Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||||
| 06213 | 06223 | 10019380 | White smoke, lacks power, exhaust odor, surges, runs rough, or no start - 6.0l. *tt | 03/13/2006 | |
| 041601 | 11/14/2005 | 05228 | 10018745 | Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running. *tt | 01/12/2006 |
| 18598 | 05/01/2005 | 10017911 | Intermittent 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 present | 12/07/2005 | |
| 18525 | 04/01/2005 | 10017875 | Buck/jerk, lacks power, black smoke, rolling idle, surge, mil on, and diagnostic trouble codes p2263, p0299, or p0401. *tt | 12/06/2005 | |
| 18734 | 07/01/2005 | 10017864 | Diagnostic trouble code p0488 set after reflash. *tt | 12/05/2005 | |
| 04221 | 06/07/2005 | 051015 | 10013393 | Malfunction indicator lamp on with misfire dtc's spark knock piston scuffing. *eh vehicles built through 4/25/2005 - 5.4l 3v engine. *tt | 04/18/2005 |
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||||
| 052623 | 01/01/2006 | 0638 | 10019385 | Coolant degas bottle overflow - 6.0l. *tt | 03/13/2006 |
| 05249 | 01/01/2005 | 052623 | 10018939 | Coolant degas bottle overflow. *tt | 01/25/2006 |
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| 06246 | 10022295 | Dtc's p006a or p132b - lacks power, surge, or flutter after field service action 06e17. *kb | 07/25/2007 | ||
| 052625 | 01/01/2006 | 0697 | 10020069 | Misfire, lack of power, buck/jerk, excessive smoke or crank/no start. *tt | 07/18/2006 |
| 05148 | 01/01/2005 | 10016809 | Low power-cold side charge air cooler (cac) disconnected-oil leak at cac connections-6.0l-vehicles built 4/1/2004 through 2/15/2005. *sc | 10/11/2005 | |
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||||
| 05139 | 01/01/2005 | 10016842 | Diesel exhaust smell in cab-6.0l engine. *sc | 10/12/2005 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER | |||||
| 19245 | 06/01/2006 | 10020150 | Repeat turbocharger or vgt replacement. *tt | 07/28/2006 | |
| 18694 | 06/01/2005 | 10017873 | Lack of power and/or dtc p2263 or p0299 after turbocharger replacement - service tip. *tt | 12/06/2005 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||||
| 0617 | 04/01/2006 | 10019945 | Voluntary emission recall 06e17 supplement #1: control module recalibration. corrosion may exist at the electrode surface on the exhaust pressure (ep) sensor; fuel delivery timing during cold weather may not be optimal; and/or exhaust gas | 05/17/2006 | |
| 05E15 | 08/18/2005 | 10017996 | Voluntary emission recall 05e15 - supplement #2. exhaust pressure sensor replacement, on-board diagnostic system and engine control module recalibrations. *tt | 12/12/2005 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE) | |||||
| 18607 | 05/01/2005 | 10017912 | Dtc's p0488 (egr throttle position range/performance) and/or p1334 (egr throttle position sensor minimum stop performance) setting after pcm reprogramming. *tt | 12/07/2005 | |
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 | ||||||
| EA05003 | FORD MOTOR COMPANY | 02/15/2005 | 11/02/2005 | ENGINE STALLING | 05V270000 | |
| 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 | ||||||
| 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 | ||||||
| EA05003 | FORD MOTOR COMPANY | 02/15/2005 | 11/02/2005 | ENGINE STALLING | 05V270000 | |
| 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 | ||||||
| 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 | |||
| 10/15/2009 | 120000 | ||
| Tl*the contact owns a 2004 ford f-350 sd diesel. the contact was driving approximately 60-70 mph with a camper in tow as the vehicle stalled with the illumination of the abs warning light. the dashboard also became abnormally dim. after inspecting the vehicle, the contact discovered that the vehicle battery was dad and replaced it with the camper battery. the vehicle was taken to a local repair shop where they performed a diagnostic but they were unable to determine the cause of the failure. the vehicle battery was recharged and the failure did not recur for another four months. the vehicle was then taken to the same local mechanic where the mechanic replaced the fuel injector. the computer was removed from the vehicle and taken to an authorized dealer for a reset flash. the vehicle performed as normal until the failure recurred one year later. the vehicle was taken to an authorized dealer where the contact was awaiting the replacement of the fuel injector. the contact referenced recall 05v270000 (electrical system:wiring) but did not confirm if the vehicle was included in the recall. the approximate failure mileage was 120,000 and the current mileage was approximately 150,000. | |||
| 10/15/2009 | 120000 | ||
