Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING
022202/04/2002630628Some vehicles may exhibit an intake manifold crossover (first runner) coolant seepage condition. *tt04/19/2002
99B2912/01/1999612219Some vehicles may experience engine coolant leaks at the engine front cover gasket. owner notification program providing replacement of the engine front cover gasket. *tt06/07/2000
1318609/01/19996090542Information regarding front cover & water pump bolts-torque valve revision/3.8-4.2l. *mjs03/21/2000
9920710/04/19996089651Subject on engine coolant leaking into the engine oil on some vehicles. *tt02/11/2000
9913106/28/1999606484Concerns with engine coolant leaking into engine oil on some vehicles. *tt08/25/1999
ENGINE AND ENGINE COOLING - COOLING SYSTEM - FAN
BC103139702002/01/199751771Vehicles built between 8/15/96 and 11/4/96 may experience a concern with the cooling fan to the electric motor retainer coming loose or separting. *jd07/17/1997
BC313397022102/21/199751723Concern of cooling fan to electric motor coming loose. *tw06/27/1997
ENGINE AND ENGINE COOLING - ENGINE
0721210/01/200710023943Some 1997-2008 vehicles equipped with a 4.6l 2v, 5.4l 2v, or 6.8l 2v engine--spark plug thread repair procedure--not covered under new vehicle limited warranty. *nj this includes f-53 motorhome chassis. updated 2/23/10. *pe02/20/2008
0222111/11/200210008304Engine-gear driven synchronizers-incorrect installation-camshaft position synchronizer (cmp) installation tool correct application. *mj07/27/2004
87019710/22/200210000592Incorrectly installed gear driven camshaft position (cmp) sensor synchronizer assemblies causing surge, lost of power, malfunction indicator lamp on and diagnostic trouble codes p1336, p1309 and p0340. *tt03/25/2003
1452001/01/2000620471Subject regarding installation of crankshaft pulley torque specification. *tt08/09/2001
1452012/01/2000616835Information pertaining to 4.6l 4v pulley instructions. *tt03/13/2001
99B29#104/01/200099B29613562Information regarding replacment of engine front cover gasket. **mr07/21/2000
1318009/01/19996090538Information regarding camshaft position (cmp) sensor alignment tool chart. *mjs03/21/2000
699709/01/19996090310Some service manuals may list the incorrect camshaft position sensor alignment tool for vehicles with various engine sizes. *tt03/14/2000
699609/01/19996090309Information regarding a change in the torque values of the engine front cover water pump bolts. *tt03/14/2000
99679508/01/1999608762Subject regarding vehicles equipped with 4.6l engine regardless of transmission, may exhibit a (front end accessory drive (fead) belt- belt noise, damage, and / or belt comes off). *tt12/03/1999
987404/13/1998601343A new silicone gasket and sealant. *yc07/24/1998
9761003/17/199751990Blower motor- chirping or squeaking from blower motor at low speeds. *jd07/17/1997
BC035197230101/23/199751439An engine oil leak at the rear crankshaft oil seal. *jd06/27/1997
BC035196112611/26/199650743Ford improvement program request for information on oil leak at the rear crankshaft oil seal. *tw06/17/1997
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
0124612/10/2001630515Engine oil system priming procedures, service tips for reports of premature engine failure. *tt04/18/2002
021401/21/2002630001Some engine assemblies with aluminum cylinder heads repaired in-vehile have been found to leak coolant and/or oil from the cylinder head gasket area. *tt04/11/2002
0120510/15/2001627927Some vehicles may exhibit vacuum or air leaks in the intake manifold and / or engine system causing diagnostic trouble codes p0171 and or p0174. *tt02/26/2002
1515808/01/2001624571Some vehicles may exhibit a fead belt jump-off toss. *yh11/07/2001
014703/05/2001619424Subject regarding engine oil recommendations for use in 2001 vehicles - sae 5w-20 motor oil. *tt05/30/2001
98310802/01/1998607402Effective march 2, 1998m3.8l engine assembly is added to fqr(ford quality renewal) assembly program. *ak12/21/2000
1153004/01/1998613794When diagnosing crank / no start on certain vehicles equipped with passive anti-theft (pats) check the customers key ring for any magnetic objects like the mobile speedpass key which may affect the signal transmission between the pats key a08/03/2000
1217411/01/1998613224Some vehicles may exhibit a hard start/long crank, cold start stall, cold rough idle concern. *mjs06/19/2000
98310702/25/1998607401Brief information regarding engines being added to the fqr (ford quality renewal) assembly program. *tt09/22/1999
9981605/03/1999606420Ford motor company now recommends sae 5w-30 viscosity grade for servicing any ford gasoline-powered vehicle regardless of model year. *tt08/19/1999
