Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING
04160111/14/20050522810018745Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running. *tt01/12/2006
022202/04/2002630628Some vehicles may exhibit an intake manifold crossover (first runner) coolant seepage condition. *tt04/19/2002
ENGINE AND ENGINE COOLING - COOLING SYSTEM - FAN
032602/03/200310002476Revised cooling fan motor available. *tt09/03/2003
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
1638011/01/200210008319Service cylinder head gasket for 4.6l applications. *tt07/27/2004
0314407/21/200310003744Engine misfire or rough running condition with coil on plug (cop) ignition systems may be more accurately diagnosed using the optional worldwide diagnostic system (wds) coil on plug (cop) kit. 2003 super duty f series included. *tt10/29/2003
1482104/01/2001619315Some vehicles equipped with 4.6l romeo engine may exhibit an oil leak from the cylinder head gasket area. *tt05/23/2001
1486404/01/2001619335Subject regarding certain vehicles with 4.6l romeo engines exhibiting an oil leak from the cylinder head gasket area. *tt05/23/2001
0021410/16/2000618547Information regarding revised engine mounts for severe duty vehicles. *jb04/16/2001
011101/22/2001618063On some vehicles, the engine mounts may not exhibit satisfactory durability under severe operating conditions that may be encountered by police, taxi or limo / livery vehicles such as extended idling at high ambient temperatures. *04/03/2001
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
0124612/10/2001630515Engine oil system priming procedures, service tips for reports of premature engine failure. *tt04/18/2002
021401/21/2002630001Some engine assemblies with aluminum cylinder heads repaired in-vehile have been found to leak coolant and/or oil from the cylinder head gasket area. *tt04/11/2002
0120510/15/2001627927Some vehicles may exhibit vacuum or air leaks in the intake manifold and / or engine system causing diagnostic trouble codes p0171 and or p0174. *tt02/26/2002
01211010/29/2001627768Some vehicles equipped with the romeo built 4.6l 2v engine may exhibit an engine oil leak or oil weepage from the cylinder head gasket at the right hand rear or the left hand front of the engine. *tt02/22/2002
1515808/01/2001624571Some vehicles may exhibit a fead belt jump-off toss. *yh11/07/2001
1502606/01/2001622846Some vehicles may exhibit a stall at idle after start-up condition. *tt10/23/2001
014703/05/2001619424Subject regarding engine oil recommendations for use in 2001 vehicles - sae 5w-20 motor oil. *tt05/30/2001
469908/01/1998615238On some vehicles, the engine may be overfilled with oil. this may be caused by misinterpretation of the oil level indicator (dipstick) markings. *tt01/09/2001
1344811/01/1999614618Some vehicles may exhibit engine oil that has a milky appearance at predelivery inspection due to condensation in the crankcase. *tt11/28/2000
1295007/01/1999610750Some vehicle engines may crank without starting. *tt05/12/2000
9981605/03/1999606420Ford motor company now recommends sae 5w-30 viscosity grade for servicing any ford gasoline-powered vehicle regardless of model year. *tt08/19/1999
994703/08/1999604763Engine experiencing roughness at idle due to exhaust system resonance. *tt05/12/1999
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
1177408/01/1998615274Some vehicles may exhibit a rattle noise from the exhaust system nvh damper on the left hand damper only. *tt01/10/2001
465608/01/1998615192Some vehicles may exhibit a rattle noise from exhaust system nvh damper on the left hand damper only. *tt01/03/2001
830004/01/2000613634Some vehicles may exhibit a bang / popping noise heard from the exhaust system during cool-down. **mr07/26/2000
1302507/01/1999610768Some vehicles may exhibit a bang popping noise heard from the exhaust system during cool-down. *tt05/12/2000
650607/01/1999610663Some vehicles may exhibit an exhaust moan / roar heard on slight acceleration and at speeds near 42 mph for single exhaust and near 62 mph on dual exhaust cars. *tt05/10/2000
1289306/01/1999606922Some vehicle may exhibit an exhaust moan hear on slight acceleration. *tt09/08/1999
98201010/12/1998603695Experiencing a buzzing or rattling noise from the exhaust system. *yc03/02/1999
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
05N0412/14/200510018959Extended coverage program 05n04 - extended coverage for composite intake manifold. this program is being provided as a settlement to a class action lawsuit. the terms of the settlement extend the coverage of the all-composite intake manif01/25/2006

