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
036103/31/200310001855Malfunction indicator lamp on with or without rough running, lack of power, surge or poor fuel economy with diagnostic trouble codes p0401, p0402, p1400, p1401. *tt *jb07/23/2003
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
0217209/02/200210008576Engine-oil leak from positive crankcase ventilation (pcv) valve area-vehicles built before 5/17/2002 equipped with 4.6l 2v engine only. *mj08/05/2004
0222111/11/200210008304Engine-gear driven synchronizers-incorrect installation-camshaft position synchronizer (cmp) installation tool correct application. *mj07/27/2004
1638011/01/200210008319Service cylinder head gasket for 4.6l applications. *tt07/27/2004
0325612/22/200310008278Engine-romeo built 4.6l 2v-tick noise from engine-engines built before 9/17/2003. *mj07/26/2004
1710409/01/200310004045Ticking/tapping noise with the engine warmed up and the transmission in gear at idle. 2003 e150 included. *tt11/17/2003
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
0316408/18/200310003118Some vehicles, equipped with the 4.6l 2v engine, with an engine build date prior to 8/29/03 may exhibit an engine tick noise that is present at all temperatures during idle. 2004 models included. *tt10/08/2003
1664402/01/200310002509Some vehicles equipped with a 3.8l engine and the t5 transmission may exhibit high idle between shifts. *tt09/04/2003
032202/03/200310002472Streamlined diagnostic procedure for vehicles with malfunction indicator lamp (mil) on and diagnostic trouble codes (dtcs) p0401, p0402, p1400 or p1401, or runs rough, lacks power, surge, poor fuel economy, and the above listed dtcs without09/03/2003
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
1593405/01/2002637840Some vehicles with the tr6350 manual transmission may exhibit a light ticking / rattle noise while driving after a cold engine start. *tt12/06/2002
02170208/01/2002636189Some vehicles equipped with a 4.6l 2v engine built before may 17, 2002, may exhibit an oil leak coming from the crankcase / valve cover area. *tt11/06/2002
025403/18/2002636045On some vehicles equipped with the 4.6l engine, the front end accessory drive (fead) belt may hydroplane on the water pump pulley whenthe belt is splashed with water. *tt11/04/2002
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
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 - GAS RECIRCULATION VALVE (EGR VALVE)
02M0106/01/200402M0110007207Customer satisfaction program 02m01 supplement #4. certain ford 2000 through 2003 vehicles equipped with a tube-mounted egr pressure sensor - additional egr pressure sensor warranty coverage. *tt supplement #3. *mj supplement #606/03/2004

Investigations


NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
ENGINE AND ENGINE COOLING
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK PLUG EJECTION FROM CYLINDER HEAD
 On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi
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
09/05/2011103000
 The fourth spark plug on my 2002 ford mustang gt 4.6l vehicle blew out. this resulted heavy loss of power, shaking, and more importantly fuel fumes to come out. the incident occurred on an interstate at high-speed and i was very fortunate to safely make it over to the emergency lane. the cost to repair the damage to the car is estimated at $2500. this is a very common safety issue with the ford 8-cylinder engines for what i gathered through independent research after the incident. the threads are too thin around the spark plug and the heat causes them to blew out - literally.
09/05/2011103000
 The fourth spark plug on my 2002 ford mustang gt 4.6l vehicle blew out. this resulted heavy loss of power, shaking, and more importantly fuel fumes to come out. the incident occurred on an interstate at high-speed and i was very fortunate to safely make it over to the emergency lane. the cost to repair the damage to the car is estimated at $2500. this is a very common safety issue with the ford 8-cylinder engines for what i gathered through independent research after the incident. the threads are too thin around the spark plug and the heat causes them to blew out - literally.
09/05/2011103000
 The fourth spark plug on my 2002 ford mustang gt 4.6l vehicle blew out. this resulted heavy loss of power, shaking, and more importantly fuel fumes to come out. the incident occurred on an interstate at high-speed and i was very fortunate to safely make it over to the emergency lane. the cost to repair the damage to the car is estimated at $2500. this is a very common safety issue with the ford 8-cylinder engines for what i gathered through independent research after the incident. the threads are too thin around the spark plug and the heat causes them to blew out - literally.
09/05/2011103000
 The fourth spark plug on my 2002 ford mustang gt 4.6l vehicle blew out. this resulted heavy loss of power, shaking, and more importantly fuel fumes to come out. the incident occurred on an interstate at high-speed and i was very fortunate to safely make it over to the emergency lane. the cost to repair the damage to the car is estimated at $2500. this is a very common safety issue with the ford 8-cylinder engines for what i gathered through independent research after the incident. the threads are too thin around the spark plug and the heat causes them to blew out - literally.
