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2003 Ford F-250

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2003 Ford F-250 do not stand out strongly from the model-year median of 119.

About this comparison →

When problems were reported

Mileage at the reported incident

80 reports with mileage · 36 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 24 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Tires. Review the 20 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 13 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

6 crash reports8 fire reports4 injury reports

Structure complaints

5 reports
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Mileage unknown · Jun 30, 2026
Service BrakesStructureUnknown Or Other

The customer purchased a vehicle from Metro Motors on May 8, 2026, after visiting the dealership three times and speaking with multiple sales representatives. During each visit, the customer specifically stated that the vehicle would be used to tow a trailer and repeatedly asked whether it was safe and suitable for towing. The s…

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The customer purchased a vehicle from Metro Motors on May 8, 2026, after visiting the dealership three times and speaking with multiple sales representatives. During each visit, the customer specifically stated that the vehicle would be used to tow a trailer and repeatedly asked whether it was safe and suitable for towing. The sales staff consistently represented that the vehicle was in good working condition, had low mileage, showed no significant issues on the Carfax report, and would be an excellent vehicle for towing. The customer was discouraged from test driving the vehicle because it was low on fuel, and sales staff stated that the only reason it had not sold was the snowplow attached to the front. Immediately after taking possession of the vehicle on May 8, the customer experienced a serious issue with the electronic parking brake repeatedly engaging while driving. The customer contacted Metro Motors on the next business day and was instructed by the manager, Nate, to bring the vehicle back. Metro Motors later determined that the parking brake cable was broken and that the brakes were in poor condition. After discussions, the dealership agreed to perform repairs if the customer paid for the parts. After the repairs were completed, the customer noticed smoke coming from the wheels and immediately returned the vehicle to Metro Motors. The dealership retained the vehicle but failed to communicate the nature of the problem or any repair costs until notifying the customer that the vehicle was ready for pickup on June 6, 2026. Before taking possession of the vehicle again, the customer arranged for an independent mechanic to inspect it. Although the dealership manager was initially hesitant to allow the inspection, he ultimately permitted it. The mechanic determined that the vehicle's frame was broken and that it was unsafe to operate, particularly for towing, which was the purpose repeatedly disclosed to Metro Motors before purchase.

NHTSA ODI #11747388

62,000 miles · Mar 3, 2017
StructureWheels

REPLACED 4 NEW TIRES ON MY FORD F-250 TRUCK 9/20/2013. YOKOHAMA GEOLANDAR H/T-S, LT235/85R16. ON APPROXIMATELY 5/10/2016, WHILE ON FREEWAY,BEGAN TO FEEL A VIBRATION WHILE DRIVING. FELT LIKE WHEEL OUT OF BALANCE. THE LEFT REAR TIRE TREAD CAME OFF THE TIRE CAUSING SEVERE DAMAGE TO THE TRUCK BED. APPROXIMATELY 28,500 MILES ON THE T…

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REPLACED 4 NEW TIRES ON MY FORD F-250 TRUCK 9/20/2013. YOKOHAMA GEOLANDAR H/T-S, LT235/85R16. ON APPROXIMATELY 5/10/2016, WHILE ON FREEWAY,BEGAN TO FEEL A VIBRATION WHILE DRIVING. FELT LIKE WHEEL OUT OF BALANCE. THE LEFT REAR TIRE TREAD CAME OFF THE TIRE CAUSING SEVERE DAMAGE TO THE TRUCK BED. APPROXIMATELY 28,500 MILES ON THE TIRES. TIRE REMAINED INFLATED. I CONTACTED YOKOHAMA TO OPEN A CASE FILE. I SENT THEM THE TIRE FOR EXAMINATION PER THEIR REQUEST. THEY SENT ME THE ANALYSIS BACK WITH A BUNCH OF PHOTOS BLAMING THE FAILURE ON ROAD DEBRIS. APPROXIMATELY 5 WEEKS LATER ON 7/2/2016 I EXPERIENCED THE SAME VIBRATION WHILE ON A TRIP OUT OF TOWN. THIS TIME THE RIGHT REAR TIRE TREAD CAME OFF THE TIRE CAUSING SEVERE DAMAGE TO THE RIGHT SIDE TRUCK BED. APPROXIMATELY 29,000 MILES ON THE SECOND TIRE. CONTACTED YOKOHAMA TO OPEN ANOTHER CASE FILE. CURRENTLY IN LITIGATION AS OF 3/3/2017 FOR $7,111 FOR VEHICLE DAMAGE AND 4 NEW TIRES. FORTUNATELY NOBODY WAS HURT BECAUSE OF THESE DEFECTIVE TIRES.

