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
1664402/01/200310002509Some vehicles equipped with a 3.8l engine and the t5 transmission may exhibit high idle between shifts. *tt09/04/2003
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
00260612/01/2000617219Subject regarding oil pump liquid injection seal (lis) gasket service procedures. *tt03/14/2001
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
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
1489205/01/2001620177Information pertaining to heater case replacement service tip. *tt07/19/2001
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
0026612/25/2000616831Some 3.8l engines may have oil pumps built with a new sealing process called liquid injection sealing (lis). *tt03/13/2001
837303/01/2000612769Some vehicles equipped with 3.8l engines may exhibit engine spark knock on heavy acceleration with 87 octane fuel. *tt06/12/2000
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
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
12/02/2011140000
 So i thought i had a simple thermostat issue. went to change the thermostat and noticed the manifold housing (plastic) had a nice crack in it. when doing research on this, i noticed there have been numerous complaints/instances of this happening to other people. now i am in the process of finding a new intake manifold and will have to pay to have it installed. this seems to be an issue that the department of transportation should be involved in. poor manufacture design with numerous incidents of failure that result in unnecessary high repair costs placed on the consumer. i am the original owner of this vehicle and think it is rediculous!
12/02/2011140000
 So i thought i had a simple thermostat issue. went to change the thermostat and noticed the manifold housing (plastic) had a nice crack in it. when doing research on this, i noticed there have been numerous complaints/instances of this happening to other people. now i am in the process of finding a new intake manifold and will have to pay to have it installed. this seems to be an issue that the department of transportation should be involved in. poor manufacture design with numerous incidents of failure that result in unnecessary high repair costs placed on the consumer. i am the original owner of this vehicle and think it is rediculous!
12/02/2011140000
 So i thought i had a simple thermostat issue. went to change the thermostat and noticed the manifold housing (plastic) had a nice crack in it. when doing research on this, i noticed there have been numerous complaints/instances of this happening to other people. now i am in the process of finding a new intake manifold and will have to pay to have it installed. this seems to be an issue that the department of transportation should be involved in. poor manufacture design with numerous incidents of failure that result in unnecessary high repair costs placed on the consumer. i am the original owner of this vehicle and think it is rediculous!
12/02/2011140000
 So i thought i had a simple thermostat issue. went to change the thermostat and noticed the manifold housing (plastic) had a nice crack in it. when doing research on this, i noticed there have been numerous complaints/instances of this happening to other people. now i am in the process of finding a new intake manifold and will have to pay to have it installed. this seems to be an issue that the department of transportation should be involved in. poor manufacture design with numerous incidents of failure that result in unnecessary high repair costs placed on the consumer. i am the original owner of this vehicle and think it is rediculous!
12/02/2011140000
 So i thought i had a simple thermostat issue. went to change the thermostat and noticed the manifold housing (plastic) had a nice crack in it. when doing research on this, i noticed there have been numerous complaints/instances of this happening to other people. now i am in the process of finding a new intake manifold and will have to pay to have it installed. this seems to be an issue that the department of transportation should be involved in. poor manufacture design with numerous incidents of failure that result in unnecessary high repair costs placed on the consumer. i am the original owner of this vehicle and think it is rediculous!
12/02/2011140000
 So i thought i had a simple thermostat issue. went to change the thermostat and noticed the manifold housing (plastic) had a nice crack in it. when doing research on this, i noticed there have been numerous complaints/instances of this happening to other people. now i am in the process of finding a new intake manifold and will have to pay to have it installed. this seems to be an issue that the department of transportation should be involved in. poor manufacture design with numerous incidents of failure that result in unnecessary high repair costs placed on the consumer. i am the original owner of this vehicle and think it is rediculous!
