks, you would think they would make things right. no wonder u.s. auto makers are failing. just more corporate greed. *tr
05/06/2009130000
 Tl*the contact owns a 2003 ford f250 super duty. while driving 70 mph, the vehicle shut off. the contact lost control of the power steering and brakes. the failure occurs at least forty times per week. the contact stated that he must turn off the vehicle and give it time to restart. he is in the process of taking the vehicle to the dealer for inspection. the manufacturer is aware of the failure, but will not provide compensation since there are no recalls for the issue. the failure mileage was 130,000 and current mileage was 180,000.
12/08/2008648541
 2003 f250 6.0 diesel icp sensor, leaking oil in the wire connector. the truck stalls at idle and the rpm's jump up while driving making you go faster then you are. icp sensor being replaced. *tr
05/19/20081
 Original spark plug in f250 5.4 liter shot out of motor. *tr
05/25/200623400109/12/2003
 Dt*: the contact stated without warning on various occasions, the vehicle looses 80 percent of the power. this occurrence is not dependent on the speed. the vehicle was taken to the dealership, where multiple components have been replaced, but the problem persists. the turbo charger has been replaced twice, the turbo boost and egr valve has been replaced and the computer has been reprogrammed.
02/28/20035412/21/2002
 The vehicle would lose power steering when applying the brakes. the power steering would return after letting off the brakes. the vehicle had been to the dealer on three separate occasions. the dealer changed various parts and the problem recurred. *ak the hydro boost was not operating properly and the engine had an oil leak due to the glow plug boss bar orings. *sc *jb
10/01/20041
 Ford f 250 safety issue. *bf the pedal displayed a dead pedal when the vehicle was first started, there would be a three second pause condition. ford was unable to fix this condition. *sc *jb
03/08/20042600204/26/2003
 Intermittently while driving at any speed and without any warning vehicle suddenly accelerated. also, had brake problems. dealership inspected vehicle several times, but could not duplicate or correct the problem. *ak erratic acceleration and surging, oil on bell housing and smoking. vehicle acts like it doesn't know when to accelerate or shift gears. consumer met with an engineer from ford and said that they're aware of the problem, and informed the consumer that they're working on a new software to remedy the problem. when vehicle made another sudden acceleration, dealer said that it was the egr valve and oil was coming from the cam position sensor. cam sensor and egr valve were replaced. however, vehicle still posses problem with acceleration on vehicle. *la
ENGINE AND ENGINE COOLING - COOLING SYSTEM
10/20/20081021731
 My husband and i were pulling our camper to virginia for vacation and half way there we could smell antifreeze. by the time we got to martinsville and got our camper backed up at the campground white smoke was coming out of our tailpipe and later overheated. we called aaa the next morning and had it towed to a local dealer where they had informed us that it was the egr cooler. they put the new egr cooler on and we got our truck back 2 days later. we did not drive the truck anymore until we were pulling our camper home to ohio and noticed the same things were happening. the white smoke and antifreeze smell we also had loss of power. i made my husband pull over and low and behold we had no antifreeze in the truck. the dealership had put 2 bottles of antifreeze and changed our oil because of antifreeze in the oil. we called the dealership and they told us to try and limp it home. we were not going to be any part of that and asked the gas station attendant where the closest ford dealership was located. they told us the get off the next exit and go 1/2 mile up the road. we made it a 1/4 mile from the dealership and had to pull over because truck was overheating. tried to start truck back up and nothing. got a tow truck to tow us to this dealership where they told us our engine was vapor locked. we only had gone 130 miles from the other dealership before this happened. dealership is telling us that ford has been having issues with the 6.0 liter v6 f-250 super duty diesel engines. have an ongoing lawsuit with dealership and ford. would like to know of other issues with these trucks because we are over warrant by 2,000 miles. *tr
03/25/2008680001
 Vehicle has a oil cooler and egr cooler defect. common problem by many f250 owners. ford is aware of the problem and has issued a superseded part number for the oil cooler, egr cooler is unchanged. when these components fail it causes the vehicle to overheats when towing a load and can consume several gallons of coolant. it's a safety concern due in part that if a vehicle overheats and shuts off while towing a heavy load the vehicle will lose braking power. *tr
ENGINE AND ENGINE COOLING - ENGINE
06/05/2002850001
 I have a 2003 ford f250 with the 5.4l engine with about 80,000 miles. i purchased the truck new. the number 3 oem spark plug backed out and blew out of the head. i contacted ford, they recommended i cover all expenses and have it towed and repaired at ford dealership. i paid a local mechanic to repair it. he is unsure what will happen in the future. he said it could be dangerous and might cause a fire if it happens again. *tr
07/03/2008101999
 Tl*the contact owns a 2003 ford f250 super duty. while driving approximately 35 mph, the vehicle began to making a hissing noise. the contact pulled the vehicle over to the side of the road and the hissing stopped. he looked under the hood, restarted the vehicle, and noticed that the number 4 spark plug blew out of the engine head with a failed coil. the vehicle was taken to a dealer and they stated that a new engine was needed. the current mileage was 102,300 and failure mileage was 101,999.
