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2004 Ford Explorer

Owner reports · Recalls · Investigations

More warning signs than most Explorer years

Owner complaints for the 2004 Ford Explorer are substantially higher than the model-year median of 609.

About this comparison →

When problems were reported

Mileage at the reported incident

1,093 reports with mileage · 211 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.

  • Power Train. Review the 460 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Structure. Review the 426 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Visibility. Review the 100 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

58 crash reports15 fire reports67 injury reports

Visibility complaints

100 reports
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96,607 miles · Jul 28, 2010
Visibility

TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THE DRIVER AND PASSENGER SUN VISORS WERE FRACTURED. THE DEALER ADVISED REPLACING THE VISORS AT HER EXPENSE. THE DRIVER SIDE SUN VISOR WAS REPLACED. THE CONTACT STATED THE FAILURE RECURRED ON THE DRIVER SIDE SUN VISOR. THE PASSENGER SIDE SUN VISOR WAS NEVER REPLACED. T…

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TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THE DRIVER AND PASSENGER SUN VISORS WERE FRACTURED. THE DEALER ADVISED REPLACING THE VISORS AT HER EXPENSE. THE DRIVER SIDE SUN VISOR WAS REPLACED. THE CONTACT STATED THE FAILURE RECURRED ON THE DRIVER SIDE SUN VISOR. THE PASSENGER SIDE SUN VISOR WAS NEVER REPLACED. THE MANUFACTURER WAS NOT CONTACTED. THE FAILURE AND CURRENT MILEAGES WERE 96,607.

NHTSA ODI #10345802

88,200 miles · Jul 3, 2010
Visibility

DEFECTIVE CLIP/HINGE IN SUNVISOR ASSEMBLY OF 2004 FORD EXPLORERS, BREAKS AND CRACKS WITH NORMAL USE DUE TO FAULTY DESIGN. SAFETY HAZARD DUE TO THE FACT THAT ONCE IT BREAKS TO A CERTAIN POINT THE SUNVISOR WILL HANG IN DRIVERS VIEW AND IMPEDE VISION. A LARGE AMOUNT OF PEOPLE ARE HAVING THE SAME PROBLEM I AM HAVING. SOME OF THEI…

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DEFECTIVE CLIP/HINGE IN SUNVISOR ASSEMBLY OF 2004 FORD EXPLORERS, BREAKS AND CRACKS WITH NORMAL USE DUE TO FAULTY DESIGN. SAFETY HAZARD DUE TO THE FACT THAT ONCE IT BREAKS TO A CERTAIN POINT THE SUNVISOR WILL HANG IN DRIVERS VIEW AND IMPEDE VISION. A LARGE AMOUNT OF PEOPLE ARE HAVING THE SAME PROBLEM I AM HAVING. SOME OF THEIR COMMENTS CAN BE VIEWED AT HTTP://WWW.CARCOMPLAINTS.COM/FORD/EXPLORER/2004/ACCESSORIES-INTERIOR/SUPPORTS_FOR_SUN_VISORS_CRACKED.SHTML TO BEGIN YOUR INVESTIGATION. LUCKILY OURS CAME APART WHEN THE CAR WAS STOPPED, BUT SOMEONE USING THE VISOR TO INCREASE VISIBILITY MAY NOT BE SO FORTUNATE. *TR

NHTSA ODI #10341331

67,670 miles · Jun 6, 2010
Visibility

WHILE ATTEMPTING TO CLOSE THE WINDOW ON HATCHBACK, THE WINDOW HINGES BROKE. *TR

NHTSA ODI #10334787

Mileage unknown · May 19, 2010
Visibility

REAR WINDOW HINGES ON 2004 FORD EXPLORER BROKE. *TR

NHTSA ODI #10331140

57,000 miles · May 3, 2010
Visibility

TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE FIBER GLASS FITTING UNDER THE WINDOW NEXT TO THE TAILGATE BEGAN CRACKING AND WAS BECOMING PROGRESSIVELY WORSE. THE OWNER HAD NOT CONTACTED THE DEALER. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 57,000.

