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2003 Ford Expedition

Owner reports · Recalls · Investigations

More warning signs than most Expedition years

Owner complaints for the 2003 Ford Expedition are substantially higher than the model-year median of 155.

About this comparison →

When problems were reported

Mileage at the reported incident

463 reports with mileage · 152 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Engine And Engine Cooling. Review the 127 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 104 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes, Hydraulic. Review the 61 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

57 crash reports36 fire reports39 injury reports

Unknown Or Other complaints

21 reports
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120,000 miles · Jul 8, 2020
Unknown Or OtherFire

FUEL TANK VAPOR RECOVERY UNIT DEVELOPED A CRACK DUE TO MANUFACTURING DEFECTS IN PLASTIC WELD, PERMITTING GASOLINE VAPOR AND GASOLINE FUEL TO ESCAPE FROM THE FUEL TANK IN AN UNCONTROLLED AND UNSAFE WAY. THE PROBLEM MANIFESTED AS A FUEL VAPOR LEAK WHEN THE VEHICLE WAS PARKED ON A 0-DEGREE SURFACE (LEVEL SURFACE) AND AS A CONTINUO…

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FUEL TANK VAPOR RECOVERY UNIT DEVELOPED A CRACK DUE TO MANUFACTURING DEFECTS IN PLASTIC WELD, PERMITTING GASOLINE VAPOR AND GASOLINE FUEL TO ESCAPE FROM THE FUEL TANK IN AN UNCONTROLLED AND UNSAFE WAY. THE PROBLEM MANIFESTED AS A FUEL VAPOR LEAK WHEN THE VEHICLE WAS PARKED ON A 0-DEGREE SURFACE (LEVEL SURFACE) AND AS A CONTINUOUS FUEL DRIP WHEN THE VEHICLE WAS PARKED ON A 10-DEGREE DOWNSLOPE, WITH THE FRONT OF THE VEHICLE POINTED DOWN-HILL.

NHTSA ODI #11338287

186,000 miles · Jun 22, 2020
Electrical SystemUnknown Or Other

MY FUSE AND RELAY PANEL HAS A DEFECT AND NOW MY TRUCK WON'T START. *TR

NHTSA ODI #11330232

25 miles · Aug 20, 2019
Electrical SystemUnknown Or OtherCrash

I HAVE A HUGE PROBLEM WITH MY 03 FORD EXPEDITION SHUTTING OF RANDOMLY IT IS VERY DANGEROUS ON HIGHWAYS YOU LOSE POWER STEERING AND ALL POWER TO MOTOR ALMOST CAUSED ACCIDENTS MANY TIMES I BELIEVE MANY PEOPLE HAVE THIS PROBLEM AND IT ALL RELATES TO THE FUSE BOX PLEASE MAKE THIS A RECALL SO MANY PEOPLE CAN GET HURT OR EVEN KILLED

NHTSA ODI #11245286

204,000 miles · May 3, 2019
Electrical SystemUnknown Or OtherVisibility/wiper

THE VEHICLE WAS STATIONARY, WHEN UNLOCKING THE VEHICLE WITH THE KEYLESS ENTRY, IT MOVED THE SIDEVIEW MIRRORS AND NEVER MOVWS BACK. I PUT THE MIRRORS BACK WHERE THEY BELONG AND EVERY FOLLOWING TIME WHEN I UNLOCK THE VEHICLE WITH THE KEY FOB, IT CONTINUES TO DO THE SAME. I BOUGHT THE VEHICLE THIS WAY.

NHTSA ODI #11205517

184,786 miles · Aug 13, 2018
Unknown Or Other

SPARK PLUGS SHOT OUT WITHOUT ANY WARNNG WHILE VEHICLE WAS IN MOTION. THE LOUD POPPING NOISE CAUSED ME TO SWERVE WHILE IN BACK TO BACK TRAFFIC. AFTER GAING CONTROL OF THE VEHICLE, MANUVERED VEHICLE TO FIRST AVAILABLE EXIT ONTO A SERVICE ROAD. VEHICLE CONTINUED TO MAKE LOUD POPPING NOISE EVERYTIME I PRESSED ON THE ACCELERATOR. BE…