06/16/200655238111/04/2002
 Tl* the contact owns a 2003 ford f250 super duty truck. while driving 55 mph the spark plugs fell out of the engine. the contact drove to the side of the road and the vehicle was towed to the dealer. the failure mileage was 55,238. the dealer stated that the failure was due to the spark plugs being loose. the current mileage was 60,000. *ak
06/05/200531000207/25/2003
 Dt: a shift cable broke on june 5, 2005. contacted the dealer, they fixed it. had several issues with the truck but this one was the bad one. the dealer gave no idication why it broke. also, they had to pull out the motor because of an oil leak. took the vehicle to dealer again because an emergcey light came on. spoke with the service manager all he could say was that it happened to a couple of them. *ak
09/30/20031000109/25/2003
 Oil leak. *la
04/23/2003458
 When the consumer first starts the vehicle, during the first few miles the vehicle is very sluggish. the vehicle had several near misses due to this sluggishness. this has happened on many occasions while driving at any speed. the vehicle was taken to the dealer, who informed the consumer that the sluggishness was normal. the manufacturer is aware of the problem. *ph
10/16/200340005
 The truck stalls without warning while driving. when this occur, the truck loses all power, including brakes and steering. this has resulted in two accidents. in one of the accidents, the truck went into a ditch and the air bags failed to deploy upon impact. the occupants sustained minor injuries. the dealership performed a diagnostic test, but no failure code was found. the manufacture is providing no assistance in this matter. *ph
22061
 When turning in either direction vehicle stalled without warning. the cause of the problem has not been determined. *ak
08/09/20039000104/17/2003
 Driving 70mph truck dies . engine has less than 10000 miles . frequently pull 8000 lb trailer,boat and other equipment . serios concerns about losing power bakes and power steering with engine dying.dealer has changed icp sensor twice in a 300 mile span.have read about this beeing a widespread problem with the new 6.0 powerstroke engine.*ak
08/02/20031
 New 2003 f-250 6.0 diesel ford with 412 miles just lost power on the freeway at 70mph...very dangerous situation with no steering or power brakes...from all the webs site about these truck i can see that i am not the only one with this problem...act now before someone is killed driving this truck...*ak
ENGINE AND ENGINE COOLING - ENGINE - DIESEL
03/26/200520000101/01/2004
 Tl*the contact owns a 2003 ford f-250hd. the contact stated that while driving at any given speed the vehicle would jerk. the vehicle was taken to a dealer and inspected where it was determined that the failure occurred from the injector wire harness. the vehicle was repaired at a cost of $100.00. four years later the contact noticed a antifreeze smell in the vehicle. the vehicle was taken to a dealer and inspected where it was determined that the oil cooler had failed. the vehicle was repaired at a cost of $844.00. three months later the contact attempted to start the vehicle and the vehicle would not start. the contact is in the process of taking the vehicle to a dealer for further inspection. the contact called the manufacturer and was informed to take the vehicle to a dealer for further inspection. the failure mileage was 20,000 and the current mileage is 76,286. bl the dealer determined the high pressure oil pump and injector failed. the anti-lock brakes were inoperative as well. updated 10/07/09.
