NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
127 reportsClear category filter95,000 miles · Jun 18, 2007
Engine And Engine CoolingFire
TL*THE CONTACT OWNS A 2003 FORD EXPEDITION. WHILE DRIVING 80 MPH, THE VEHICLE CAUGHT FIRE UNDER THE HOOD. THE CONTACT STATED THAT THE AIR CONDITIONING SHUT OFF AND THE BLOWER PRODUCED WARM AIR BEFORE THE FIRE OCCURRED. HE SMELLED SOMETHING BURNING AND HE SHUT DOWN THE ENGINE COMPLETELY. THE CONTACT THEN NOTICED SMOKE COMING …
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TL*THE CONTACT OWNS A 2003 FORD EXPEDITION. WHILE DRIVING 80 MPH, THE VEHICLE CAUGHT FIRE UNDER THE HOOD. THE CONTACT STATED THAT THE AIR CONDITIONING SHUT OFF AND THE BLOWER PRODUCED WARM AIR BEFORE THE FIRE OCCURRED. HE SMELLED SOMETHING BURNING AND HE SHUT DOWN THE ENGINE COMPLETELY. THE CONTACT THEN NOTICED SMOKE COMING FROM THE DEFROSTER VENT UNDER THE WINDSHIELD. THE STATE POLICE AND FIRE DEPARTMENT ARRIVED AND EXTINGUISHED THE FIRE. THE VEHICLE WAS TOWED FROM THE SCENE. THE VIN, PURCHASE DATE, AND ENGINE SIZE WERE UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 95,000.
NHTSA ODI #10193603
64,000 miles · Jun 15, 2007
Engine And Engine Cooling
64000 ON 2003 FORD EXPEDITION BLEW THE #2 PLUG WHILE TRAVELING AT HIGHWAY SPEED AND CRUISE CONTROL ON. HAD A HELA COIL PUT IN. CONTACTED THE DEALER, NO RESPONSE, 2 WEEKS LATER 68000 BLEW THE #3 PLUG SITTING AT A TRAFFIC LIGHT AGAIN HAD A HELA COIL REPAIR. AGAIN NO HELP FROM THE DEALER, AND TOLD THERE WAS NO OPEN RECALL ON …
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64000 ON 2003 FORD EXPEDITION BLEW THE #2 PLUG WHILE TRAVELING AT HIGHWAY SPEED AND CRUISE CONTROL ON. HAD A HELA COIL PUT IN. CONTACTED THE DEALER, NO RESPONSE, 2 WEEKS LATER 68000 BLEW THE #3 PLUG SITTING AT A TRAFFIC LIGHT AGAIN HAD A HELA COIL REPAIR. AGAIN NO HELP FROM THE DEALER, AND TOLD THERE WAS NO OPEN RECALL ON THAT MOTOR . I AM FILING A COMPLAINT WITH THE ATTORNEY GENERALS OFFICE IN MINNESOTA. BOTH REPAIRS WERE DONE AT A DIFFERENT FORD DEALERSHIP, THEY STATED REPLACING THE HEAD WA S THE CORRECT FIX, BUT FORD ALLOWED THEM TO DO HELA COILS, BUT IMAGINE THAT, THEY WON'T WARRANTY IT !! *AK
NHTSA ODI #10193479
59,022 miles · Apr 22, 2007
Engine And Engine Cooling
ON APRIL 13, 2007 MY 2003 FORD EXPEDITION WITH THE 5.4 LITER TRITON ENGINE BLEW OUT THE #3 SPARK PLUG DESTROYING THE THREADS AND REQUIRING A TOTAL HEAD REPLACEMENT. THE COST OF THIS REPAIR, IN SPITE OF THE FACT I PURCHASED THE EXTENDED WARRANTY, WAS $3655.22. UPON FURTHER RESEARCH I HAVE FOUND THAT APPARENTLY THIS IS A VERY COMM…
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ON APRIL 13, 2007 MY 2003 FORD EXPEDITION WITH THE 5.4 LITER TRITON ENGINE BLEW OUT THE #3 SPARK PLUG DESTROYING THE THREADS AND REQUIRING A TOTAL HEAD REPLACEMENT. THE COST OF THIS REPAIR, IN SPITE OF THE FACT I PURCHASED THE EXTENDED WARRANTY, WAS $3655.22. UPON FURTHER RESEARCH I HAVE FOUND THAT APPARENTLY THIS IS A VERY COMMON OCCURRENCE AFFECTING THOUSANDS OF FORD OWNERS. *TR