NHTSA ODI #10328593

58,616 miles · Jan 1, 2010
Visibility

PLASTIC PIN SECURING BLEND DOOR ACTUATOR BREAKS, FREEZING BLEND DOOR IN POSITION.(COOL) UNABLE TO GET HEAT FROM VEHICLE HVAC SYSTEM. CAN NOT DEFROST/DEFOG WINDOWS IN COLD/WET WEATHER. VISIBILITY IS LIMITED DURING COLD/WET WEATHER. THE REDUCED VISIBILITY CAUSED ME TO VEER OFF OF PAVEMENT IN A RURAL AREA NEAR MY HOME BECAUSE I …

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PLASTIC PIN SECURING BLEND DOOR ACTUATOR BREAKS, FREEZING BLEND DOOR IN POSITION.(COOL) UNABLE TO GET HEAT FROM VEHICLE HVAC SYSTEM. CAN NOT DEFROST/DEFOG WINDOWS IN COLD/WET WEATHER. VISIBILITY IS LIMITED DURING COLD/WET WEATHER. THE REDUCED VISIBILITY CAUSED ME TO VEER OFF OF PAVEMENT IN A RURAL AREA NEAR MY HOME BECAUSE I COULD NOT SEE THE LANE MARKERS. RESEARCH ON THE INTERNET SHOWS THIS IS A RECURRING, COMMON PROBLEM. FORD MOTOR CO. IS AWARE OF THE ISSUE BUT HAS NOT TAKEN STEPS TO RESOLVE THIS DANGEROUS SITUATION. *TR

NHTSA ODI #10297750

53,000 miles · Dec 16, 2009
Visibility

TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE REAR WINDOW PANEL HAD DEVELOPED CRACKS. THE VEHICLE HAS NOT BEEN DIAGNOSED BY THE DEALERSHIP . THE CURRENT AND FAILURE MILEAGES WERE 53000.

NHTSA ODI #10296098

56,000 miles · Dec 10, 2009
StructureVisibility

CRACKS APPEARED BELOW THE REAR WINDOW OF MY FORD EXPLORER. THERE WAS NO ACCIDENT. *TR

NHTSA ODI #10295240

55,000 miles · Oct 23, 2009
Visibility

TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE GLASS FOR THE REAR LIFT GATE HAS DEVELOPED CRACKS IN IT. THE REAR DEFROSTER WAS ALSO INOPERATIVE. HE NOTIFIED THE DEALER, AND A TECHNICIAN STATED THAT IT WOULD COST $500.00 TO REPLACE THE COMPONENT. THE TECHNICIAN ALSO ADDED THAT THEY WERE AWARE OF THE FAILURE. NO REPAIRS WERE MADE. …

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TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE GLASS FOR THE REAR LIFT GATE HAS DEVELOPED CRACKS IN IT. THE REAR DEFROSTER WAS ALSO INOPERATIVE. HE NOTIFIED THE DEALER, AND A TECHNICIAN STATED THAT IT WOULD COST $500.00 TO REPLACE THE COMPONENT. THE TECHNICIAN ALSO ADDED THAT THEY WERE AWARE OF THE FAILURE. NO REPAIRS WERE MADE. THE MANUFACTURER WAS NOTIFIED, BUT NO ASSISTANCE WAS PROVIDED. HE HAS PICTURES OF MULTIPLE VEHICLES WITH THE SAME MODEL TYPE, INCLUDING HIS VEHICLE, WITH IDENTICAL FAILURES. THE FAILURE MILEAGE WAS 55,000. THE CURRENT MILEAGE WAS 65,000.

NHTSA ODI #10289464

Mileage unknown · Oct 10, 2009
Visibility

BLEND DOOR ACTUATOR PIN IS DEFECTIVE. I HAVE RESEARCHED THIS PROBLEM ONLINE AND IT IS A WIDESPREAD ISSUE. HEAT / DEFROST WILL NOT WORK. IN THE WINTERTIME THIS MAKES DRIVING EXTREMELY HAZARDOUS. *TR

NHTSA ODI #10286989

Official recalls

0

No recalls in this snapshot.

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

4

EA09013 · Vehicle Rollaway Allegations

Opened Aug 18, 2009 · Closed Feb 12, 2013

Status: closed (inferred from source dates) · Power Train:automatic Transmission:gear Position Indication (prndl); Power Train:automatic Transmission:lever And Linkage:column Shift; Steering; Steering:column; Steering:column LOCKING:ANTI-THEFT Device

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.

Additional source detail variants (5)

Power Train:automatic Transmission:gear Position Indication (prndl)

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.

