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 |
| 0222 | 02/04/2002 | 630628 | Some vehicles may exhibit an intake manifold crossover (first runner) coolant seepage condition. *tt | 04/19/2002 | |
| ENGINE AND ENGINE COOLING - COOLING SYSTEM - FAN | |||||
| 15893 | 05/01/2002 | 637773 | Some vehicles may exhibit an inoperative engine cooling fan. *tt | 12/06/2002 | |
| 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 | |
| 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 |
| 16380 | 11/01/2002 | 10008319 | Service cylinder head gasket for 4.6l applications. *tt | 07/27/2004 | |
| 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 | |
| 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 | |
| 03157 | 08/04/2003 | 10003187 | Grinding type noise from the timing chain area. *tt | 10/10/2003 | |
| 03164 | 08/18/2003 | 10003118 | Some vehicles, equipped with the 4.6l 2v engine, with an engine build date prior to 8/29/03 may exhibit an engine tick noise that is present at all temperatures during idle. 2004 models included. *tt | 10/08/2003 | |
| 0322 | 02/03/2003 | 10002472 | Streamlined diagnostic procedure for vehicles with malfunction indicator lamp (mil) on and diagnostic trouble codes (dtcs) p0401, p0402, p1400 or p1401, or runs rough, lacks power, surge, poor fuel economy, and the above listed dtcs without | 09/03/2003 | |
| 15793 | 04/01/2002 | 637509 | Some vehicles may exhibit a slight oil leak at the cylinder head to block joint. *tt | 12/02/2002 | |
| 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 | |
| 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 | |
| 00214 | 10/16/2000 | 618547 | Information regarding revised engine mounts for severe duty vehicles. *jb | 04/16/2001 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||||
| 15850 | 05/01/2002 | 637694 | Some vehicles equipped with a 4.6l romeo engine may exhibit a slight oil leak or weep at the cylinder head to block joint. *tt | 12/04/2002 | |
| 15881 | 05/01/2002 | 637746 | Subject regarding engine stumble / hesitation cold only condition. *tt | 12/04/2002 | |
| 16068 | 07/01/2002 | 636263 | Some vehicles may exhibit an engine vibration at 1100-1500 rpm. *tt | 11/07/2002 | |
| 0254 | 03/18/2002 | 636045 | On some vehicles equipped with the 4.6l engine, the front end accessory drive (fead) belt may hydroplane on the water pump pulley whenthe belt is splashed with water. *tt | 11/04/2002 | |
| 15668 | 02/01/2002 | 630732 | Concerns with hesitation/stumble , cold only , when shifting from park to drive or park to reverse. *tt | 04/23/2002 | |
| 01246 | 12/10/2001 | 630515 | Engine oil system priming procedures, service tips for reports of premature engine failure. *tt | 04/18/2002 | |
| 15415 | 11/01/2001 | 630431 | Some vehicles may exhibit an engine vibration between 1100-1300 rpm when the transmission is placed in either park or neutral. *tt | 04/17/2002 | |
| 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 | |
| 15158 | 08/01/2001 | 624571 | Some vehicles may exhibit a fead belt jump-off toss. *yh | 11/07/2001 | |
| 15026 | 06/01/2001 | 622846 | Some vehicles may exhibit a stall at idle after start-up condition. *tt | 10/23/2001 | |
| 0147 | 03/05/2001 | 619424 | Subject regarding engine oil recommendations for use in 2001 vehicles - sae 5w-20 motor oil. *tt | 05/30/2001 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||||
| 16412 | 11/01/2002 | 10008342 | Sulphur smell from exhaust under investigation (qsf). *mj | 07/28/2004 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE) | |||||
| 02M01 | 06/01/2004 | 02M01 | 10007207 | Customer satisfaction program 02m01 supplement #4. certain ford 2000 through 2003 vehicles equipped with a tube-mounted egr pressure sensor - additional egr pressure sensor warranty coverage. *tt supplement #3. *mj supplement #6 | 06/03/2004 |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||||
| 05N04 | 12/14/2005 | 10018959 | Extended 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 manif | 01/25/2006 | |
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 | |||
| 01/31/2013 | 82700 | 1 | |
| My father in law was driving my vehicle when a gmc yukon pulled out in front of him. my father in law hit the side of the yukon and only one air bag deployed which was the passanger side,my father in law was taken to the hospital bc of no feeling below his waist and the paramedics were unable to stabilize his blood pressure. *tr | |||
