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
ENGINE AND ENGINE COOLING - ENGINE
0651301/01/200610019912Engine misfire with diagnostic trouble code (dtc) pewee, p0302, p0303, p0304, p0305, p0306, p0307, p0308, and p0316. *tt05/10/2006
053102/21/200510012947Maf diagnostic service tip - vehicles equipped with egr system module (esm). *tt04/05/2005
1754402/01/200410008115Generator noise in cold ambient temperatures. *mj07/22/2004

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
02/14/201194000
 Engine began idling roughly, and eventually the engine warning light came on. the problem was diagnosed as a crack in the cylinder head for number 8 cylinder. talking to lincoln mechanics and checking various discussion groups on the web showed that a large number of other lincoln aviators, and other vehicles with the same engine were experiencing this same failure. the rough idle can be alleviated by increasing the idle speed or taking the car out of gear while idling. both of these actions are dangerous and can lead to accidents.
02/14/201194000
 Engine began idling roughly, and eventually the engine warning light came on. the problem was diagnosed as a crack in the cylinder head for number 8 cylinder. talking to lincoln mechanics and checking various discussion groups on the web showed that a large number of other lincoln aviators, and other vehicles with the same engine were experiencing this same failure. the rough idle can be alleviated by increasing the idle speed or taking the car out of gear while idling. both of these actions are dangerous and can lead to accidents.
02/14/201194000
 Engine began idling roughly, and eventually the engine warning light came on. the problem was diagnosed as a crack in the cylinder head for number 8 cylinder. talking to lincoln mechanics and checking various discussion groups on the web showed that a large number of other lincoln aviators, and other vehicles with the same engine were experiencing this same failure. the rough idle can be alleviated by increasing the idle speed or taking the car out of gear while idling. both of these actions are dangerous and can lead to accidents.
12/10/201089500
 My 2004 lincoln aviator engine has a burnt valve with less than 90k miles on it. rich morton lincoln dealership in glen burnie, md says my repair will be $5,400 if i want to fix it, which they do not recommend. i see online that many others have the very same problem with this vehicle. i have also had to tow in my car as several times the gearshift stuck in park and could not be shifted to drive. i spoke with other owners who had the same problem. also, my tailgate window randomly flys up while driving, just like other owners have reported. my main issue is that my vehicle, an expensive one, is now not driveable and needs the $5,400 repair because of a defect in manufacture that ford will not acknowledge. help, please.
12/10/201089500
 My 2004 lincoln aviator engine has a burnt valve with less than 90k miles on it. rich morton lincoln dealership in glen burnie, md says my repair will be $5,400 if i want to fix it, which they do not recommend. i see online that many others have the very same problem with this vehicle. i have also had to tow in my car as several times the gearshift stuck in park and could not be shifted to drive. i spoke with other owners who had the same problem. also, my tailgate window randomly flys up while driving, just like other owners have reported. my main issue is that my vehicle, an expensive one, is now not driveable and needs the $5,400 repair because of a defect in manufacture that ford will not acknowledge. help, please.
12/10/201089500
 My 2004 lincoln aviator engine has a burnt valve with less than 90k miles on it. rich morton lincoln dealership in glen burnie, md says my repair will be $5,400 if i want to fix it, which they do not recommend. i see online that many others have the very same problem with this vehicle. i have also had to tow in my car as several times the gearshift stuck in park and could not be shifted to drive. i spoke with other owners who had the same problem. also, my tailgate window randomly flys up while driving, just like other owners have reported. my main issue is that my vehicle, an expensive one, is now not driveable and needs the $5,400 repair because of a defect in manufacture that ford will not acknowledge. help, please.
12/10/201089500
 My 2004 lincoln aviator engine has a burnt valve with less than 90k miles on it. rich morton lincoln dealership in glen burnie, md says my repair will be $5,400 if i want to fix it, which they do not recommend. i see online that many others have the very same problem with this vehicle. i have also had to tow in my car as several times the gearshift stuck in park and could not be shifted to drive. i spoke with other owners who had the same problem. also, my tailgate window randomly flys up while driving, just like other owners have reported. my main issue is that my vehicle, an expensive one, is now not driveable and needs the $5,400 repair because of a defect in manufacture that ford will not acknowledge. help, please.
05/13/200890000
 When i turn on my 2004 lincoln aviator to warm up in the morning the smell of the gas is so strong. when i am at a red light or stop sign the car shakes so much that i have to put it the car in neutral to avoid the car from turning off. when i am driving the car jerks and stalls i feel scared when driving on the freeway because my car sometimes doesnt go as fast as the other cars because it stalls. the car drives rough and makes a whinning noise all the time. everytime i turn on the ac it makes a loud popping sound. i have not had my vehicle fixed or looked at due to my financial circumstance. my vehicle does not have warranty. i fear for the safety of me, my family and the public when i drive this vehicle.