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SPARK PLUGS SHOT OUT WITHOUT ANY WARNNG WHILE VEHICLE WAS IN MOTION. THE LOUD POPPING NOISE CAUSED ME TO SWERVE WHILE IN BACK TO BACK TRAFFIC. AFTER GAING CONTROL OF THE VEHICLE, MANUVERED VEHICLE TO FIRST AVAILABLE EXIT ONTO A SERVICE ROAD. VEHICLE CONTINUED TO MAKE LOUD POPPING NOISE EVERYTIME I PRESSED ON THE ACCELERATOR. BECAUSE I DID NOT KNOW WHAT THE NOISE WAS, MY GRANDCHILDREN AND I WERE STARTLED AFRAID. I PULLED ONTO A VACANT LOT AND TURNED THE MOTOR OFF. I HAD TO CALL SOMEONE TO COME AND PICK MY GRANDCHILDREN UP AND CALLED MY INSURANCE COMPANY. THEY ARRANGED FOR A TOW. ALTHOUGH I WAS PARKED OUT OF TRAFFIC, SITTING THERE ALONE, WAITING FOR THE TOW TRUCK FOR ABOUT 2 HOURS. IT WAS DARK BY THE TIME THE TOW TRUCK ARRIVED. MY HUSBAND DID NOT GET OFF UNTIL AROUND 8:00PM. I WAS VERY AFRAID!!! I TAKE MEDICATION AND TREATMENT FOR MY NERVES. THE SAME THING HAPPENED AGAIN ON 11-13-2017 AFTER THE VEHICLE HAD BEEN -REPAIRED!!! -THE FIRST TIME.

NHTSA ODI #11119615

200,000 miles · Jun 30, 2017
EngineUnknown Or Other

MY MOMS 2003 FORD EXPIATION HAD IS SPRAK PLUG BLOW OUT I HAVE LOOKED ALL OVER THE INTERNET AND THINK IS SHOULD HAVE A RECALL BECAUSE IT IS A VERY COMMON PROBLEM

NHTSA ODI #11002486

150,000 miles · Jan 13, 2016
Unknown Or Other

THE FRAME OF MY 2003 FORD EXPEDITION HAS RUSTED TO THE POINT THAT I HAVE BEEN TOLD TO GET RID OF THE VEHICLE. THE FRAME IS ABOUT TO SELF DESTRUCT. ONE OF THE STRAPS THAT HOLDS THE GAS TANK TO THE FRAME HAS RUSTED. REPLACEMENTS ARE NOT AVAILABLE. THE STEEL BRAKE LINES ALONG THE FRAME ARE ALSO RUSTED. I HAVE HAD ONE REPLACED …

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THE FRAME OF MY 2003 FORD EXPEDITION HAS RUSTED TO THE POINT THAT I HAVE BEEN TOLD TO GET RID OF THE VEHICLE. THE FRAME IS ABOUT TO SELF DESTRUCT. ONE OF THE STRAPS THAT HOLDS THE GAS TANK TO THE FRAME HAS RUSTED. REPLACEMENTS ARE NOT AVAILABLE. THE STEEL BRAKE LINES ALONG THE FRAME ARE ALSO RUSTED. I HAVE HAD ONE REPLACED ALREADY. THE AREA BELOW ALL 4 DOORS IS MISSING DUE TO RUST. YOU CAN SEE THE FRAME THROUGH THE MISSING STEEL. IT APPEARS THAT FORD USES NOTHING TO KEEP THEIR VEHICLES FROM RUSTING! THIS IS A DISGRACE. FORD HAS BEEN MANUFACTURING VEHICLES FOR MORE THAN 100 YEARS AND STILL CANT MAKE ONE THAT DOES NOT RUST. THEIR PLANNED OBSOLESCENCE PROGRAM IS COSTING ITS CUSTOMERS BILLIONS OF DOLLARS IN REPLACEMENT COSTS. I FEEL THEY SHOULD BE HELD ACCOUNTABLE CONSIDERING THE COST TO REPLACE THESE VEHICLES. THERE SHOULD BE NO TIME LIMIT ON RUST. IN THIS DAY AND AGE, THEY SHOULD HAVE FIGURED OUT HOW TO RUST PROOF A VEHICLE PROPERLY. I WANT A REPLACEMENT VEHICLE FROM THEM AT THEIR COST!

NHTSA ODI #10819977

129,000 miles · Oct 4, 2015
Electrical SystemFuel/propulsion SystemUnknown Or Other

CARS STALLED WHILE TURNING LEFT AGAINST TRAFFIC. WOULD NOT START RIGHT AWAY. HAD TO WAIT A FEW MINUTES TRYING TO START IT AND FINALLY IT STARTED AND I COULD CLEAR THE INTERSECTION. VERY DANGEROUS AND FORTUNATE THAT ONCOMING TRAFFIC WAS ABLE TO STOP. HAVE CLEANED THROTTLE BODY, AIC BUT FUSE ON FUSE BOX IS MELTED CAUSING INTERM…

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CARS STALLED WHILE TURNING LEFT AGAINST TRAFFIC. WOULD NOT START RIGHT AWAY. HAD TO WAIT A FEW MINUTES TRYING TO START IT AND FINALLY IT STARTED AND I COULD CLEAR THE INTERSECTION. VERY DANGEROUS AND FORTUNATE THAT ONCOMING TRAFFIC WAS ABLE TO STOP. HAVE CLEANED THROTTLE BODY, AIC BUT FUSE ON FUSE BOX IS MELTED CAUSING INTERMITTENT OPERATION. STARTED OUT ONCE A MONTH AND NOW FREQUENTLY TO INCLUDE THIS LAST ONE IN TRAFFIC.

