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2003 Land Rover Range Rover

Owner reports · Recalls · Investigations

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What owners reported most

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When problems were reported

Mileage at the reported incident

84 reports with mileage · 13 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 74 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Steering. Review the 8 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 6 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

1 crash reports1 fire reports0 injury reports

What owners actually said

97 reports
61,000 miles · Jul 17, 2006
Power Train

VEHICLE SHUT OFF WHILE DRIVING AND THE FRONT WHEELS LOCKED CAUSING ME TO COME TO A FULL STOP. HAD TO TAKE THE KEY OUT OF THE IGNITION, PUT IT IN PARK AND THEN TRY TO RESTART. IT SEEMS THAT RANGE ROVERS 03' AND ABOVE HAVE A PROBLEM WITH THE DIFFERENTIALS THAT FAIL AND CUT OFF THE VEHICLE'S COMPUTER. I WAS FORTUNATE THAT I WAS TR…

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VEHICLE SHUT OFF WHILE DRIVING AND THE FRONT WHEELS LOCKED CAUSING ME TO COME TO A FULL STOP. HAD TO TAKE THE KEY OUT OF THE IGNITION, PUT IT IN PARK AND THEN TRY TO RESTART. IT SEEMS THAT RANGE ROVERS 03' AND ABOVE HAVE A PROBLEM WITH THE DIFFERENTIALS THAT FAIL AND CUT OFF THE VEHICLE'S COMPUTER. I WAS FORTUNATE THAT I WAS TRAVELING AT A LOW SPEED. DEALER IN HOUSTON, TX FINALLY ACKNOWLEDGED THE PROBLEM AND I HAVE SCHEDULED AN APPOINTMENT TO GET IT FIXED. *JB

NHTSA ODI #10162690

30 miles · Jul 3, 2006
Power Train

TRUCK STOPPED ABRUPTLY IN THE MIDDLE OF THE ROAD TRAVELING AT APPROXIMATELY 40 MPH. I WAS UNABLE TO MOVE THE VEHICLE ONCE IT STOPPED IN THE MIDDLE OF A BUSY INTERSECTION. THE TRUCK WAS IMMOBILE AND MADE A SEVERE GRINDING NOISE. A CAB DRIVER HAD TO PUSH MY TRUCK TO THE SIDE OF THE ROAD FOR SAFETY. THERE WAS NO WARNING LIGHT UNTIL…

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TRUCK STOPPED ABRUPTLY IN THE MIDDLE OF THE ROAD TRAVELING AT APPROXIMATELY 40 MPH. I WAS UNABLE TO MOVE THE VEHICLE ONCE IT STOPPED IN THE MIDDLE OF A BUSY INTERSECTION. THE TRUCK WAS IMMOBILE AND MADE A SEVERE GRINDING NOISE. A CAB DRIVER HAD TO PUSH MY TRUCK TO THE SIDE OF THE ROAD FOR SAFETY. THERE WAS NO WARNING LIGHT UNTIL THE TRUCK DIED WHICH SAID "SELECT NEUTRAL" TRUCK HAD TO BE TOWED AND DIFFERENTIAL ASSEMBLY HAD TO BE REPLACED. *JB

NHTSA ODI #10161326

23,300 miles · Jun 19, 2006
Power Train

NO EVENTS LEADING UP TO THE COMPLETE FAILURE OF THE FRONT DIFFERENTIAL ON A 2003 RANGE ROVER. I THOUGHT THIS WAS VERY UNUSUALLY FOR A VEHICLE WITH ONLY 23K MILES SO I DID A QUICK SEARCH ON THE INTERNET TO FIND THIS A KNOWN ISSUE AS A RESULT OF A BAD DESIGN ON 2003+ NEWER RANGE ROVER'S SO THE PROBLEM WILL HAPPEN AGAIN. THE DEAL…