NHTSA ODI #10958553

100,000 miles · Aug 16, 2016
EngineFuel/propulsion SystemStructure

TL* THE CONTACT OWNS A 2003 FORD F-250. THE CONTACT STATED THAT THE VEHICLE MADE AN ABNORMAL NOISE AND STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED TO A DEALER WHO REPLACED THE OIL PUMP. THE CONTACT ALSO INDICATED THAT THERE WERE MULTIPLE FAILURES WITH THE VEHICLE. AT LEAST TWELVE FUEL INJECTORS WERE REPLACED BY THE DEALER AT …

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TL* THE CONTACT OWNS A 2003 FORD F-250. THE CONTACT STATED THAT THE VEHICLE MADE AN ABNORMAL NOISE AND STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED TO A DEALER WHO REPLACED THE OIL PUMP. THE CONTACT ALSO INDICATED THAT THERE WERE MULTIPLE FAILURES WITH THE VEHICLE. AT LEAST TWELVE FUEL INJECTORS WERE REPLACED BY THE DEALER AT LEAST TWELVE TIMES; HOWEVER, THE MAIN FAILURE WAS THE TURBO BRACKET BEING UNSTABLE. THE DEALER DIAGNOSED THAT THE FOUR BOLTS WERE RUSTED WITH CORROSION AND THE BOLTS, WHICH WERE NOT IN PLACE AND THE J-TUBE INTERNALLY FRACTURED. THE DEALER REPLACED THE FOUR BOLTS AND THE J-TUBE. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 100,000.

NHTSA ODI #10896379

Mileage unknown · Oct 17, 2014
StructureTires

ON 10/11/14 WE WERE TRAVELING FROM OUR HOME IN HAVELOCK, NC TO THE CHARLOTTE AREA. WITH ABOUT 20 MINUTES INTO THE TRIP WE FELT A VIOLENT VIBRATION AND THEN THE REAR PASSENGER TIRE BLEW! MIRACULOUSLY, MY HUSBAND WAS ABLE TO PULL HIS FORD F-250 PICKUP TO THE SIDE OF THE ROAD AND THANKFULLY NO ONE WAS HURT! THE TIRE WAS FLAT WIT…

