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2003 Ford F-350

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2003 Ford F-350 do not stand out strongly from the model-year median of 93.

About this comparison →

When problems were reported

Mileage at the reported incident

58 reports with mileage · 32 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 19 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Vehicle Speed Control. Review the 13 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 11 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

11 crash reports8 fire reports5 injury reports

What owners actually said

90 reports
150,000 miles · May 5, 2017
Tires

TL* THE CONTACT OWNS A 2003 FORD F-350 EQUIPPED WITH BF GOODRICH RUGGED TERRAIN T/A TIRES, SIZE: 285/75/16. WHILE DRIVING 75 MPH, THE FRONT PASSENGER SIDE TIRE SUSTAINED TREAD SEPARATION. THE CONTACT STATED THAT THERE WAS DAMAGE DOWN TO THE FENDER AND FENDER WELL OF THE VEHICLE. THE CONTACT STATED THAT THE TIRE WAS STILL FULLY I…

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TL* THE CONTACT OWNS A 2003 FORD F-350 EQUIPPED WITH BF GOODRICH RUGGED TERRAIN T/A TIRES, SIZE: 285/75/16. WHILE DRIVING 75 MPH, THE FRONT PASSENGER SIDE TIRE SUSTAINED TREAD SEPARATION. THE CONTACT STATED THAT THERE WAS DAMAGE DOWN TO THE FENDER AND FENDER WELL OF THE VEHICLE. THE CONTACT STATED THAT THE TIRE WAS STILL FULLY INFLATED. THE CONTACT STATED THAT AAA WAS ABLE TO REPLACE THE TIRE, BUT ALL OF THE REMAINING TIRES ALSO SHOWED EVIDENCE OF TREAD SEPARATION. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN AND DOT NUMBER WERE UNKNOWN. THE APPROXIMATE VEHICLE FAILURE MILEAGE WAS 150,000 AND THE TIRE FAILURE MILEAGE WAS 20,000.

NHTSA ODI #10983660

133,003 miles · Sep 26, 2016
Engine

DRIVING ALONG LOUD NOISE PULLED OVER TO FIND A SPARK PLUG BLEW OUT OF THE ENGINE BLOCK TAKING THE THREADS WITH IT. NO FIRE THANK GOODNESS!

NHTSA ODI #10909834

105,000 miles · May 26, 2015
EnginePower Train

I WAS DRIVING DOWN THE ROAD AND I HEARD A LOUD POP. THE ENGINE HAD A VERY ABRUPT LOSS IN POWER AND BEGAN SHAKING AS I TRIED TO ACCELERATE. I WAS ON A 2 LANE ROAD AND HAD NO CHOICE BUT TO TRY AND MAINTAIN MY SPEED TO PREVENT CAUSING AN ACCIDENT FROM BEING REAR ENDED. AFTER DRIVING SEVERAL MILES TO A PLACE I COULD SAFELY STOP, I C…

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I WAS DRIVING DOWN THE ROAD AND I HEARD A LOUD POP. THE ENGINE HAD A VERY ABRUPT LOSS IN POWER AND BEGAN SHAKING AS I TRIED TO ACCELERATE. I WAS ON A 2 LANE ROAD AND HAD NO CHOICE BUT TO TRY AND MAINTAIN MY SPEED TO PREVENT CAUSING AN ACCIDENT FROM BEING REAR ENDED. AFTER DRIVING SEVERAL MILES TO A PLACE I COULD SAFELY STOP, I CHECKED UNDER THE HOOD AN A SPARK PLUG HAD BEEN SHOT FROM THE ENGINE. AFTER REVIEWING THIS ON THE WEB, THERE ARE MANY COMPLAINTS LIKE MINE WHERE SPARK PLUGS WERE SHOT OUT OF ENGINES. NHTSA NEEDS TO EVALUATE THIS AS REVIEW. HAD THE ENGINE CAUGHT FIRE I WOULD NOT HAVE KNOWN AND I HAD NO WHERE TO PULL OFF THE ROAD. THIS IS A RESULT OF AN CYLINDER HEAD WITH INADEQUATE THREADS FOR SPARK PLUGS TO THREAD INTO AND TAKE HOLD OVER TIME THE ALUMINUM WEAKENS AND THIS HAPPENS. IF THIS WASN'T A PROBLEM WHY DID FORD REDESIGN CYLINDER HEADS AFTER THESE MODEL ENGINES TO ACCOMMODATE MORE THREADING TO HOLD THE SPARK PLUGS IN THE ENGINE?

