Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING
04160111/14/20050522810018745Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running. *tt01/12/2006
022202/04/2002630628Some vehicles may exhibit an intake manifold crossover (first runner) coolant seepage condition. *tt04/19/2002
1318609/01/19996090542Information regarding front cover & water pump bolts-torque valve revision/3.8-4.2l. *mjs03/21/2000
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
03140408/23/20040416110011162Engine misfire or running - coil on plug (cop) ignition systems - wds cop kit diagnostic tips. to include various 2005 models. * ar this article 04161 supersedes tsb 03-14-04.01/06/2005
1638011/01/200210008319Service cylinder head gasket for 4.6l applications. *tt07/27/2004
0222111/11/200210008304Engine-gear driven synchronizers-incorrect installation-camshaft position synchronizer (cmp) installation tool correct application. *mj07/27/2004
0314407/21/200310003744Engine misfire or rough running condition with coil on plug (cop) ignition systems may be more accurately diagnosed using the optional worldwide diagnostic system (wds) coil on plug (cop) kit. 2003 super duty f series included. *tt10/29/2003
1452001/01/2000620471Subject regarding installation of crankshaft pulley torque specification. *tt08/09/2001
1486404/01/2001619335Subject regarding certain vehicles with 4.6l romeo engines exhibiting an oil leak from the cylinder head gasket area. *tt05/23/2001
1452012/01/2000616835Information pertaining to 4.6l 4v pulley instructions. *tt03/13/2001
1318109/01/19996090540Information regarding camshaft position (cmp) sensor alignment tool chart (continued). *mjs03/21/2000
699609/01/19996090309Information regarding a change in the torque values of the engine front cover water pump bolts. *tt03/14/2000
699709/01/19996090310Some service manuals may list the incorrect camshaft position sensor alignment tool for vehicles with various engine sizes. *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
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
1443901/01/2000620449Some vehicles equipped with a 3.8l engine may exhibit spark knock on heavy accel with 87 octane fuel. hot weather and lower octane fuel may exaggerate the condition. *tt08/08/2001
1398703/01/2001620289Some vehicles equipped with 3.8l engines may exhibit engine spark knock on heavy acceleration with 87 octane fuel. hot weather and lower octaine fuel can contribute to the cause of a slight knock on heavy acceleration. though no damage07/24/2001
014703/05/2001619424Subject regarding engine oil recommendations for use in 2001 vehicles - sae 5w-20 motor oil. *tt05/30/2001
011901/22/2001618080Some vehicles may exhibit a hesitation and in some cases engine backfiring through the induction system on cold starts (27 degrees c / 80 degrees f) with no diagnostic trouble codes present. *tt04/03/2001
1453812/01/2000616990Some police interceptors may exhibit poor acceleration at wide open throttle after the 3-4 shift from 110 mph up to the vehicle speed limiter (130 mph). *tt03/14/2001
1217411/01/1998613224Some vehicles may exhibit a hard start/long crank, cold start stall, cold rough idle concern. *mjs06/19/2000
837303/01/2000612769Some vehicles equipped with 3.8l engines may exhibit engine spark knock on heavy acceleration with 87 octane fuel. *tt06/12/2000
99610805/01/1999606971Conditions with a hard start or diagnostic trouble code (dtc) p1233. *tt09/08/1999
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
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
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
04100311/01/20040421610013368Exhaust leak - cracked or separated right side exhaust pipe - 3.8l and 3.9l engines. *tt04/15/2005
0410305/31/200410008992Exhaust leak. right side exhaust pipe on 3.8l or 3.9l engine. *tt09/07/2004
98201010/12/1998603695Experiencing a buzzing or rattling noise from the exhaust system. *yc03/02/1999
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
98231011/23/1998603724Mass air flow (maf)- sensor contamination- service tip. *ak03/03/1999
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR
CSP-08B0105/16/200810026389Ford: certain 1999-2001 model year vehicles up to 6000 lb gvwr registered in new york and certain 2001 vehicles up to 6000 lb gvwr registered in the state of maine, certified for sale in california-federal emission warranty refund. *pe10/23/2008
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
01/03/200553396308/29/2000
 On january 3, 2005, the heater core on my 1999 mustang had to be completely replaced, including the thermostat. the windows had fogged up before and the car smelled like syrup but i thought it was just vents. the heating core had to be replaced and the coolant had to be recharged and replaced also this came up to $700 dollars. on august 16 2005, 2 weeks after changing the coolant the water pump had to be replaced, once again the system had to be flushed the cost was$400. on july 2006 i had the coolant system flushed and changed, 1 month after the coolant was changed the windows starting fogging up, i was driving my vehicle and i was unable to get a clear view of the road due to the foggy windows, the heating core once again has to be replaced, is going to cost me another $600 dollars to fix this, i have all of the paperwork from firestone, i have kept up with all of the maintenance required by the manufacturer. *jb
05/07/2003
 When the consumer started his vehile in vehicle in the morning it was very loud for about 15-20 minutes. he also stated that when he made a right turn there was a loud knocking noise. the vehicle was taken to a mechanic who thought the problem was the manifold heater valve. *nlm
ENGINE AND ENGINE COOLING - COOLING SYSTEM
04/04/201167000
 Tl*the contact owns a 1999 ford mustang. the contact stated the vehicle had a cracked manifold and it was leaking antifreeze. the vehicle was taken to a mechanic who stated that the manifold needed to be replaced. the dealer was contacted and offered no assistance. the manufacturer informed him that there were no recalls or warranties and offered no assistance. the failure mileage was 67,000.
