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 |
| 18572 | 04/01/2005 | 10017881 | No start/hard start n hot soak restart. *tt | 12/06/2005 | |
| 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 | |
| 051313 | 01/01/2005 | 10016798 | Hard start/no start condition during cold ambeint temperatures after short hot soak period-4.0l engine. *sc | 10/07/2005 | |
| 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 |
| 041910 | 10/04/2004 | 10010719 | Oil leak from oil filter adapter - 4.0l sohc engine built before 4/1/2004. *tt | 12/07/2004 | |
| 02177 | 09/02/2002 | 10008581 | Cooling system-motorcraft premium gold engine coolant-serivce tips. *mj | 08/05/2004 | |
| 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 | |
| 17326 | 11/01/2003 | 10008171 | Engine auxiliary oil cooler line and the right side motor mount squeaking noise from front exterior while driving over bumps. *tt | 07/22/2004 | |
| 17544 | 02/01/2004 | 10008115 | Generator noise in cold ambient temperatures. *mj | 07/22/2004 | |
| 16508 | 01/01/2003 | 10005087 | Vibration condition. contact request st. louis region. oasis. *tt | 01/29/2004 | |
| 17167 | 09/01/2003 | 10004060 | Multiple vehicles with 3.0l or 4.0l engines lacks power/runs rough/black smoke. 2004 sport trac included. *tt | 11/17/2003 | |
| 16968 | 07/01/2003 | 10003844 | Driveability conditions due to calibration vehicles equipped with the 4.0l sohc engine. idle air control (iac) valve replacement for these symptoms is typically not effective. *tt | 11/04/2003 | |
| 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 | |
| 17049 | 08/01/2003 | 10003162 | Rough idle / engine shake. *tt | 10/09/2003 | |
| 17069 | 08/01/2003 | 10003176 | Rough/rolling idle or hesitation after first startup or a rough/rolling engine speed when returning to idle after a short trip. *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 | |
| 16771 | 04/01/2003 | 10002658 | Rough / rolling idle and hesitation on acceleration after a first cold startup. *tt | 09/10/2003 | |
| 16902 | 06/01/2003 | 10002613 | Engine roughness / rolling rpm when returning to idle (i.e., coming to a stop) after a short trip. *tt | 09/08/2003 | |
| 0335 | 02/17/2003 | 10002482 | Idle air control (iac) valve diagnostic service tips. *tt | 09/03/2003 | |
| 870197 | 10/22/2002 | 10000592 | Incorrectly 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. *tt | 03/25/2003 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||||
| 02216 | 10/28/2002 | 10013064 | Excessive sulfur smell from exhaust. *eh | 04/07/2005 | |
| 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 |
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 | |||
| 09/02/2011 | 134600 | ||
| We have experienced two well known issues with the explorer/mountaineer. the body panel on the back hatch is cracked in the middle and friday we had the spark plug blow out of the head/socket stripping the threads out to the point that the common repair kit used for these instances won't work and the only solution is a replacement head which is quoted at a $3500 job and the vehicle is only worth about $5700. i understand ford accepts no responsibility for this engine/head defect despite the fact that it has occured on factory tightened plugs. | |||
| 05/23/2007 | 74494 | 3 | 12/30/2002 |
| Tl*the contact owns a 2003 mercury mountaineer. the contact stated that the rear driver's side wheel bearing was replaced 3 times within 16 months. on october 1, 2008, while driving out of the driveway at an unknown speed, she heard a loud noise. the vehicle was towed to the repair shop and the mechanic stated that the rear driver's side wheel bearing failed. the contact stated that the vehicle was not driven on dirt roads, only in the city. she feels that either the wheel bearing is defective or the ford dealer did not properly correct the previous failures. the ford dealer stated that the vehicle is out of warranty and the wheel bearing is only good for 12,000 miles. the manufacturer took a report and stated that they will forward her information to the dealer. from there, the dealer will determine if the vehicle will be repaired. the failure mileage was 74,494 and current mileage was 104,000. updated 11/14/08 *cn the driver side visor was hanging down, the vehicle stalled on several occasions. the lower ball joints and outer tie rod ends were replaced. the rear hatch window cracked. the vehicle would crank, but it would not start. updated 11/18/08. *jb | |||
| 08/19/2003 | 6 | 01/01/2003 | |
| The problem persisted and concern with stalled vehicle, serviced and problem still continue. *bf these problems elevated to vehicle stalling, the alternator was replaced, there were continuous occurrences of the battery fail/check engine indicator light, vibration when braking, and the torque converter locked. the consumer requested a new lease and or early termination of the lease. *sc | |||