10/15/20034
 While driving at an undetermined speed engine check light appeared. consumer contacted dealership on four separate occasions, but problem recurred. *ak
ENGINE AND ENGINE COOLING - COOLING SYSTEM
110/22/1999
 Consumer states she has had to take vehicle in for several repairs, she experienced a burning smell and smoke coming from the engine, which resulted in oil getting on the engine due to dealer leaving the oil cap off, also water pump had to replaced, as well as the rocker arm gasket. *jb
110/22/1999
 Consumer states she has had to take vehicle in for several repairs, she experienced a burning smell and smoke coming from the engine, which resulted in oil getting on the engine due to dealer leaving the oil cap off, also water pump had to replaced, as well as the rocker arm gasket. *jb
ENGINE AND ENGINE COOLING - ENGINE
01/25/200866500109/20/2003
 Apparent head gasket leak - loosing coolant through exhaust on 2000 mustang with 3.8 liter engine. this is a know issue with mid 90's 3.8 ford engines and still seems to be an issue. *tr
12/15/200569990111/20/2000
 I have a 2000 ford 3.8 liter mustang. it has a vibration and covert ford says its needs new motor. i bought this car new, took great care of motor, it just turned 70,000 miles. covert says it has excessive end play on the crankshaft due to wear. i think i have an american-made problem. 70,000 miles???? thanks for any help that you can give me. they want $4,600.00. i think ford owes me most of that at the very least because i sure can't afford to fix it. you know its funny also because up to this point that car had never broken down and had never been in the shop . this is other than 15 oil changes two batteries and two sets of tires... i just think its not normal. please help with suggestion. *jb
5
 Consumer stated while traveling, the engine stalled. vehicle is now in its fifth repair. dealer has been contacted. please provided any further information. *ph
05/13/200230500506/01/2000
 The problem is the engine stalls. this happens when the engine is warm or cold. it also happens after the clutch has been disengaged after being at speed and the rpms are decreasing to the programmed idle rpm. however, instead of stopping at the idling rpm, the engine rpm dips to low and the engine stalls. i lose power steering and brakes which cause a very dangerous situation. i also noticed that this happens more often if i am going around a turn or turning on the ac (both items require more power from the engine)while disengaging the clutch. in total, this has happened 5 times during the 30500 miles. *ts *jb ****dimsii ivoq entry posted after 12-12-02 cut over to artemis****761876
2
 Valve cover failed, due to carbon build up in the intake manifold. *yh
110/22/1999
 Consumer states she has had to take vehicle in for several repairs, she experienced a burning smell and smoke coming from the engine, which resulted in oil getting on the engine due to dealer leaving the oil cap off, also water pump had to replaced, as well as the rocker arm gasket. *jb
110/22/1999
 Consumer states there was a loud cranking noise under the vehicle, dealer replaced the motor mounts. *jb
06/01/20000
 Consumer was traveling about 45mph on the highway, applied clutch and power went out. no power steering/no brakes. no prior warning. vehicle just stopped. vehicle was at the dealership . mechanic could not duplicate the problem on the diagnostic machine.*ak
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
12/09/200591000108/28/2004
 Took my 2000 mustang to the dealer to repair a knocking problem i was hearing when the car accelerated. eventually after 3 visits and talking to 3 service advisors the knocking was heard. they replaced $1300 worth of parts, and said it was fixed. drove it no more than 10 minutes and took it right back because the knocking was not fixed. they then told me that the motor was something inside the motor. so i had it replaced. was returned 1 week later due to a problem with it staying running. the problem was identified as a rocker arm that had come loose. the car was returned 2 weeks later for the same knocking issue that was originally reported and no one knew what is wrong with it.*ak
07/19/2002
 This is the 2nd air pump to be replaced on vehicle. engine check light illuminated, indicating a loss of performance. engine was sluggish and idling high at stops. ford was contacted. please provide more information.*ak
08/07/2000506/01/2000
 When clutch disengages rpms drop too low and vehicle stalls. loses all power steering and brakes. dealer can not identify cause. *ak consumer adds engine stalls easier if a/c is on, and/or when brakes are applied. dealer replaced powertrain control module and mass air flow, but problem still exist. also consumer is a hearing metallic ticking noise on cold engine. air bladder deflates after 1/2 hour. dealer replaced seat air bladder. drivers side front and back window will not seal after rolling up at times. *tt
05/30/200030
 Car kills out frequently when turning; when the car stalls out, the wheels lock up and nearly cause accidents. the stalling began immediately after we pruchased the vehicle. when i took it into the dealer, they stated there had been numerous complaints of the mustang gt's killing out around corners. they have no fix at this point and have made no concern for my safety. i've nearly gotten into a hand full of accidents because of this defect. i'm riding around in a brand new car that i consider very unsafe. you never know when it will stall out and lock up. the dealer initially stated they believed the stalls were caused by the hot weather. well, it's now december in denver, co and it's quite cold out and the car is still killing out around corners. within the last 3 months, the problem is occuring even more frequently. the problem seems to be getting worse at time progresses. ford has not offered me a replacement vehicle until they can figure out the problem. this is my only vehicle to and from work and i put my life in jeopardy everytime i drive it. my warranty expires at 36, 000 miles and i will be left to deal with this problem that i've had since day one of my purchase. *ak
