Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| 18397 | 02/01/2005 | 10012958 | Lack of power, surge, and/or diagnostic trouble codes p2263 or p0299. *tt | 04/05/2005 | |
| 02177 | 09/02/2002 | 10008581 | Cooling system-motorcraft premium gold engine coolant-serivce tips. *mj | 08/05/2004 | |
| 16403 | 11/01/2002 | 10008334 | Engine-light tick or rattle type noise from engine after cold start. *mj | 07/28/2004 | |
| 02227 | 11/11/2002 | 10008310 | Engine-cylinder head deck leak-4.6 and 5.4l engines-new service-only gasket and cylinder head kits availability. *mj | 07/27/2004 | |
| 04115 | 06/14/2004 | 04186 | 10008255 | No start or constant engine misfire - fuel injection control module (ficm) diagnosis - 6.0l diesel. *tt | 07/23/2004 |
| 17554 | 02/01/2004 | 10008119 | Oil/dust film at cac connections. *mj | 07/22/2004 | |
| 17667 | 03/01/2004 | 10007424 | Oil leak from front or rear of engine. *tt | 06/22/2004 | |
| 17460 | 01/01/2004 | 10007317 | Oil leak that seems to be coming from head gasket area. including ford f450/550 my2003. *tt | 06/10/2004 | |
| 03911 | 05/12/2003 | 10002783 | Rough idle and/or hesitation when acclerating on certain super duty vehicles equipped with a 5.4l or 6.8l engine. *tt | 09/17/2003 | |
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||||
| 17472 | 01/01/2004 | 10007321 | Low power condition and/or diagnostic trouble code (dtc) p2263. 6.0l diesel engine. also includes my2003 ford f450/550. *tt | 06/10/2004 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS | |||||
| 16518 | 10/30/2003 | 10004881 | Accessory drive belt squealing noise from the engine area when the engine fan clutch is engaged while operated in hot dusty climates. various models including 2003 f450/550. *tt | 01/13/2004 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER | |||||
| 18069 | 08/01/2004 | 10011181 | Low power and/or diagnostic trouble code p0299 or p2263 - turbocharger diagnostic service tip. *tt | 01/07/2005 | |
Investigations
| NHTSA ID | Manufacturer | Date open | Date close | Subject | Recall campaign | |
|---|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK PLUG EJECTION FROM CYLINDER HEAD | ||
| On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi | ||||||
| ENGINE AND ENGINE COOLING - ENGINE | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK PLUG EJECTION FROM CYLINDER HEAD | ||
| On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi | ||||||
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | ||||||
| PE04070 | FORD MOTOR COMPANY | 10/07/2004 | 02/15/2005 | ENGINE STALLING | ||
| Twenty five of the odi failure reports are duplicative of ford complaints.twenty odi reports do not contain a vin (and may or may not be duplicative of ford reports).the 14 alleged crashes and 2 alleged injuries were all minor.submitted during preliminary evaluation (pe) 04-070, ford's response to odi's information request (ir) letter contained about 5,000 consumer reports (mors) and 8,700 field reports (cqis).ford reviewed the complaints and categorized them.the manufacturer reports shown above represent a count of unique vehicles that ford categorized as allegedly stalling due to a subject engine component ('a' category, see ford's ir response letter for further detail); some of these vehicles received multiple reports.odi has not yet confirmed ford's categorization of these reports, nor has odi confirmed ford's categorization of the remaining reports (which ford states do not pertain to the alleged defect).ford submitted nearly 19,000 warranty claims, many of which involved claims for a technical service bulletin (tsb 04-13-08) and field service action (fsa 03b05) which ford identified as potential remedies for stalling complaints.odi has not confirmed that either of these are a remedy for engine stalling complaints.several other dealer communications related to engine stall were also submitted as well as over 50 product modifications, 15 of which involve revisions to the software for the electronic engine control unit.further investigation is required and odi is upgrading pe04-070 to an engineering analysis (ea).during the ea, odi will establish and update manufacturer failure report counts, further investigate the frequency and trend of stalling complaints, and determine the scope and safety implication of stalling events.odi will also investigate ford's remedies, their effectiveness, and whether further action is required. | ||||||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK PLUG EJECTION FROM CYLINDER HEAD | ||
| On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi | ||||||
Consumer Complaints
| Fail date | miles | occurences | Purchase date |
|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||
| 01/15/2005 | 1 | ||
| The consumer is experiencing tremendous coolant leakage, which is causing extreme over heating. the vehicle does not have any heat. *jb | |||
| 12/20/2004 | 2 | ||
| The consumer tried to start the vehicle, but it would not start. the consumer waited a couple of hours, went out and the vehicle started. the vehicle was taken to a mechanic and the wiring harness was replaced. four days later the vehicle would not start again, later on, the consumer was informed that the vehicle was on fire. the vehicle was totaled. *jb *sc | |||
| 12/06/2004 | 1 | ||
| While driving vehicle would lost power steering and brakes. vehicle was taken to dealer for checkup, and results showed that oil was leaking inside the engine causing the problem.*ak | |||