Power Train:automatic Transmission:lever And Linkage:column Shift

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.

Steering:column

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.

Steering:column LOCKING:ANTI-THEFT Device

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.

Steering

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.

PE09020 · Vehicle Rollaway Allegations

Opened Apr 21, 2009 · Closed Aug 19, 2009

Status: closed (inferred from source dates) · Steering; Steering:column; Steering:column LOCKING:ANTI-THEFT Device

IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), FORD STATED CONSUMER REPORTS OF HIGHER THAN EXPECTED EFFORTS WHEN SHIFTING INTO AND OUT OF PARK COULD BE A RESULT OF A GROOVE BEING WORN INTO THE SWING ARM RAMP OF THE STEERING COLUMN. THE SWING ARM IS A COMPONENT BOLTED TO THE STEERING COLUMN THAT ASSISTS IN SHIFTING THROUGH THE TRANSMISSION GEARS.AN ENGINEERING EVALUATION CONDUCTED BY FORD OF RETURNED STEERING COLUMNS FOUND THE GROOVE COULD BE CREATED OVER TIME IF CONSUMER SHIFT MORE QUICKLY FROM THE DRIVE OR REVERSE TO PARK THAN THE BRAKE SHIFT INTERLOCK (BSI) SOLENOID PIN RETRACTS AFTER THE BRAKE PEDAL IS APPLIED. IN NOVEMBER OF 2004, FORD RELEASED A REDESIGNED BSI SOLENOID WITH A SHORTER PIN RETRACTING TIME AS A SERVICEABLE COMPONENT. FORD HAS NOTED THE SHORTER RETRACTION TIME SIGNIFICANTLY LESSENS THE LIKELIHOOD OF BSI SOLENOID PIN TO SWING ARM CONTACT EVEN WITH RAPID CONSUMER SHIFTS.FORD ALSO ISSUED A TECHNICAL SERVICE BULLETIN, TSB 04-22-12, TO INSTRUCT SERVICE TECHNICIANS ON THE PROPER DIAGNOSIS AND VEHICLE REPAIR. REVIEWING COMPLAINTS TO ODI AND DATA SUBMITTED BY FORD, ODI HAS IDENTIFIED 200 ALLEGED INCIDENTS OF UNINTENDED VEHICLE MOVEMENT AFTER CONSUMERS BELIEVE THEY HAVE SHIFTED THE VEHICLE INTO PARK, RESULTING IN 85 ALLEGED CRASHES AND 32 ALLEGED INJURIES.IN ADDITION TO THE REPORTS OF ALLEGED INCIDENTS OF UNINTENDED VEHICLE MOVEMENT, ODI HAS ALSO IDENTIFIED 883 REPORTS OF CONSUMERS ALLEGING DIFFICULTY OR THE INABILITY TO SHIFT THE VEHICLE INTO PARK.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA09-013) TO FURTHER ASSESS THE SCOPE, FREQUENCY AND RISK TO MOTOR VEHICLE SAFETY OF THE ALLEGED DEFECT IN THE SUBJECT VEHICLES.

Additional source detail variants (3)