BC035197020101/02/199751132Engine oil leak at the rear crankshaft oil seal. *jd06/27/1997
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS
1277105/01/19996092663Some vehicles with a manual transmission may exhibit a fead belt concern (front end accessory drive). *tt01/24/2001
1306108/01/19996091860Some vehicles may exhibit a front end accessory drive (fead) belt toss. *tt11/15/2000
631406/01/1999606793Some vehicles with manual transmission may exhibit a fed belt concern. *tt11/08/2000
99679508/01/1999608762Subject regarding vehicles equipped with 4.6l engine regardless of transmission, may exhibit a (front end accessory drive (fead) belt- belt noise, damage, and / or belt comes off). *tt12/03/1999
98201810/12/1998603703The front end accessory drive ( fead ) belt may become broken or frayed and / or detach from ( or roll off of) the engine. *yc03/02/1999
BC328897020602/06/199751884Vehicles may exhibit a cold start engine fead belt chirp noise. *tw07/17/1997
BC031496110111/01/199650722Serpentine accessory drive belt roll-off or loss of alignment. *tw06/17/1997
BC969096100110/01/199650548Vehicles equipped w/ a manual trans, the accessory drive belt may come off of the pulleys under high rpm conditions. *tt05/27/1997
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
1207311/01/1998613050Vehicles with federal emission equipped 1998, may exhibit a fuel smell in the passenger compartment at times. *mjs06/16/2000
98201010/12/1998603695Experiencing a buzzing or rattling noise from the exhaust system. *yc03/02/1999
986403/30/1998601312Information on a buzzing or rattle noise from the exhaust system. *tt07/21/1998
BC049096111211/12/199650763Instructions for replacing diagnosed failed component. *tw06/17/1997
BC040796111511/15/199650753Instructions for replacing diagnosed failed parts. *tw06/17/1997
BC971496110111/01/199650860Diagnostic instructions for servicing evaporative emission purge flow system. *tw06/17/1997
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
503111/01/1998613072Some vehicles and certain federal emission equipped vehicles may exhibit a fuel smell in the passenger compartment at times. *tt06/16/2000
98231011/23/1998603724Mass air flow (maf)- sensor contamination- service tip. *ak03/03/1999
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
05N0412/14/200510018959Extended coverage program 05n04 - extended coverage for composite intake manifold. this program is being provided as a settlement to a class action lawsuit. the terms of the settlement extend the coverage of the all-composite intake manif01/25/2006

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
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 - 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
10/25/2007821005003/01/2000
 I have been having a problem with my 1997 ford mustang. this is a problem that has gotten progressively worse over the past few years. at first, when starting my car, the engine would turn over yet the car would immediately die. after a couple of attempts, the car would eventually start and stay started. now, when attempting to start my car, the engine turns over yet the car dies immediately. in most cases, the car does not start until it has been serviced. it has been taken to 3 service providers (including ford), who have been unable to duplicate and/or fix the problem. recently, ford replaced my air flow valve and sensor and just after picking the car up and driving it for about 30 minutes, i went into a store just to come out and find that my car won't start. once started the car always continues to run with no problem. please please help! *tr
ENGINE AND ENGINE COOLING - COOLING SYSTEM
09/12/200105/01/1997
 Subject: 1997 ford mustang gt, vehicle id 1falp42x5vf110479. no safety defect. *ak
07/17/2001102/01/1997
 This car was bought with an extended warranty which never honored by the dealer. ford replaced (fired) the general manager of this dealership for dishonest practices. the car was purchased 5/97 with 13001 miles on it we picked up the extended warranty at time of purchase as per statement of general manager at the time. no safety defect listed in summary. *ak
2
 The heater failed vehicle overheated and cracked the aluminum head.*et
12/06/1999102/01/1999
 1. spark plug wire clamps not staying connected to spark plugs causing arcing and damage to 5 spark plug wires. 2. rupture of coolant crossover tube on front of intake manifold resulted in almost total loss of coolant on about a one block length of road at approximately 35mph. recall 97m91 had been previously investigated (feb. 1999) with no damage found. failure occurred in dec. 1999.
