Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY
1250703/01/1999605273All vehicles built december 1998 and after are equipped with a revised upper radiator hose changed in production. *tt11/09/2000
580903/01/1999605219Information regarding production change to upper radiator hose. *tt06/04/1999
ENGINE AND ENGINE COOLING - ENGINE
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
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
463208/01/1998615170Hard start / no start condition. *tt01/03/2001
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER
690009/01/19996090205Some vehicles built prior to 4/1/1999 may exhibit turbocharger noise, exhaust noise, or oil / soot presence on rear of engine or turocharger. *tt03/10/2000
991312708/01/1999609045Information on diagnosing 7.3l dit vehicles built prior to 4/1/99 exhibiting a turbocharger noise, exhaust noise, or oil / soot presence on rear of engine or turbocharger. *tt12/07/1999

Investigations


NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
ENGINE AND ENGINE COOLING
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.
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
PE06011FORD MOTOR COMPANY02/27/200606/23/2006ENGINE STALLING
 The cam position sensor (cps) provides a critical signal to the subject vehicle (sv) engine management system, the loss of which results in an engine stall.during pe06-011, ford stated in their response to odi that it is continuing to investigate allegations of cps related engine stall and further advised that an update will be provided upon completion of the investigation.ford data shows that 20% of the 716,000 svs are equipped with manual transmissions which are capable of back-driving the engine when a stall occurs; power assisted steering and braking are not lost during engine back-drive.ford data also indicates that back-drive occurs in automatic transmission vehicles above certain road speeds.the manufacturer reports noted reference 755 unique vehicles; 2 are duplicative of odi reports.in its review of customer and field reports, ford identified some 800 reports alleging one or more engine stalls potentially related to a cps failure in these 755 vehicles (ford
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.
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
09/17/20091650001
 Took my truck to the laird noller ford dealership for a cam sensor recall in november 2008. they could not make the repair that day and my appointment was rescheduled for after christmas 2008. the dealership told me that there was a recall on the parking brake module and they would replace it at the same time they replaced the cam sensor. approximately a week after christmas (it was a wednesday) i took it back in for the repairs. they told me they would have it done at the end of the day, but at the end of the day they called back and said it would not be done until the next week. so, that next monday (january 3rd ish 2009) they called, i went to pick up my truck and all the recall repairs were made. everything was good until september 17th 2009. i had my truck parked in my driveway, the emergency brake set (it has a manual transmisson), so it would warm up that morning. i was walking back to my house when i heard a load pop, i turned to see what was happening, and my truck began rolling out of my drive way and smashed into a tree. called my insurance company, told them my parking brake module broke and that ford had just replaced it earlier in the year. they towed my truck to a body shop. i called ford next, and told them about the crash. they said that they would gather all my paper work and my insurance company would get a hold of them, and they would talk with them about who would pay for the damages. then i called my insurance company, and told them who to talk to. my insurance decided the parking brake had failed, and that i needed to take it to ford to get it checked out. ford looked at it, and agreed that yes the part (factory recalled and replaced part) had failed, and proceeded to price me a new one. they told me mine was out of warranty. the replacement part allegedly had only a 12 month 12,000 warranty, and i was at 10 months, 14,000 on a part that doesn't wear because of mileage. the parking brake was not replaced and failure occurs during every use. *tr
06/01/2007600001
 I have had two major problems with this truck. my first issue was very dangerous in my opinion. the cam sensor went out which caused my truck to suddenly stop while i was driving it. every system shut down including brakes. more than once i was going 70mph and it suddenly stopped - i had to guide myself to the shoulder and stop the truck with no brakes. very very scary! i had the truck to several dealers al told me they had no idea what was wrong. finally i talked to my cousin, a dodge mechanic, he explained that ford knew of a serious defect with their cam sensor on that year truck - he explained what it should cost to fix it. i took it to a private mechanic and he fixed it in his shop for exactly what my cousin said it would cost. ford still has not acknowledged they knew of a problem. second problem was with my brakes. the left front caliper broke off and jammed in the rest of the brake and stopped my truck very suddenly. i almost went through the windshield. i had them replaced with ford parts. i have had the new brakes back into the dealer several times as they seem to be doing the same as the first set - pulling to the left and not working particularly well. i was told it was due to the way i drive - downhill and steering to the right while braking - nonsense- i anticipate having the same problem at any time and stopping, dangerously, suddenly on the main street of my small town just as happened last time. *tr