Steering:column

IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), FORD STATED CONSUMER REPORTS OF HIGHER THAN EXPECTED EFFORTS WHEN SHIFTING INTO AND OUT OF PARK COULD BE A RESULT OF A GROOVE BEING WORN INTO THE SWING ARM RAMP OF THE STEERING COLUMN. THE SWING ARM IS A COMPONENT BOLTED TO THE STEERING COLUMN THAT ASSISTS IN SHIFTING THROUGH THE TRANSMISSION GEARS.AN ENGINEERING EVALUATION CONDUCTED BY FORD OF RETURNED STEERING COLUMNS FOUND THE GROOVE COULD BE CREATED OVER TIME IF CONSUMER SHIFT MORE QUICKLY FROM THE DRIVE OR REVERSE TO PARK THAN THE BRAKE SHIFT INTERLOCK (BSI) SOLENOID PIN RETRACTS AFTER THE BRAKE PEDAL IS APPLIED. IN NOVEMBER OF 2004, FORD RELEASED A REDESIGNED BSI SOLENOID WITH A SHORTER PIN RETRACTING TIME AS A SERVICEABLE COMPONENT. FORD HAS NOTED THE SHORTER RETRACTION TIME SIGNIFICANTLY LESSENS THE LIKELIHOOD OF BSI SOLENOID PIN TO SWING ARM CONTACT EVEN WITH RAPID CONSUMER SHIFTS.FORD ALSO ISSUED A TECHNICAL SERVICE BULLETIN, TSB 04-22-12, TO INSTRUCT SERVICE TECHNICIANS ON THE PROPER DIAGNOSIS AND VEHICLE REPAIR. REVIEWING COMPLAINTS TO ODI AND DATA SUBMITTED BY FORD, ODI HAS IDENTIFIED 200 ALLEGED INCIDENTS OF UNINTENDED VEHICLE MOVEMENT AFTER CONSUMERS BELIEVE THEY HAVE SHIFTED THE VEHICLE INTO PARK, RESULTING IN 85 ALLEGED CRASHES AND 32 ALLEGED INJURIES.IN ADDITION TO THE REPORTS OF ALLEGED INCIDENTS OF UNINTENDED VEHICLE MOVEMENT, ODI HAS ALSO IDENTIFIED 883 REPORTS OF CONSUMERS ALLEGING DIFFICULTY OR THE INABILITY TO SHIFT THE VEHICLE INTO PARK.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA09-013) TO FURTHER ASSESS THE SCOPE, FREQUENCY AND RISK TO MOTOR VEHICLE SAFETY OF THE ALLEGED DEFECT IN THE SUBJECT VEHICLES.

Steering:column LOCKING:ANTI-THEFT Device

IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), FORD STATED CONSUMER REPORTS OF HIGHER THAN EXPECTED EFFORTS WHEN SHIFTING INTO AND OUT OF PARK COULD BE A RESULT OF A GROOVE BEING WORN INTO THE SWING ARM RAMP OF THE STEERING COLUMN. THE SWING ARM IS A COMPONENT BOLTED TO THE STEERING COLUMN THAT ASSISTS IN SHIFTING THROUGH THE TRANSMISSION GEARS.AN ENGINEERING EVALUATION CONDUCTED BY FORD OF RETURNED STEERING COLUMNS FOUND THE GROOVE COULD BE CREATED OVER TIME IF CONSUMER SHIFT MORE QUICKLY FROM THE DRIVE OR REVERSE TO PARK THAN THE BRAKE SHIFT INTERLOCK (BSI) SOLENOID PIN RETRACTS AFTER THE BRAKE PEDAL IS APPLIED. IN NOVEMBER OF 2004, FORD RELEASED A REDESIGNED BSI SOLENOID WITH A SHORTER PIN RETRACTING TIME AS A SERVICEABLE COMPONENT. FORD HAS NOTED THE SHORTER RETRACTION TIME SIGNIFICANTLY LESSENS THE LIKELIHOOD OF BSI SOLENOID PIN TO SWING ARM CONTACT EVEN WITH RAPID CONSUMER SHIFTS.FORD ALSO ISSUED A TECHNICAL SERVICE BULLETIN, TSB 04-22-12, TO INSTRUCT SERVICE TECHNICIANS ON THE PROPER DIAGNOSIS AND VEHICLE REPAIR. REVIEWING COMPLAINTS TO ODI AND DATA SUBMITTED BY FORD, ODI HAS IDENTIFIED 200 ALLEGED INCIDENTS OF UNINTENDED VEHICLE MOVEMENT AFTER CONSUMERS BELIEVE THEY HAVE SHIFTED THE VEHICLE INTO PARK, RESULTING IN 85 ALLEGED CRASHES AND 32 ALLEGED INJURIES.IN ADDITION TO THE REPORTS OF ALLEGED INCIDENTS OF UNINTENDED VEHICLE MOVEMENT, ODI HAS ALSO IDENTIFIED 883 REPORTS OF CONSUMERS ALLEGING DIFFICULTY OR THE INABILITY TO SHIFT THE VEHICLE INTO PARK.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA09-013) TO FURTHER ASSESS THE SCOPE, FREQUENCY AND RISK TO MOTOR VEHICLE SAFETY OF THE ALLEGED DEFECT IN THE SUBJECT VEHICLES.