03/24/2008108000
 Tl-the contact owns a 2002 ford mustang. the contact stated the intake manifold leaks coolant while driving 30 mph. the contact stated the leak can cause the engine to malfunction and maybe a fire. the contact called the manufacturer and the manufacturer stated there is no recall and the vehicle is out of warranty so there is nothing they can do. the has not taken the vehicle to the dealer. the contact also stated the spark plugs came out of the cylinder head while driving. the vehicle is currently at a local mechanic under going repairs to the cylinder head. the contact stated these are safety issue that the manufacturer are ignoring and can cause a crash. the failure mileage was 108,000. jo
03/24/2008108000
 Tl-the contact owns a 2002 ford mustang. the contact stated the intake manifold leaks coolant while driving 30 mph. the contact stated the leak can cause the engine to malfunction and maybe a fire. the contact called the manufacturer and the manufacturer stated there is no recall and the vehicle is out of warranty so there is nothing they can do. the has not taken the vehicle to the dealer. the contact also stated the spark plugs came out of the cylinder head while driving. the vehicle is currently at a local mechanic under going repairs to the cylinder head. the contact stated these are safety issue that the manufacturer are ignoring and can cause a crash. the failure mileage was 108,000. jo
03/24/2008108000
 Tl-the contact owns a 2002 ford mustang. the contact stated the intake manifold leaks coolant while driving 30 mph. the contact stated the leak can cause the engine to malfunction and maybe a fire. the contact called the manufacturer and the manufacturer stated there is no recall and the vehicle is out of warranty so there is nothing they can do. the has not taken the vehicle to the dealer. the contact also stated the spark plugs came out of the cylinder head while driving. the vehicle is currently at a local mechanic under going repairs to the cylinder head. the contact stated these are safety issue that the manufacturer are ignoring and can cause a crash. the failure mileage was 108,000. jo
03/24/2008108000
 Tl-the contact owns a 2002 ford mustang. the contact stated the intake manifold leaks coolant while driving 30 mph. the contact stated the leak can cause the engine to malfunction and maybe a fire. the contact called the manufacturer and the manufacturer stated there is no recall and the vehicle is out of warranty so there is nothing they can do. the has not taken the vehicle to the dealer. the contact also stated the spark plugs came out of the cylinder head while driving. the vehicle is currently at a local mechanic under going repairs to the cylinder head. the contact stated these are safety issue that the manufacturer are ignoring and can cause a crash. the failure mileage was 108,000. jo
03/24/2008108000
 Tl. the contact owns a 2002 ford mustang. the contact stated the intake manifold leaks coolant while driving 30 mph. the contact stated the leak can cause the engine to malfunction and maybe a fire. the contact called the manufacturer and the manufacturer stated there is no recall and the vehicle is out of warranty so there is nothing they can do. the has not taken the vehicle to the dealer. the contact also stated the spark plugs came out of the cylinder head while driving. the vehicle is currently at a local mechanic under going repairs to the cylinder head. the contact stated these are safety issue that the manufacturer are ignoring and can cause a crash. the failure mileage was 108,000. jo
01/30/2009905661
 I went to drive my car friday morning and heard a squeaking noise i took it to the shop and had 3 pulleys replaced on it and it was still squeaking they replaced the water pump still squeaking i had 3 mechanics check the car and they told me with the miles that was on my car i should not be having problems coming from my crankshaft i don't even have 100,000 miles on the car yet. *tr
07/07/2003
 While traveling on highway and without prior warning vehicle shut down, causing the vehicle to run into a guardrail. *ak
ENGINE AND ENGINE COOLING - ENGINE
07/18/2003
 While traveling on the highway and without prior warning vehicle shut down and will not restart. *ak
06/11/20031000108/01/2002
 The vehicle shook and vibrated while driving which almost caused an accident. the vehicle also stalled several times while driving. the dealership replaced the engine with a re-manufactured one. *ak *cb *nlm
04/17/20032548308/21/2002
 The vehicle stalled while driving. when the consumer attempted to restart the vehicle it stalled again and sometimes does not start at all. *nlm the control valve was changed with no codes showing in the system. before, the mecahnic stated that the problem was due to the weather and the gas. the right rear tire had a bubble in the sidewall and was replaced. scc
 Vehicle would lose power at different times and speeds. mass air sensor replaced, but the mechanic found that there was no gasket. also, mechanic found that there was too much air where filter would be. please describe details.*ak
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
06/01/200545000107/13/2002
 2002 ford mustang v6 with manual transmission. engine increases rpms even when foot is off the accelerator pedal. this happens in gear and between shifts. even though vehicle is under warranty, ford refuses to fix the problem. they say that this is a normal vehicle characteristic and no further repairs should be performed. the problem is consistent and worsening. i think this is dangerous and ford should resolve the problem.