Investigations


NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
ENGINE AND ENGINE COOLING
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK PLUG EJECTION FROM CYLINDER HEAD
 On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi
ENGINE AND ENGINE COOLING - ENGINE
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK PLUG EJECTION FROM CYLINDER HEAD
 On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK PLUG EJECTION FROM CYLINDER HEAD
 On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi

Consumer Complaints


Fail datemilesoccurencesPurchase date
ENGINE AND ENGINE COOLING
12/01/201190200
 Tl- the contact owns a 1999 mercury grand marquis. the contact stated that the vehicle would stall sporadically and without warning. a local mechanic diagnosed that the intake manifold would need to be replaced. the dealer was contacted, but denied any assistance with repairs to the defect. the manufacturer was not made aware of the failure and the vehicle was not repaired. the failure mileage was 90,200 and the current mileage was 91,000. kmj
12/01/201190200
 Tl- the contact owns a 1999 mercury grand marquis. the contact stated that the vehicle would at anytime. a local mechanic diagnosed that the intake manifold would need to be replaced. the dealer was contacted, but denied any assistance with repair to the defect. the manufacturer was not contacted. the vehicle was not repaired. the failure mileage was 90,200 and the current mileage was 91,000. nw
06/25/201080000
 Vehicle would shake violently at any speed from 45-80mph. took to a mechanic said the front end needed to be replaced. $800.00 later it still did it, then took back said the tires needed to be replaced although we had 80,000 mile tires, and only had 35,000 miles put on them. replaced the tires for $600.00. still shook, took to a different mechanic said it was the transmission failing. during scheduled maintainence found cracked intake manifold, antifreeze and oil in spark plugs, cleaned out changed spark plugs, ran fine until the manifold leaked more coolant into the spark plugs and now we are at square one. researched online found a bunch of places saying it was recalled, when i called the dealership they said no recalls. price of replacing the part was $615.00 if i had one alternator, or $650.00 if i had another.
03/08/2011183172
 While driving, (at any speed)the car's engine shut down several times. each time i heard a beep and warning lights came on- check engine, traction control and abs. after a minute or so, the engine would start normally. the engine shut down 6 times ! each time i heard the beep and warning lights illuminated including traction control and check engine lights. i was on my way home with my newborn in the car,it just cuts off, and it nearly caused an accident on the highway as many other cars almost ran into me because the car shut off while i was driving on the highway. this is a very dangerous condition, especially as power steering and power brakes are lost on shut-down. i am literally afraid of driving my vehicle as no one knows what is wrong with my vehicle. this needs to be addressed asap as someone could get seriously hurt or killed. including children!....by the way, this has been happening all week.
11/01/20091000001
 We never received notification of the manifold defect and recently discovered that there was a recall. our car is a 1999 grand marquis with cracked manifold intake. we took it to the local dealer and they said that they cannot do any warranty adjustments since the deadline was exhausted. we called summer of 2009 to let them be aware of this problem. though they were nice, they were still firm on denying us repair or adjustments under the law suit and recall. now what do we do since we never received notification nor were we aware of any problem with the car? *tr
01/11/200954300
 Tl* the contact owns a 1999 mercury grand marquis. he could not accelerate past 30-35 mph. the vehicle was taken to an authorized dealer for diagnostic testing. the technician stated that the failure was because of a plastic intake manifold. the vehicle was repaired with the replacements of a metal intake manifold and spark plugs. the following day after the service repair, he experienced rough idling while starting the engine cold. the authorized dealer was notified of the failure, but no remedy was available. the failure mileage was 54,300. the current mileage was unavailable.