Steering

IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), FORD STATED CONSUMER REPORTS OF HIGHER THAN EXPECTED EFFORTS WHEN SHIFTING INTO AND OUT OF PARK COULD BE A RESULT OF A GROOVE BEING WORN INTO THE SWING ARM RAMP OF THE STEERING COLUMN. THE SWING ARM IS A COMPONENT BOLTED TO THE STEERING COLUMN THAT ASSISTS IN SHIFTING THROUGH THE TRANSMISSION GEARS.AN ENGINEERING EVALUATION CONDUCTED BY FORD OF RETURNED STEERING COLUMNS FOUND THE GROOVE COULD BE CREATED OVER TIME IF CONSUMER SHIFT MORE QUICKLY FROM THE DRIVE OR REVERSE TO PARK THAN THE BRAKE SHIFT INTERLOCK (BSI) SOLENOID PIN RETRACTS AFTER THE BRAKE PEDAL IS APPLIED. IN NOVEMBER OF 2004, FORD RELEASED A REDESIGNED BSI SOLENOID WITH A SHORTER PIN RETRACTING TIME AS A SERVICEABLE COMPONENT. FORD HAS NOTED THE SHORTER RETRACTION TIME SIGNIFICANTLY LESSENS THE LIKELIHOOD OF BSI SOLENOID PIN TO SWING ARM CONTACT EVEN WITH RAPID CONSUMER SHIFTS.FORD ALSO ISSUED A TECHNICAL SERVICE BULLETIN, TSB 04-22-12, TO INSTRUCT SERVICE TECHNICIANS ON THE PROPER DIAGNOSIS AND VEHICLE REPAIR. REVIEWING COMPLAINTS TO ODI AND DATA SUBMITTED BY FORD, ODI HAS IDENTIFIED 200 ALLEGED INCIDENTS OF UNINTENDED VEHICLE MOVEMENT AFTER CONSUMERS BELIEVE THEY HAVE SHIFTED THE VEHICLE INTO PARK, RESULTING IN 85 ALLEGED CRASHES AND 32 ALLEGED INJURIES.IN ADDITION TO THE REPORTS OF ALLEGED INCIDENTS OF UNINTENDED VEHICLE MOVEMENT, ODI HAS ALSO IDENTIFIED 883 REPORTS OF CONSUMERS ALLEGING DIFFICULTY OR THE INABILITY TO SHIFT THE VEHICLE INTO PARK.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA09-013) TO FURTHER ASSESS THE SCOPE, FREQUENCY AND RISK TO MOTOR VEHICLE SAFETY OF THE ALLEGED DEFECT IN THE SUBJECT VEHICLES.

RQ08003 · Rear Liftgate Glass Hatch Failure

Opened Jun 23, 2008 · Closed Oct 24, 2008

Status: closed (inferred from source dates) · Structure:body:hatchback/liftgate; Structure:body:hatchback/liftgate:hinge And Attachments; Structure:body:hatchback/liftgate:support Device/strut; Visibility:glass, Side/rear

THIS INVESTIGATION WAS OPENED ON JUNE 23, 2008, BASED ON 34 COMPLAINTS INVOLVING EIGHT INJURIES IN WHICH THE REAR LIFTGATE GLASS HATCH ON MODEL YEAR 2004 FORD EXPLORERS OR MERCURY MOUNTAINEERS BROKE OFF AND FELL, USUALLY WHILE INDIVIDUALS WERE OPERATING THE GLASS HATCH OR LOADING OR UNLOADING ITEMS FROM THE REAR OF THE VEHICLE.FORD CONDUCTED RECALL 04V-442 IN 2004 TO ADDRESS SIMILAR PROBLEMS ON MODEL YEAR 2002 AND CERTAIN MODEL YEAR 2003 FORD EXPLORERS AND MERCURY MOUNTAINEERS.THE INFORMATION FORD PROVIDED IN RESPONSE TO ODI'S INFORMATION REQUEST LETTER INDICATED THAT FAILURES WITH 2004 VEHICLES WERE PRIMARILY LIFTGATE GLASS HATCH HINGE FAILURES RELATED TO CORROSION AT THE HINGE PIN, WHEREAS THE FAILURES THAT PROMPTED THE RECALL WITH THE EARLIER MODELS WERE PRIMARILY RELATED TO PROBLEMS WITH THE GLASS HATCH'S STRUTS OR FRACTURE OF A PRIOR HINGE DESIGN AT THE BOSS/BOLT CONNECTION AT THE GLASS.ODI'S REVIEW OF FORD'S WARRANTY, COMPLAINT, AND INJURY DATA FOR THE 2004 VEHICLES INDICATES THAT THESE RATES ARE SIGNIFICANTLY LOWER THAN THOSE FOR THE RECALLED POPULATION.A POTENTIAL DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME.ODI WILL CONTINUE TO MONITOR COMPLAINTS AND TAKE APPROPRIATE ACTION AS NECESSARY.THIS INVESTIGATION IS CLOSED.