12/01/19971
 Vehicle experiencing a coolant leak. nlm
03/12/199903/01/1999
 No summary listed for this vehicle. *ak
ENGINE AND ENGINE COOLING - COOLING SYSTEM - FAN
10/01/2001202/01/1998
 While driving, vehicle began to overheat, the engine cooling fan caught on fire and exploded. consumer purchased a new cooling fan but the vehicle continues to overheat and smoke. the service manager explained that the bearings had seized and the vehicle was in need of a new engine. there is a recall on said part but this vehicle is not included. *jg
08/11/1998104/24/1997
 Engine fan failed causing steam to come from under the hood. nlm
ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY
11/03/1997
 Vehicle overheats daily.
ENGINE AND ENGINE COOLING - ENGINE
09/07/2010150000
 Tl- the contact owns a 1997 ford mustang . the contact stated that the intake manifold is cracked and is causing coolant to leak . the contact stated that it is a design flaw and that its made out of plastic. the dealer was contacted and they stated that they could not see any vehicles past 10 years. this will be the second manifold that will have to be replaced. there have been no repairs. the failure and the current mileage was 150000.cv
11/20/2004105600107/15/2003
 Excessive rattling..rough idle..while engine is running..a slight humming can be heard over the dual exhaust..nothing major has happened as of yet.*ak
08/18/2003112750304/22/1998
 Head gaskets blown causing the upper radiator hose to swell and rub the air conditioning compressor clutch. the hole in the hose caused all the coolant to leak out and causing a misfire in the engine. the head gaskets were blown on three of the six cylinders. the engine is a 3.8l v6 in a 1997 mustang.*ak
11/15/2002
 While driving at 65 mph the vehicle started over heating. consumer had vehicle serviced by a mechaninc who informed him that the the head gasket had blown and leaked water into the engine. the mechanic also indicated that this is a very common problem. ts
02/25/2002111/06/1997
 Engine is leaking radiator fluid, caused by a crack, heater is taking longer to get warm. dealer stated that oil may cause engine to lock up. vehicle was diagnosed by the service techniciian at dealer. *ak. consumer stated radiator fluid is leaking from the front valve cover, which is also causing loss of heat.*jb
02/01/200208/01/1997
 Timing cover gasket leaking may lead to head gasket problem.. *ak
06/01/1999311/06/1996
 With 60,000 miles on vehicle head gasket blewout, and had to be replaced at consumers expense by dealership. then 4,000 miles later, timing gasket blewout which was covered under a manufacturer service program. then, with 68,000 miles on vehicle, it started vibrating while traveling at approximately 65 mph, and revved to over 6000 rpm. consumer pulled to the side of road where engine stopped working. 3.8 liter v6 engine had to be replaced by the dealership because of complete failure. *ak air conditioner would lose power after 45 minutes of operation, dealer stated an accumulater and orifice tube was needed. the connector to the cruise control system was cracked almost in half causing the cable to disengage from the cruise control system. *slc
05/29/200106/01/1998
 Engine light keeps coming on. people with 97 mustangs are having problems all over the internet with there head gaskets cracking and engine lights coming on due to engine problems. mine only has 44,900 miles! do something. *ak
03/30/2001
 Front timing gasket failed, causing loss of coolant from 3.8l v6 engine. dealer notifed, and informed consumer that vehicle was out of its warranty, and not covered under a manufacturer's recall. feel free to provide any further details on this matter. *ak
03/05/20010
 Antifreeze drips out from defective timing cover, and starts causing a burning smell, and severe engine damage. consumer feels fumes are dangerous. *ak
1
 The vehicle is leaking coolant due to the faulty timing valve gasket. *slc
06/18/2000110/01/1999
 Timing cover is also leaking and saw on the internet that that can also cause major damage. *ak
07/20/2000
 Vehicle broke down from engine stalling. consumer found out through the dealer that there was a manufacturer's recall 99b29. but this vehicle was not included due to vin. dealer said it was the timing gasket cover. *ak
12/10/1997105/30/1997
 Engine pings under load and/or acceleration between roughly 3,500 and 4,700 rpms.