08/10/2008520001
 Cracked intake manifold on a 1999 mercury grand marquis with only 52000 miles on it. cost $1200 to repair. was not notified of recall. 52000 miles is only about 4.3 years of actual use. it is unfair that low mileage drivers should be punished for conserving energy. *tr
11/19/20071500001
 I noticed coolant leaking from somewhere in the engine compartment, but initially had trouble finding where the leak was coming from. i finally discovered that the intake manifold was cracked at the plastic thermostat housing. *tr
06/24/2006158200112/15/2005
 Cracking plastic intake manifold on mercury v-8 car over heats due to water/coolant leaking looking into getting fixed. *jb
05/12/200594000101/09/2002
 Complete cracking of plastic intake manifold causing completer loss of coolant and $1400 repair with the new replacement metal manifold.
08/15/200367000
 I had to fix the leak 3 times. finally, my mechanic noticed the crack on the intake manifold. it is made of hard plastic! what in the world anyone would design such part in plastic? how can such material sustain extreme heat for long periods of time. i purchased new one and it is plastic again with a little improvement. but it is mostly plastic again. i believe this is service scam. you make parts to only last 4 years and make money from selling auto parts. the dealership person sold me the parts stated that he had sold 6 of them last week alone and he has it in stock all the time. you know the problem but failed to inform consumers. i want a satisfactory answer before buying another american car.
ENGINE AND ENGINE COOLING - COOLING SYSTEM
06/09/200465000
 I recieved noticed of intake manifold on fords passengers cars failure and of the settlement offered to repair and warrant said intake manifold.at that time i owned a 1999 grand marquis ls.before getting said notice i had took my car to landers ford dealership in jackson,ms hwy 80 west where the intake manifold was repaired by dealership because of failure out of pocket expense cost me $879.00 when i recieved noticed of lawsuit and or claims on said intakemanifold i returned to that dealership but was turned away with no resolve said dealership went out of business months later never to compensate me for out of pocket expense or giving me extened warranty info.ford corprate office refuse to help after i explain i had my receipts to said claim and gave me no lead way of what to do.now i am stuck with no warranty no out of pocket cost and the same car needing the same work done again here in 2011 ford handled this lawsuit claims very very poorly and info has it that ford has stop making the grand marquis and crown victorial.
07/14/2005103000107/11/2005
 I have a 1999 mercury grand marquis. the plastic intake manifold cracked. i have learn that this is a problem alot of people have with the ford vehicles.
ENGINE AND ENGINE COOLING - ENGINE
01/18/2010120000
 Cracked the air intake on my 1999 mercury grand marquise. it was made out of cheap plactic. i had to step on the throttle to get out of the way, and my car started steaming. come to find out, the intake manifold cracked. it's only $300 for the part, not including labor.
02/08/2010680001
 Fatigue cracking of the coolant crossover passage of the all nylon-composite intake manifold on our 1999 mercury grand marquis. (vin # [xxx]). component has failed, resulting in replacement, costing $888.00 component was subject to recall (http://fordmanifoldsettlement.com/notice.html). contacted ford customer care phone line. they have refused to compensate us or this repair. information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6). *tr
04/03/2004680000303/10/2000
 My 1999 mercury grand marquis has a persistant oil leak from the right rear of the engine head that is exactly as described in ford motor company's technical service bulletin 02-22-07.*ak the dealership, irvine lincoln mercury, has had three tries to correct the problem under warranty and have failed to succeed. the warranty expired last month and now they say that i will have to pay to have the problem repaired even though the unresolved complaint condition goes back well into the warranty period.