5007/01/2000
 The engine stalls while driving, in traffic, on the freeway, where/whenever. it just cuts out, whether the engine is warm or cold. we have had it to 5 different dealerships to fix the problem and they say there is nothing wrong or they don't know what's wrong.*ak
01/01/2001112/01/2000
 Engine failed after owning car for only 2 weeks. car died in the middle of an intersection. tow truck picked it up, and dealership said that the engine harness was not properly wired. air conditioning made loud noises when running. dealership said that the water was dropping directly on to the 1500 degree exhaust pipe causing the loud noise. because the heat shield wasn't properly functioning, dealership placed a pipe underneath to divert the water.*ak
01/01/2001112/01/2000
 Engine failed after owning car for only 2 weeks. car died in the middle of an intersection. tow truck picked it up, and dealership said that the engine harness was not properly wired. air conditioning made loud noises when running. dealership said that the water was dropping directly on to the 1500 degree exhaust pipe causing the loud noise. because the heat shield wasn't properly functioning, dealership placed a pipe underneath to divert the water.*ak
12/01/1999
 Upon rapid deceleration, engine stalls. when this occurs, all power assist features (brakes, steering) are lost. this has happened several times and has been dismissed as not able to recreate by the dealership.*ak
04/01/2000
 Car died out while driving at 45mph, almost went off the road because power brakes went out. this is happening to a lot of 1999-2001 mustang gts and ford seems to not know how to fix it. *ak
11/20/2000405/17/2000
 Fuel consumption is not what it should be, vehicle is a 6cyl, 3.8 ltr engine, 15gl tank, consumer gets 200-210 miles per tank, not 320-340 as owner's manual states. vehicle has been to dealer 4 times for this, cannot remedy. twice vehicle was picked up by consumer and vehicle had been dented while at dealer.*ak
02/20/2001601/01/2001
 Vehicle will intermittently stall when i am attempting to come to a stop. when this happens i lose my power brakes and this has caused me to have to swerve to avoid hitting the car in front of me. this has happened at least 6 times. dealer replaced fuel pump the first time. the second time the idle air control valve. and third the same iac valve. it will still stall. i believe this to be a serious safety issue and am filing the lemon law.*ak
08/01/2000
 Engine stalled.entire power would go down. vehicle will begin to stall without prior warning at any speed. vehicle has been taken to the dealer on nine different occasions, but omputer did not shown any signs. dealer has not provided any type of remedy.*ak
10/01/2000606/01/2000
 Engine stalls when full braking applied at highway speeds, causing sudden loss of power assisted steering and braking. 2 seperate instances. dealer checked and found nothing noteable, made minor adjustment to throttle settings. 1 week later, second instance occurred, motor dying 3 times. driver forced to place manual transmission in neutral, depress clutch, and restart motor, which restarted each time, but forced driver to attempt to start car, control car, and stop car simultaniously.*ak
11/29/20001010/01/2000
 Car since new has had a multitude of failures to include the total failure of the parking brake, total evacuation of the master brake cylinder of fluid, brake go to the floor, clutch assembly vibrates to the point it is audable in the car and can be felt in the controls, rear end claunks, the body is miss alligned, engine misses at idle, these are all problems since new, ford has just looked at the car for the fifth time and has failed to respond to major safety items.
05/04/2000
 Vehicle was leaking oil from underneath the hood. also, consumer was traveling about 65mph and looked though rearview mirrior and noticed black smoke coming from the exhaust pipe. *ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
07/21/200798000108/01/2005
 I noticed an exhaust leak from the passengers side exhaust manifold. turns out the weld that hold the exhaust manifold to the rest of the exhaust has failed, it is now being held up by exhaust hangers and metal strapping, until it will be repaired. *jb
07/19/2002
 This is the 2nd air pump to be replaced on vehicle. engine check light illuminated, indicating a loss of performance. engine was sluggish and idling high at stops. ford was contacted. please provide more information.*ak
07/10/200208/01/2099
 Engine check light came on so i took the car to a local dealer. he informed me that the eec test code was p0411 which deals with emissions. when the dealer removed a hose to inspect the component, water came out of the hose. the dealer informed me that the entire air pump was full of water and had burned out as a result. i will have to have the pump and relay replaced at a cost of $275 for parts and $120 for labor. he further informed me that this was extremely rare and he did not know how the water could have gotten in to the pump. i called ford customer care and informed them of the problem and they informed me that they had no other complaints of this nature, but would file the information away for future reference. according to the dealer, this problem does not affect driveability of the car, and since virginia doesn't require emissions control testing, there is no requirement to have it replaced, however, the check engine soon light will remain on until the air pump and relay are replaced.*ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
08/01/20024
 Consumer cannot fill up gas tank completely. vehicle checked by dealer 4 times, and problem still exists. dealer has replaced fuel filler pipe, tube assembly, fuel vapor control valve solenoid and fuel vapor storage canister assembly.*ak
08/01/20024