NHTSA ODI #10721515

248,000 miles · Jan 20, 2015
Fuel/propulsion System

VEHICLE STALLED AT 55 MPH ON HIGHWAY. *TR

NHTSA ODI #10676690

80,000 miles · Sep 11, 2014
Structure

TL* THE CONTACT OWNS A 2003 FORD F-350. THE CONTACT STATED THAT THE BED OF THE VEHICLE WAS RUSTED AND CAUSED SHARP EDGES TO DEVELOP. THE CONTACT WAS UNABLE TO UTILIZE THE BED. THE VEHICLE WAS NOT REPAIRED AND THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 80,000.

NHTSA ODI #10632394

Mileage unknown · Jul 2, 2014
Engine

I CALLED FORD MOTOR COMPANY MY 2003 FORD F350 SD. SC. 4X4 5.4 ENG. WITH THE PROBLEM WITH BOTH EXHAUST MANIFOLDS ROTTING AWAY & THE STUDS & NUTS THAT HOLD THE EXHAUST MANIFOLDS TO ENGINE HEADS THAT THEY WERE ALL ROTTING AWAY , THEY TOLD ME WE WON'T FIX THE PROBLEMS FOR FREE . I WOULD LIKE FOR TO INVESTIGATE THIS PROBLEM BEFORE MA…

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I CALLED FORD MOTOR COMPANY MY 2003 FORD F350 SD. SC. 4X4 5.4 ENG. WITH THE PROBLEM WITH BOTH EXHAUST MANIFOLDS ROTTING AWAY & THE STUDS & NUTS THAT HOLD THE EXHAUST MANIFOLDS TO ENGINE HEADS THAT THEY WERE ALL ROTTING AWAY , THEY TOLD ME WE WON'T FIX THE PROBLEMS FOR FREE . I WOULD LIKE FOR TO INVESTIGATE THIS PROBLEM BEFORE MANY PEOPLE WILL GET INJURY OR MANY FATALITY WILL HAPPEN WHEN THE EXHAUST MANIFOLDS FALL OFF AND CATCH ON FIRE & BURN UP BECAUSE FIRE COMES OUT OF THE ENGINE TO THE EXHAUST MANIFOLDS . I TALKED TO MANY FORD DEALERS THEY TOLD ME THAT THEY HAVE REPLACED MANY OF THESE EXHAUST MANIFOLDS WITH THE SAME PROBLEMS I HAVE & HAD TO CHARGE THE OWNER OF THESE TRUCKS & MANY OTHER YEARS OF THESE FORD TRUCKS . PLEASE HELP ME & MANY OTHER OWNERS OF THESE FORD TRUCKS TO MAKE FORD MOTOR COMPANY RECALL THIS PROBLEMS BEFORE PEOPLE WILL DIE & FIX THIS PROBLEM FOR FREE . THANKS *TR

NHTSA ODI #10607928

40,000 miles · Apr 10, 2014
Electrical System

TL* THE CONTACT OWNS A 2003 FORD F-350. THE CONTACT STATED THAT AFTER REMOVING THE KEY FROM THE IGNITION SWITCH, THE ENGINE CONTINUED TO OPERATE ERRONEOUSLY. AFTER REINSERTING THE KEY INTO THE IGNITION THE CONTACT WAS ABLE TO SHUT THE ENGINE OFF. THE CONTACT STATED THAT THE FAILURE RECURRED MULTIPLE TIMES. THE CONTACT ALSO INDIC…

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TL* THE CONTACT OWNS A 2003 FORD F-350. THE CONTACT STATED THAT AFTER REMOVING THE KEY FROM THE IGNITION SWITCH, THE ENGINE CONTINUED TO OPERATE ERRONEOUSLY. AFTER REINSERTING THE KEY INTO THE IGNITION THE CONTACT WAS ABLE TO SHUT THE ENGINE OFF. THE CONTACT STATED THAT THE FAILURE RECURRED MULTIPLE TIMES. THE CONTACT ALSO INDICATED THAT WHILE ATTEMPTING TO START THE VEHICLE THE KEY WOULD SPORADICALLY BECOME STUCK IN THE IGNITION SWITCH OR SHE WOULD BE UNABLE TO TURN THE IGNITION SWITCH TO START THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 40,000.