| Tl-the contact owns a 2004 ford f-350 super duty diesel. while driving approximately 60-70 mph at night pulling his camper the vehicle stalled. he stated before the failure the dashboard became dim and the abs light illuminated on the dashboard. he lost all power to the vehicle and coasted to the side of the road. he started checking fuses and the vehicles battery, after checked the vehicle he determined that the truck battery was dead and replaced it with the battery from the camper. the vehicle was taken to a local repair shop and they performed a diagnostic and was unable to find a cause of the failure. the contact stated he recharged the truck battery and it worked for three or four months. later the failure happen again, and the vehicle was taken again to the same local mechanic and the mechanic replaced the fuel injector and pulled the computer out and took it to an authorized ford dealer. the ford dealer performed a reset flash to the computer. the contact stated a year later the vehicle stalled again. the vehicle was taken to an authorized ford dealer and he has authorized the dealer to replaced the fuel injector. the contact referenced recall 05v270000(electrical system:wiring) but was not sure if his vehicle was part of the recall since the dealer was unable to provide him with that information. the approximately failure mileage was 120,000 and the current mileage was approximately 150,000. vwb | |||
| 02/13/2011 | 80000 | ||
| Tl- the contact owns a 2004 ford f350 super-duty. the contact stated while driving the vehicle engine light illuminated. the vehicle was taken to the dealer whom performed a diagnosed. the failure as located at the engine head gasket. the dealer advised to permanently correct the engine head gasket failure the stud package will need to be replaced. the vehicle has not been repaired. the manufacturer declined to assist with the stud package replacement. the failure and the current mileage were 80,000. li | |||
| 06/07/2010 | 115000 | ||
| Tl-the contact owns a 2004 ford f-350 superduty. the contact stated that the nozzle on the fuel injector separated from the body of the injector which caused progressive engine damage. the contact noticed this failure when the vehicle began emitting black smoke and running rough. the vehicle was taken to an authorized dealership where the contact was informed that the engine needed to be replaced. another dealership installed the new engine which was also defective and had to be replaced due to oil being in the antifreeze. the contact called the manufacturer who offered no assistance. the vin was unavailable when the complaint was filed. the current mileage was approximately 115,800. the failure mileage was approximately 115,000-bk | |||
| 08/08/2010 | 144000 | ||
| Tl- the contact owns a 2004 ford f350 super duty. the engine head-gasket failed. the failure causes the engine to lose water. the vehicle wasn | |||
| 03/01/2010 | 127600 | 1 | |
| 3 issues: 1) vehicle stopped at red lite, foot on the brake, engine rpm suddenly increase, last time 3/4/10. 2) vehicle dies, last time died 3 time on 3/1/10, took to ford dealership, ntf 3) sudden loss of power, 3/1/10, ntf, repeated on 3/2/10, vehicle goes to idle state. *tr | |||
| 10/12/2009 | 67000 | ||
| Tl* the contact owns a 2004 ford f350 super duty. while driving 45 mph the vehicle stalled without warning. shortly afterwards while driving 20 mph the rear brakes failed. upon further inspection he noticed that the rear brake line was corroded, and that the valve cover gasket had failed. the dealer and manufacturer were contacted, but because the parts were unavailable no assistance was provided. he made the replacements himself. the current and failure mileages were 67,000. | |||
| 09/15/2008 | 66000 | 1 | |
| 2004 ford f350 crew cab diesel sat idle in driveway for approx. 6 weeks. a fire started in engine comp. while vehicle was off and unoccupied. *tr | |||
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||
| 02/15/2008 | 30000 | 3 | 06/20/2004 |
| While traveling 60 mph, the vehicle lost power but did not stall. before turbo went out the vehicle had fire sparks coming from the exhaust pipe. the vehicle was taken to the dealership where the turbo was replaced. this occurred at least three more times and the dealership reattached the hose from the turbo to the engine. as of 02/13/06 the turbo hose to intake manifold continues to blow off causing loss of power and large amount of smoke emitted from exhaust pipe. massive oil leak from engine and continued large amount of smoke from exhaust when pulling load. *tr | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 05/15/2006 | 115905 | 3 | |
| I own a 2004 f350 super duty ford 6.0 turbodiesel. i have had to replace the egr cooler three times starting in 2006. the last problem i had started out like the egr cooler then i developed and oil lose the when i ask the diesel mech. i was told the it sounded like a head gasket. that same diesel mech. informed me that in the last 5 years he himself had to repair literally hundreds of 6.0 ford diesels for the same problem. my problem is that the problems i had started after the warranty was out and i was unable to get an extended warranty on the 6.0 engine due to what the warranty agent described as a major engine development flaw by the 6.0 designers. looking on the internet i have seen thousands of complaints for the same thing. yet i have seen no help from ford. *tr | |||