| 07/14/2004 | 25000 | 1 | |
| Vehicle hesitate when trying to accelerate. dealership was notified, but did not resolve the problem. *ak | |||
| 05/05/2003 | |||
| Vehicle wont move, when temperature is below o degree. has to wait about a minute to warm-up. dealer has inspected the vehicle and could not duplicate or correct the problem. (diesel engine) | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 06/04/2010 | 98000 | ||
| Tl- the contact owns a 2003 ford f350 . the contact stated that while driving 45 mph a spark plug flew out of the engine department and hit the hood of the vehicle. the contact was then able to pull over and was then was able to drive it to a garage shop. the shop diagnosed stating that a coil and a spark plug will have to be replaced. the vehicle was repaired. this has occurred 2 additional times. the vin is not available.the failure mileage was 98000 and the current mileage was 101000.cv | |||
| 07/21/2003 | 1500 | 1 | 05/31/2003 |
| Consumer stated while driving at 60 mph, the vehicle started smoking and rattling. after pulling over to the shoulder to investigate the problem, the vehicle failed to restart. after taking the vehicle to the dealer, it was found the fuel injector was faulty and the engine failed. there were no indication light on at all. *ph all accounts took place approx. 11:30 p.m. on an extremely busy freeway. as of 08/20/03, ford had not complied with either replacing the engine or vehicle. *ph also the consumer stated the coolant was low, and there was steam coming from under the hood. *jb | |||
| 03/24/2003 | 700 | 19 | 03/06/2003 |
| While driving approximately 70 mph on highway, the vehicle stalled 4 separate times, which resulted in loss of power steering and brake control. dealer advised the problem was corrected, but was unable to guarantee the vehicle would not stall again. *jb after the vehicle was picked up it stalled 15 times. *scc | |||
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||
| 04/26/2006 | 21000 | 7 | 03/15/2003 |
| Dt*: the contact stated while driving the vehicle stalled and lost power. this occurred at various speeds, and in all incidents the vehicle restarted. the vehicle was later driven to the dealer, who replaced and reprogrammed the turbo-charger. however this did not remedy the problem. on the most recent visit to the dealer the turbo charger was replaced, but the problem still occurred. updated 05/30/06. *ak | |||
| 08/23/2004 | 1 | ||
| Consumer request for reimbursement for engine replacement in the 2003 ford f350.*mr the consumer had a multitude of problems with the vehicle lacking power and blowing out white smoke, at times the vehicle would hesitate on start up, it jerked when the consumer attempted to accelerate, there was a rattling noise when the consumers foot was released from the accelerator. the intake manifold had popped lose. the consumer was told because an after market chip was installed in the vehicle, the engine would not be covered under warranty. *jb | |||
| 08/31/2004 | 6000 | 3 | 09/08/2003 |
| Turbo charger is on it's third failure and instalation. i only have 11,000 miles on the ford f-350, the wasted time on my end is rediculous. from what i heard ford and the dealerships are indundated with this problem, but they are refusing to recall. | |||
| 02/11/2005 | 13 | 08/29/2003 | |
| 2nd request fax re consumer's concerns re his 2003 ford f-350 6.0 l diesel truck due to loss of power/irreparable turbo lag.*mr the vehicle has been taken to the dealer several times but they have been unable to correct the problem. the problem has progressed to the point that the vehicle has complete loss of power at stop, particularly when in reverse. on two separate occasions the consumer was unable to backup an incline. lots of exhaust smoke came from the tail pipe but there was no power. *nm | |||
| 03/15/2004 | 18000 | 12 | 05/01/2003 |
| While driving 70 mph, the vehicle shut off. *ak the rear differentail made a grinding sound and shuddered when a turn was made. *jb | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER | |||
| 08/01/2004 | 15000 | 3 | 12/31/2002 |
| While driving the turbo hose to the turbo charger continuously blew off. consumer experienced this problem several times. took vehicle to dealer to be repaired. however, problem recurred. *ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||
| 09/15/2003 | 1 | ||
| A bad odor was coming from inside of the vehicle through the vents. exhaust system was causing the smell. on one occasion, consumer had to pull over to the shoulder because he became very ill. dealer was aware of the problem. *ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL | |||
| 09/30/2003 | 1 | ||
| While warming up the vehicle for more than fifteen minutes an exhaust smell came inside of vehicle, causing consumer to become ill. driver was concerned that carbon dioxide poison gas was escaping inside of vehicle as well. vehicle was towed to the dealer for analysis. dealership mechanic could not duplicate the problem. *ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE) | |||
| 11/02/2003 | 70000 | 10 | |
| While driving vehicle stalled. dealership indicated that this was due to a malfunction in the fuel injectors. the fuel injectors were replaced 8 times, and the egr valve was replaced twice. *ak | |||