08/04/200961000102/01/2003
 Tl*the contact owns a 2003 ford f250 super duty. while driving 15 mph, the check engine light illuminated in the vehicle. shortly after, he noticed that the vehicle barely accelerated while pulling out of a parking space. the vehicle would also stall at low speeds. once he restarted the engine, the vehicle would operate normally. the contact took the vehicle to the dealer and they stated that they would diagnose the failure. the dealer stated that the vehicle needed a new injection control pressure sensor module (icp) installed in the vehicle. through research, he found nhtsa campaign id number 05v270000, nhtsa action number ea05003 (electrical system:wiring). in 2004, a 2004 engine was placed in the vehicle. he believes that the vehicle was experiencing the same defect because it had a 2004 engine. the manufacturer stated that his vin was not included in the recall. the vin was unknown. the current and failure mileages were 61,000. updated 08/31/09 *bf updated 09/03/09.*jb
10/19/2007192000110/05/2007
 My truck died on my way home and almost caused me to not only run into a bunch of trees, but almost hit another car in the oncoming lane. my truck just shut off without warning and i had no power steering, power brakes, or any way of an easy stop. i had to get the passenger in the car to help me steer the 7500lb vehicle to the side of the road. i had heard that the camshaft position sensor is notorious for going out at the worst possible moment and didn't believe it until i experienced it myself. i did a little research the next morning and my truck was giving me all the signs of a bad cps. i went to the ford dealership and bought a new cps for just under $30. i installed it in the parking lot i ended up in and after a few cranks, my truck started right up and hasn't given me any other problems since then pertaining to the cps. i am very disappointed that ford would mass produce a product that could possibly kill or injure someone in this manner. i believe the average person (man/woman) would not be able to steer this vehicle by themselves if the cps went out on them. i am very lucky i survived this with no injuries of any kind. i hope everyone that drives this series of truck is also as lucky as myself. *tr
10/13/200784920309/11/2005
 9/11/05 purchased 4/29/06 truck stalled towed into rancho ford 5/11/06 truck repaired 2/6/07 tune-up performed at north county ford ($525.01) ?engine light is on? noted on invoice. truck returned same day. technician stated ?engine light caused by bad glow plug. not a main concern.? 9/27/07 oil change 9/28/07 spoke with technician: icp connector, engine harness, injector harness and injectors 6 and 7 are bad and need to be replaced 9/28/07 i called ford customer service and asked for a total reimbursement or a new truck 10/3/07 received truck back 10/4/07 received call stating ford believes all work is complete and claim is denied. 10/13/07 truck will not start 10/15/07 called ford asking for new truck 10/16/07 received call from rancho ford stating: injector harness and number 8 injector are bad 10/22/07 received call from stating ford will not cover the cost of the towing and the request for replacement has been denied. 10/24/07 received truck from rancho ford repairs seemed to mirror what north county ford had done. 10/25/07 sent email to (gm north county ford) and (gm rancho ford) that contained this timeline. 10/25/07 spoke with from north county ford and he stated that he did not understand why ford would not cover the towing because it was under warranty. he also stated that the engine that is in my truck (the 6.0l) are known to have these problems and he has seen ?many? cases where all the injectors need to be replaced. i asked why his invoice stated after repairs to injectors 6 and 7, ?all injectors good? and just ten days later injector 8 needed to be replaced. he said ford does not allow the dealerships to replace parts until complete failure. basically injector 8 could have tested poor and they were not able to replace it. *tr
09/04/200790087112/14/2002
 On september 4, 2007, my vehicle would not start. i towed it to the nearest ford dealer where they worked on it and replaced the cam sensor (trouble code p-0340). i have complained about this code popping up since 15,000 miles. the vehicle now has 90,000 mile. this is the same sensor used on all 7.3 diesel engines since 1999 through 2003. all of the diesel forums say that this sensor is always going out. why isn't ford doing something about this since they obviously know about the problem. this is an expensive problem to fix and the part should have been redesigned by now. there should be a recall on this part. *tr updated 12-12-07. *kb updated *jb
10/28/2006145000107/31/2002
 Camshaft position sensor fails when driving causing engine to stop. *jb
03/21/200653000103/08/2003
 I own a 2003 ford f-250 super duty with a 7.3 litre diesel engine. i came over a hill and was faced with stopped traffic. i had a load in the truck bed making the truck heavier. the truck stalled and my power braking was lost. i had to steer into the medium curb in order to stop the vehicle. i came very close to hitting the rear of a small car in front of me, and she had a baby in the car. i have replaced the camshaft position sensor and the truck no longer stalls. another name for the part is a diesel cam sensor. many people that i know have the same problem with the same truck. *jb
09/16/2005507/01/2003
 2003 ford f250 super duty 6.0l power stroke. i have had this truck for 2 years it just seems to be a never ending issue. i have had the computer reflashed 3 times, 3 fuel injectors replaced ect ect ect. most recently i have had problems with the coolant blowing out of the tank it has broke my air restriction gauge 2 times, after repeated complaints to the dealer of this issue they return the truck to me saying there is not any problems with the coolant system, then why is there a stain under my hood from coolant? this happens more often during towing however it is only a 7000lb trailer? my egt's are not high? now this week the truck has started to surge idle up to 1200-1300 rpms for no reason and sometimes stall? what are my options! its an expensive truck and i cant keep sending it to the shop every few months for problems. 100 dollar deductibles get expensive!!!! will someone please help i know its not the ford mechanics faults they are more than likely sick off this truck also, thanks. *nm
01/18/200510009/13/2003
 My computer was re-flashed in january by a local ford dealership (mike fitzpatrick). since then my truck has very little power during the first few minutes of start-up. this is the most noticable during the first start-up of the day, but does happen periodically throughout the day. the ford dealership has done very little to correct the issues. i have contacted ford directly and they did respond, but the local service manager told them it was fixed and have heard no follow-up from ford. a ford engineer has been requested to insepct the problem, but for 7 months no ford engineer has looked at my truck!