Additional source detail variants (4)

Structure:body:hatchback/liftgate

THIS INVESTIGATION WAS OPENED ON JUNE 23, 2008, BASED ON 34 COMPLAINTS INVOLVING EIGHT INJURIES IN WHICH THE REAR LIFTGATE GLASS HATCH ON MODEL YEAR 2004 FORD EXPLORERS OR MERCURY MOUNTAINEERS BROKE OFF AND FELL, USUALLY WHILE INDIVIDUALS WERE OPERATING THE GLASS HATCH OR LOADING OR UNLOADING ITEMS FROM THE REAR OF THE VEHICLE.FORD CONDUCTED RECALL 04V-442 IN 2004 TO ADDRESS SIMILAR PROBLEMS ON MODEL YEAR 2002 AND CERTAIN MODEL YEAR 2003 FORD EXPLORERS AND MERCURY MOUNTAINEERS.THE INFORMATION FORD PROVIDED IN RESPONSE TO ODI'S INFORMATION REQUEST LETTER INDICATED THAT FAILURES WITH 2004 VEHICLES WERE PRIMARILY LIFTGATE GLASS HATCH HINGE FAILURES RELATED TO CORROSION AT THE HINGE PIN, WHEREAS THE FAILURES THAT PROMPTED THE RECALL WITH THE EARLIER MODELS WERE PRIMARILY RELATED TO PROBLEMS WITH THE GLASS HATCH'S STRUTS OR FRACTURE OF A PRIOR HINGE DESIGN AT THE BOSS/BOLT CONNECTION AT THE GLASS.ODI'S REVIEW OF FORD'S WARRANTY, COMPLAINT, AND INJURY DATA FOR THE 2004 VEHICLES INDICATES THAT THESE RATES ARE SIGNIFICANTLY LOWER THAN THOSE FOR THE RECALLED POPULATION.A POTENTIAL DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME.ODI WILL CONTINUE TO MONITOR COMPLAINTS AND TAKE APPROPRIATE ACTION AS NECESSARY.THIS INVESTIGATION IS CLOSED.

Structure:body:hatchback/liftgate:hinge And Attachments

THIS INVESTIGATION WAS OPENED ON JUNE 23, 2008, BASED ON 34 COMPLAINTS INVOLVING EIGHT INJURIES IN WHICH THE REAR LIFTGATE GLASS HATCH ON MODEL YEAR 2004 FORD EXPLORERS OR MERCURY MOUNTAINEERS BROKE OFF AND FELL, USUALLY WHILE INDIVIDUALS WERE OPERATING THE GLASS HATCH OR LOADING OR UNLOADING ITEMS FROM THE REAR OF THE VEHICLE.FORD CONDUCTED RECALL 04V-442 IN 2004 TO ADDRESS SIMILAR PROBLEMS ON MODEL YEAR 2002 AND CERTAIN MODEL YEAR 2003 FORD EXPLORERS AND MERCURY MOUNTAINEERS.THE INFORMATION FORD PROVIDED IN RESPONSE TO ODI'S INFORMATION REQUEST LETTER INDICATED THAT FAILURES WITH 2004 VEHICLES WERE PRIMARILY LIFTGATE GLASS HATCH HINGE FAILURES RELATED TO CORROSION AT THE HINGE PIN, WHEREAS THE FAILURES THAT PROMPTED THE RECALL WITH THE EARLIER MODELS WERE PRIMARILY RELATED TO PROBLEMS WITH THE GLASS HATCH'S STRUTS OR FRACTURE OF A PRIOR HINGE DESIGN AT THE BOSS/BOLT CONNECTION AT THE GLASS.ODI'S REVIEW OF FORD'S WARRANTY, COMPLAINT, AND INJURY DATA FOR THE 2004 VEHICLES INDICATES THAT THESE RATES ARE SIGNIFICANTLY LOWER THAN THOSE FOR THE RECALLED POPULATION.A POTENTIAL DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME.ODI WILL CONTINUE TO MONITOR COMPLAINTS AND TAKE APPROPRIATE ACTION AS NECESSARY.THIS INVESTIGATION IS CLOSED.

