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 | |||||
| 12720 | 05/01/1999 | 6091697 | Some vehicles may develop a coolant leak at the worm gear clamp located at the joint between the metal intake coolant tube and the flexible rubber coolant hose. *tt | 11/09/2000 | |
| 6232 | 05/01/1999 | 607031 | Some vehicles may develop a coolant leak at the worm gear clamp located at the joint between the metal intake coolant tube and the coil resulting in engine misfire with diagnostic trouble code p0304 and / or rough idle. *tt | 11/03/2000 | |
| 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 |
| 02227 | 11/11/2002 | 10008310 | Engine-cylinder head deck leak-4.6 and 5.4l engines-new service-only gasket and cylinder head kits availability. *mj | 07/27/2004 | |
| 03144 | 07/21/2003 | 10003744 | Engine 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. *tt | 10/29/2003 | |
| 16683 | 03/01/2003 | 10001937 | False failure of the vapor management valve (vmv). *tt *jb | 07/28/2003 | |
| 13846 | 03/01/2001 | 620275 | Some vehicles built 7/1998 to 6/1999 equipped with a 4.6 / 5.4l winsor built engines may exhibit an oil leak from the cylinder heat gasket area. *tt | 07/23/2001 | |
| 14864 | 04/01/2001 | 619335 | Subject regarding certain vehicles with 4.6l romeo engines exhibiting an oil leak from the cylinder head gasket area. *tt | 05/23/2001 | |
| 14821 | 04/01/2001 | 619315 | Some vehicles equipped with 4.6l romeo engine may exhibit an oil leak from the cylinder head gasket area. *tt | 05/23/2001 | |
| 13846 | 02/01/2000 | 612444 | Some vehicles built 7/1998 to 6/1999 equipped with a 4.6 / 5.4l windsor built engines may exhibit an oil leak from the cylinder head gasket area. *tt | 06/08/2000 | |
| 8093 | 02/01/2000 | 612291 | Some vehicles built 7/1998 to 6/1999 equipped with a 4.6 / 5.4l windsor built engine may exhibit an oil leak from the cylinder head gasket area. *tt | 06/07/2000 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||||
| 01246 | 12/10/2001 | 630515 | Engine oil system priming procedures, service tips for reports of premature engine failure. *tt | 04/18/2002 | |
| 15517 | 01/01/2002 | 630043 | Subject regarding exaggerated engine braking on deceleration. *yd | 04/12/2002 | |
| 0214 | 01/21/2002 | 630001 | Some engine assemblies with aluminum cylinder heads repaired in-vehile have been found to leak coolant and/or oil from the cylinder head gasket area. *tt | 04/11/2002 | |
| 01205 | 10/15/2001 | 627927 | Some vehicles may exhibit vacuum or air leaks in the intake manifold and / or engine system causing diagnostic trouble codes p0171 and or p0174. *tt | 02/26/2002 | |
| 01122 | 06/25/2001 | 622661 | On some vehicles there may be an oil leak from the right hand head gasket at the rear of the block / head joint. *tt | 10/22/2001 | |
| 0147 | 03/05/2001 | 619424 | Subject regarding engine oil recommendations for use in 2001 vehicles - sae 5w-20 motor oil. *tt | 05/30/2001 | |
| 0142 | 03/05/2001 | 619419 | Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. *tt | 05/30/2001 | |
| 14372 | 09/01/2001 | 618640 | Information on idle vibration or engine droan on acceleration. *jb | 04/18/2001 | |
| 5257 | 12/01/1998 | 615374 | Information on vehicles exhibiting cold engine knock. *tt | 01/13/2001 | |
| 4981 | 12/01/1998 | 615321 | Some vehicles equipped with 5.4l engines may exhibit a cold start engine knock concern until warmed up. *tt | 01/13/2001 | |
| 12798 | 05/01/1999 | 607112 | Some vehicles equipped with engines produced by windsor engine plant may exhibit an engine knock at initial cold startup. *tt | 01/05/2001 | |
| 13331 | 10/01/1999 | 6092152 | Some vehicles equipped with engines produced by windsor engine plant may exhibit an engine knock at initial cold startup. *tt | 11/27/2000 | |
| 12139 | 11/01/1998 | 613160 | Some vehicles equipped with 4.6l or 6.8l engines may exhibit a cold start engine noise until warmed up. *mjs | 06/19/2000 | |
| 6350 | 07/01/1999 | 610653 | Some vehicles equipped with engines produced by windsor engine plant may exhibit an engine knock at initial cold startup. *tt | 05/10/2000 | |
| 13322 | 10/01/1999 | 609613 | Some vehicles may exhibit an engine knock at initial cold startup. *tt | 04/04/2000 | |
| 7155 | 10/01/1999 | 6090791 | Vehicles equipped with windsor engines only may exhibit an engine knock at initial cold startup. *tt | 03/30/2000 | |
| 13285 | 09/01/1999 | 6090709 | Experiencing engine knock at initial cold startup. *tt | 03/23/2000 | |
| 996034 | 05/01/1999 | 606947 | Experiencing a engine knock at cold start-up. *tt | 09/08/1999 | |
| 99816 | 05/03/1999 | 606420 | Ford motor company now recommends sae 5w-30 viscosity grade for servicing any ford gasoline-powered vehicle regardless of model year. *tt | 08/19/1999 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS | |||||
| 14365 | 09/01/2000 | 618636 | This bulletin addresses concerns a noise at intial engine startup when cold from the accessory drive belt. *jb | 04/18/2001 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||||