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NO EVENTS LEADING UP TO THE COMPLETE FAILURE OF THE FRONT DIFFERENTIAL ON A 2003 RANGE ROVER. I THOUGHT THIS WAS VERY UNUSUALLY FOR A VEHICLE WITH ONLY 23K MILES SO I DID A QUICK SEARCH ON THE INTERNET TO FIND THIS A KNOWN ISSUE AS A RESULT OF A BAD DESIGN ON 2003+ NEWER RANGE ROVER'S SO THE PROBLEM WILL HAPPEN AGAIN. THE DEALERSHIP SAID IT WAS $2,700 REPAIR IF OFF WARRANTY. LAND ROVER SHOULD HAVE TO DO A REDESIGN OF THIS PROBLEM INSTEAD OF SCREWING THE OWNERS WHO WILL HAVE TO PAY FOR THE REPAIR OF THIS ISSUE IN THE FUTURE. IT ALSO SOUNDS LIKE THIS IS A MAJOR SAFETY ISSUE IF THE PROBLEM HAPPENS AT HIGH SPEEDS. IT LEFT ME STRANDED IN THE MIDDLE OF THE ROAD DURING A RAIN DOWNPOUR. *JB

NHTSA ODI #10160183

41,526 miles · May 26, 2006
Power Train

THE FIRST TIME THE FRONT DIFFERENTIAL WENT I WAS PULLING ONTO MY STREET. ALL OF A SUDDEN, OUT OF NO WHERE, THERE WAS A LOUD METAL ON METAL GRINDING NOISE. I IMMEDIATELY STEPPED ON THE BRAKE, BUT BY THAT TIME THE TRUCK WASN'T GOING ANYWHERE ANYWAY. I PUT THE TRUCK INTO PARK, AND WALKED TO THE HOUSE EXTREMELY ANNOYED THAT THIS …

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THE FIRST TIME THE FRONT DIFFERENTIAL WENT I WAS PULLING ONTO MY STREET. ALL OF A SUDDEN, OUT OF NO WHERE, THERE WAS A LOUD METAL ON METAL GRINDING NOISE. I IMMEDIATELY STEPPED ON THE BRAKE, BUT BY THAT TIME THE TRUCK WASN'T GOING ANYWHERE ANYWAY. I PUT THE TRUCK INTO PARK, AND WALKED TO THE HOUSE EXTREMELY ANNOYED THAT THIS COULD HAPPEN TO A NEW VEHICLE. I WENT BACK OUT AND STARTED THE TRUCK AND PUT IT INTO DRIVE, WHICH YIELDED A LOUD GRINDING NOISE. I HAD NO CLUE WHAT WAS WRONG, BUT IT WAS OBVIOUS THAT I WASN'T DRIVING ANYWHERE. WHEN THE TOW TRUCK CAME FOR IT, IT WAS IMMOVABLE ON IT'S OWN. THERE WAS NO PRE-WARNING TO THIS EVENT, THE TRUCK WAS STILL UNDER WARRANTY, AND LAND ROVER, I THOUGHT, FIXED THE PROBLEM. HOWEVER, THE SAME PROBLEM OCCURRED AGAIN LAST WEEK IN TUCSON, ARIZONA. (MAY 06) THE TRUCK NOW HAS 55,000 MILES AND IS NOT UNDER WARRANTY. THE LAND ROVER DEALERSHIP IN TUCSON WANTS ME TO PAY $800 TO COVER THE LABOR TO FIX IT, AND THEY BROUGHT THAT PRICE DOWN FROM $1400. I AM APPEALING TO LAND ROVER HEADQUARTERS, AS THIS IS A DANGEROUS PROBLEM THAT WAS NOT FIXED WITH THE INSTALLATION OF A NEW DIFFERENTIAL AND DRIVESHAFT THE FIRST TIME. IF I HAD BEEN ON A HIGHWAY OR STUCK IN THE MIDDLE OF NO WHERE WITH AN INFANT, THIS SITUATION COULD HAVE HAD SERIOUS RAMIFICATIONS. IF YOU WOULD LIKE THE OLD PART, PLEASE LET ME KNOW, AND I WILL REQUEST IT FROM THE AUTO MALL RANGE ROVER DEALERSHIP IN TUCSON. HOWEVER, I CANNOT PROMISE THEIR COOPERATION. *JB