NHTSA ODI #10579010

15,000 miles · Feb 27, 2014
Engine And Engine Cooling

CRACKED "Y" PIPE IS LEAKING DIESEL EXHAUST FUMES INTO CAB OF TRUCK. THIS OCCURRED PREVIOUSLY WHEN THE TRUCK WAS UNDER WARRANTY BACK IN 2004 BUT NOW IT IS NOT UNDER WARRANTY NOR IS THERE A RECALL. I HAVE BROUGHT THIS UP TO SEVERAL DEALERS IN THE AREA BUT UNLESS IT IS UNDER WARRANTY THEY WON'T COVER THE REPAIR. HOWEVER, I FEEL …

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CRACKED "Y" PIPE IS LEAKING DIESEL EXHAUST FUMES INTO CAB OF TRUCK. THIS OCCURRED PREVIOUSLY WHEN THE TRUCK WAS UNDER WARRANTY BACK IN 2004 BUT NOW IT IS NOT UNDER WARRANTY NOR IS THERE A RECALL. I HAVE BROUGHT THIS UP TO SEVERAL DEALERS IN THE AREA BUT UNLESS IT IS UNDER WARRANTY THEY WON'T COVER THE REPAIR. HOWEVER, I FEEL IT IS A MAJOR SAFETY HAZARD WHICH I FEEL SHOULD BE ADDRESSED IMMEDIATELY, AS DIESEL FUMES ARE LINKED TO CANCER OR COULD LEAK TO AN ACCIDENT IF SOMEONE IS OVERCOME BY THE FUMES, WHICH COULD LEAD TO A DEATH. PLEASE LOOK INTO THIS HAZARD AND LET ME KNOW IF YOU HAVE ANY QUESTIONS, I WOULD BE HAPPY TO ANSWER. I DO KNOW FROM TALKING TO MECHANICS THAT THIS DOES OCCUR OFTEN IN THESE TRUCKS.

NHTSA ODI #10567257

283,000 miles · Jan 30, 2014
Service BrakesCrash

I THOUGHT MY FOOT SLIPPED OFF THE BRAKE AND TAPED THE REAR END OF THE CAR IN FRONT OF ME. SCRATCHED THE BUMPER OF THE CAR I TAPPED. I WAS ON I 95S TOWARDS FREDERICKSBURG, VA WHEN MY BRAKE WARNING LIGHT CAME ON. TAPED BRAKE AND THE PEDAL ALMOST WENT TO THE FLOOR, BUT I DID HAVE SOME BRAKING. GOT THE TRUCK TO THE REPAIR SHOP, DIAG…

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I THOUGHT MY FOOT SLIPPED OFF THE BRAKE AND TAPED THE REAR END OF THE CAR IN FRONT OF ME. SCRATCHED THE BUMPER OF THE CAR I TAPPED. I WAS ON I 95S TOWARDS FREDERICKSBURG, VA WHEN MY BRAKE WARNING LIGHT CAME ON. TAPED BRAKE AND THE PEDAL ALMOST WENT TO THE FLOOR, BUT I DID HAVE SOME BRAKING. GOT THE TRUCK TO THE REPAIR SHOP, DIAGNOSED WILL HOLE IN BRAKE LINE CAUSED BY RUST. REPLACED 18 FT OF LINE. *TR

NHTSA ODI #10562202

130,000 miles · Oct 4, 2013
Engine

TL* THE CONTACT OWNS A 2003 FORD F-350. THE CONTACT STATED THAT THE ENGINE COOLANT LEVEL WAS FOUND TO BE PREMATURELY LOW. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION, WHO ADVISED THE CONTACT THAT THE HEAD GASKET HEAD BOLTS WERE DEFECTIVE. THE MANUFACTURE WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAI…

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TL* THE CONTACT OWNS A 2003 FORD F-350. THE CONTACT STATED THAT THE ENGINE COOLANT LEVEL WAS FOUND TO BE PREMATURELY LOW. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION, WHO ADVISED THE CONTACT THAT THE HEAD GASKET HEAD BOLTS WERE DEFECTIVE. THE MANUFACTURE WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 130,000.

NHTSA ODI #10546769

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.