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ON 10/11/14 WE WERE TRAVELING FROM OUR HOME IN HAVELOCK, NC TO THE CHARLOTTE AREA. WITH ABOUT 20 MINUTES INTO THE TRIP WE FELT A VIOLENT VIBRATION AND THEN THE REAR PASSENGER TIRE BLEW! MIRACULOUSLY, MY HUSBAND WAS ABLE TO PULL HIS FORD F-250 PICKUP TO THE SIDE OF THE ROAD AND THANKFULLY NO ONE WAS HURT! THE TIRE WAS FLAT WITH MUCH OF THE TREAD SEPARATED FROM THE TIRE. ALSO, SIGNIFICANT DAMAGE WAS CAUSED TO THE WHEEL WELL OF THE TRUCK BECAUSE OF THE BLOWOUT. AFTER HAVING ALLSTATE MOTOR CLUB COME AND ASSIST US, AND REPLACE THE BLOWOUT, WE WERE ON OUR ROAD AGAIN. THREE DAYS LATER ON OCTOBER 14TH WE WERE HEADED BACK TO HAVELOCK WHEN ONCE AGAIN THE TRUCK BEGAN TO SHAKE VIOLENTLY. MY HUSBAND MADE IT TO MY BROTHER-IN-LAWS DRIVEWAY, GOT OUT AND NOTICED THE FRONT PASSENGERS TIRE HAD A MAJOR BUBBLE IN IT. WE ALMOST HAD A SECOND TIRE BLOWOUT! NOW WE WERE THINKING THERE MUST BE SOMETHING WRONG WITH THESE TIRES SINCE TWO OF THEM FAILED WITHIN 3 DAYS. THE TIRES ON OUR TRUCK ARE BF GOODRICH MUD TERRAIN T/A KM2 LT285/75R16 DOT # BFYUCF213810. THESE TIRES ON OUR PICKUP HAVE PLENTY OF TREAD LEFT ON THEM AND SHOULD NOT HAVE FAILED! I HAVE BEEN IN CONTACT WITH MICHELIN (THE PARENT COMPANY OF BF GOODRICH). THEY TOLD ME TO GO TO MY LOCAL FAMILY TIRE TO HAVE THEM INSPECT OUR TIRES AND THEN HAVE THEM CONTACT MICHELIN ON THEIR FINDINGS. THEY ALSO SAID I WOULD NEED THE BLOWN OUT TIRE, WHICH I NO LONGER HAVE, TO RECEIVE ANY COMPENSATION FOR THAT. I BELIEVE I AM IN FOR A "RUN AROUND" FROM MICHELIN BEFORE I RECEIVE (IF I DO RECEIVE) ANY KIND OF COMPENSATION. I'VE SEEN ONLINE TOO WHERE SEVERAL SIMILAR TIRES FROM BF GOODRICH HAVE BEEN RECALLED DUE TO TREAD SEPARATION. I DO BELIEVE THE TIRES MENTIONED ABOVE ARE UNSAFE AND COULD CAUSE LOSS OF LIFE! I ALSO BELIEVE MICHELIN IS PUTTING THE ALMIGHTY DOLLAR BEFORE HUMAN SAFETY! *TR

NHTSA ODI #10648513

90,000 miles · Jul 7, 2011
Structure

TL* THE CONTACT OWNS A 2003 FORD F-250. THE CONTACT STATED THE SEAM THAT HOLDS THE ROOF IN PLACE FRACTURED FROM THE FRONT OF THE VEHICLE TO THE REAR. THE VEHICLE WAS INSPECTED BY A DEALER WHO ADVISED HIM THAT THEY WERE AWARE OF THE FAILURE AND THAT HE WOULD NEED TO HAVE THE SEAL GRIND OUT AND REPLACED. THE VEHICLE WAS NOT REPAI…

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TL* THE CONTACT OWNS A 2003 FORD F-250. THE CONTACT STATED THE SEAM THAT HOLDS THE ROOF IN PLACE FRACTURED FROM THE FRONT OF THE VEHICLE TO THE REAR. THE VEHICLE WAS INSPECTED BY A DEALER WHO ADVISED HIM THAT THEY WERE AWARE OF THE FAILURE AND THAT HE WOULD NEED TO HAVE THE SEAL GRIND OUT AND REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 90,000. IN 2 HOURS I LOCATED 12 ADDITIONAL FORD VEHICLES AT DEALERSHIPS WITH THE SAME PROBLEM. 2006 AND OLDER VEHICLES INCLUDING MY OWN 2005 FREESTAR. I BELIEVE IF INVOLVED IN AN ACCIDENT THE ROOF WILL DISLODGE CAUSING THE OCCUPANTS TO BE EJECTED. THE MANUFACTURE WAS CONTACTED THEY ARE AWARE AND REFUSED TO ASSIST. UPDATED 10/18/2011 *LN *TR

