Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
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

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.
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.
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
09/01/2010160000
 Tl- the contact owns a 2002 ford f350 super duty. the contact stated that his vehicle would stall intermittently and when that failure occured, he would notice smoke coming from the engine. the dealer was unable to duplicate the failure. the vehicle had not been repaired. the current mileages were 164,000 and the failure mileages were 160,000. bw
01/20/20101700001
 I have a 2002 for f350 superduty, i first had a spark plug blow out almost a year ago on cylinder 1 it was a loud pop then fluttering sound with reduced power, a smell like burning oil- gas, i was going down the high way when it happened & was unable to stop immediately, but when i did go under the hood the spark plug was jammed under the fuel line for the injectors & i still smelled a faint oder of gas, the coil was arching on the metal tubing above the spark plug. i figured it was the fault of my mechanic when he replaced the spark plugs, one year earlier, maybe he striped the thing or something. i fixed the problem with a heli coil everything was fine for a few months then it happened again with the same plug i again fixed it making sure to tighten the plug down good, three months later the same thing so i again fixed it each time having to purchase a new coil. now year after the first incident 2 years since the plugs were installed, cylinder 2 just blew out a plug and destroyed its coil, so i began to think theres something going on here, somethings wrong!, & looked on line for the answer. there are hundreds of complaints, and no one is doing anything about it! this is the fourth time in a year this has happened! & i'm fed up! i have the spark plug & coil from this last. i believe this is a hazard, with gas being fed to the cylinder and the coil arching on the metal around it, its only a matter of time before a truck explodes, or has an accident & someone dies! *tr
11/10/20081
 Truck was losing power- then oil began to leak- oil leak became worse. took to mechanic. needed to replace o ring and turbo!! *tr
03/22/200860000108/25/2002
 On the morning of saturday march 22, 2008. my 2002 ford f350 super duty engine caught on fire while sitting in my driveway. it was sitting for roughly 10 hrs. when it started on fire. vehicle is destroyed and did some damage to my house, but thankfully no one was hurt. *tr
11/01/20072007/05/2007
 Vehicle keeps cutting out. engine splutters and jerks, all the lights blink on the dash board, and engine quits. it has let me standed in traffic five or six times. it can happen just going down the road or when you are pulling out from a stop, there is never any warning. in 7 miles i had to restart my vehicle 5 times. it started in november 2007. i thought there may be moisture in the fuel filter, so had all filters changed and truck put on computer. dealer could not find a problem. the problem has steadly gotten worse; from once or twice a week to five or six times in less than 10 miles. i can no longer rely on my vehicle getting me where i need to go. *tr
11/22/200328838111/01/2002
 With truck in park i would start engine and truck would instantly go to 5,000 rpm by itself and stay there. i could turn ignition off pull out key and truck would run by itself for 10-30 second and then die. i would hate for this to happen to someone on the highway and not be able to turn truck off.*ak
ENGINE AND ENGINE COOLING - ENGINE
02/22/2008100000
 Tl*the contact owns a 2002 ford f350 sd. the contact stated that the cam shaft sensor has failed three times after being replaced. the engine remained idle but there was no power and the vehicle failed to move forward. after the sensor was replaced the vehicle functioned normally for at least seven months. the dealer stated that they were not going to replace the sensor again since they are not sure what should be repaired. the dealer also stated that because the sensor had to be replaced so many times, it may not have caused the failure to occur. the failure mileage was 100,000 the current mileage is 250,000.