05/13/200890000
 When i turn on my 2004 lincoln aviator to warm up in the morning the smell of the gas is so strong. when i am at a red light or stop sign the car shakes so much that i have to put it the car in neutral to avoid the car from turning off. when i am driving the car jerks and stalls i feel scared when driving on the freeway because my car sometimes doesnt go as fast as the other cars because it stalls. the car drives rough and makes a whinning noise all the time. everytime i turn on the ac it makes a loud popping sound. i have not had my vehicle fixed or looked at due to my financial circumstance. my vehicle does not have warranty. i fear for the safety of me, my family and the public when i drive this vehicle.
06/29/200521000
 Tl-the contact owns a 2004 lincoln aviator. while driving at approximately 55 mph the check engine light illuminated on the dashboard. the vehicle was taken to an authorized dealer where the contact was informed an ignition coil needed to be replaced. the ignition coil was replaced. approximately 4 months later the failure recurred. the vehicle was again taken to an authorized dealer where the ignition coil was replaced. the failure continued to recur on several other ignition coils in which the contact replaced them himself. the contact stated that the failure continues to recur. the failure mileage was 21,000 and the current mileage was 144,000. sm.
06/20/2008480001
 The back hatch panel cracked was fixed , the steering not right some times its hard to steer. main problem is cylinder coils going bad alot. now #8 coil went bad and has been replaced 2times, and its still in the shop they cant find out why it keeps coming up #8 still misfiring .. they think its the head now. i understand lincoln has had so many problems with this that they have allowed a 10yr. extended warranty on all the coils. is this right ? i want lincoln to do something. i am so mad right now . i will never buy another lincoln. help me. *tr
02/12/2008104/14/2006
 2004 lincoln aviator with engine problems. consumer states that the dealer stated that the car would be repaired but at her expense because of her neglect. mechanic determined that there was no oil in the vehicle. *kb there was also a noise coming from the steering column when making a turn. *jb
06/01/200752000111/30/2003
 Engine misfire due to cylinder leakage. ford recommends replace cylinder head with tsb 06-5-13 for 2003-2004 mustang, 1999-2004 navigator, 2003-2003 blackwood, 2003-2005 aviator, 2003-2004 marauder. cylinder head replacement will be made if car is still under warranty
ENGINE AND ENGINE COOLING - ENGINE
07/07/201074000
 2004 lincoln aviator 74,000 miles. while attempting to merge onto interstate 95 s the vehicle shuddered and lost power unable to accelerate. final determination by a mechanic determined the #8 cylinder was not holding pressure because the valve was not sealing correctly. the 4.6l v8 ford engine's valve's are powder coated and this caused the value to stick and overtime warped the valve's components due to excessive heat. this is an engine design defect and the engine and will require a complete valve job to replace the head, head gasket and faulty valve stem. ford has issued a technical bulletin on the subject but will not perform a voluntary recall. this is a serious safety issue and could cause serious injury or death if the vehicle losses power while merging with or evading oncoming traffic
07/07/201074000
 2004 lincoln aviator 74,000 miles. while attempting to merge onto interstate 95 s the vehicle shuddered and lost power unable to accelerate. final determination by a mechanic determined the #8 cylinder was not holding pressure because the valve was not sealing correctly. the 4.6l v8 ford engine's valve's are powder coated and this caused the value to stick and overtime warped the valve's components due to excessive heat. this is an engine design defect and the engine and will require a complete valve job to replace the head, head gasket and faulty valve stem. ford has issued a technical bulletin on the subject but will not perform a voluntary recall. this is a serious safety issue and could cause serious injury or death if the vehicle losses power while merging with or evading oncoming traffic
07/07/201074000
 2004 lincoln aviator 74,000 miles. while attempting to merge onto interstate 95 s the vehicle shuddered and lost power unable to accelerate. final determination by a mechanic determined the #8 cylinder was not holding pressure because the valve was not sealing correctly. the 4.6l v8 ford engine's valve's are powder coated and this caused the value to stick and overtime warped the valve's components due to excessive heat. this is an engine design defect and the engine and will require a complete valve job to replace the head, head gasket and faulty valve stem. ford has issued a technical bulletin on the subject but will not perform a voluntary recall. this is a serious safety issue and could cause serious injury or death if the vehicle losses power while merging with or evading oncoming traffic
07/07/201074000
 2004 lincoln aviator 74,000 miles. while attempting to merge onto interstate 95 s the vehicle shuddered and lost power unable to accelerate. final determination by a mechanic determined the #8 cylinder was not holding pressure because the valve was not sealing correctly. the 4.6l v8 ford engine's valve's are powder coated and this caused the value to stick and overtime warped the valve's components due to excessive heat. this is an engine design defect and the engine and will require a complete valve job to replace the head, head gasket and faulty valve stem. ford has issued a technical bulletin on the subject but will not perform a voluntary recall. this is a serious safety issue and could cause serious injury or death if the vehicle losses power while merging with or evading oncoming traffic
08/19/201079000
 I recently purchased a 2004 lincoln aviator. about a month after i purchased this vehicle it started to develop problems. the rear bearing seal failed and oil is leaking out. the gear shifter on the console is starting to stick and not go into gear. i understand the aviator is having a lot of problems in these areas. the vehicle only had 79000 miles on it when i purchased it. ford must have used inferior materials to make the aviator. please look into this and if so force ford to recall the aviator and replace the inferior parts with parts that are safe and reliable.
