NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
127 reportsClear category filter96,000 miles · Sep 11, 2009
Engine And Engine Cooling
MY 2003 FORD EXPEDITION JUST BLEW A SPARK PLUG OUT OF THE CYLINDER HEAD. IT WAS THE SECOND TO LAST CYLINDER PASSENGER SIDE. THERE WAS RAW FUEL AND VAPORS COMING INTO THE ENGINE COMPARTMENT AND A FIRE COULD HAVE STARTED HAD A SPARK IGNITED THOSE FUMES. THESE ARE THE FACTORY PLUGS AND FACTORY HEAD AND THE FORD DEALER COMMENTED …
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MY 2003 FORD EXPEDITION JUST BLEW A SPARK PLUG OUT OF THE CYLINDER HEAD. IT WAS THE SECOND TO LAST CYLINDER PASSENGER SIDE. THERE WAS RAW FUEL AND VAPORS COMING INTO THE ENGINE COMPARTMENT AND A FIRE COULD HAVE STARTED HAD A SPARK IGNITED THOSE FUMES. THESE ARE THE FACTORY PLUGS AND FACTORY HEAD AND THE FORD DEALER COMMENTED THAT THIS WAS A FAIRLY COMMON ISSUE BUT THAT FORD HAS NOT ISSUED A RECALL YET. NOW I AM OUT $2800 FOR WHAT SEEMS TO BE A DEFECT IN THE DESIGN OF THE HEAD. *TR
NHTSA ODI #10283624
102,000 miles · Sep 8, 2009
Engine And Engine Cooling
I HAVE PARK MY TRUCK AND WENT TO HAVE DINNER WITH MY FAMILY AND UPON MY RETURN WHEN I START MY TRUCK. THE ENGINE MAKE A LOUD SOUND AND SPARK PLUG BLOW OUT FROM THE ENGINE. *TR
NHTSA ODI #10283123
117,000 miles · Sep 5, 2009
Engine And Engine Cooling
MY 2003 FORD EXPEDITION BLEW A SPARK PLUG OUT OF THE ENGINE TODAY. AFTER READING ABOUT EVENTS LEADING UP TO THIS FAILURE, MY AUTO WAS ACTING EXACTLY LIKE ALL THE OTHERS. A SLIGHT TICKING SOUND WHILE THE ENGINE IDLES. WHILE DRIVING 20MPH, A SLIGHT LOUD BAM OCCURRED AND THE ENGINE BEGAN TO IDLE HARD. THE CAR WAS TOWED 70 MILES TO…
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MY 2003 FORD EXPEDITION BLEW A SPARK PLUG OUT OF THE ENGINE TODAY. AFTER READING ABOUT EVENTS LEADING UP TO THIS FAILURE, MY AUTO WAS ACTING EXACTLY LIKE ALL THE OTHERS. A SLIGHT TICKING SOUND WHILE THE ENGINE IDLES. WHILE DRIVING 20MPH, A SLIGHT LOUD BAM OCCURRED AND THE ENGINE BEGAN TO IDLE HARD. THE CAR WAS TOWED 70 MILES TO A REPAIR CENTER NEAR MY HOME AND I NOW AM TO DECIDE ON A NEW MANIFOLD OR A COIL REPAIR THAT IS RISKY. HOW A COMPANY CAN OPERATE WITH CRITICAL ENGINE PART THAT ARE SO POORLY DESIGNED IS BEYOND MY IMAGINATION. THE INTERNET IS FILLED WITH COMPLAINTS OF SPARK PLUGS POPPING OUT OF ENGINES IN F150S AND EXPLORER/EXPEDITIONS. IT IS A SHAME THAT SUCH A SIMPLE THING AS ENGINEERING A THREAD DEEP ENOUGH TO HOLD A SPARK PLUG IN PLACE FOR THE LIFE OF A CAR IS TOO CHALLENGING FOR A CAR COMPANY. THIS REPAIR SHOULD BE THE RESPONSIBILITY OF THE MANUFACTURER. THEY WERE ABLE TO HANDLE REPLACING MILLIONS OF FIRESTONES AND SHOULD BE HELD TO A STANDARD CLOSE TO THEIR REPUTATION AS A TOUGH VEHICLE. WITHOUT RECOURSE, FORD WILL FIND IT ACCEPTABLE TO CUT CORNERS AND ENGINEER SUB PAR PART. *TR
NHTSA ODI #10282978
94,000 miles · Aug 2, 2009
Engine And Engine Cooling
2003 FORD EXPEDITION 5.4L EJECTION OF FACTORY SPARK PLUG FORM CYLINDER HEAD. *TR