11/27/20037000606/10/2003
 Purchased 2003 f-250 sd with 6.0l diesel engine in june 2003. to date, vehicle has been to ford service six (6) times -- all related to the engine. the first time, we were travelling down interstate at 70 mph when truck hesitated and died. we were unable to restart the truck and had to coast to next exit and into a service station. we were told the pcm (power control module - brains of the engine) failed. since then, the truck's service engine soon light has come on and each time ford service attributes the problem to different parts of the engine - go figure. this has all taken place before even having the truck for one year!!
01/10/200416000101/08/2004
 Pilot injection deactivated without prior concent.*ak
03/21/2004297106/10/2003
 Power booster for power steering coolant leaks, blown turbo charger. *jb
05/05/20031740704/03/2003
 I paid cash for a 2003 6.0 ltr f250, and i have had it in the shop 7 times. i is having performance problems, starting problems, and getting poor gas mileage. the dealership and ford will not take the truck back. this truck is a danger on the road. it needs to be recalled, and taken off the street until ford fixes the problem.*ak
05/05/20031740704/03/2003
 Truck running rough. has problems starting. gets poor gas mileage.*ak
01/09/20031200212/20/2002
 Vehicle's motor stopped running in traffic, causing loss of power assist on steering and brakes. *la
09/01/200316007
 Vehicle sometimes surges at a stop light by 250-300 rpm. vehicle stalls on road and bucks at 55 and 70 mile area before this happens. one day vehicle sounded like all the lifters were stuck. sounded like metal parts flying together coming from engine. rough idle and smokes at times. gas gauge sometimes sticks on full for 50-60 miles then falls to 3/4 or less. sometimes no power and then at times with power. mileage fell from 16.9 city to 12.5 to 13.2. rpm needle 1,500 to 2,500 without engine surging. this vehicle has been in the shop 7 times with only 5,000 miles. engineer drove it 50 miles and said no problems. *la
10/01/2003109/08/2003
 I recently purchased a 2003 ford super duty with a 6.0l diesel, i now have 6100 miles on it, i took the unit to my dealer at 1,100 and complained of erratic idle, low fuel mileage, 18 on the highway, 15 in town, cold start hesitation while accelerating and the air filter indicator was broken, they had my truck for 6 hours, which wasn't the problem, i was told there is some software issues in the pcm, and they were working on it, i called ford cac (customer assistance center), i was told the same, i was advised if it was a component issue that ford would extend the warranty on that part, i said no way, i wanted the part changed even if there was after a problem if my truck was out of warranty. i then received a phone call from the district rep up in north carolina, i told him what was going on, he said he was a policy/complaint person and was not in the technical side of things, i now have 6100 miles on the truck and still no change, i sent a email to the ford cac, 5 days ago with no response. i'm going to call the cac again and the dealer. if this is fords idea of customer service they should re-think it. *jb
06/09/20031001406/09/2003
 I own a new 2003 ford f-250 with a 6.0 liter diesel engine. on intermittent and unpredictable occasions, the engine will not accelerate when the accelerator pedal is pushed down. these occasions are totally unpredictable, and have almost caused me to be in a number of accidents. repeated attempts by ford motor company to fix the problem have been unsuccessful. i have repeatedly been told by ford motor company customer service that they are fully aware of the problem, and have their engineers working around the clock on the matter. they have refused to provide me with another comparable vehicle, or reimburse me for the loss of use of the vehicle. this vehicle is an accident waiting to happen, and ford will do nothing about it, except to tell me that they are working on it. *jb
05/15/2003150004/18/2003
 Purchased a 2003 f250 super duty 6.0 l diesel in april 2003. it has been in the shop 4 times in which fuel injectors were replaced and reprogrammed. we have been told by the dealer they do not have any fixes for the rough idle, loss of power, occasional acceleration (for no reason). our truck is used on a ranch. we are often hauling horse, pulling water tanks over a wide variety of terrain. the problems are becoming life threatening to my husband as well as our livestock. we depend on this truck for our livelihood. regardless of how bad it runs we can not let it sit in the shop- cattle will starve. complained to the ford customer relations, they had the regional rep call, she ask if we would accept a goodwill $ in the amount of 1 month payment and said we could expect a fix july 31,2003. i told her i would accept $ as long as she understood it was not shut up $ and the truck would be fixed. she said it was $ to compensate for some of the problems we have already experienced in time lost. the dealer still has no new information to fix the truck but told us to bring it back in and they would look at it again. in the mean time i have been trying to get back in touch with ford regional rep, andre chidder(not sure about the spelling) no luck, ford customer relations said they could not contact her again on my behalf because they have done that once and can;t reopen my case. (no one told me my case was closed) i found a number for her in the internet and will try again. this truck is dangerous and should be recalled ...now failure are daily, dates vary since purchase date. *nlm