710/01/2002
 Engine stall during braking after hard acceleration while in nuetral and pressing the clutch. dt
07/25/200210
 The car intermittently stalls on deceleration. when decelerating to a stop, pushing in the clutch and braking will cause the vehicle to die. there is no warning or definite rate of speed or rpm. it occurs occasionally. the dealer attempted to fix by adjusting the voltage on the throttle position switch, second reprogrammed the computer. the third occurance stated they could not duplicate the problem. this is a safety issue because when the car dies while braking, you lose power steering and braking ability.*ak
08/04/2002
 While drving gas pedal became stuck to the floor. consumer attempted to brakes, and vehicle slowed to approximately 55mph, but would not stop. consumer then collided with the curb. vehicle checked by dealer, who advised consumer that an engine problem existed. *ak
07/29/2002204/01/2002
 The car dies unexpectedly. the check engine light comes on but the dealer says that they cannot find anything wrong with the car. this has happened on two different occasions, (while the car is idling and when the car is in gear moving). ford said that this has been reported on numerous occasions but they cannot fix the problem because when the diagnostic check is done no problem codes are recorded. have you heard of this problem occurring and what can i do to get the problem fixed.*ak
07/14/2002
 While driving on flat or incline surface at low speeds vehicle will stall with no warning. dealer notified.*ak
06/02/20021305/01/2002
 Engine stall and will die at braking. common problem with mustangs. engine died numorous times nearly causing an accidnets.*ak
06/22/2001306/01/2002
 While turning at 30mph, vehicle stalls with no warning. dealer notified. cause unknown.*ak this vehicle loses all electrical power including the ignition. this vehicle is still in the posession of the dealer. *jg
05/13/2002204/01/2002
 Engine stalled when applying brakes firmly even though the car was in neutral and the clutch pedal was pushed down. this incident almost caused an accident due to absence of power brakes, power steering, and acceleration. *ak
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS
06/29/2004693614
 While driving 40 mph and when brakes were depressed the vehicle pulled from side to side. *ak there was a clunk after the brakes were released, the front tires rubbed on the frame when turning, three belts were installed within 6000, the vehicle smelled like oil, even with the a/c on. the motor rattled before the gears were shifted, with the a/c on the motor would surge up and down to the point where the vehicle would pull. after the consumer would take his foot off of the gas there would be a slight acceleration, the vehicle would hesitate and lunge forward. the vehicle was sometimes hard to start and must be cranked several times. there was a rattle in the rear of the rear of the vehicle as if something was loose moving back and forth. poor alignment had worn the tires on the outside edge. the bolt from the vehicle was found in the driveway, and the rear window had an air leak. *sc *jb
10/22/2001
 While traveling at highway speed of 60 mph sepentine belt came off and caused loss of power steering and power brakes. dealer notified, and made repairs. feel free to provide any further information on this matter.*ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
08/09/20081
 On my 2002 ford mustang v6 the ac condensation drips to my manifold and keeps cracking the weld. i have to get it rewelded every six months. the guy at the shop tells me he gets at least 10 a month with the same problem. *tr
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
 Vehicle would lose power at different times and speeds. mass air sensor replaced, but the mechanic found that there was no gasket. also, mechanic found that there was too much air where filter would be. please describe details.*ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR
09/09/2005102/28/2002
 Dt: 2002 ford mustang. the consumer stated the exhaust intake on the catalytic converter broke in half. the air conditioner condenser dripped on the catalytic converter intake. this caused the break. ford was aware of the problem. the exhaust went into the engine, and the pipe was hanging on the road. the dealership will not fix the vehicle under the emissions warranty. there is a technical service bulletin, 04216.*ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
02/26/200615500109/17/2003
 Dt*: the contact stated the vehicle was taken to a service dealer to replace two exhaust mufflers. after two and half months the new stanley steel mufflers became severely rusted. when the service dealer was alerted, they refused to acknowledge any warranty on the mufflers.