08/19/201079000
 I recently purchased a 2004 lincoln aviator. about a month after i purchased this vehicle it started to develop problems. the rear bearing seal failed and oil is leaking out. the gear shifter on the console is starting to stick and not go into gear. i understand the aviator is having a lot of problems in these areas. the vehicle only had 79000 miles on it when i purchased it. ford must have used inferior materials to make the aviator. please look into this and if so force ford to recall the aviator and replace the inferior parts with parts that are safe and reliable.
08/19/201079000
 I recently purchased a 2004 lincoln aviator. about a month after i purchased this vehicle it started to develop problems. the rear bearing seal failed and oil is leaking out. the gear shifter on the console is starting to stick and not go into gear. i understand the aviator is having a lot of problems in these areas. the vehicle only had 79000 miles on it when i purchased it. ford must have used inferior materials to make the aviator. please look into this and if so force ford to recall the aviator and replace the inferior parts with parts that are safe and reliable.
08/19/201079000
 I recently purchased a 2004 lincoln aviator. about a month after i purchased this vehicle it started to develop problems. the rear bearing seal failed and oil is leaking out. the gear shifter on the console is starting to stick and not go into gear. i understand the aviator is having a lot of problems in these areas. the vehicle only had 79000 miles on it when i purchased it. ford must have used inferior materials to make the aviator. please look into this and if so force ford to recall the aviator and replace the inferior parts with parts that are safe and reliable.
08/28/2008625001
 I purchased an 04 lincoln aviator in dec. 2006, in aug. 2007 i noticed it was not running right. it was stalling when accelerating or decelerating. it would sputter like it was out of fuel. the problem worsened for the next 6 wks. no mechanic could tell me what was wrong because the engine light had not come on. in oct. 2007, i was driving on the interstate when my car lost all power for a split second. i took it to the mechanic who could not tell me what was wrong still. then my check engine light came on and i was told it was a coil pack. i had that replaced and 2 days later, the problem started again. i went to my mechanic who told me to take the car to ford, because a car with that few miles should not be having engine trouble. i took it to ford who told me it was another coil pack. i searched the internet and found that there was a voluntary service recall issued for the coil packs on this vehicle for up to 120,000 miles. i told ford of this and the repairs were covered. i asked them to replace the remaining 6 coil packs, they said they could only do it as they went bad. they said that it would not break down, it would just run bad. 08/28/08 the engine light came on while driving and i lost all power driving 60mph down the highway. i lot my steering and breaks. it took all the strength i had to maneuver the car off the road. once the vehicle slowed, it was not stopping (on a hill), i had to use the e break to stop it. i took it to ford who replaced 2 more coil packs. i contacted the manufacture ford to make them aware of the problem and to try to work something out. i decided i did not want to be driving around a death mobile. they would do nothing for me, except replace the parts as they go bad. i still have 4 bad coil packs & 4 more chances to avoid injury over an undefined time period. ford is knowingly & willingly putting my family at risk in this vehicle, that they know could break down at any minute. *tr
02/01/2008560001
 Check engine light came on 2 years ago or so. took into shop. replaced coil #8 and spark plugs. several months later, light comes on again, this time #7. 2 days later, light comes on again, must have been a defective part, replaced the replaced #7. another 2 days later, light back on. i'm told it's a cylinder head problem and they won't know what exactly the problem is until they take the cylinder heads off. or i can get a new engine.... lincoln wants no responsibility for such a catastrophic and known problem. since my mileage is over their warranty (although at the onset it wasn't). gee, i wonder why no one wants to buy an american made car! *tr
11/04/200413650206/25/2004
 At 13,650 miles the engine destroyed itself due to a defective crankshaft. i was driving home at night in the rain when the engine light came on and a loud banging sound was coming from the engine compartment. i immediately pulled off the highway & called roadside assistance. i waited for 3 hours for a tow truck and eventually had to call ct state police who summoned a wrecker. the lower half of the engine was completely destroyed. manufacturer replaced the engine with a new engine assembly and engineers requested the old engine be sent to them for inspection as they had never seen this defect before. i was without my vehicle for 15 days. the first night i picked it up the engine light came on after less than 20 miles on my way home, again at night. it was not a dummy light. another defective part had to be replaced. this time it was the egr module. i am now experiencing occasional skips when the vehicle tries to shift to upper gears from a dead stop. i am confident this product is a lemon and have worked fruitlessly to try to get the dealer/manufacturer to provide a replacement vehicle. this vehicle is unsafe and unreliable and i have received no consideration for a replacement other than to treat the transaction as a new vehicle purchase with mine as a trade. at the time of the first event, i had only owned this car for 4 months and put roughly 6,700 miles on it as it was a dealer's demo, driven by the owner of the dealership. it had over 6000 miles at purchase and i had only made 3 car payments at the time of failure. this is ridiculous! *nm