NHTSA ODI #10279082
99,876 miles · Jul 18, 2009
Engine And Engine Cooling
DRIVING FROM LAS VEGAS TO PHX WE WERE AT WICKENBERG, AZ A LOUD POP OCCURRED AND KNOCKING SOUND FROM THE ENGINE. THE SMELL OF GAS WAS PRESENT AND WOULDN'T RUN PROPERLY. THE FORD DEALERSHIP IN WICKENBERG WAS LUCKILY OPEN AND INSTRUCTED US THAT THE SPARK PLUGS HAD BLOWN OUT IN THE 1ST AND 2ND CYLINDERS. THEY DID ALSO TELL US THAT T…
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DRIVING FROM LAS VEGAS TO PHX WE WERE AT WICKENBERG, AZ A LOUD POP OCCURRED AND KNOCKING SOUND FROM THE ENGINE. THE SMELL OF GAS WAS PRESENT AND WOULDN'T RUN PROPERLY. THE FORD DEALERSHIP IN WICKENBERG WAS LUCKILY OPEN AND INSTRUCTED US THAT THE SPARK PLUGS HAD BLOWN OUT IN THE 1ST AND 2ND CYLINDERS. THEY DID ALSO TELL US THAT THIS OCCURS OFTEN IN AND THERE IS A TEMP FIX FOR IT. THEY TAPPED OUT THE HEAD AND INSERTED A STEEL SLEEVE FOR THOSE 2 CYLINDERS. TAKING 2 HOURS IT WAS FIXED AND WE WERE ON OUR WAY VERY HAPPY TO HAVE IT FIXED BUT NOT HAPPY AT ALL AT FORD FOR HAVING SUCH A BLATANT DESIGN FLAW. THIS NEEDS TO BE FIXED. *TR
NHTSA ODI #10277285
71,000 miles · Jul 15, 2009
Engine And Engine Cooling
SPARK PLUG BLOW OUT ON 2003 FORD EXPEDITION 5.4 L ENGINE. *TR
NHTSA ODI #10276922
Mileage unknown · Jun 16, 2009
Engine And Engine Cooling
WHILE DRIVING MY 2003 FORD EXPEDITION EDDIE BAUER ONE OF THE EIGHT SPARK PLUGS BLEW OUT OF THE ENGINE. *TR
NHTSA ODI #10273982
86,882 miles · Jun 4, 2009
Engine And Engine Cooling
I OWN A 2003 FORD EXPEDITION WITH A 5.4,AND WHILE DRIVING AROUND TOWN WE NOTICED THE VEHICLE STARTED RUNNING ROUGH,SO WE TOOK IT TO A LOCAL SHOP TO HAVE IT LOOKED AT AND UPON INSPECTION WE FOUND THAT THE NUMBER 7 PLUG HAD BLOWN OUT AND CAUSED DAMAGE TO THE COIL WHICH CAUSED THE ROUGH RUNNING,THE MECHANIC AT THE SHOP SAID THIS IS…
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I OWN A 2003 FORD EXPEDITION WITH A 5.4,AND WHILE DRIVING AROUND TOWN WE NOTICED THE VEHICLE STARTED RUNNING ROUGH,SO WE TOOK IT TO A LOCAL SHOP TO HAVE IT LOOKED AT AND UPON INSPECTION WE FOUND THAT THE NUMBER 7 PLUG HAD BLOWN OUT AND CAUSED DAMAGE TO THE COIL WHICH CAUSED THE ROUGH RUNNING,THE MECHANIC AT THE SHOP SAID THIS IS VERY COMMON WITH THESE TRUCKS AND MOTORS,SO AT THE COST $700 I GOT IT FIXED WITH THE UNDERSTANDING THAT THIS COULD HAPPEN AGAIN BECAUSE OF THE WAY THESE MOTORS ARE MADE. *TR
NHTSA ODI #10272828
135,000 miles · Jun 2, 2009
Engine And Engine Cooling
WHILE DRIVING ON A LOCAL ROAD IN CLEAR WEATHER MY 03 EXPEDITION SUDDENLY THREW PLUG #7. IN SO DOING IT DESTROYED THE COIL ASSEMBLY, BUT THE IMPACT OF THE COIL ASSEMBLY ON THE FUEL RAIL SAVED THE CAR'S HOOD FROM FURTHER DAMAGE (THE TOP OF THE COIL ASSEMBLY CLEARLY EVIDENCED THE IMPACT MARK FROM CONTACT WITH THE FUEL RAIL). GIVE…