| 05/02/2008 | 115000 | ||
| Tl*the contact owns a 2004 ford f350 super duty. while attempting to accelerate from a stop, the vehicle hesitated when the accelerator pedal was depressed. the instrument panel lights illuminated and then the vehicle shut off completely. the vehicle was able to be restarted. the vin was not included in nhtsa campaign id number 05v270000 (electrical system:wiring). the failure mileage was 115,000. | |||
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||
| 03/01/2011 | 4 | 12/01/2003 | |
| 2004 ford f-350 sd. consumer writes in regards to vehicle engine *tgw the consumer stated two turbochargers were replaced on the vehicle under warranty. the turbocharger needs to be replaced again. also the egr cooler, head gasket, oil cooler lines and the injectors all failed. *jb | |||
| 04/27/2004 | 10 | 12/01/2003 | |
| 2004 ford f350 truck. consumer states defective egr valve being replaced several times.*tgw the consumer stated he has been to the dealer 10 times due to numerous check engine light issues. the engine idled fast. the dealer stated it was normal as the vehicle had a hydro-boost.*jb | |||
| 03/30/2010 | 68000 | 2 | |
| I have a ford f-350 with a 6.0 diesel engine. this engine has been nothing but trouble. which creates a hazard for all who own one and to the public . this is the second time i have complained to you about this engine. why aren't you people doing something with ford and international. two times my truck has dumped half the oil out going down the road. once when the high pressure pump blew a seal and again when the oil cooler and egr cooler busted. if this truck is doing it then all the other 6.0 diesel trucks on the road are too. if you google the oil coolers and egr coolers you will see just how big the problem is. if this is not a hazard then i don't know what is. if they sold say, 300,000 of these trucks a year from 2003 to 2007 , that's 5 years times 300,000 times 5 quarts (less than half, truck holds 15 qts)5 x 300,000 x 5 = 7,500,000 qts of possible oil spilled or 1,875,000 gallons of oil spilled if these trucks only spill 5 quarts over their life time. most of the trucks will do it more than once. when the oil cooler busts the oil goes into the radiator and out the over flow into the environment. updated 05/04/10.*jb | |||
| 09/06/2004 | 8 | 09/03/2004 | |
| 2004 ford f-350 with a oil leak. consumer states that the oil leak was between the engine block and the bell housing for transmission. he states that the vehicle has been serviced 7-8 times for the same oil leak. *kb the manufacturer stated even though there was oil seepage, there was no safety or diesel engine durability issue involved. the consumer was informed the oil leak was normal. the manufacturer's opinion was that the oil was leaking from the oil pan, however, the consumer disagreed with their findings. the steering damper was replaced due to a leak. *jb | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||
| 09/19/2006 | 29868 | 1 | |
| I purchased a used ford f350 super duty 4x4 truck on 11-18-2005, from butler ford in medford or. since this purchase i have had repeated problems with the turbocharger system on this truck (check engine light on, egr valve,eec &egr , mass air flo sensor, hoses blowing off turbo charger) i have taken this truck to be repaired many times at multiple ford dealerships across the united states ( i was on a vacation, and had continual problems with the hoses blowing off the turbocharger) at the last repair attempt i was told that ford motor co. was replacing turbochargers on these trucks. i had the turbocharger replaced and had the truck about 1 week when the check engine light came on again , i returned the truck to the dealer repair shop(300.00 in fees again!) when the truck was returned to me i took a trip, approximately 400 miles and again the check engine light is on. each time this check engine light comes on i have problems with the hoses connecting the turbocharger to the engine manifold blowing off, the truck looses power stranding me on the road. i have had to replace the hoses on my own to continue driving this truck. the last incident i had with this problem i was almost hit by a logging truck while trying to direct traffic around my disabled truck, the trucker who almost hit me called the oregon state police and i was told to remove the truck from the highway or i would receive a citation for having an unsafe vehicle . i have tried to resolve this problem with ford motor co. customer relations center .when i contact them they tell me there is nothing they can do about this problem even though this truck was still under warranty when it was purchased and has had repeated repair attempts for the same problem. *tr | |||