09/18/200682230206/19/2002
 My 20002 ford f-350 v10 pickup truck blew out a spark plug. the first time i thought nothing of it, i replaced it and the coil for $120.00. two days later it blew out again this time while i was traveling on a main road, the truck died in the street from 40 mph to zero in no time at all. i was almost rear ended my a very large 18 wheeler carrying a large excavating machine . luckily he had room to pass me on my left ,before any damaged was done. after some research i have found out that ford has known about this problem for years. there has been thousands of people have their spark plugs blown out of the cylinder walls , due to faulty threadings in the cylinder wall. when will ford be held accountable for the expensive repair, when someone dies. *nm
07/27/200691326107/01/2004
 I have a 2002 ford f350 with triton v10 engine. on 07/27/06 the spark plug blew out causing lack of power to my vehicle and a damaged coil. *jb
04/19/200543350111/07/2001
 At 43,350 the spark plug blew out of the cylinder requiring the right head to be replaced. *jb
ENGINE AND ENGINE COOLING - ENGINE - DIESEL
02/22/2008430001
 2002 ford f350 super duty quad cab le 7.3l diesel parked in my back yard with the engine block heater plugged in. i heard an explosion and looked out the window. my truck was burning from under the hood. the whole front end was on fire. the grill, bumper rubber, headlights and intercooler burned away. when the fire department finally put it out you could see that all the rubber, plastic, wiring and batteries were completely burned away. *tr
03/10/2007104/01/2002
 Tl*the contact owns a 2002 ford f-350 sd. the contact stated that he received a recall notice for the engine and engine cooling: engine: diesel (nhtsa campaign id 07v553000). the manufacturer stated that they would not reimburse the cost to have the vehicle shippied to the dealer. the contact felt that the manufacturer should be responsible for shipping cost. the currrent mileage was 62,000 and there had been no failure to date updated 04-09-08 *bf
12/10/200758347306/11/2003
 Tl*the contact owns a 2002 ford f350 super duty. the vehicle was taken to the dealer to have a safety recall repaired. at that time, the contact was informed that the vehicle needed to have an oil change. also, the oil pan needed to be changed because it was rusting and pitting. the cost to replace the oil pan on her diesel engine is $2,399.82. the contact stated that the rear universal had to be replaced at 27,770 miles and then had to be replaced a second time, in addition to the carrier bearings at 47,325 miles. the vehicle was under warranty the first time, but the contact paid for the repair the second time. the recall number was unknown. the current and failure mileages were 58,347. updated 02-04-08. *kb the consumer stated replaced weatherstrip, replaced rear u joint, disc pads replace, and replaced broken console lid. updated 02/04/08 *tr
07/30/20071240001
 Camshaft position sensor failed on my '02 ford f-350 power stoke diesel. *tr
07/25/2007109/15/2002
 I own a 2002 f350 ford diesel truck. i just had to pay $2221.70 to replace a rusted out oil pan. this should have been a simple, low cost job but since ford used defective metal in their oil pans causing them to rust out and the cross member between the frame, the whole engine has to be removed to change the pan. every diesel ford truck owner will have to replace their oil pan within 6 years or it will begin leaking causing the engine to shutdown anywhere. how can i begin a class action recall at ford's expense for this unnecessary and very costly job ? *jb
03/19/200786400110/31/2002
 Vehicle stalled without warning and would not restart. fortunately, failure happened just before i pulled out of a parking lot otherwise i would have been stuck lengthwise across road in the middle of a left turn. part that failed was the camshaft position sensor. don't know if i still have the original part. after part was replaced vehicle started without problem. *tr
01/13/200767400106/15/2002
 Defective cam position sensor caused vehicle to stall on freeway. replaced cps. *tr
02/10/200764000108/05/2004
 2002 ford f-350, with 7.3l power stroke diesel .failure of the cps. *jb
04/11/2006260001
 Motor died in middle of intersection. *jb
11/15/20061
 Truck would pickup every once in a while then finally i was getting off the interstate and it died. the cps had failed i put a new one in and it runs fine. *tr
04/16/200735587109/14/2001
 Loss of the cps sensor on my 02 ford f350. the sensor went out while i was traveling down i87. i was able to pull off the road but the failure left me stranded with no cell service in the middle of a northeaster on 4/16/07. *tr
11/06/2006143000109/03/2004
 Driving my 2002 ford superduty f350, no warning, driving in traffic and truck died in a tunnel. result was cam position sensor. over $400 in parts, labor and towing bill. caused traffic to slow down and go around me. *tr
11/08/200663050110/28/2001
 I have 63000 miles on my 2002 f350 super duty pick-up (7.3l diesel). my truck stalled 3 times while driving, once while turning across traffic. the fault codes indicated an intermittent camshaft position sensor. i replaced the sensor myself, and the problem has been corrected. i have the old sensor available. this is a known problem among ford truck owners. stalling while driving causes loss of power steering, loss of power brakes, and obvious stop in traffic. *nm