| 8021 | 04/01/2000 | 613615 | Exhibiting a crackling / popping noise from the exhaust. **mr | 07/26/2000 | |
| 982010 | 10/12/1998 | 603695 | Experiencing a buzzing or rattling noise from the exhaust system. *yc | 03/02/1999 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE) | |||||
| 05417 | 03/07/2005 | 10014666 | Intermittent rough idle - non-commanded egr (exhaust gas recirculation valve) flow. *tt | 05/05/2005 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||||
| 0554 | 03/21/2005 | 10014685 | Use of stainless steel exhaust studs in service for 5.4l 2v engine. *tt | 05/05/2005 | |
| 17320 | 11/01/2003 | 10008169 | Broken exhaust manifold studs. *tt | 07/22/2004 | |
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 AND ENGINE COOLING | |||
| 09/21/2011 | 99000 | ||
| Tl* the contact owns a 1999 lincoln navigator. the contact stated that the vehicle caught on fire while parked with the engine off. the dealer was contacted in regards to the failure but denied any assistance with repairs. the manufacturer was not contacted and the vehicle was not repaired. the failure and current mileage was 99,000. the vin was not available. | |||
| 09/21/2011 | 99000 | ||
| Tl- the contact owns a 1999 lincoln navigator. the contact stated that the vehicle caught on fire while parked with the engine off. the dealer was contacted in regards to the failure but denied any assistance with repairs. the manufacturer was not contacted and the vehicle was not repaired. the failure and current mileage was 99,000. the vin was not available. kmj | |||
| 09/21/2011 | 99000 | ||
| Tl- the contact owns a 1999 lincoln navigator. while the vehicle was turned off, the contact stated that the vehicle caught on fire. the dealer was contacted, but denied any assistance with repairs to the failure. the manufacturer was not contacted. the vehicle was not repaired. the failure and current mileage was 99,000. nw | |||
| 01/04/2011 | 81025 | ||
| Water, vapor, condensation keeps getting on to the coil on plug assembly on the passenger side of my engine causing water build up, electrical failure, misfires and spark plug explosions in to my engine, causing fragments of metal and plastic to fire in to my engine. this has happened to me several times now, been repaired, and continues to happen. despite 6 separate technical service bulletins, ford / lincoln have not recalled this problem with the 1999 to 2006 5.4l v8 engine, leading to thousands of people like me having to continually fix this problem, which is caused by a design / safety flaw in the engine / component construction. i was nearly killed today on the freeway because the truck hesitated and misfired while i was going up a large hill, stuck between two semi-trucks and i couldn't move out of the way due to failure to accelerate. | |||
| 04/07/2010 | 220000 | ||
| Tl- the contact owns a 1999 lincoln navigator. the contact stated the sparks plug burn out and pop out then burning the coil attached. the contact stated these had already been in the vehicle when the failure occurred. the suspension on the vehicle goes in and out as well. the contact stated when this happens the suspension does not inflate and they have to turn the vehicle off for about a half an hour to get it to reset. the vehicle had not been inspected at the time of the complaint. the failure mileage was 220000 and the current mileage was 240000.rl | |||
| 11/15/2010 | 86000 | ||
| 1999 lincoln navigator-spark plug blow out | |||
| 06/22/2009 | 190000 | ||
| Tl*the contact owns a 1999 lincoln navigator. while proceeding to enter the vehicle, the contact noticed flames coming from the passenger side of the hood. she was unable to extinguish the fire and called the fire department. the fire department extinguished the flames and filed a report. there were no failures prior to this incident. the contact called her insurance company to file a claim and was informed that an insurance adjuster would inspect the vehicle. the cause of the failure was undetermined. the contact is in the process of notifying the manufacturer. the failure mileage was 190,000. | |||
| 07/21/2008 | 140000 | ||
| Tl*the contact owns a 1999 lincoln navigator. after driving and parking the vehicle, it exploded. the contact noticed black smoke and a fireball, and then the windows blew out. the police officer stated that the origin of the failure could never be determined because everything was burned to the ground, including the transmission and engine. it was noticed, however, that the fire seemed to have started from the front end. before she exited the vehicle, the contact did not notice any warning lights or signs of overheating prior to the malfunction. a police report was filed. she consulted the manufacturer and was advised to call back. the current and failure mileages were approximately 140,000. | |||