 Consumer cannot fill up gas tank completely. vehicle checked by dealer 4 times, and problem still exists. dealer has replaced fuel filler pipe, tube assembly, fuel vapor control valve solenoid and fuel vapor storage canister assembly.*ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR
08/21/200790850304/14/2004
 Ford designed the a/c drain line located above the right exhaust pipe leading to the catalytic converter on the 3.8 liter v6 engine. the cold condensation from the a/c dripping onto the pipe causes the pipe to crack or in some cases causes the catalytic converter to rupture or crack. this is an expensive repair. i know of 3 people in my business that this has happened to in just the past 6 months. one case the converter had to be replaced and in the other 2 the exhaust pipe had to be removed and welded at the cracks. stainless steel pipes are welded different then the old steel pipes and require a special welding technique and equipment driving up the cost of the repair. this crack left unattended could lead to carbon monoxide entering the cockpit area. *tr
220001
 Owner was complaining that the engine light keeps coming on. owner took the vehicle to the dealer and was told that they were not responsible. owner took the vehicle to another dealer and was told that the catalytic converter had been removed causing the vehicle to shut down due to excessive heat. provide further details. *nm
01/01/2001112/01/2000
 Engine failed after owning car for only 2 weeks. car died in the middle of an intersection. tow truck picked it up, and dealership said that the engine harness was not properly wired. air conditioning made loud noises when running. dealership said that the water was dropping directly on to the 1500 degree exhaust pipe causing the loud noise. because the heat shield wasn't properly functioning, dealership placed a pipe underneath to divert the water.*ak
01/01/2001112/01/2000
 Engine failed after owning car for only 2 weeks. car died in the middle of an intersection. tow truck picked it up, and dealership said that the engine harness was not properly wired. air conditioning made loud noises when running. dealership said that the water was dropping directly on to the 1500 degree exhaust pipe causing the loud noise. because the heat shield wasn't properly functioning, dealership placed a pipe underneath to divert the water.*ak
405/09/2000
 While driving fumes would come inside through passenger's compartment. this would cause driver to get headachs & nausea. fumes were carbon monoxide. have taken to dealership 3 times, each time mechanic could not solve problem. *ak the dealer could not fix the problem but the fume created considerable health problems to the consumer. *yh
03/01/2000
 Converter glowing orange and making noises equivalent to hammer hitting metal. heat can be felt coming through driver's side floor board to the point that it feels as though heater is on high. was told this is normal, converters run up to 1800 degrees, and should only be concerned if it hits 2000 degrees. how am i supposed to know what temperature it's running?*ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CRANKCASE (PCV)
12/19/19993510/01/1999
 When i come to complete stops, (e.g. @ a red light) the tachometer slowly rises to 3,000 - 3,500 rpm's and the engine compartment shakes and roars as if i am accelerating. this has occurred at least 35 times since the original occurrence on 12/19/1999. i have not driven the vehicle since 02/29/1999. the car has been to two ford dealerships six time to fix the problem. the following items have been replaced: air bypass valve, iac (3 times - they claimed each one, including the original was faulty), on board computer. yet the problem still persists. ford has finally agreed to reacquire my vehicle. i have spoken to other 2000 mustang gt owners (all with vehicles built in 09/1999) they also have idle issues. the two i have spoken with have a reverse problem. theirs idle so low, the vehicle stalls. i think ford should look into the gt's that were built early in the model year. i have not heard of anything with the gt's built later in the year. *ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE)
2
 Egr valve failed. *yh
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
08/12/2005751252
 A/c condensation drain tube drips on exhaust manifold causing the exhaust to brake. its an on-going problem that should be corrected. the only remedy is to weld the tube back together. from many shops i've spoken to this is a problem they see and know a lot about. *nm
01/12/2005600001
 While driving 55 mph the intake manifold split without warning. as a result all the coolant and water leaked from the engine. the cause had not been determined. please provide additional information. *jb
104/02/2003
 The vehicle muffler failed and caused an accident. the front and rear end of the vehicle was damaged and the hood flew open and shattered the windshield. *ts *nlm
01/01/2001112/01/2000
 Engine failed after owning car for only 2 weeks. car died in the middle of an intersection. tow truck picked it up, and dealership said that the engine harness was not properly wired. air conditioning made loud noises when running. dealership said that the water was dropping directly on to the 1500 degree exhaust pipe causing the loud noise. because the heat shield wasn't properly functioning, dealership placed a pipe underneath to divert the water.*ak
01/01/2001112/01/2000
 Engine failed after owning car for only 2 weeks. car died in the middle of an intersection. tow truck picked it up, and dealership said that the engine harness was not properly wired. air conditioning made loud noises when running. dealership said that the water was dropping directly on to the 1500 degree exhaust pipe causing the loud noise. because the heat shield wasn't properly functioning, dealership placed a pipe underneath to divert the water.*ak
05/04/2000
 Vehicle was leaking oil from underneath the hood. also, consumer was traveling about 65mph and looked though rearview mirrior and noticed black smoke coming from the exhaust pipe. *ak