| 01/31/2013 | 82700 | ||
| My father in law was driving my vehicle when a gmc yukon pulled out in front of him. my father in law hit the side of the yukon and only one air bag deployed which was the passanger side,my father in law was taken to the hospital bc of no feeling below his waist and the paramedics were unable to stabilize his blood pressure. | |||
| ENGINE AND ENGINE COOLING | |||
| 04/07/2011 | 164200 | ||
| While driving my 2001 mercury grand marqui i heard a noice from the engine compartment inmediatelly the engine sounded very loud as if there was an exhaust leak, the engine started running very rough and the check engine light came on, after checking found that the rear spark plug on the right side of the engine had been blown out of its socket and it broke the ingnition coil, gas would spray out of the spark plug cavity creating an unsafe condition, i had to buy a repair tool kit and a new coil and spark plug to repair the prpblem because the dealer (nick mayer in west lake, ohio would not fix it even though i only had the car for 6 days, they said that it was a used car with no warranty so they would not work with me, it ended up costing me over $100.00 to fix a problem that the dealer or manufacturer should had been force to correct. | |||
| 10/15/2008 | 92374 | 1 | |
| Temp gauge is not connected. i recently had to have the replace the intake manifold and the shop informed me that there was nothing to connect it to. *tr | |||
| 05/06/2008 | 124301 | 1 | |
| Small piece of plastic from intake went into the cylinder #4 and rapped around one of the values causing this value to stay open so cylinder #4 has no compression. *tr | |||
| 03/01/2005 | 1 | 11/01/2000 | |
| The head gasket on the consumer's 2001 mercury grand marquis leaked oil. *nm *sc the problem was caused by metal chips left between the head gaskets and block. *jb | |||
| 02/01/2005 | 2 | ||
| Re: defect in the ford motors, inc. engine produced at romeo engine plant, romeo michigan. *bf the vehicle leaked oil out of the right, rear area of the head near the valve cover. six months prior, the consumer's wife smelled oil burning. the consumer stated that he changes his own oil, and never noticed an oil leak. *sc *jb | |||
| 12/15/2001 | 20000 | ||
| Consistent problem with turn signal and air-conditioning malfunction. fuse blows-no turn signal or air conditioning. possible electrical problem and safety/fire hazard. cerame dealership in st. louis, mo has not been unable to locate the problem. dealership service has replaced one wire and a sensor. problem still exists. taking vehicle back to dealership to resolve 6/23/03. | |||
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||
| 08/26/2009 | 128000 | 1 | |
| Intake manifold cracked, and busted, resulted in towing. *tr | |||
| 09/04/2004 | 36000 | 3 | |
| Engine coolant light kept coming on. vehicle shut down. this occurred when driving at any speed. vehicle began to down shift. it drove erratically. consumer took vehicle to dealership on several occasions. dealership provided some services that were non effective to the problem. *ak | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 08/01/2009 | 102000 | 1 | 08/22/2001 |
| Tl*the contact owns a 2001 mercury grand marquis. the composite intake manifold which is where the thermostat mounts into the head of the motor has failed. the vehicle was repaired by a local mechanic. the contact stated that the dealers fee would exceed the local mechanic | |||
| 03/02/2007 | 18200 | 6 | 10/17/2001 |
| My sister and i'm writing this report on her behalf. her car is a 2001 mercury grand marquis. last month, (feb '07) while driving, the car's engine shut down several times. each time she heard a beep and warning lights came on- check engine, traction control and another she can't recall. after a minute or so, the engine would start normally. she took it to the ford dealer, sawgrass ford in sunrise, fl. the problem recurred and she again took the car to the dealer. the last time they found a transmission problem and repaired it. (the transmission had been giving problem, but she took the car to repair the shut-down problem). yesterday (mar 1, 2007) the engine shut down 4 times ! each time she heard the beep and warning lights illuminated including traction control and check engine lights. she was on her way home and it nearly caused an accident as another car almost ran into her. the car is to go back to sawgrass ford (for the third time) on monday, mar 5 '07. the car will be towed, not driven, as this is a very dangerous condition, especially as power steering and power brakes are lost on shut-down. interestingly, i had the same problem with my 2000 grand marquis im may and june 2005 . i reported this to you (nhtsa) and you wrote me back, assigning ref.