Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING - COOLING SYSTEM
1406204/01/2000613705Some vehicles may exhibit a cooling system leak due to a broken constant tension clamp. **mr07/27/2000
853404/01/2000613665Some vehicles may exhibit a cooling system leak due to a broken constant tension clamp. **mr07/26/2000
ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY
1461701/01/2001617995Subject pertaining to broken thermostat. *jb04/03/2001
1458301/01/2001617968Concerns with broken thermostats on engines. *jb04/02/2001
ENGINE AND ENGINE COOLING - ENGINE
0222111/11/200210008304Engine-gear driven synchronizers-incorrect installation-camshaft position synchronizer (cmp) installation tool correct application. *mj07/27/2004
0319909/29/200310004038Rattle/buzz sound from under the vehicle on 4.0l single overhead cam (sohc) engines. *tt11/14/2003
033502/17/200310002482Idle air control (iac) valve diagnostic service tips. *tt09/03/2003
87019710/22/200210000592Incorrectly installed gear driven camshaft position (cmp) sensor synchronizer assemblies causing surge, lost of power, malfunction indicator lamp on and diagnostic trouble codes p1336, p1309 and p0340. *tt03/25/2003
1456001/01/2001617944Vehicles may experience start up timing chain noise. *jb04/02/2001
00M1211/01/2000616507Ford motor company is providing additional coverage for the 4.0l sohc camshaft chain tensioner and lower intake manifold gasket. *tt03/01/2001
1310108/01/19996091905Subject regarding the sbds relative cam timing test. *tt11/16/2000
1404804/01/2000613703Some vehicles may experience an oil leak at the rear crankshaft area after service. **mr07/27/2000
849304/01/2000613654Some vehicles may experience an oil leak at the rear crankshaft area after service. **mr07/26/2000
713810/01/19996090757Service tip information when servicing the 4.0l sohc short block assembly. *tt03/29/2000
1326009/01/19996090690Service tips information provided to assist when servicing vehicles with short block assembly. *tt03/23/2000
1317009/01/19996090518Information regarding 4.0 l sohc camshaft bolt torque. *mjs03/21/2000
1318109/01/19996090540Information regarding camshaft position (cmp) sensor alignment tool chart (continued). *mjs03/21/2000
699709/01/19996090310Some service manuals may list the incorrect camshaft position sensor alignment tool for vehicles with various engine sizes. *tt03/14/2000
698609/01/19996090291Information regarding 4.0l sohc camshaft bolt torque. *tt03/13/2000
991309408/01/1999609039Concerns with 4.0l sohc engines equipped vehicles exhibiting an oil leak from the oil pressure switch boss of the engine block. *tt12/07/1999
99687408/01/1999608805Subject pertaining to the sbds relative cam timing test which has been temporarily removed from use on some vehicles due to noise concerns. *tt12/06/1999
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
028104/29/2002637920Some vehicles equipped with the 4.0 sohc (single over-head cam) engine may exhibit a primary timing chain rattle noise. *tt12/09/2002
027604/15/2002636013Information on diagnosing engine rattle noise from primary chain drive area between 2000-3000 rpm on cold engine operation only. *tt11/04/2002
1549612/01/2001630605Some vehicles built before april 23, 2001 may exhibit a hard start/long crank after sitting for an hour or more due to fuel system contamination. *tt04/18/2002
0124612/10/2001630515Engine oil system priming procedures, service tips for reports of premature engine failure. *tt04/18/2002
1547012/01/2001630576Concerns with spark knock noise or chain rattle noise between 2000-3000 rpm, during cold engine operation only. *tt04/18/2002
1542211/01/2001630442Some vehicles may exhibit a hard start/long crank condition after sitting for an hour or more. *tt04/17/2002
1556701/01/2002630105Some vehicles built before april 23, 2001 may exhibit a hard start/long crank after sitting for an hour or more. *tt04/12/2002
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
1486804/01/2001619337Some vehicles equipped with the 4.0 sohc engine may exhibit a primary chain rattle noise (sometimes described as a spark knock-type noise). *tt05/23/2001
00M1212/01/2000616816Subject regarding owner notification suppllemental program for vehicles equipped with 4.0l sohc engines - camshaft chain tensioner and lower intake manifold gasket additional coverage. *tt03/13/2001
1333410/01/19996092156Some vehicles equipped with 4.0l sohc engine may exhibit a hesitation on acceleration during engine warm up. *tt11/27/2000
1333510/01/19996092158Some vehicles equipped with 4.0l sohc engines may exhibit a slight hesitation on acceleration during engine warm up. *tt11/27/2000
1330010/01/19996092122Some vehicles with 4.0l sohc engines may exhibit a vibration / moan / boom at idle. *tt11/27/2000
1326109/01/19996091661Service tips when servicing a 4.0l sohc short block assembly. *tt11/09/2000
1409004/01/2000613716Some vehicles may exhibit a hard start / no start condition when attempting to start the vehicle. *tt08/07/2000
727010/01/19996090871Some vehicles equipped with 4.0l sohc engines may exhibit a vibration / moan / boom at idle. *tt03/31/2000
724810/01/19996090832Vehicles equipped with 4.0l sohc engine may exhibit a slight hesitation on acceleration during engine warm up. *tt03/30/2000
1317109/01/19996090520Information regarding 4.0l sohc engine noise (cam chain noise). *mjs03/21/2000
1317209/01/19996090522Information regarding sohc engine noise (cam chain noise). *mjs03/21/2000
1317709/01/19996090532Information regarding 4.0l sohc engine repair procedure update. *mjs03/21/2000
699309/01/19996090303Subject regarding 4.0l sohc engine repair procedure update. *tt03/14/2000
698709/01/19996090293Some vehicles may exhibit engine noise(cam chain noise). *tt03/13/2000
9922310/18/19996089683A no start condition when vehicle is parked on an incline with the vehicle in a nose down position and less than 1/4 tank of fuel may occur. *tt02/11/2000
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
1401003/01/2000612966Some vehicles built through 11/22/99 and equipped with 4.0l sohc engine may exhibit various driveability conditions that lead to idle air control (iac) valve replacement. *tt06/14/2000
842003/01/2000612845Some vehicles built through 11/22/99 and equipped with 4.0l sohc engine may exhibit various driveability conditions that lead to idle air control (iac) valve replacement. *tt06/13/2000

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
07/13/2004580002
 Consumer noticed an extreme amount of fluid in the driveway which did not appear to be oil. after taking the vehicle to the dealer it was discovered that head gasket blew out. consumer had the repairs done. less than two months later, while driving , the gears would not connect properly. consumer had to have the transmission replaced.*ak
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
09/01/200124000102/07/2000
 Consumer stated upon starting vehicle, vehicle engine would not turn over. dealer was contacted. engine needed to be replaced. mr *tt
02/09/2000412/01/1999
 The engine experiences noises and misses, several repair attempts however the dealership has not been able to rectify problems. *mjs
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
01/17/200541308310/04/2001
 Oxygen sensor. replaced by ford on 1/17/05. has 69336 miles.11/14/04 replaced air filter in order to extend life of o2 sensor. 2/5/04 weak fuel pump 49804 miles. 10/13/03 oxygen sensor replaced. 45742 miles. 10/9/03 mass air flow sensor replaced. 45616 miles. 8/21/03- replace iac. 43536 miles. 5/22/03 replace oxygen sensor. 41308 miles. *ak