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 - RADIATOR ASSEMBLY | |||||
| 031411 | 07/21/2003 | 10003751 | Radiator alignment pin ground clearance. *tt | 10/29/2003 | |
| 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 | |
| 0531 | 02/21/2005 | 10012947 | Maf diagnostic service tip - vehicles equipped with egr system module (esm). *tt | 04/05/2005 | |
| 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 |
| 04145 | 01/01/2004 | 10009327 | Engine vibration at idle on vehicles equipped with single exhaust. *tt | 09/23/2004 | |
| 02177 | 09/02/2002 | 10008581 | Cooling system-motorcraft premium gold engine coolant-serivce tips. *mj | 08/05/2004 | |
| 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 | |
| 0421 | 02/09/2004 | 10007363 | Engine knock during initial cold start, the knock will cease after the engine is fully warmed up. *tt | 06/16/2004 | |
| 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 | |
| 17031 | 08/01/2003 | 10003157 | Malfunction indicator lamp on with diagnostic trouble code p0316 (only) stored in memory. *tt | 10/09/2003 | |
| 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 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||||
| 0524 | 02/07/2005 | 10012940 | Idle vibration vehicles equipped with single exhaust. *eh | 04/04/2005 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR | |||||
| 04E12 | 09/01/2004 | 10010000 | Emission related service action 04e12. vehicles serviced with an incorrect right hand catalytic converter. inspect and replace right hand catalytic converter. attachments i-iii and customer notification letter. *tt | 11/03/2004 | |
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 | |||
| 08/01/2005 | 1000 | 1 | |
| 2003 grand marquis developed problems with the alternator, the throttle sticking open and alignment problems.*mr there was also a rattle noise coming from the engine and the digital readout on the dash was not reading properly. *tt | |||
| 09/16/2003 | 500 | 4 | |
| While driving at 45 mph vehicle stalled. also, early in the morning it was hard to start vehicle. vehicle was checked by the dealer, who couldn't find the cause of the problem.*ak | |||
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||
| 01/01/2010 | 114000 | 1 | |
| The plastic intake manifold of my 2003 mercury 4.6l v-8 came apart and let the coolant leak out onto the engine.this car was built in canada in mid-2002 the problem is rampant in many years of the ford co cars. and in 2001 a class action suit was filed, in which ford was directed to pay damages to all owners (1,800,000 owners) of this type of engine and ford was supposed to stop installing that item as of then. clearly they did not stop and that failure cost me over $1000.00 to repair. the repair part is now partly aluminum and part plastic. see: http://www.consumeraffairs.com/news04/2005/ford_manifold_suit.html. *tr | |||
| 06/25/2003 | 103000 | 1 | 05/28/1997 |
| My wife was driving our 1997 mercury marquis home in heavy traffic. suddenly steam began pouring out from under the hood and the hot light went on. she pulled to the edge of the road and called me. i sent a tow truck to bring the car to our home. i looked and could see water all over the engine and perhaps a hose broken. rather than tow it to the dealership, 20 miles away, i called a quality garage locally that i had dealt with before. they said the intake manifold was cracked, the water pump leaking as a minimum. the cost to replace and fix everything was $1075. while calling around for parts, the mechanic discovered that this was a common problem and ford had recalled police and city fleet vehicles for upgrade to fix this problem. upon checking with the mercury shop foreman, he confirmed that story. since i had a 100,000 mile warranty that had expired only a few months prior, i asked why ford would not help pay for the damage. i was told it was not covered. i asked why, knowing that this problem existed, why they had not fixed it under the warranty. i was told they never thought of it. lousy service, lousy engineering and i now drive a toyota. *nm | |||
| 07/26/2004 | 10000 | 1 | |
| Engine made a loud knocking sound. vehicle was taken to the dealer several times since purchase. dealer stated that there was no sound, nothing was done. another outside mechanic told him it sounded like a bearing. dealer stated that the right cylinder had to be replaced, and the vehicle was still at dealer. *ak | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 06/09/2007 | 36000 | 1 | 04/08/2007 |
| Tl*the contact owns a 2003 mercury grand marquis. while driving 10 mph, the engine began to rev and the brakes failed. the contact stated that it sounded as if the transmission snapped. the dealer stated that nothing was wrong with the vehicle, however recalls were issued for that model of vehicle. the vehicle has been at the dealer for two weeks. the powertrain was unknown. the current and failure mileages were 36,000. | |||
| 02/18/2007 | 36200 | 3 | 08/16/2003 |
| Tl*- the contact stated that while driving his 2003 mercury grand marquis (36200 failure mileage) and attempting to stop at a red light, with his foot on the brake, the vehicle accelerated and got away from the contact for about one yard. the contact had to forcefully apply the brake again, but nothing happened. while the vehicle was still accelerating, the contact had to put the vehicle in neutral and turn the power off. the vehicle was taken to a dealer, who discovered that a defective 2w7z-9f715-ba valve 226 had to be replaced. the current mileage was 36,780 miles. | |||
| 12/29/2002 | 39 | 1 | 12/29/2002 |
| Nar 02/28/2003 mr consumer experinced problems with engine since delivery of the vehicle. *cb | |||
| 03/31/2003 | 26890 | 25 | 10/10/2002 |
| 2003 mercury grand marques stalls at or near idle speed. has stalled when backing up, when starting forward from stop at traffic light. have had it into the dealer, ray pearman lincoln mercury 4 time for a total of 9 days. they have been unable to fix problem as of yet. the dealer confirmed that there was a stalling problem. they have replaced the idle air control valve and the mass air flow sensor. each time they thought they had it fixed and had me take the car, it has stalled again. one time it stalled as i was backing out of the dealer service department. it is currently at the dealer and they are trying to find the problem. *ak | |||
| 01/11/2003 | 1 | ||
| While waiting in line for gas with foot on brake, engine started to race. engine continued to race when car was put in neutral and then park. turned engine off and restarted, racing did not reoccur after restarting.*ak | |||
| 06/28/2003 | 1 | 10/14/2002 | |
| After starting and shifting into drive the engine raced and there was unexpected acceleration and the car would not stop even while applying brake. turned vehicle off after crash and the engine continued to sound like it was running. *ph | |||
| 12/24/2003 | 39 | 1 | |
| There was a severe vibration in the engine, when the vehicle idled. *jb there was a general chassis vibration at speeds of 38 which was attributed to out of rounds tires.*ts | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||
| 1 | 02/21/2003 | ||
| Stainless steel exhaust was rusted. *mr the vehicle had a stainless steel exhaust. after the return from florida where they stayed for winter, the exhaust system was found rusted. *scc *jb | |||