NHTSA ODI #10188541
73,000 miles · Mar 29, 2007
Engine And Engine Cooling
WIFE WAS DRIVING THE 2003 FORD EXPEDITION WITH 73000 MILES ON IT WHEN LOUD POPPING NOISE WAS HEARD, UPON EXAMINATION SPARKPLUG WAS FOUND TO HAVE BEEN EJECTED FROM THE ENGINE BLOCK REPAIR AT CLOSEST FORD DEALER WAS $3000. *AK
NHTSA ODI #10186469
60,055 miles · Mar 1, 2007
Engine And Engine Cooling
ENGINE FAILURE ON MY 2003 FORD EXPEDITION HAVING A 5.4 LITER TRITON V8 ENGINE. NUMBER 2 SPARK PLUG WAS BLOWN OUT AND THE COST TO REPAIR IS $3000. FORD HAS KNOWN OF THIS ISSUE FOR SOME TIME BUT WILL NOT ACCEPT BLAME. THE NUMBER OF THREADS TO HOLD THE SPARK PLUGS IS TOO FEW. *NM
NHTSA ODI #10183932
71,880 miles · Jan 11, 2007
Engine And Engine Cooling
WHILE DRIVING ALONG I SUDDENLY HEARD A LOUD 'BANG'. THINKING IT MUST BE A FLAT TIRE I PULLED OVER TO INSPECT MY TIRES. AFTER I FOUND NO ISSUES WITH MY TIRES, I NOTICED THAT THE NOISE WAS IN FACT COMING FROM MY ENGINE WHICH ALSO SMELLED AS IF SOMETHING WAS BURNING. AFTER HAVING THE VEHICLE TOWED TO BE INSPECTED, I WAS ADVISE…
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WHILE DRIVING ALONG I SUDDENLY HEARD A LOUD 'BANG'. THINKING IT MUST BE A FLAT TIRE I PULLED OVER TO INSPECT MY TIRES. AFTER I FOUND NO ISSUES WITH MY TIRES, I NOTICED THAT THE NOISE WAS IN FACT COMING FROM MY ENGINE WHICH ALSO SMELLED AS IF SOMETHING WAS BURNING. AFTER HAVING THE VEHICLE TOWED TO BE INSPECTED, I WAS ADVISED THAT THE ALUMINUM AROUND THE SPARK PLUG HAD MELTED AND I NEEDED A NEW HEAD REPLACED WHICH WILL COST OVER 3000 DOLLARS. THEY INITIALLY THOUGHT THE SPARK PLUG HAD EJECTED. WHAT WILL IT TAKE TO HAVE FORD STAND BEHIND THEIR VEHICLES? *JB
NHTSA ODI #10178438
55,300 miles · Dec 29, 2006
Engine And Engine Cooling
DRIVING NORMALLY. #3 SPARK PLUG BLEW OUT DAMAGING IGNITION COIL AND RUINING THREADS. THIS SEEMS TO BE A FREQUENT PROBLEM WITH THESE FORD TRUCK ENGINES.
NHTSA ODI #10177297
Mileage unknown · Nov 8, 2006
Engine And Engine Cooling
DT*: THE CONTACT STATED WHILE TRAVELING 65 MPH ON NORMAL ROAD CONDITIONS, A LOUD POPPING SOUND WAS HEARD. THE CONTACT PULLED THE VEHICLE TO THE SIDE OF THE ROAD AND HAD IT TOWED TO A LOCAL DEALER. UPON EXAMINATION, IT WAS DETERMINED THAT THE SPARK PLUGS BLEW DUE TO INADEQUATE ENGINE DESIGN OF THE THREADING. THE VEHICLE WAS NO…
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DT*: THE CONTACT STATED WHILE TRAVELING 65 MPH ON NORMAL ROAD CONDITIONS, A LOUD POPPING SOUND WAS HEARD. THE CONTACT PULLED THE VEHICLE TO THE SIDE OF THE ROAD AND HAD IT TOWED TO A LOCAL DEALER. UPON EXAMINATION, IT WAS DETERMINED THAT THE SPARK PLUGS BLEW DUE TO INADEQUATE ENGINE DESIGN OF THE THREADING. THE VEHICLE WAS NOT INCLUDED IN A RECALL DUE TO THE VIN. THE DEALER REPLACED THE SPARK PLUGS AND THREADING. THE CONTACT ENCOUNTERED SIMILAR COMPLAINTS ABOUT THE ENGINE AND ENGINE COOLING:ENGINE THAT RELATED TO THE CONTACT'S ISSUE.