05/03/200460000203/18/2000
 While driving 55 mph a loud noise was heard coming from the front. vehicle then stalled. consumer restarted the vehicle and pull over. then, consumer noticed that oil leaked underneath. consumer drove vehicle to the dealer for inspection, and mechanic determined that the cylinder head cracked, and needed to be replaced (20794 miles). *ak recently the consumer noticed another oil leak which appeared to be the same as that from the first cylinder head. the service manager inspected the vehicle and concluded that oil was leaking from the cylinder head again (59700 miles). *nm
11/17/200340000212/02/2000
 Problem: the car was diagnosed with a leaking head gasket & defective manifold. cost to repair $2504.80 (i paid it) i brought the car in on 11/17/03 and got it back 11/20/03. i was told the repair was complete. as i drove it off the lot the car shimmied and stalled. the car was brought right back and they still are working on it as of 11/21/03 9am. history of problem at ford: ford has issued the following technical service bulletins for these two problems ( from www.alldata.com ) 03-6-2 mar 03 engine - oil leak from r/h cylinder head gasket 02-1-4 jan 02 engine head gasket - approved replacement procedures 01-21-10 oct 01 engine - oil leaking from head gasket 02-2-2 intake manifold - cross-over channel coolant seepage according to www.lemonaidcars.com ( www.gm-v6lemons.com/mediaattn.htm )the ford 4.7 liter has had these problems before and caused ford to extend warranties to 6 yrs./ 75,000 miles on older models (www.autosafety.org/article.php?did=121&scid=59 ). they also know the manifold part used to original make the engine is defective. the repairs are costing me $2504.80 with no help from the dealer or manufacturer. *la
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
05/27/2002208/15/2001
 Consumer started vehicle at a cold start and pulled out, then came to a stop. consumer pressed the accelerator and vehicle stalled out.*ak *mj
08/16/2000109/25/1998
 Engine fire. *ak engine went on fire in driveway of home. *yh
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
12/14/200787500111/26/1998
 Tl*the contact owns a 1999 mercury grand marquis. while driving at an unknown speed, the vehicle hesitated, stalled, and the check engine light illuminated on the instrument panel. the vehicle also began to loose coolant. the vehicle was taken to a dealer and they discovered that the intake manifold was cracked. there was no recall on the intake manifold. the current mileage was 88,000 and failure mileage was 87,500.
08/08/2007123052303/01/2000
 Tl*the contact owns a 1999 mercury grand marquis. while driving 45 mph, the temperature gauge on the vehicle began to increase. the contact pulled over to allow the vehicle to cool before driving home. once she arrived home, she noticed smoke rising from the front end of the vehicle. this same failure has previously occurred twice. the vehicle was taken to a mechanic and he stated that the intake manifold needed to be changed. the current and failure mileages were 123,052.
04/28/2007138000105/29/1999
 Had spark plugs replaced. one plug exploded. was told by ford dealership service mechanic the intake manifold was cracked. car was running fine before plugs were replaced. intake manifold is plastic. (this was an issue with the 1997 model.) did the repairman crack the manifold? why is replacement part still plastic? ford/mercury price for part is $598.06; napa is $281.00. *jb
11/29/200677980109/01/1995
 Dt*: the contact stated while driving 40 mph, the engine hesitated and idled badly at a stop. the contact replaced the fuel filter, but problem continued. when taken to an independent service dealer, the diagnostics showed the manifold was cracked. the manufacturer was notified. the consumer stated the vehicle would sjip and jump. updated 12/18/06. *jb
710001
 Intake manifold blew out, sending fuel into the engine. the intake manifold was replaced. *ak
11/17/200340000212/02/2000
 Problem: the car was diagnosed with a leaking head gasket & defective manifold. cost to repair $2504.80 (i paid it) i brought the car in on 11/17/03 and got it back 11/20/03. i was told the repair was complete. as i drove it off the lot the car shimmied and stalled. the car was brought right back and they still are working on it as of 11/21/03 9am. history of problem at ford: ford has issued the following technical service bulletins for these two problems ( from www.alldata.com ) 03-6-2 mar 03 engine - oil leak from r/h cylinder head gasket 02-1-4 jan 02 engine head gasket - approved replacement procedures 01-21-10 oct 01 engine - oil leaking from head gasket 02-2-2 intake manifold - cross-over channel coolant seepage according to www.lemonaidcars.com ( www.gm-v6lemons.com/mediaattn.htm )the ford 4.7 liter has had these problems before and caused ford to extend warranties to 6 yrs./ 75,000 miles on older models (www.autosafety.org/article.php?did=121&scid=59 ). they also know the manifold part used to original make the engine is defective. the repairs are costing me $2504.80 with no help from the dealer or manufacturer. *la