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WHILE DRIVING ON A LOCAL ROAD IN CLEAR WEATHER MY 03 EXPEDITION SUDDENLY THREW PLUG #7. IN SO DOING IT DESTROYED THE COIL ASSEMBLY, BUT THE IMPACT OF THE COIL ASSEMBLY ON THE FUEL RAIL SAVED THE CAR'S HOOD FROM FURTHER DAMAGE (THE TOP OF THE COIL ASSEMBLY CLEARLY EVIDENCED THE IMPACT MARK FROM CONTACT WITH THE FUEL RAIL). GIVEN THE FACT THAT THE DAMAGED COIL INSULATION WAS NOW ARCING ITS SPARK ACROSS THE ENGINE HEAD AND THAT THE FUEL MIXTURE WAS SPEWING OUT OF THE SPARK PLUG HOLE IT'S SURPRISING THAT WE AVOIDED AN ENGINE FIRE UNDER THE PLASTIC SHROUD. I HAD THE CAR TOWED TO THE LOCAL INDEPENDENT SERVICE CENTER (PEP BOYS, LAUREL MD - THE SAME LOCATION THAT HAD CHANGED THE PLUGS A YEAR PRIOR). THEY EXAMINED ALL THE SPARK PLUG THREADS AND ADVISED THAT THEY APPEARED OK, WITH THE EXCEPTION OF THIS ONE CYLINDER. TO EFFECT REPAIRS THEY ADVISED TO HAVE THE VEHICLE TOWED TO ANOTHER OUTLET 36 MILES ($104 CHARGE) UP THE ROAD. THEY FURTHER ADVISED THAT THIS IS NOT AN UNCOMMON PROBLEM WITH THE 5.4 ENGINE AND THAT THIS MAY OCCUR IN OTHER CYLINDERS IN THE FUTURE. FORD CUSTOMER ASSISTANCE (800#) DISCLAIMS ANY KNOWLEDGE OF THIS BEING A COMMON PROBLEM AND REFERRED ME TO THE LOCAL DEALER FOR TECHNICAL ADVICE. AT THE LOCAL DEALER, THE MECHANIC WAS VERY FAMILIAR WITH THE ISSUE, PRONOUNCED IT RATHER COMMON AND ADVISED THAT FORD WOULD BE HAPPY TO REPAIR THE PROBLEM, HOWEVER HIS ESTIMATE WOULD COST ME MORE THAN TWICE THE ESTIMATED FEE FROM THE INDEPENDENT (INCLUSIVE OF THE ADDITIONAL TOW COSTS). SUBSEQUENT GOOGLE SEARCHES FOR "FORD EXPEDITION THROWN SPARK PLUG REVEAL 11,200 WEB PAGE HITS. THE WEBPAGES AT THE 1ST HIT ALONE, WWW.CONSUMERAFFAIRS.COM/AUTOMOTIVE/FORD_SPARK.HTML REVEALS A LITANY OF VERY SIMILAR COMPLAINTS OVER A NUMBER OF YEARS, SOME OF WHICH HAVE RESULTED IN MORE TRAGIC CONSEQUENCES. GIVEN THE DANGER REPRESENTED BY POTENTIAL ENGINE FIRES AND THE APPARENT FREQUENCY OF THE PROBLEM WHY HAS THERE NOT BEEN A RECALL TO EFFECT THE CORRECTION OF THIS APPARENT DEFECT. *TR
NHTSA ODI #10272619
65,000 miles · Mar 13, 2009
Engine And Engine Cooling
I HAVE A 2003 FORD EXPEDITION WITH A 5.4L ENGINE. WAS DRIVING THE TRUCK WHEN I HEARD A POP AND THE ENGINE STARTED TO MISFIRE. SPARK PLUG NO. 7 HAD BEEN EJECTED BREAKING THE COIL. I HAVE OWNED THE TRUCK SINCE IT WAS NEW AND IT HAS BEEN WELL MAINTAINED, ONLY 65000 MILES. I HAVE READ MANY OF THE OTHER COMPLAINTS ONLINE AND I'M A…
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I HAVE A 2003 FORD EXPEDITION WITH A 5.4L ENGINE. WAS DRIVING THE TRUCK WHEN I HEARD A POP AND THE ENGINE STARTED TO MISFIRE. SPARK PLUG NO. 7 HAD BEEN EJECTED BREAKING THE COIL. I HAVE OWNED THE TRUCK SINCE IT WAS NEW AND IT HAS BEEN WELL MAINTAINED, ONLY 65000 MILES. I HAVE READ MANY OF THE OTHER COMPLAINTS ONLINE AND I'M AMAZED AT THE NUMBERS OF ISSUES WITH THIS ENGINE. THIS WAS OBVIOUSLY A BAD DESIGN THAT SPANS A NUMBER OF YEARS. *TR
NHTSA ODI #10261702
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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