Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||||
| 041601 | 11/14/2005 | 05228 | 10018745 | Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running. *tt | 01/12/2006 |
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||||
| 17497 | 01/01/2004 | 10007335 | Overheating condition - cooling system fill/bleed procedure. *tt | 06/14/2004 | |
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| 07212 | 10/01/2007 | 10023943 | Some 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. *pe | 02/20/2008 | |
| 06513 | 01/01/2006 | 10019912 | Engine misfire with diagnostic trouble code (dtc) pewee, p0302, p0303, p0304, p0305, p0306, p0307, p0308, and p0316. *tt | 05/10/2006 | |
| 031404 | 08/23/2004 | 04161 | 10011162 | Engine 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 |
| 03256 | 12/22/2003 | 10008278 | Engine-romeo built 4.6l 2v-tick noise from engine-engines built before 9/17/2003. *mj | 07/26/2004 | |
| 17858 | 06/01/2004 | 10008260 | Engine ticking noise. *tt | 07/23/2004 | |
| 17519 | 01/01/2004 | 10007349 | 4.6l supercharged engine may exhibit a lack of power and no boost when the vehicle is initially delivered to the dealership. *tt | 06/14/2004 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||||
| 041003 | 11/01/2004 | 04216 | 10013368 | Exhaust leak - cracked or separated right side exhaust pipe - 3.8l and 3.9l engines. *tt | 04/15/2005 |
| 04103 | 05/31/2004 | 10008992 | Exhaust leak. right side exhaust pipe on 3.8l or 3.9l engine. *tt | 09/07/2004 | |
Investigations
| NHTSA ID | Manufacturer | Date open | Date close | Subject | Recall campaign | |
|---|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK PLUG EJECTION FROM CYLINDER HEAD | ||
| On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi | ||||||
| ENGINE AND ENGINE COOLING - ENGINE | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK PLUG EJECTION FROM CYLINDER HEAD | ||
| On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi | ||||||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK PLUG EJECTION FROM CYLINDER HEAD | ||
| On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi | ||||||
Consumer Complaints
| Fail date | miles | occurences | Purchase date |
|---|---|---|---|
| ENGINE | |||
| 05/08/2012 | 75000 | ||
| Tl* the contact owns a 2004 ford mustang. the contact stated that while driving, a loud noise was heard coming from under the vehicle. the contact took the vehicle to a repair shop where they advised that the air compressor condensation dripped onto the exhaust pipe and the exhaust piped needed to be re-welded. the vehicle was repaired. the contact notified the manufacturer and was advised that there were no recalls for the vehicle or the failure. the failure mileage was 75,000. | |||
| ENGINE AND ENGINE COOLING | |||
| 03/14/2005 | 800 | 3 | 11/18/2004 |
| Dt: the consumer states that 2004 ford mustang was having mechanical problems. the transmission fluid was gushing out and the vehicle was taken to a dealership for repairs. the dealership fixed the transmission fluid problem. the next problem was oil leaking. the vehicle has been in the dealership twice for repairs and it was still leaking oil. the owner contacted ford for help. ford had the car taken to the dealership that ford recommended. the problem is still not fixed. the dealership says that the oil is leaking from the engine. the transmission had to have a seal replace a line, and the engine is still leaking. the owner says that he can not drive the drive because it will blow up the engine. the owner refused to drive the car when he found all these problems, so he didn't burn the car up. there have been two different dealerships that have worked on the car. the owner said that the dealers had claimed to fix the car, but did not fix it. the car also has had a tire problem that the owner had to replace. the dealership said that it was wear and tear. the car has less than 800 miles on it. *ak | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 01/17/2006 | 23250 | 2 | |
| In the morning, after driving my car approximately 10 minutes, (before entering the freeway on ramp) the engine just shut off. i was able to turn the key to the off position, and while still moving (in second or third gear) i was able to restart the car on the first attempt. i did use the vehicle mid-day without any mishaps. later that evening after driving home approximately 40 minutes, (after exiting the freeway) the engine shut off again (while in third gear). i was able to again turn the key to the off position, and while in motion i was able to restart the car on the first attempt. on the drive home that evening and the next morning there were no further mishaps. i contacted the ford dealer that evening, and was advised to bring in the car the next morning. i was not advised to have it towed or that it would be unsafe to operate. the mechanics drove the vehicle for 12 miles, and were unable to duplicate the motor turning off. they advised me that they had thoroughly checked the car, but were unable to find anything wrong, and the car was ready to be picked up. i was expressed my concern repeatedly about driving everyday on the freeway to their representative, but was offered no explanation as to why the engine just turned off. at this point i continue to be concerned about the safety of driving this vehicle. *jb | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||
| 09/06/2004 | 20000 | ||
| In 2004 my mom bought a new 2004 ford mustang with the 3.9 v-6 motor and within a couple of months it started ticking real loud when you first start it up. come to find out it was a passenger side exhaust leak that just got worse, and at the same time her engine started making loud chirping and crazy noises to find out it was the cam positioning sensor that went out. well she paid about $550.00 to get the sensor fixed but she couldn't afford the exhaust to.so still to this day she drives her nice looking mustang carefully around town that sounds like its ready to die, and i wouldn't trust driving that thing 10 miles out of town. it might not be an eye sore but it sure is an ear sore, and is stressing years off my old broke mothers life. we've always been a ford family and my dad retired from ford proving grounds. but that is the sorriest ford we've ever seen.oh yeah, plus the automatic transmission never shifted right from day 1, and she has had to replace the alternator, battery ,a pulley, the serpentine belt etc.and it has a lot of rattles and road noise,and it just barely made 60,000 miles. | |||
| 12/27/2003 | 100 | 1 | 12/26/2003 |
| Repeated intermittent fuel smell during operation of vehicle in interior compartment. *la | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||
| 08/07/2005 | 12500 | 1 | 06/03/2005 |
| Tl*the contact owns a 2004 ford mustang. the contact stated that the tail pipe was protruding too far from the vehicle, which caused a massive injury to his son's arm. the tail pipe is cut in a 2.9 inch edge instead of being rounded. he believed that it should be further back (approximately one inch) to avoid injuries. the failure mileage was 12500 and current mileage was 15,600 updated 01/11/08. *lj updated*jb | |||
| 08/07/2005 | 13000 | 1 | 06/09/2005 |
| 1) we purchased a 2004 ford mustang convertible. the vehicle was parked in our garage. the exhaust tail pipe has a poor design due to the design cut on the end which leaves two sharp pointed edges like the end of knives. the points are located approximately 1 inch past the bumper. all other vehicles we have seen have rounding tail pipe ends and the ends are flush with the bumper or under the vehicle. 2) the failure of the design of the exhaust tail pipe with the sharp razor cuts leaving two pointed knife like ends and placed past the bumper in the manufacturing process resulted in my three year old having a massive upper arm injury requiring surgery after falling behind the 2004 ford mustang. as he fell his right shoulder slid down past the bumper and the pointed sharp edge sticking past the end of the bumper tore into his arm above the elbow to the very top of his shoulder. the injury required many hours of surgery and we hope no other child will have to go through this meaningless design flaw by ford motor company and their oem manufacture 3) we have tried to correct the problem by asking the ford dealer for assistance which was refused and reported the injury to ford executive offices in michigan. due to non-response by ford we have placed a normal safe rounded tail pipe extension on the vehicle. the rounding tail pipe is used in all other vehicles that we have seen. the exhaust tail pipe has not been recalled at this time on the ford mustangs for 2004 and 2005 which are the same design and placement. *jb | |||