04/04/201167000
 Tl-the contact owns a 1999 ford mustang. the contact stated the vehicle has a cracked manifold and it is leaking antifreeze. the vehicle was taken to a mechanic who stated the manifold needed to be replaced. the dealer was contacted and offered no assistance. the manufacturer was contacted and informed him there are no recalls or warranty and offered no other assistance. the failure mileage was 67,000...mw
ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY
1
 Radiator leaks. mjs
ENGINE AND ENGINE COOLING - ENGINE
03/11/2004590001004/14/1999
 I have a 1999 mustang 3.8l-v6. recently, the car began to expel a white vapor from the tailpipe when the engine is hot, along with a vibration noise. this has happened as many as 2-3 times per day. i took the car to a ford dealer for service and replaced an air pump. this did not correct the problem. i did some research on the internet and found that many people have had the same problem which turned out to be due to blown head gaskets. i discussed that issue with the dealer representative and they said that there is no record of that kind of problem with a 1999 mustang. i have found that this is not true.
07/20/2002108/01/1999
 Vehicle would vibrate severely when driving. intermittently transmission would not go into gear. dealer contacted.*ak the dealer could not understand how the transmission had no leaks but was out of transmission fluid. this vehicle has had 2 blown head gaskets, the rear seal in the motor was replaced, the heater core, the transmission, and the catalytic convertor have all been replaced. *jg
03/01/2001
 Vehicle started to overheat while driving, dealer determined headgasket was blown and rear seal of engine had to be replaced.*ak
05/10/1999102/01/1999
 The pulley slides on to an aluminum sleeve that is part of the front plate on the engine. i was doing a routine inspection when i noticed the pulley slightly tilted. i applied pressure to the belt and was able to pull the pulley, bolt that goes into the plate to hold the pulley on, and the metal sleeve that was broken off of the front engine plate. if this pulley would have came off, the belt would have been instantly frayed by an adjacent engine component resulting in loss of control of the vehicle and possibly power steering. i contacted ford and they told me there were no reports, recalls, or factory defects. i appreciate any assistance you can provide in letting me know if this is a factory defect or just shoddy workmanship in my particular vehicle. my home number is 011-49-6333-980903. i live in germany. thank you for any assistance you provide. *ak
105/18/1999
 Idler pulley missing. nlm
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
02/01/20013006/01/2000
 Car stalls when starting on a cold engine regardless of outside temp. something sticks under hood. if you hold your foot on accelerator, it will stay running but will abruptly die when let off pedal. even if you start driving, it can still stick, causing engine shutoff while moving resulting in loss of p. steering, brakes, etc., has been in under warranty once, was not fixed. does this on about 1 out of 10 cold starts randomly. have heard numerous complaints about this from other mustang owners. needs to be a recall !*ak
403/01/2002
 Car will kill at 10 mph all of a sudden and leave me wit no brakes or steering. *ak
502/01/2000
 Applying brakes the engine will stall and kill suddenly and the power stearing and breaking will not work. *ak
 While driving at any speed vehicle completely shutdown without warning, nearly causing several collisions. cause unknown. dealer cannot identify cause. please give any further details. *ak
03/21/200109/01/1999
 Ford mustang conv. 1999 3.8 liter engine. reported engine problems/acceleration probs 3 times to dealerships ( one time to another dealership outside ford jurisdiction that noticed excessive gasket leakage) before 12,000 miles. finally, after not being able to find problem all dealership visits, finally replaced w/ refurbished engine demonstrating same problem at 31207 miles approximately. (please note- it appears as though dealership on two occasions tried to change the problems i notated to the dealership when i told the representative my complaints. gave me back invoice two times with modifications that were not original complaint! on the second time- tracked down the manager and complained directly and asked why the dealership had done this. he had no answer for this employees action.) the only difference with the new refurbished engine is that there is no burning smell and the engine unexpectedly vibrates so violently that the whole car shakes and gearshift vibrates to and fro violently- the initial acceleration complaint remains. the violent engine shaking does not happen all the time. this new engine has been installed only 3 days. transmission/ clutch assembly- gasket replacement (excessive burning smell in vehicle). no coating under vehicle to protect interior components- dealership fixed. inside of windshield cracked/ chipped internally- no apparent reason. vehicle is garage kept. brake assembly replaced per recall. interior dashboard loses color- replaced two times. convertible top apparatus-excessive rust- needs replacement. cd player stopped working since 20,000 miles but had replaced due to time constraints at 30,000 miles. convertible roof gasket- replaced due to defect. there are other problems but i am sick of typing. this is absolutely the worst ford product i have ever purchased. not only that, but the delray lincoln/mercury repair department appears corrupt. i wonder if they have to pay for the repairs and what their incentives are for ly
09/01/1999
 I took the car back to the dealership 2 days after purchased and asked for another car the car's doors were out of line there was paint missing the windsheld had a crack on it from the factory. i always changed my oil every 3000 miles and the guy would ask why it was low but, said it wasn't dangleous low so i thought it was normal. come to realize it was using oil. now the top is leaking. all i wanted was for them to get me another car from day 2 and they said it was mine it had already been titled to me and would cost me to get into another car. the dealership wouldn't call me back after i informed them of the problem after a month i called them back and asked when they was going to fix my car, i felt like they had sold it to me now it was my problem and it has been a big problem since i got it. this was the 3rd car i had purchased from this company and that didn't matter. the heck with you its yours is how i felt they were telling me. i have been trying to get them to do something for a year and a half telling everyone i know but, i can't seem to get anywhere. if you know someone who can help with this problem please call me. i don't want this to happen to anyone one else. i wouldn't wish this pain on anyone!!! the car was sold to me new but, it had almost 200 miles on it . there two slips in my car where a girl had driven it on 2 seperate times. if anyone can help please call me 336-681-0224. i don't know where to turn.