Structure:body:hatchback/liftgate:support Device/strut

THIS INVESTIGATION WAS OPENED ON JUNE 23, 2008, BASED ON 34 COMPLAINTS INVOLVING EIGHT INJURIES IN WHICH THE REAR LIFTGATE GLASS HATCH ON MODEL YEAR 2004 FORD EXPLORERS OR MERCURY MOUNTAINEERS BROKE OFF AND FELL, USUALLY WHILE INDIVIDUALS WERE OPERATING THE GLASS HATCH OR LOADING OR UNLOADING ITEMS FROM THE REAR OF THE VEHICLE.FORD CONDUCTED RECALL 04V-442 IN 2004 TO ADDRESS SIMILAR PROBLEMS ON MODEL YEAR 2002 AND CERTAIN MODEL YEAR 2003 FORD EXPLORERS AND MERCURY MOUNTAINEERS.THE INFORMATION FORD PROVIDED IN RESPONSE TO ODI'S INFORMATION REQUEST LETTER INDICATED THAT FAILURES WITH 2004 VEHICLES WERE PRIMARILY LIFTGATE GLASS HATCH HINGE FAILURES RELATED TO CORROSION AT THE HINGE PIN, WHEREAS THE FAILURES THAT PROMPTED THE RECALL WITH THE EARLIER MODELS WERE PRIMARILY RELATED TO PROBLEMS WITH THE GLASS HATCH'S STRUTS OR FRACTURE OF A PRIOR HINGE DESIGN AT THE BOSS/BOLT CONNECTION AT THE GLASS.ODI'S REVIEW OF FORD'S WARRANTY, COMPLAINT, AND INJURY DATA FOR THE 2004 VEHICLES INDICATES THAT THESE RATES ARE SIGNIFICANTLY LOWER THAN THOSE FOR THE RECALLED POPULATION.A POTENTIAL DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME.ODI WILL CONTINUE TO MONITOR COMPLAINTS AND TAKE APPROPRIATE ACTION AS NECESSARY.THIS INVESTIGATION IS CLOSED.

Visibility:glass, Side/rear

THIS INVESTIGATION WAS OPENED ON JUNE 23, 2008, BASED ON 34 COMPLAINTS INVOLVING EIGHT INJURIES IN WHICH THE REAR LIFTGATE GLASS HATCH ON MODEL YEAR 2004 FORD EXPLORERS OR MERCURY MOUNTAINEERS BROKE OFF AND FELL, USUALLY WHILE INDIVIDUALS WERE OPERATING THE GLASS HATCH OR LOADING OR UNLOADING ITEMS FROM THE REAR OF THE VEHICLE.FORD CONDUCTED RECALL 04V-442 IN 2004 TO ADDRESS SIMILAR PROBLEMS ON MODEL YEAR 2002 AND CERTAIN MODEL YEAR 2003 FORD EXPLORERS AND MERCURY MOUNTAINEERS.THE INFORMATION FORD PROVIDED IN RESPONSE TO ODI'S INFORMATION REQUEST LETTER INDICATED THAT FAILURES WITH 2004 VEHICLES WERE PRIMARILY LIFTGATE GLASS HATCH HINGE FAILURES RELATED TO CORROSION AT THE HINGE PIN, WHEREAS THE FAILURES THAT PROMPTED THE RECALL WITH THE EARLIER MODELS WERE PRIMARILY RELATED TO PROBLEMS WITH THE GLASS HATCH'S STRUTS OR FRACTURE OF A PRIOR HINGE DESIGN AT THE BOSS/BOLT CONNECTION AT THE GLASS.ODI'S REVIEW OF FORD'S WARRANTY, COMPLAINT, AND INJURY DATA FOR THE 2004 VEHICLES INDICATES THAT THESE RATES ARE SIGNIFICANTLY LOWER THAN THOSE FOR THE RECALLED POPULATION.A POTENTIAL DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME.ODI WILL CONTINUE TO MONITOR COMPLAINTS AND TAKE APPROPRIATE ACTION AS NECESSARY.THIS INVESTIGATION IS CLOSED.

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.

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