NHTSA ODI #10172968
75,000 miles · Aug 30, 2006
Engine And Engine Cooling
VEHICLE WAS BROUGHT INTO FORD DEALER FOR A "TAPPING NOISE" IN ENGINE AREA.. DEALER RAN A TEST AND FOUND NOTHING WRONG. SEVERAL DAYS LATER ENGINE STARTING MAKING POPPING NOISES AND WAS UNABLE TO DRIVE VEHICLE DUE TO ENGINE NOT OPERATING PROPERLY..SAME DEALER TOWED TO THEIR FACILITY AND SAID SPARK PLUG IN #3 CYLINDER CAME LOOSE AN…
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VEHICLE WAS BROUGHT INTO FORD DEALER FOR A "TAPPING NOISE" IN ENGINE AREA.. DEALER RAN A TEST AND FOUND NOTHING WRONG. SEVERAL DAYS LATER ENGINE STARTING MAKING POPPING NOISES AND WAS UNABLE TO DRIVE VEHICLE DUE TO ENGINE NOT OPERATING PROPERLY..SAME DEALER TOWED TO THEIR FACILITY AND SAID SPARK PLUG IN #3 CYLINDER CAME LOOSE AND WAS EJECTED AND DAMAGED THE HEAD. THEY WANT $3K TO REPAIR THIS...VEHICLE HAS 75K MILES WITH NO MORE WARRANTY. *JB
NHTSA ODI #10167057
18 miles · May 16, 2006
Engine And Engine Cooling
1.) I WAS JUST DRIVING THE VEHICLE AND THE SPARK PLUG BLEW OUT OF THE ENGINE. 2.) I HAVE A 2003 FORD EXPEDITION 5.4 L TRITON V8 WITH 78,000 MILES AND THE SPARK PLUG BLOW OUT OF THE ENGINE. 3.) A FORD DEALER IS REPLACING THE HEAD ON MY EXPEDITION, COST $3000. *JB
NHTSA ODI #10157627
NHTSA investigations
1DP05005 · Spark Plug Ejection From Cylinder Head
Opened Sep 22, 2005 · Closed Jan 4, 2006
Status: closed (inferred from source dates) · Engine And Engine Cooling; Engine And Engine Cooling:engine; Engine And Engine Cooling:engine:gasoline
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?S ANALYSIS SHOWED, IT IS POSSIBLE FOR A SPARK PLUG TO DETACH FROM THE ENGINE CYLINDER THREADS IN THE SUBJECT VEHICLES.HOWEVER, ODI?S ANALYSIS OF 474 COMPLAINTS DESCRIBING SUCH INCIDENTS FOUND ONLY A VERY FEW ALLEGED ANY SAFETY-RELATED CONSEQUENCES.NONE OF THESE SHOWED ANY EVIDENCE OF A SERIOUS SAFETY CONSEQUENCE.GIVEN THE LARGE POPULATION AND RELATIVELY LONG EXPOSURE TIME OF THE SUBJECT VEHICLES, THE COMPLAINT ANALYSIS INDICATES THAT THE RISK TO MOTOR VEHICLE SAFETY FROM THE ALLEGED DEFECT IS VERY LOW.IN VIEW OF THE FOREGOING, IT IS UNLIKELY THAT NHTSA WOULD ISSUE AN ORDER FOR THE NOTIFICATION AND REMEDY OF THE ALLEGED DEFECT AT THE CONCLUSION OF THE INVESTIGATION REQUESTED IN THE PETITION.THEREFORE, IN VIEW OF THE NEED TO ALLOCATE AND PRIORITIZE NHTSA?S LIMITED RESOURCES TO BEST ACCOMPLISH THE AGENCY?S SAFETY MISSION, THE PETITION IS DENIED.