05/14/2006110000209/02/1998
 Spark plug blew out of cylinder head, which cost over $2000.00 in repairs in late 2004 and now again another spark plug blew out and the estimate for repair is $4400.00. *jb
10/05/20058000001
 Spark plug blew through the cylinder head of vehicle causing the cylinder head to be replaced at a cost of 3600.00. *jb
10/02/200581000103/01/1999
 Dt: the contact stated a spark plug ejected from her husband's vehicle. the spark plug caused damage to the engine and blew the cylinder head. the service dealer confirmed it. the dealer replaced the cylinder head. the replacement corrected the problem. the contact said this was the same problem as experienced in the investigation for the engine and engine cooling, nhtsa action number dp05005. *ak
ENGINE AND ENGINE COOLING - ENGINE
12/24/20082044291
 I was going to the store to finish christmas shopping. i was stopped in the parking lot waiting to turn left when i heard a very load bang from under the hood. i first thought something on the exhaust broke. when i parked i opened the hood and found the #5 spark plug coil and wire hanging from the left side of the engine with the spark plug still in the boot. i attempted to thread the plug back in but found the threads in the head were stripped out. the spark plugs and boots were changed once since i've owned the truck, which was about a year ago. the new plugs were all torqued to exactly 11 foot lbs as specified by ford. i just had the truck towed home today so no repairs have been made yet. *tr
06/14/20081053731
 Ford f350 v10, multiple spark plug ejections from cylinder heads. has happened many times, reinserted plugs per fords recommendation, as if i was unable to properly torque plugs. now i am left with my families truck, stripped heads and no money to fix it. *tr
10/18/2005172365201/20/2004
 I was driving down the freeway towing a trailer and lost all power to the engine for about 10 seconds. the 1999 ford f350 sd 7.3 diesel engine regained power and surged forward. this happened several times during this trip and subsequent dates. i attached a obd2 reader, which gave me the code for the cam position sensor. i replaced the cps and the problem stopped. the dealer told me that this is a common problem and the parts worker had the part number memorized when he sold me a new one. i now carry a spare cps and a 10 mm wrench in the vehicle in case it happens again. this is a quality control issue or an engineering issue. please let ford know that i will by a dodge or chevy next time. *nm
06/17/2006123350109/15/2001
 Driving along and engine suddenly and completely died with no warning. truck had to be towed. problem was the camshaft position sensor. replacing this part with a new one has solved the problem so far. i have the old part. *nm
05/22/2006500001
 I am the owner of a 1999 ford f-350 diesel super duty truck with duels. while driving, the check engine light will come on intermittently. when this happens, the truck will not accelerate. it's still running, but you can't go any where. pressing the gas pedal is useless. sometimes the light will go off and acceleration is restored. other times, i have to steer the truck over to the side of the road and either put the truck in park which will sometimes make the check engine symbol disappear or turn the truck off and restart it. this makes for a very dangerous situation where i am at risk of being rear-ended. i am very fortunate not to have been in an accident yet and pray i won't be. please help or point me in the right direction to get help! thank you! *nm
04/07/2006110/25/2004
 Spark plug shot out of engine - stripped threads. *jb
02/14/200556500106/05/2004
 Truck has 56k miles on it. my wife was driving a couple of miles from hom ewhen she heard a loud bang or pop noise which shook the truck. the truck then continued making a loud noise, she drove back home and after looking at the engine, i determined that a coil pack had blown off. the spark plug was also attached to it so the next morning i called my local ford dealer, av ford and they said more than likely it's what they call a 'blown plug'. they estimated the head should be replaced since this would strip the threads of the head. the service advisor said this is a common problem and that both heads should be replaced at a cost of $5800 because otherwise i might have the same problem again in a short amount of time. i did some research online and found that this problem is very common with the ford v10 engines from about 1999-2003. i talked to a couple of other ford service techs at other dealerships and they agreed that it's a very common problem that ford is not recognizing or doing anything about. i called ford consumer relations to complain about the defect and they said before they can help me, i need to have the dealer officially look it over. the truck is at the dealership and they want $5800 to fix it. there are several hundred or even thousands of posts online of other ford owners that have experienced this same problem with the v10 engine. the defect is that the aluminum heads do not have enough threads to hold the spark plugs securely and eventually they will vibrate loose enough to blow out causing unrepairable damage to the head.