NHTSA ODI #10410853

Official recalls

2

11V352000 · Exterior Lighting:brake Lights; Exterior Lighting:tail Lights

Jul 13, 2011

FORD IS RECALLING CERTAIN MODEL YEAR 2011 RANGER TRUCKS BUILT FROM JANUARY 25, 2011, THROUGH APRIL 25, 2011 AT THE TWIN CITIES ASSEMBLY PLANT, AND SERVICE PARTS DISTRIBUTED TO DEALERS FOR CERTAIN 2004 THROUGH 2011 MODEL YEAR RANGER TRUCKS, 2002 THROUGH 2005 MODEL YEAR EXCURSION VEHICLES, AND 2002 THROUGH 2007 MODEL YEAR F-250, F-350, F-450, AND F-550 TRUCKS FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THE MULTI-FUNCTION SWITCH WAS SHIPPED WITH A SUBCOMPONENT (SLIDER) THAT MAY EXPERIENCE DEFORMATION. A MULTI-FUNCTION SWITCH WITH A DEFORMED SLIDER MAY MALFUNCTION CAUSING THE TURN SIGNAL, TAIL LIGHTS, HAZARD WARNING SIGNAL FLASHERS AND/OR BRAKE LIGHTS NOT TO ACTIVATE.

Consequence & remedy

Consequence: NON-FUNCTIONING LIGHTS COULD INCREASE THE RISK OF A CRASH.

Remedy: DEALERS WILL REPLACE THE SWITCHES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 15, 2011. OWNERS MAY CONTACT FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.

Additional source detail variants (2)

Exterior Lighting:brake Lights

FORD IS RECALLING CERTAIN MODEL YEAR 2011 RANGER TRUCKS BUILT FROM JANUARY 25, 2011, THROUGH APRIL 25, 2011 AT THE TWIN CITIES ASSEMBLY PLANT, AND SERVICE PARTS DISTRIBUTED TO DEALERS FOR CERTAIN 2004 THROUGH 2011 MODEL YEAR RANGER TRUCKS, 2002 THROUGH 2005 MODEL YEAR EXCURSION VEHICLES, AND 2002 THROUGH 2007 MODEL YEAR F-250, F-350, F-450, AND F-550 TRUCKS FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THE MULTI-FUNCTION SWITCH WAS SHIPPED WITH A SUBCOMPONENT (SLIDER) THAT MAY EXPERIENCE DEFORMATION. A MULTI-FUNCTION SWITCH WITH A DEFORMED SLIDER MAY MALFUNCTION CAUSING THE TURN SIGNAL, TAIL LIGHTS, HAZARD WARNING SIGNAL FLASHERS AND/OR BRAKE LIGHTS NOT TO ACTIVATE.

Consequence: NON-FUNCTIONING LIGHTS COULD INCREASE THE RISK OF A CRASH.

Remedy: DEALERS WILL REPLACE THE SWITCHES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 15, 2011. OWNERS MAY CONTACT FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.

Exterior Lighting:tail Lights

FORD IS RECALLING CERTAIN MODEL YEAR 2011 RANGER TRUCKS BUILT FROM JANUARY 25, 2011, THROUGH APRIL 25, 2011 AT THE TWIN CITIES ASSEMBLY PLANT, AND SERVICE PARTS DISTRIBUTED TO DEALERS FOR CERTAIN 2004 THROUGH 2011 MODEL YEAR RANGER TRUCKS, 2002 THROUGH 2005 MODEL YEAR EXCURSION VEHICLES, AND 2002 THROUGH 2007 MODEL YEAR F-250, F-350, F-450, AND F-550 TRUCKS FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THE MULTI-FUNCTION SWITCH WAS SHIPPED WITH A SUBCOMPONENT (SLIDER) THAT MAY EXPERIENCE DEFORMATION. A MULTI-FUNCTION SWITCH WITH A DEFORMED SLIDER MAY MALFUNCTION CAUSING THE TURN SIGNAL, TAIL LIGHTS, HAZARD WARNING SIGNAL FLASHERS AND/OR BRAKE LIGHTS NOT TO ACTIVATE.

Consequence: NON-FUNCTIONING LIGHTS COULD INCREASE THE RISK OF A CRASH.

Remedy: DEALERS WILL REPLACE THE SWITCHES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 15, 2011. OWNERS MAY CONTACT FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.

04V327000 · Electrical SYSTEM:12V/24V/48V Battery

Jul 7, 2004

ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES EQUIPPED WITH 6.0L DIESEL ENGINES, THE ENGINE GROUND STUD THAT ATTACHES THE NEGATIVE BATTERY TERMINAL EYELET TO THE ENGINE BLOCK MAY BE LOOSE.