09/01/199906/01/1999
 No summary listed for above vehicle. *ak
06/23/2000
 Intermittently when driving vehicle stalls and dies without warning. dealer has duplicated the problem. however, problem has not been corrected.*ak
09/14/1999404/01/1999
 3.8l engine replaced by dealer, replacement engine same problems. *ak
02/02/2000
 When applying brakes the vehicle would suddenly stall, and power brakes would go out completly. driver could not stop at all. *ak
08/07/1999506/01/1999
 3 problems, brakes shudder and car jumps forward upon braking, upon acceleration when foot remove from gas pedal car continues to accelerate, lights on dash board randomly go off and on ie. o/d light and service engine light.
07/07/199920003/01/1999
 Engine has constant problem of stalling missfiring,hesitates,loss of power,always in and out of dealership they cannot fix problem. stalled one time in middle of busy intersection.
7
 When driving the vehicle at any given time and speed the engine will stall out and the power brakes and steering will also cut off. dealer has seen vehicle about 7 times, and problem can't be duplicated. *ak
4
 Vehicle has had continual problems with the engine, misfires, hesitates, loses power, stalls and idles hard. mjs
 Vehicle keeps misfiring and then it stalls. dealer cannot fix defect. *ak
 With brake to the floorboard engine idles without indications. vehicle accelerates own it's own. speed/idle is not reduced when foot is removed from gas pedal. vehicle remains with dealer because cause cannot be determined and repairs cannot be made. *ak
05/05/199905/01/1999
 The docks in this engine set up a harmonic vibration between 1800-2300rpm. ford has determined this is a normal condition for some of these engines. to the unsuspecting buyer of this automobile he/she will have to endure a melodic, approx every second, vibration that is transmitted through the car. from what i have read on various bulletin boards this problem was brought to ford's attention prior to my purchase but they still continue to produce the automobile and now have concluded this is normal. please look into this for those of us who have been taken advantage off. sincerely, bill chase. *ak
02/16/1999402/10/1999
 Vehicle intermittently cuts off. vehicle has been in /out of dealer shop on four occasions, and problem still occurring. also, remote control keys for car do not work. *ak
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS
105/18/1999
 Serpentine belt coming apart was chaffing into the timing chain cover. nlm
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
05/20/2002500001005/10/2002
 Check engine light stays on constantly. engines idles rough and stales at about 1500 rpm's. if you turn on the heater or ac. the problem gets worse. i scanned the car and got a misfire code and an egr code. replaced all ignition parts and all emission parts and the code and problem won't go away. help please. any info can be sent to skippema@yahoo.com thanks
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR
07/20/2002108/01/1999
 Vehicle would vibrate severely when driving. intermittently transmission would not go into gear. dealer contacted.*ak the dealer could not understand how the transmission had no leaks but was out of transmission fluid. this vehicle has had 2 blown head gaskets, the rear seal in the motor was replaced, the heater core, the transmission, and the catalytic convertor have all been replaced. *jg
07/11/200104/01/1999
 Egr system caused buck or skip feeling. has been in and out of verious dealers since purchase date. other dealers have experienced same problem with no resolutions. will provide more details if needed.*ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE)
204/21/1999
 Egr tube replaced. *mjs
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
07/25/200365000102/05/2000
 Dt: caller's says vehicle had a cracked manifold intake. caller believed this part should not break down. dealer and manufacturer did offer him any help. caller had to replace the gasket two years ago, and it was getting worse all the time. *ak *nm
05/20/20031
 The exhaust manifold was cracked when the vehicle started to lose power and made a loud noise as if the muffler had fallen off. also, there was a rust spot on the roof of the vehicle. *jb