NHTSA ODI #10158305

Mileage unknown · May 13, 2006
Power Train

I WAS DRIVING IN AN AREA WHERE TWO FREEWAYS MERGE WITH MY SEVEN YEAR OLD DAUGHTER IN THE BACK SEAT OF MY 2003 RANGE ROVER. I WAS TAKING HER TO THE DOCTOR AS SHE WAS FEELING ILL. ALL OF A SUDDEN, WITHOUT ANY WARNING, THE DIFFERENTIAL BROKE. I WAS BARELY ABLE TO GET TO THE SIDE OF THE FREEWAY. I HAD TO CALL 911. APPARENTLY RANGE R…

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I WAS DRIVING IN AN AREA WHERE TWO FREEWAYS MERGE WITH MY SEVEN YEAR OLD DAUGHTER IN THE BACK SEAT OF MY 2003 RANGE ROVER. I WAS TAKING HER TO THE DOCTOR AS SHE WAS FEELING ILL. ALL OF A SUDDEN, WITHOUT ANY WARNING, THE DIFFERENTIAL BROKE. I WAS BARELY ABLE TO GET TO THE SIDE OF THE FREEWAY. I HAD TO CALL 911. APPARENTLY RANGE ROVER KNOWS ABOUT THIS DEFECT, BUT HAS NOT ISSUED PRODUCT RECALLS. IT WAS AN EXTREMELY SCARY EVENT FOR ME AND MY DAUGHTER. *JB

NHTSA ODI #10157495

20,000 miles · Nov 30, 2005
Steering

DT: THE CONTACT STATED THE STEERING WHEEL CAME LOOSE AND FELL INTO THE CONTACT'S LAP WHILE DRIVING. HE WAS ABLE TO MANUALLY RAISE THE STEERING WHEEL UP INTO THE COLUMN AND DRIVE THE VEHICLE TO THE DEALER. THE DEALER DISCOVERED A PLASTIC PART ON THE STEERING COLUMN ASSEMBLY BROKE. THIS PART WAS REPLACED WITH A METAL PART. ALS…

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DT: THE CONTACT STATED THE STEERING WHEEL CAME LOOSE AND FELL INTO THE CONTACT'S LAP WHILE DRIVING. HE WAS ABLE TO MANUALLY RAISE THE STEERING WHEEL UP INTO THE COLUMN AND DRIVE THE VEHICLE TO THE DEALER. THE DEALER DISCOVERED A PLASTIC PART ON THE STEERING COLUMN ASSEMBLY BROKE. THIS PART WAS REPLACED WITH A METAL PART. ALSO, THE TELESCOPIC STEERING ADJUSTED AUTOMATICALLY. THIS CAUSED THE POSITION OF THE STEERING WHEEL TO CHANGE RANDOMLY WHILE DRIVING. THE DEALER ATTEMPTED TO CORRECT THE PROBLEM BY REPROGRAMMING THE SOFTWARE. NO FURTHER REPAIRS HAVE BEEN MADE AT THIS TIME. *AK UPDATED 1/23/2006 - *NM

NHTSA ODI #10144016

26,000 miles · Nov 11, 2005
Power Train

ON TWO OCCASIONS MY DRIVE SHAFT AND FRONT DIFFERENTIAL SEPARATED. I WAS DRIVING ON THE HIGHWAY IN JANUARY OF 2004 AND HAD 26,000 MILES ON MY CAR WHEN I EXPERIENCED A LOUD GRINDING NOISE AND LOST POWER TO THE VEHICLES. THE MESSAGE CENTER TOLD ME TO PUT THE CAR IN NEUTRAL. I WAS ON A HILL AND THE TRANSMISSION DID NOT HOLD . I R…