Consequence & remedy

Consequence: IF THE GROUND WIRE IS LOOSE, ELECTRICAL CURRENT MAY FLOW TO THE RADIO SUPPRESSION STRAP CAUSING IT TO HEAT AND POTENTIALLY MELT OR IGNITE ADJACENT COMPONENTS WHICH COULD RESULT IN A FIRE.

Remedy: DEALERS WILL REPLACE THE ENGINE GROUND STUD AND THE RADIO SUPPRESSION STRAP AND ADJACENT COMPONENTS WILL BE INSPECTED FOR DAMAGE AND REPLACED, IF NECESSARY. THE RECALL BEGAN ON JULY 23, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.

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

2

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.

PE04070 · Engine Stalling

Opened Oct 7, 2004 · Closed Feb 15, 2005

Status: closed (inferred from source dates) · Engine And Engine Cooling:engine:diesel

TWENTY FIVE OF THE ODI FAILURE REPORTS ARE DUPLICATIVE OF FORD COMPLAINTS.TWENTY ODI REPORTS DO NOT CONTAIN A VIN (AND MAY OR MAY NOT BE DUPLICATIVE OF FORD REPORTS).THE 14 ALLEGED CRASHES AND 2 ALLEGED INJURIES WERE ALL MINOR.SUBMITTED DURING PRELIMINARY EVALUATION (PE) 04-070, FORD'S RESPONSE TO ODI'S INFORMATION REQUEST (IR) LETTER CONTAINED ABOUT 5,000 CONSUMER REPORTS (MORS) AND 8,700 FIELD REPORTS (CQIS).FORD REVIEWED THE COMPLAINTS AND CATEGORIZED THEM.THE MANUFACTURER REPORTS SHOWN ABOVE REPRESENT A COUNT OF UNIQUE VEHICLES THAT FORD CATEGORIZED AS ALLEGEDLY STALLING DUE TO A SUBJECT ENGINE COMPONENT ('A' CATEGORY, SEE FORD'S IR RESPONSE LETTER FOR FURTHER DETAIL); SOME OF THESE VEHICLES RECEIVED MULTIPLE REPORTS.ODI HAS NOT YET CONFIRMED FORD'S CATEGORIZATION OF THESE REPORTS, NOR HAS ODI CONFIRMED FORD'S CATEGORIZATION OF THE REMAINING REPORTS (WHICH FORD STATES DO NOT PERTAIN TO THE ALLEGED DEFECT).FORD SUBMITTED NEARLY 19,000 WARRANTY CLAIMS, MANY OF WHICH INVOLVED CLAIMS FOR A TECHNICAL SERVICE BULLETIN (TSB 04-13-08) AND FIELD SERVICE ACTION (FSA 03B05) WHICH FORD IDENTIFIED AS POTENTIAL REMEDIES FOR STALLING COMPLAINTS.ODI HAS NOT CONFIRMED THAT EITHER OF THESE ARE A REMEDY FOR ENGINE STALLING COMPLAINTS.SEVERAL OTHER DEALER COMMUNICATIONS RELATED TO ENGINE STALL WERE ALSO SUBMITTED AS WELL AS OVER 50 PRODUCT MODIFICATIONS, 15 OF WHICH INVOLVE REVISIONS TO THE SOFTWARE FOR THE ELECTRONIC ENGINE CONTROL UNIT.FURTHER INVESTIGATION IS REQUIRED AND ODI IS UPGRADING PE04-070 TO AN ENGINEERING ANALYSIS (EA).DURING THE EA, ODI WILL ESTABLISH AND UPDATE MANUFACTURER FAILURE REPORT COUNTS, FURTHER INVESTIGATE THE FREQUENCY AND TREND OF STALLING COMPLAINTS, AND DETERMINE THE SCOPE AND SAFETY IMPLICATION OF STALLING EVENTS.ODI WILL ALSO INVESTIGATE FORD'S REMEDIES, THEIR EFFECTIVENESS, AND WHETHER FURTHER ACTION IS REQUIRED.