NHTSA ODI #10779619

157,000 miles · Sep 24, 2015
Unknown Or Other

WHILE DRIVING MY VEHICLE, SEVERAL TIMES, IT STALLED. IT BEGAN TO STALL EVERY FEW MONTHS. IT LATER STALLED WEEKLY AND LATER DAILY. EACH TIME, THE CHECK ENGINE LIGHT APPEARED (IT DID NOT APPEAR EACH AND EVERY TIME), I WOULD HAVE IT CHECKED BY A MECHANIC. I ALWAYS GOT THE P0231 ERROR CODE. I HAVE HAD MY FUEL PUMP, FUEL RELAY, FUEL…

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WHILE DRIVING MY VEHICLE, SEVERAL TIMES, IT STALLED. IT BEGAN TO STALL EVERY FEW MONTHS. IT LATER STALLED WEEKLY AND LATER DAILY. EACH TIME, THE CHECK ENGINE LIGHT APPEARED (IT DID NOT APPEAR EACH AND EVERY TIME), I WOULD HAVE IT CHECKED BY A MECHANIC. I ALWAYS GOT THE P0231 ERROR CODE. I HAVE HAD MY FUEL PUMP, FUEL RELAY, FUEL FILTERS, TRANSMISSION AND SEVERAL OTHER THINGS REPLACED. NONE OF THE PREVIOUS LISTED REPAIRS FIXED THE ISSUE. RECENTLY ON 09/07/2015, I WAS DRIVING 35 MPH. MY VEHICLE STALLED ON A TRAIN TRACK. IT DID NOT START RIGHT AWAY. AFTER SEVERAL ATTEMPTS, I WAS ABLE TO GET IT GOING FOR A FEW SECONDS, LONG ENOUGH TO MOVE IT. I WAS TERRIFIED. IT HAS BEEN PARKED EVER SINCE. MY MECHANIC WILLINGLY DID A HOUSE CALL AND EXPLAINED THE REAL ISSUE. HE STATED THAT THE ISSUE WAS A FAULTY FUSE BOX LOCATED IN THE KICK PANEL OF THE PASSENGER SIDE. HE STATED THAT IF I GET IT REPAIRED, IT IS JUST A MATTER OF TIME BEFORE IT HAPPENS AGAIN, DUE TO THE FAULTY DESIGN OF THE WINDSHIELD AND THE LOCATION OF THE BOX. HE ALSO STATED THAT IF I GET IT REPLACED, I WOULD NEED TO GET IT FROM THE DEALER. REPLACING IT IS VERY EXPENSIVE DUE TO THE MANUFACTURER SELLING THE WHOLE ASSEMBLY TO INCLUDE FUSES AND RELAYS. I AM NOT SURE HOW FAR THIS COMPLAINT WOULD GO, BUT IT'S WORTH COMPLAINING ABOUT.

NHTSA ODI #10775890

189,000 miles · Mar 7, 2015
Unknown Or OtherCrash

ENGINE JUST SHUT OFF ALL OF THE SUDDEN WITHOUT WARNING WHILE DRIVING DOWN THE ROAD.

NHTSA ODI #10692756

Official recalls

1

03V094000 · Structure

Mar 7, 2003

CERTAIN PICKUP TRUCK, VAN, AND MINI VAN CONVERSIONS EQUIPPED WITH SOUTHERN COMFORT BUILT RUNNING BOARDS THAT CONTAIN CERTAIN COURTESY LIGHTS MANUFACTURED BY AMERICAN TECHNOLOGY COMPONENTS, INC. THESE UNITS CONTAIN A COURTESY LIGHT OR LIGHTS THAT MIGHT OVERHEAT WHEN THE WIRE HARNESS IS EXPOSED TO EXCESSIVE MOISTURE AND ROAD SALT.

Consequence & remedy

Consequence: THIS OVERHEATING CONDITION CAN CAUSE THE RUNNING BOARD TO MELT OR CAUSE A FIRE.

Remedy: DEALERS WILL REPLACE THE WIRING HARNESS ON THESE RUNNING BOARDS. OWNER NOTIFICATION BEGAN MARCH 7, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT SOUTHERN COMFORT AT 1-800-745-6096.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

1

DP05005 · 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.