08/10/200310010006/02/2003
 My truck is a 2003 ford f250 with the 6.0 diesel and a 6 speed manual transmission. the problem is in starting out from a dead stop. the truck is so sluggish i have been almost hit in crossroads many times!!!! you don't know from time to time if you will have enough power to pull out!!!!!!! there are days i could push it through an intersection faster than i will move under it's own power. also when pulling my camper there was 2 occasions where i had to put the truck in 4 wheel drive low to start the load up an exit ramp and then stop at the top to take it out of low range to gain speed thus hindering traffic!!! please look into this! there are many names i can give you from folks having the same problem all have the 6.0 diesel. *nlm
01/16/200315001/10/2003
 At high altitudes the 6.0 liter diesel will need 15-20 minutes to warm up before it will go anywhere. if i try to drive truck before that, it will spit sputter and die. i hope i am never in a hurry or have an emergency. temperature does not seem to affect this, it happens daily no matter what temp is. no fatalities yet, i work construction, if someone on my job gets hurt they may die waiting for truck to warm up. *jb
04/06/20031420203/17/2003
 The valve that measures restriction on the air intake prior to the air filter has broken apart twice. this was spontaneous while driving.(air filter restriction gauge). *jb
03/18/2003216303/15/2003
 My husband and i recently purchased a ford f250 super duty 6.0 liter diesel pickup truck. this is a new engine that was just released this year. there are already many service bulletins listed on this particular truck from ford. the problem with our truck started with the check engine light coming on. we had owned the truck for three days and it was in the shop for the first time. a part was replaced and two days later the light was back on again. back to the shop for the second time in less than a week from the date of purchase. the next part being replaced was delayed in shipping. the dealership offered to remove the needed part from another truck on the lot but was warned by ford that they were aware of the defective part and using one from another truck would not correct the problem. four days later we were able to pick up the repaired truck. five days later the light is back on again and now it is also running rough, slow acceleration, stalling, slow response from a stop, etc. fords latest bulletins to their dealers is that there is no fix for this at the present time. this is a very dangerous situation which could result in an accident from the slow acceleration and stalling. this vehicle should be taken off the market until they resolve the problem. those that have already purchased this vehicle need corrective repair action or reimbursement. after finding similar complaints already listed i am wondering why they are still selling these to the public. apparently there are many people that are having the same problem. are you going to wait until there is a serious injury or death and then try to correct the problem? please help! nb
02/14/2003201/10/2003
 My wife and i recently purchased a 2003 f250. while on vacation camping in florida the truck failed to start one morning. the truck took 5 days to repair due to a ruptured high pressure oil line inside the engine which was consequently shutting down all fuel pressure. the truck is currently in the shop for almost stalling on my way to work last week. dealer indicated this was due to a ruptured fuel line inside the engine which was subsequently dumping diesel into the crank case....where will it end? truck is less than 3 months old and will have been in the shop for almost 3 weeks after this recent failure.*jb
01/09/200327512/09/2002
 I recently purchased a ford f250 super duty 6.0 liter diesel pickup. this is a new engine just released this year. their are already many service bulletins on this from ford. one of the main problems is running rough, stalling, slow response from a stop, etc. fords latest bulletins to their dealers is their is no fix for this at the present time. this is a dangerous situation which could result in an accident. it is my believe these should be taken off the market until they resolve the problem. i am wondering why they are still selling these to the public and not informing them their could be a problem with them. i presently own one of these and it has been in the shop for over 30 days since dec 9th. at the present time my is so bad i cannot drive it anymore because of stalling on the highway. there are many people out their having the same problem. are we going to wait until there is a serious injury and then try to correct the problem? ts