06/08/200399000101/06/1999
 3 car pile up. our truck was the 3rd vehicle. impact speed 35 to 45 mph. we have a 1 ton truck that had the frame bent and motor mount that broke. repair damage est. to be $9,000. the air bags did not deploy.*ak
ENGINE AND ENGINE COOLING - ENGINE - DIESEL
11/20/20091000001
 On novemebr 20, 2009 i took my ford f350 to a dealer for recall work, cam sensor replacement 07s57. the dealer did not replace the sensor but visual checked it. i wrote a letter to ford on november 30, 2009 explaining the problem and they assigned case number to my problem. on january 7, 2010 i wrote a second letter to ford asking for a decision and have not received a response. all i want is a ford guaranteed cam sensor installed in my truck per the recall notice. *tr
05/28/2005225000212/06/2003
 Multiple cps failures. i've had 2 sensors fail in a 40,000 mile period. when the sensor fails the engine shuts off. it's not a fun ride when you have a trailer weighing close to 10,000 pounds on the back of a truck that looses power without warning. i now carry a brand new packaged spare sensor and tools to change it in my truck at all times. *tr
04/16/2007185500109/20/2006
 The vehicle suddenly lost accelerating power, then lost all power, brakes and steering. i was able to pull over with no problems. new cam sensor solved problem. *jb
09/12/20051160001
 Lost cps on ford 7.3 psd. *nm
03/06/200490000302/26/2000
 1999 f350 7.3 diesel - cps failure caused engine to stall- no brakes or steering- caused accident-3rd cps
08/20/2005101300404/20/2005
 I was driving and my truck stalled before getting to a complete stop. i was about to reach bumper to bumper traffic. luckily there was grass on the right hand side and i pulled in there to avoid hitting a car. had to go over the sidewalk. after turning off, i tried to start with no luck. after 10 minutes i tried again and it started. a little down the road same thing happened, it stalled. happened like 2 more times until i got to work. called my mechanic and he stated that the cps usually goes out and he bought one for me. installed it and it worked. just waiting for the next time it happens as i have read these things give out all the time. *jb
08/20/200130000208/05/2001
 I owned a 99.5 ford f350 with the 7.3l diesel and manual transmission. at around 30k miles, driving down the highway at 65 mph while towing a loaded trailer, the truck shut off. this left me with no power steering and no power brakes or abs brakes. had the incident occurred on a steeper grade or busier time of day, it could have been deadly. after pulling over to the shoulder, the truck restarted and ran briefly before shutting down again. it had to be towed at that point. the truck was still under warranty. after the second attempt at fixing the truck, which led to another high speed stall with loss of control, they finally replaced the cam position sensor (cps). i had told them that this was probably the problem when i had it towed the first time. it seems common knowledge among ford 7.3l diesel owners that this part fails without warning at as early as 500 miles on the odometer. most owners carry a spare in their trucks to avoid being stranded. my concern is that this has become a major safety issue with these trucks as more and more families use them as grocery-getters and/or the family wagon. a less experienced driver or a driver in a more hazardous setting would not have fared as well as i did. i urge you to research this problem and bring it to light so that ford can no longer sweep it under the rug until people get hurt. as these trucks get more miles on them the odds increase dramatically that the cps will fail leaving the vehicle in an uncontrollable state in many instances. *jb
10/13/2005193000510/12/2003
 The cam position sensor on my '99 ford f-350 w/ 7.3l power stroke is failing intermittently. these failures cause the engine to shut down instantly with no warning. when the engine shuts down there is a loss of power steering and brakes. this has occurred in traffic on interstate 283 in pa causing the vehicle to loss steering and brakes in rush hour traffic with no warning. on one other occasion this occurred in a parking lot causing loss of control of the vehicle while turning due to loss of steering and brakes when the vehicle stalled, causing a minor collision with a curb. no property personal injury occurred. this is a common problem with these vehicles and in my opinion is a very serious safety issue. *jb
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
12/12/2001287981511/15/2001
 Dt: bought truck 11-15-01. since then you have had repaeted problems with the front hub bearings. the 1st time they went out was 12-12-01, again on 2-11-02, and 2-14-02. again 4-23-03. now currently out again. in the past ford has worked with this issue, now will not. 3-15-05 new engine was installed, now has check engine light on and knocking noises. dealer is refusing repairs unless pays out of pocket.