07/06/200646000103/10/2002
 Out of state on vacation. shut vehicle off and then it wouldn't start. called ford warranty - only ford dealer in area couldn't get it in until the following week. talked to friend that is a diesel mechanic who advised that the cps always goes bad in 7.3's and to replace it. located one at napa for $190.00 - borrowed tools and installed. truck then started right up and has run fine since. only 46,000 miles on truck!! took old cps to local ford dealer along with bill and am attempting to recover expenses under warranty as the manual says it is covered. local dealer wasn't very optimistic. *jb
04/08/200524000110/26/2001
 This happened several months ago, but my f-350 power stroke had the dreaded cam position failure. my daughter was stuck at an intersection in 5 o'clock traffic and the truck was dead. i carried a spare sensor in the glove box knowing that this is a very common failure. imagine being in the left lane of the interstate when it decides to fail. lose power steering and power brakes. read about cps failures on thedieselstop.com. could fail when turning left in front of on coming traffic. i feel this is a very dangerous flaw in this motor. *jb
11/02/200559833209/18/2002
 My vehicle is a 2002 ford f-350 xlt 4x4 power stroke diesel...auto trans. the diesel engine unexpectedly shut down due to a defective synchronizer ( cam position sensor or cps ) while towing a heavy boat & trailer ( 9,800 lbs ), the engine suddenly and unexpectedly shut off for no apparent reason. when this happens there is no power steering or brakes. this makes the truck hard to steer and stop, and is a very dangerous condition,especially while towing a trailer. the first time it happened, i narrowly missed hitting a telephone pole, as i did not know the engine had died until i continued to steer the vehicle around a slight corner and it would not turn until i exerted heavy effort on the steering wheel. ( no power steering when the engine dies) a woman would never be able to steer this vehicle when this occurs. i then tried to stop the truck, and with the engine stalled ,there was no power brakes either. with heavy towing weight, this is also extremely dangerous. there was no accident or damage, but this is a dangerous condition. i found that it is common knowledge to ford dealers & powerstroke owners that these cam sensors fail often, resulting in the engine shutting off unexpectedly,or sometimes causing it not to start if the engine does not start , this is not a dangerous condition, however if the engine dies while towing a trailer, there is a good possibility of losing control due to the extreme effort required to stop and / or steer the truck when the engine shuts off. the part number for the replacement cam sensor is : f7tz-12k073-a. i have the old sensor available for inspection if ford wants it, but i am sure they are well aware of this problem with these trucks. there were no computer trouble codes stored when this happens. i have had 3 other ford powerstroke diesels and the cam sensor has failed on every one of them. ford needs to seriously look into this problem with these sensors. *nm
10/20/200593000108/19/2003
 2002 f350 diesel, i bought this vehicle new in august 2003 and have presently 93,000 miles. the oil pan to the motor has rusted through. i feel this item should last the life of the vehicle. i have been in touch with a couple of ford dealers and they both said this is a common problem with this truck. i was quoted $1600.00 to have this problem taken care of. there has been no recalls as of yet to take care of this. *jb
08/01/2005407/01/2002
 2002 ford 350 developed problems with the braking system.*mr the consumer stated even under moderate braking the front rotors warped which caused brake and handling problems. the brakes have been an ongoing problem. the belt tensioner and battery was replaced. the check engine light illuminated.*jb
06/27/200330000104/11/2002
 I have a ford f-350 diesel that and i have experienced and extreme loss of fuel economy. i have gone from 15 mpgto 8mpg. ford said that they cannot find any problems with the engine. the engine also overheats while puling a light trailer. the wait to start light also stays on. the dealer said they are aware of that problem.*ak
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
03/28/200698000110/11/2001
 While driving heard a loud popping noise and truck began running rough and lost some power. pulled to side of highway, opened hood and saw that i lost #9 spark plug. was offered through ford to either replace the head for $3400.00 or replace entire motor for $6200.00. no other options. ford does not recommended heli-coil. when asked the dealer and ford representative what can be done to help offset this cost, they replied nothing. *nm
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
07/08/200578000102/01/2002
 Dt: contact had a 2004 ford f-350 super duty truck and the studs to the manifold rusted. consumer noticed this about 3 weeks ago on 7-8-05. the dealer stated this was normal wear. the truck had 78,000 miles on it. this is the first time she had problems with the manifold. the dealer stated consumer needed to get the studs replaced at her own expense. *ak *nm