ENGINE AND ENGINE COOLING - ENGINE - OTHER FUEL TYPES - TURBO-CHARGER
03/21/2004297106/10/2003
 Power booster for power steering coolant leaks, blown turbo charger. *jb
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
11/01/2010125000
 The turbo on the low end struggles. egr is having problems. truck hesitates when starting off, it is a potential problem for wrecks because the motor hesitates from take off. turning out to be a safety hazard
11/01/2010125000
 The turbo on the low end struggles. egr is having problems. truck hesitates when starting off, it is a potenetial problem for wrecks because the motor hesitates from take off. turning out to be a safety hazard
11/01/2010125000
 The turbo on the low end struggles. egr is having problems. truck hesitates when starting off, it is a potential problem for wrecks because the motor hesitates from take off. turning out to be a safety hazard
11/01/2010125000
 The turbo on the low end struggles. egr is having problems. truck hesitates when starting off, it is a potenetial problem for wrecks because the motor hesitates from take off. turning out to be a safety hazard
11/01/2010125000
 The turbo on the low end struggles. egr is having problems. truck hesitates when starting off, it is a potential problem for wrecks because the motor hesitates from take off. turning out to be a safety hazard
11/01/2010125000
 The turbo on the low end struggles. egr is having problems. truck hesitates when starting off, it is a potenetial problem for wrecks because the motor hesitates from take off. turning out to be a safety hazard
11/01/2010125000
 The turbo on the low end struggles. egr is having problems. truck hesitates when starting off, it is a potential problem for wrecks because the motor hesitates from take off. turning out to be a safety hazard
11/01/2010125000
 The turbo on the low end struggles. egr is having problems. truck hesitates when starting off, it is a potenetial problem for wrecks because the motor hesitates from take off. turning out to be a safety hazard
07/16/200361000
 I understand that there is a technical service bulletin on the 2003 ford f 250 2w/4w drive v-10 motor. was this motor [v10-6.8l vin s] recalled ? was ford to repair / or replace these defective motors? the vin # on the truck is 1ftnw21s33ed41612.
03/25/2008680001
 Vehicle has a oil cooler and egr cooler defect. common problem by many f250 owners. ford is aware of the problem and has issued a superseded part number for the oil cooler, egr cooler is unchanged. when these components fail it causes the vehicle to overheats when towing a load and can consume several gallons of coolant. it's a safety concern due in part that if a vehicle overheats and shuts off while towing a heavy load the vehicle will lose braking power. *tr
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR
12/16/2002012/16/2002
 Mechanical problems/ poor assy of vehicle
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
03/23/2005110/01/2002
 2003 f-250 super duty 4x4 gas. 46,000 miles. found 2 broken exhaust manifold studs on passenger side of engine. while investigating exhaust leak also found 2 front ball joints bad. ford states that it is out of warranty and that it is normal wear and tear. i find this unacceptable. this vehicle was purchased less than 3 years ago. most of the miles are traveling between texas and pa. this is a 3/4 ton super duty truck. ford needs to stand behind their product. *ak
11/02/20035918305/05/2003
 I purchashed the 6 liter 2003 250 truck in may of 2003, and nothing but a nightmare ever since. it has already had a cracked exhaust manifold which was causing poisonous fumes to enter the cab, the dealer fixed it and said it happens. well it only had 5,918 miles on it. i bought this new truck so i wouldn't have to be taking it to be fixed all the time. well since that day in may the truck has been in the shop 3 times for no power, poor gas milage, surging and bucking while in the tow / haul feature. and all they do is re-program it and say that is the problem. well i disagree and i feel this truck is unsafe and is a time bomb waiting to happen. i feel that someone needs to start a class action lawsuit against ford or they need to step up and stand behind their supposed quality and make the customers happy and safe. henry ford would be disgusted if he were alive today,that whoever is the careless individuals in charge are allowing this truck to remain on the road. does ford need another firestone on their hands before they see what is going on . i sure hope that someone doesn't lose a family member before something is done. i can say that i will never purchase a new ford vehicle again please someone help us, before its to late. thank you. *ak