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ON TWO OCCASIONS MY DRIVE SHAFT AND FRONT DIFFERENTIAL SEPARATED. I WAS DRIVING ON THE HIGHWAY IN JANUARY OF 2004 AND HAD 26,000 MILES ON MY CAR WHEN I EXPERIENCED A LOUD GRINDING NOISE AND LOST POWER TO THE VEHICLES. THE MESSAGE CENTER TOLD ME TO PUT THE CAR IN NEUTRAL. I WAS ON A HILL AND THE TRANSMISSION DID NOT HOLD . I ROLLED BACK INTO TRAFFIC ON THE OFF RAMP UNTIL I CAME TO A SOMEWHAT FLAT PART OF ROAD AND WAS ABLE TO GET THE EMERGENCY BRAKE TO HOLD. IT TOOK OVER TWO WEEK TO HAVE THE VEHICLE FIXED LAND ROVER WOULD NOT RELEASE THE PARTS TO FIX MY VEHICLE. THE SECOND TIME HAPPENED ONE WEEK AFTER MY 60,000 MILE SERVICE. I DID THIS SERVICE EARLY. THE CAR HAD 58,000 MILES THE SECOND TIME THE DRIVE SHAFT AND FRONT DIFFERENTIAL DID THE SAME THING. I EXPERIENCED A LOUD GRINDING NOISE LIKE THE BOTTOM WAS FALLING OUT OF THE CAR. I WAS ONCE AGAIN TRAVELING AT ABOUT 60 MILES PER HOUR. I WAS ABLE TO STOP WITH THE EMERGENCY BRAKE ON THE SIDE OF THE HIGHWAY. I HAVE READ MANY REPORTS OF THIS HAPPENING TO OTHERS TWICE. I DO NOT UNDERSTAND WHY THEIR IS NOT A RECALL FOR THIS OR A CHECK AT EACH SERVICE TO DETECT THIS DEFECT. BOTH TIMES I WAS TRAVELING ON THE HIGHWAY AND PUT IN A POTENTIALLY DANGEROUS POSITION WITH MY DAUGHTER IN THE CAR. SOMETHING NEEDS TO BE DONE TO PREVENT OTHERS FROM THIS EXPERIENCE AND THE POTENTIAL DANGEROUS CONSEQUENCES. *JB

NHTSA ODI #10142458

Mileage unknown · Sep 19, 2005
Power Train

BEARING FAILURE IN FRONT DIFFERENTIAL: NO EVENT LEADING UP TO THE FAILURE. AS I WAS EMERGING FROM THE LINCOLN TUNNEL IN NYC WITH 4 LANES OF TRAFFIC ON EITHER SIDE, WITH OUT ANY WARNING MY CAR WOULD NOT MOVE FORWARD AND IF I PRESSED ON THE GAS I HEARD A VERY LOUD GRINDING NOISE. I WAS LUCKY AS I WAS NOT GOING VERY FAST AND WAS …

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BEARING FAILURE IN FRONT DIFFERENTIAL: NO EVENT LEADING UP TO THE FAILURE. AS I WAS EMERGING FROM THE LINCOLN TUNNEL IN NYC WITH 4 LANES OF TRAFFIC ON EITHER SIDE, WITH OUT ANY WARNING MY CAR WOULD NOT MOVE FORWARD AND IF I PRESSED ON THE GAS I HEARD A VERY LOUD GRINDING NOISE. I WAS LUCKY AS I WAS NOT GOING VERY FAST AND WAS ABLE TO IMMEDIATELY PULL OVER TO THE SIDE. IF I WAS ON THE HIGHWAY THERE IS A HIGH PROBABILITY THAT THERE COULD HAVE BEEN A DANGEROUS IF NOT FATAL ACCIDENT. CAR HAD TO BE TOWED. RANGE ROVER MOUNT KISCO FIXED THE CAR AT NO CHARGE. I WAS TOLD THAT THERE HAVE BEEN OTHER INCIDENCES LIKE THIS WITH OTHER 2003 RANGE ROVERS. I ASKED RANGE ROVER TO NOTIFY OWNERS OF 2003 RANGE ROVERS AND THEY TOLD ME THEY ARE ONLY RESPONSIBLE TO FIX THE AUTOMOBILE. I ASKED HOW MANY INCIDENTS THERE WERE REGARDING THE BEARING IN THE DIFFERENTIAL AXLE AND THEY TOLD ME THEY DID NOT KNOW AND NO ONE HAS THE STATISTICS. I CALLED RANGE ROVER NORTH AMERICA AND RECEIVED THE SAME ROBOTIC ANSWERS. IT APPEARS THEY ARE NOT INTERESTED IN DRIVER'S SAFETY BUT ONLY INTERESTED IN INSURING THEY MAKE MONEY AND ARE FREE OF ALL LIABILITIES. THEY REPEATEDLY ASKED IF I WAS HAPPY ABOUT THE SERVICE I RECEIVED. I KEPT TELLING THEM IT IS NOT ABOUT THE SERVICE OR ME. I AM HERE TO TELL WHAT HAPPENED AND TO TRY AND PREVENT SOMEONE ELSE HAVING THE SAME PROBLEM. THE NEXT PERSON MAY NOT HAVE AN OPPORTUNITY TO TELL THEIR STORY. I WILL DO MY BEST TO MAKE RANGE ROVER AMERICA TAKE THEIR RESPONSIBILITIES SINCERELY. I STRONGLY FEEL RANGE ROVER SHOULD NOTIFY THE OWNERS OF 2003 RANGE ROVERS AND TELLING THEM TO KEEP THEIR WHEELS IN ALIGNMENT AND TO INSURE THE OWNERS KNOW OF THE RISKS INVOLVED. *JB