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
06/16/19991006/01/1997
 No summary listed for above vehicle. *ak
02/27/200006/01/1997
 Recall is for mustangs made prior to dec. 31, 1996 although later more recent models have the same problem. no safety defect listed in summary. *ak
6
 The check engine light stays on in the car, and the engine keeps missing, consumer took it to ford 5 times and private mechanic 6 times, no one can figure out what's wrong with it.*et
05/01/1999311/01/1996
 Engine head gaskets, timing gasket cap, and engine itself all failed on a 1997 ford mustang lx coupe
07/20/2000
 Vehicle broke down from engine stalling. consumer found out through the dealer that there was a manufacturer's recall 99b29. but this vehicle was not included due to vin. dealer said it was the timing gasket cover. *ak
12/21/1998204/01/1998
 No summary
104/24/1997
 Engine overheated causing a/c to shut off. nlm
10/14/19971009/01/1997
 Suspension pulls to the left. transmission would not go into reverse or grinds. engine loses power with engine light on. brakes pads on left side metal to metal. second brake job. all problems still existas.
12/01/199706/01/1997
 When driving at any speed there is some knocking noise coming from vehicle and vehicle is stalling. also, engine check light keeps coming on. consumer can't determine the problem. *ak
08/29/1998506/01/1997
 @ 7000 miles the transmission assembly went out & had to be replaced. at 14000 miles front end misaligned, needed 2 new front tires & alignment, @ 21000 miles drivers window quit, @ 21797 brakes began grinding needed replacement pads,@ 21000 miles engine started spark knocking & continues to date. 5 attempts to correct not corrected.@27,462 miles dealer decarboned engine & again 300 miles later. still spark knocking. begining lemon law processes 3/28/99. *ak( dot number: )
01/03/1999111/01/1996
 Car had been running hot with anit-freeze in engine. car finally over heated and was taken to bp gas station, 4499 roswell rd., atlanta ga 30342, 404/255-5341 or 404/252-8204 chuck allen manager mr. allen 1st said timing gasket failed & would cost $200 to fix. then when he removed timing cover found a major crack in it next to a bolt hole, stress point & that it would cost over $500 to fix now. also stated that this fairly new car with low miles should not be having this kind of problem and that it is more than likely a defect from manfacturer. car had been to banner ford, 1665 scott blvd, decatur ga 30033, 404/633-4005, stephen c. watson, sr. on 08/18/98 with 34,143 miles car still under a 3y/36m warranty for running hot & stalling in traffic. they replaced fule gage tank unit, but should have noticed oil & anti-freez dripping did nothing. 10/24/98 car back to banner 36,440 miles 440 miles over warranty - they gave an oil change & top off fluids again the fact that the car is dripping oil & anti-freeze has not been either noticed or just not mentioned & reported. two months later the engine finally gives out and the cars is 2,100 miles over warranty & the dealership, tidwell, where purchased svc manager says i'm out of luck and with an attitude! could you please investigate or advise me, sincerely,.......shelby pease
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR
11/13/1997
 There is a strong fuel smell in the cab of vehicle states' consumer. catalytic converter has been changed twice. problem with smell still exist. please describe further. ts
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
06/26/20041
 While driving 40 mph consumer noticed fluid leaking from underneath the vehicle. consumer was able to maintain control of vehicle, and drove it to the dealer for inspection. mechanic determined that intake manifold needed to be replaced due to a blowout. *ak
12/17/20031
 The consumer took vehicle into be inspected, and mechanic noticed that the plastic intake manifold cracked, causing fluid to leak onto the engine. *ak
1
 Consumer was having a problem with intake manifold that was made of plastic. he had to have it replaced with the retro fit manifold which was aluminum and plastic. consumer found a recall on the internet dealing with intake manifold, and took the vehicle to a dealer to have it repaired, but ford would not repair it. consumer spent over $600.00 for repairs. did not think this was fair since ford knew the problem.*ak