Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING
1859805/01/200510017911Intermittent crank no start due to an egr throttle plate that is stuck closed. the engine may seem like it has no compression due to a faster than normal cranking speed of greater than 200 rpm. dtc p0488 or p1334 may or may not be present12/07/2005
1873407/01/200510017864Diagnostic trouble code p0488 set after reflash. *tt12/05/2005
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER
1924506/01/200610020150Repeat turbocharger or vgt replacement. *tt07/28/2006
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
05E1508/18/200510017996Voluntary emission recall 05e15 - supplement #2. exhaust pressure sensor replacement, on-board diagnostic system and engine control module recalibrations. *tt12/12/2005

Investigations


NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
ENGINE AND ENGINE COOLING
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
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
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
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
05/27/2008700001
 For the past 4 months we have had our truck in the shop three times, because of the egr valve. truck constantly blows out black smoke and has no pick up speed. still having issues the day after the truck was taken into the shop. *tr
ENGINE AND ENGINE COOLING - ENGINE
05/13/2009138000
 Tl-the contact owns a 2004 ford f250 sd. the fuel injection control module failed on his vehicle. he had to purchase the parts but could not install it himself. he has to take the vehicle to the dealer to install the parts because they had to reprogram the computer. the repairs cost him $1000. the dealer informed him there are no recalls or warranty for his vin. the manufacturer was contacted and offered no other assistance. the failure mileage was 138,000...mw
02/21/201085000
 Tl*the contact owns a 2004 ford f250 superduty. the contact stated that while driving approximately 60 mph, the engine ejected spark plugs. the vehicle was taken to a licensed mechanic and repaired by adding an insert into the engine head. the failure had occurred again after the repair was performed. the failure mileage was approximately 85,000. the current mileage was approximately 85,400.
04/01/2006511/06/2004
 2004 f 250 engine light illuminated , engine surged and ran rough. *ts the vehicle also stalled. the dealer attempted to resolve the problem but each time the problem recurred. *nm
ENGINE AND ENGINE COOLING - ENGINE - DIESEL
06/19/20041151206/18/2004
 Vehicle loss of power and whine noise from motor and /or turbo causing truck to have major hesitation and lack of power at freeway and surface street speeds--several time this happens when driving on a regular basis. *tr
04/14/2006105/15/2004
 Purchased new 2004 f250 6.0l turbo diesel. since purchase, have repeatedly experienced intermittent surging, stumbling, & stalling. have returned vehicle numerous time with no trouble found. subsequent recall came out and was performed in september 2005. intent of recall was to address stated problems. started experiencing problem again in february of 2006. shop visit on 12 april 2006 revealed egr?? problem, and was replaced. problems reappeared the next morning. will take to the shop for another round!! *nm
08/22/200518659404/16/2004
 1) while entering interstate and/or traveling at interstate speeds, and hauling a trailer. 2) the cac(charge air cooler) duct blows off of the turbo. this leaves the vehicle with a lack of power, requiring finding a safe place to pull off the road. 3) existing hardware is re-attached and torqued to spec, and redesigned parts have also been installed. *nm
08/17/2004150010003/12/2004
 Engine stalls, hesitation, rough running, would not start, heavy smoke exhaust
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
01/24/20087000603/04/2005
 2004 f250 crew cab diesel 4x4 check engine light cam on at 7,800 mi after truck died when driving took it in they said nothing was wrong, 200 miles later i started loosing power , and stalling kept recurring, they got a code that read internal failure, erratic back pressure in exhaust . they put a new sensor in it made no difference still stalling 20,000 mi took it in again, for stalling , lack of power bad fuel mpg, hesitating on take off . check engine light on , and a loud clunking in the front passenger side . they put a new sensor in , an no difference at 26,000 they replaced the turbo it ran good for a week or so but fuel mpg never improved and it slowly lost power again , and all the other issues still remain the same. i got under the truck and had to locate the problem and found that the leaf spring was loose and caused the bushings to be destroyed, they wouldn't fix any of it , and i paid for a 2000 extended warranty . im currently trying to get other owners of the 6.0 diesel motors to get together a file a class action suit . *tr
11/25/200539600110/01/2004
 Dt: the contact stated the throttle stuck. when the brake pedal was depressed the vehicle stopped. the vehicle was towed to a certified dealer. diagnostics were performed. the air mass sensor was cleaned. the vehicle is now driving correctly. *ak updated 12/27/05. *jb
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
03/30/200816675108/15/2004
 Exhaust manifold bolts broken, leading to carbon monoxide (as well as other exhaust gases) being released into passenger compartment. *tr