Additional source detail variants (3)
Engine And Engine Cooling:engine
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?S ANALYSIS SHOWED, IT IS POSSIBLE FOR A SPARK PLUG TO DETACH FROM THE ENGINE CYLINDER THREADS IN THE SUBJECT VEHICLES.HOWEVER, ODI?S ANALYSIS OF 474 COMPLAINTS DESCRIBING SUCH INCIDENTS FOUND ONLY A VERY FEW ALLEGED ANY SAFETY-RELATED CONSEQUENCES.NONE OF THESE SHOWED ANY EVIDENCE OF A SERIOUS SAFETY CONSEQUENCE.GIVEN THE LARGE POPULATION AND RELATIVELY LONG EXPOSURE TIME OF THE SUBJECT VEHICLES, THE COMPLAINT ANALYSIS INDICATES THAT THE RISK TO MOTOR VEHICLE SAFETY FROM THE ALLEGED DEFECT IS VERY LOW.IN VIEW OF THE FOREGOING, IT IS UNLIKELY THAT NHTSA WOULD ISSUE AN ORDER FOR THE NOTIFICATION AND REMEDY OF THE ALLEGED DEFECT AT THE CONCLUSION OF THE INVESTIGATION REQUESTED IN THE PETITION.THEREFORE, IN VIEW OF THE NEED TO ALLOCATE AND PRIORITIZE NHTSA?S LIMITED RESOURCES TO BEST ACCOMPLISH THE AGENCY?S SAFETY MISSION, THE PETITION IS DENIED.
Engine And Engine Cooling:engine:gasoline
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?S ANALYSIS SHOWED, IT IS POSSIBLE FOR A SPARK PLUG TO DETACH FROM THE ENGINE CYLINDER THREADS IN THE SUBJECT VEHICLES.HOWEVER, ODI?S ANALYSIS OF 474 COMPLAINTS DESCRIBING SUCH INCIDENTS FOUND ONLY A VERY FEW ALLEGED ANY SAFETY-RELATED CONSEQUENCES.NONE OF THESE SHOWED ANY EVIDENCE OF A SERIOUS SAFETY CONSEQUENCE.GIVEN THE LARGE POPULATION AND RELATIVELY LONG EXPOSURE TIME OF THE SUBJECT VEHICLES, THE COMPLAINT ANALYSIS INDICATES THAT THE RISK TO MOTOR VEHICLE SAFETY FROM THE ALLEGED DEFECT IS VERY LOW.IN VIEW OF THE FOREGOING, IT IS UNLIKELY THAT NHTSA WOULD ISSUE AN ORDER FOR THE NOTIFICATION AND REMEDY OF THE ALLEGED DEFECT AT THE CONCLUSION OF THE INVESTIGATION REQUESTED IN THE PETITION.THEREFORE, IN VIEW OF THE NEED TO ALLOCATE AND PRIORITIZE NHTSA?S LIMITED RESOURCES TO BEST ACCOMPLISH THE AGENCY?S SAFETY MISSION, THE PETITION IS DENIED.
Engine And Engine Cooling
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?S ANALYSIS SHOWED, IT IS POSSIBLE FOR A SPARK PLUG TO DETACH FROM THE ENGINE CYLINDER THREADS IN THE SUBJECT VEHICLES.HOWEVER, ODI?S ANALYSIS OF 474 COMPLAINTS DESCRIBING SUCH INCIDENTS FOUND ONLY A VERY FEW ALLEGED ANY SAFETY-RELATED CONSEQUENCES.NONE OF THESE SHOWED ANY EVIDENCE OF A SERIOUS SAFETY CONSEQUENCE.GIVEN THE LARGE POPULATION AND RELATIVELY LONG EXPOSURE TIME OF THE SUBJECT VEHICLES, THE COMPLAINT ANALYSIS INDICATES THAT THE RISK TO MOTOR VEHICLE SAFETY FROM THE ALLEGED DEFECT IS VERY LOW.IN VIEW OF THE FOREGOING, IT IS UNLIKELY THAT NHTSA WOULD ISSUE AN ORDER FOR THE NOTIFICATION AND REMEDY OF THE ALLEGED DEFECT AT THE CONCLUSION OF THE INVESTIGATION REQUESTED IN THE PETITION.THEREFORE, IN VIEW OF THE NEED TO ALLOCATE AND PRIORITIZE NHTSA?S LIMITED RESOURCES TO BEST ACCOMPLISH THE AGENCY?S SAFETY MISSION, THE PETITION IS DENIED.
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