# 10141074. my problem was found to have been caused by a single defective spark plug ! the plug was replaced and the car has functioned normally since. the real problem was with the programming of the power control module which was confused and overwhelmed by one bad spark plug. in 2005 i wrote numerous letters to ford and they were completely unresponsive. engine shut-downs on mercury grand marquis are a serious safety issue and should be corrected. sincerely, | |||
| 04/18/2005 | 31000 | 4 | 01/06/2001 |
| While making a right turn into a parking space the engine lost power which resulted in the steering wheel and gear shift locking up. the dealer stated they could not duplicate the problem. *ak consumer got out of car and rocked it back and forth for a few minute. het got back into the car and tried to move both the wheel and the gear shift. after about 5 minutes of this they both unlocked and the car was ok for 5-6 months. *bf | |||
| 34000 | 1 | 05/11/2003 | |
| When stopping or braking the vehicle shut off. the vehicle was taken to the dealer. the dealer indicated that the vehicle's warranty was expired. *ak the consumer felt that the dealer should repair the vehicle free of charge since the original defect occurred while the vehicle was still under warranty. *nm | |||
| 09/12/2003 | 1 | ||
| Consumer states she has an idle air control valve problem. she states that sometimes when she attempts to start her vehicle, it acts as if it wants to cut off. then there are times when she is driving and has to stop, then the vehicle cuts off. *ph the consumer talked to another consumer with the same problem and had come to the conclusion that a recall should be issued. *scc *jb | |||
| 06/01/2001 | 125 | 9 | 05/31/2001 |
| While driving at 40 mph, the vehicle shimmied in the front. the vehicle was taken to the dealership, where the mechanic re-balanced and aligned the tires. the problem still existed after being taken to an independent mechanic. this was an on going problem since the beginning of purchase. the consumer had an adjudication to take the vehicle back to the dealership. *ak the vehicle had been back to the dealer on many occasions for the shimmy in the front. the dealership replaced all four tires and the driveshaft assembly. the vehicle developed an oil leak that was also ongoing, so the dealer replaced the oil pan/oil pan gasket and the rear main crank shaft seal. the ignition coil assembly had to be replaced as well. when the weather was cold, the hood would not pop open and the right front door did not close properly. *scc *jb | |||
| 09/21/2002 | 22047 | 1 | 09/01/2001 |
| Consumer stated there was a rattling noise coming from the engine when cold, dealer informed consumer the timing gear needed to be replaced, also the dashboard vibrated, however dealer stated nothing was wrong, the trim panel was loose on the door, the left front door closed too hard, the vehicle would lean to the left and there was a noise coming from the front of the vehicle when turning a corner, dealer replaced the front frame supports, the instrument cluster was scratched, the steering column trim was replaced, the radio had a poor reception, there was a pulsation coming from the brakes, however the dealer could not duplicate the problem. ph *jb | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| 08/01/2002 | 1 | 07/24/2002 | |
| While driving 45 mph, vehicle suddenly gave a jerk and engine died. consumer was able to restart vehicle. consumer felt if this happened on highway someone could have been killed. *ak the vehicle has jerked several more times since then. the dealer conducted numerous tests but could not locate the cause. the engine has not died since the first incident. *jg | |||
| 1 | 10/19/2001 | ||
| The engine idles roughly and the vehicle developed an oil leak after it had been worked on by the dealer. *yh | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||
| 08/01/2004 | 1 | ||
| Engine head gasket leaks oil/fluid down onto the catalylic converter, which could lead to a fire. there is a tsb on this particular issue. *ak | |||