| 12/03/2004 | 2 | ||
| Oil odor was coming from the vents while driving. also, a liquid was leaking from underneath the vehicle. consumer took vehicle to the dealer for inspection, and mechanic determined that the cylinder head and head gasket needed to be replaced. *ak | |||
| 01/12/2004 | 85400 | ||
| My 1999 lincoln navigator (vin 5lmpu28l0xlj10870) with 5.4l a engine with 80,000 miles. the spark plug blew out while driving on the highway. the head had to be replaced. the mechanic said that he recently had a number of customers with similar problems and thought the problem was due to a faulty design which utilized too few threads on an aluminum head. | |||
| 12/15/2003 | 100000 | 5 | 09/01/1998 |
| Spark plugs failed. as a result, vehicle jerked forward without warning. *ak coolant leaked twice in the past. the radiator assembly was reinstalled. the left front window squeaked. the trim on the front door panel was removed and reinstalled. the engine light had come on and the engine had run rough. the service dealer replaced the faulty coil pack on the #4 cylinder. the heater hose was replaced due to leakage. the heater did not blow air and displayed a burning smell. *sc | |||
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||
| 04/20/2009 | 134000 | 1 | |
| Total failure of a/c system due to main a/c hose. *tr | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 06/13/2010 | 101000 | ||
| #1 spark plug on 1999 navigator blew out on rt 80 in pa 400 miles from my home. i had to rent a u-haul truck and trailer to tow my navigator home at the cost of $600. i had to leave my race car and trailer in pa. i don't know how i am going to go get it. i have no tow vehicle. | |||
| 02/11/2004 | 5 | 09/01/1998 | |
| The vehicle stalls at 45 mph or more when on the highway. taken in for testing and results show that the computer has no codes, which recognizes failure. manufacturer has been contacted and is aware of the problem. *jb *nm | |||
| 05/30/2004 | 63755 | 1 | |
| While driving under 40 mph the engine started vibrating and hesitating. the chck engine light went on. according to lincoln, the engine needs two new cylinder heads. the car has less than 64,000 miles.*ak | |||
| 07/29/2003 | 51870 | 1 | 03/10/2003 |
| I own a 1999 lincoln navigator (ford engine 5.4l dohc) only 52000 miles. the spark plug #4 blow out of the engine while driving on the highway. i've seen many of the ford expedigion and lincoln navigator owners experience this same issue. there is obviously a default with there engine for these models and thus should be recalled.*ak | |||
| 06/26/2002 | 60000 | 1 | |
| While driving at various speeds engine will stall without warning. dealer notified.*ak vehicle would stall as soon as consumer takes off foot from accelerator pedal. dealer repaired the vehicle; however, consumer had concerns regarding the incident will happen again. *la | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| Consumer state while vehicle was cold when depressing the brakes without any indication vehicle engine would stall. vehicle was service by dealer, technician replace idle air control. please provide further information. ts | |||
| 07/31/2000 | 4 | 11/01/1999 | |
| Lincoln navigator stalling at random times and at random speeds...no warning lights to alert me of problem. this vehicle has been in three times for the same problem...and was just towed in for the fourth time, same problem.the vehicle has a serious safety defect and i am refusing to drive it. dealer cannot pinpoint the problem and admitted that there is some sort of unknown computer glitch. both the dealer and ford motor co have made this process very difficult and i am demanding a full refund under the lemon law.*ak | |||
| 07/02/2000 | 0 | 07/16/1999 | |
| While driving vehicle shutdown without any prior warning. vehicle did not indicate any warning light on reported failure. vehicle was currently at the dealership for repairs. at this point, dealership was not aware of any problems, and had no solution. *ak *ml | |||
| 08/25/1999 | |||
| When consumer makes a stop and then proceeds car would stall in the middle of traffic. consumer took car to dealer, and the dealer said that he didn't see a problem in his computer, and that he could not fix it unless it was in the computer. *ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||
| 07/07/2008 | 1 | ||
| My lincoln navigator has been sitting there for so long since my wife and i can not afford to fix it. my 1993 ford explorer has been broken down on us like you would not imagine. help is needed please. *tr | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||
| 11/02/2003 | 120000 | 1 | 03/22/2003 |
| Consumer noticed smoke coming from under the hood. consumer pulled over, popped hood, and noticed oil leaking onto the manifold. dealer was contacted. consumer found technical service bulletin 03-6-2002 from 03/31/2003 that explained the exact problem. *ak | |||