| 30 | 1 | ||
| Vehicle stalls when coming to a complete stop. dealership cannot duplicate the problem, and are unable to fix it.*ak | |||
| 05/01/2003 | |||
| Consumer stated that while driving and without warning the vehicle will surge forward causing a distraction to the consumer. dealer notified | |||
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||
| 01/03/2010 | 60000 | 1 | |
| I have 2003 mercury mountaineer and i have had it since february 2007. i have had numerous problems with it and the last problems was the breaking point. i have three more years to pay for this vehicle and i want something to be done about the problems with this vehcile. ford should be held responsible for this vehicle and fixing the problems associated with it. i purchased this vehicle from community ford in new albany, ms in february 2007 with 45,000 miles on it. i couldn't get an extended warranty or any warranty with the vehicle i was told. after a year, i had to replace the front end and it was $500.00 at george's tire services. i took it in due to this noise coming from the front and i was advised that if i didn't have the work did it would lock up on me while i am driving and cause and accident. i noticed that my structure body:hatchback/tailgate has cracked completely. my seat belt on the driver side in the back don't work. my engine cooling system aircompressor has went out and i have electrical problems where my oil gauge is constantly saying it's low. i have my oil change every 3000 miles. i am hearing this noise in the rear of the vehicle and i don't know what it is and can't afford to get going to ford to see what it is. i have been smelling this burning coming from the under the hood and i don't know what it is either. my lastest problem is my transmission is going out and i have had this vehicle for two years and i have three more years of payment on this vehicle. my transmission cost me around $3500 and i don't have any warranty on it. this is a lemon i have purchased and i think something should be done about it. *tr | |||
| 11/13/2008 | 85000 | 1 | |
| The heater stop working 3 different times, the first time they replaced the thermostat, 2nd could not find anything wrong, dealer thinks might be intake manifold or head gasket, 3rd time say must take it apart to figure out but pressure test are within normal range. *tr | |||
| ENGINE AND ENGINE COOLING - COOLING SYSTEM - FAN | |||
| 11/13/2002 | 1 | 11/13/2002 | |
| To this date the following problems are present: gas gauge sticks, air bag warning light comes on and off, driver's side door rattles and knocks, driver's side window taps, driver's side window grinds while moving up and down, clock and radio do not light up or work when start vehicle, sun roof rattles and knocks, wind gets caught between roof and headliner which creates a loud vibration, the passenger side window also rattles and knocks, there is a loud rhythmic chirp toward rear of vehicle, heating and cooling controls squeal when turning on or switching vent settings, driver's seat feels rough when moving on seat track, the 3rd steering wheel still has defect under the leather which protrudes, driver's side leather seat was damaged after being at the dealership, 2nd row middle seat is almost impossible to lock in folded position, front windshield wiper control does not stay within setting, the vehicle vibrates and the steering wheel shakes when turning the wheel at a slow speed, the third row cup holder on the driver's side does not stay down in the fitting, there is a strong exhaust smell in the cabin when engine is in hard acceleration, engine starts to stall while driving. steering wheel was defective by being malformed causing the airbag to be ineffective. the second steering wheel was also ill fitted causing sharp protruding parts on the steering wheel. the dealership has had to repair or replace the following: body work to defective paint on roof, front hood, and driver's side fender. the dealership damaged paint in two areas and only provided touch up paint. replaced noisy rear windshield wiper motor, rear hatch glass because defrost would not work, rear hatch hinges, driver's side seat track. suspension problems with vibration and pitching. vehicle lurches forward upon acceleration. *la | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR | |||
| 05/11/2005 | 2 | 03/01/2004 | |
| Dt contact states she was driving 60 mph when the vehicle stalled. the vehicle was towed to the dealer and the service mechanic said that the catalytic converter needed to be replaced. the catalytic converter was replaced last year. *nm | |||