NHTSA ODI #10137035

49,430 miles · Jun 6, 2005
Electrical System

DT: CONSUMER STATES: THE CAR WON'T START, 1ST TIME TOOK BACK FOR ENGINE LIGHT ON, 2ND TIME TOOK IT BACK BECAUSE VEHICLE WOULDN'T START, THEY SAID NEEDED TO LEAVE ON ALARM AT ALL TIMES TO GET IT STARTED, THEN GOT BACK SAME DAY STILL WOULDN'T START, TOWED BACK TO DEALER, WHO SAID IT WAS AN ELECTRICAL PROBLEM ALREADY PUT WENT THRO…

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DT: CONSUMER STATES: THE CAR WON'T START, 1ST TIME TOOK BACK FOR ENGINE LIGHT ON, 2ND TIME TOOK IT BACK BECAUSE VEHICLE WOULDN'T START, THEY SAID NEEDED TO LEAVE ON ALARM AT ALL TIMES TO GET IT STARTED, THEN GOT BACK SAME DAY STILL WOULDN'T START, TOWED BACK TO DEALER, WHO SAID IT WAS AN ELECTRICAL PROBLEM ALREADY PUT WENT THROUGH 4 BATTERIES IN VEHICLE. *AK

NHTSA ODI #10124278

23,000 miles · Apr 25, 2005
Power Train

DRIVING ON I-280 AND THE CAR MADE A METAL-TO-METAL GRINDING NOISE (VERY LOUD), PULLED OVER TORWARDS THE NEXT EXIT (BARELY MADE IT TO THE MEDIAN) AND THE CAR WOULD NOT MOVE. OTHER THAN "PARK", THE CAR MADE A TERRIBLY LOUD GRINDING NOISE IN ALL GEARS AND SPORT MODE. THE CAR WOULD NOT MOVE/DRIVE. HAD THE VEHICLE TOWED TO DEALERS…

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DRIVING ON I-280 AND THE CAR MADE A METAL-TO-METAL GRINDING NOISE (VERY LOUD), PULLED OVER TORWARDS THE NEXT EXIT (BARELY MADE IT TO THE MEDIAN) AND THE CAR WOULD NOT MOVE. OTHER THAN "PARK", THE CAR MADE A TERRIBLY LOUD GRINDING NOISE IN ALL GEARS AND SPORT MODE. THE CAR WOULD NOT MOVE/DRIVE. HAD THE VEHICLE TOWED TO DEALERSHIP. TOLD THIS MORNING BY SERVICE ADVISER THAT SERVICE BULLETIN WAS ISSUED THAT SHOULD HAVE BEEN DONE LAST TIME IN FOR SERVICE RE POWER TRAIN:DRIVELINE:DIFFERENTIAL UNIT. APPEARS FROM MY RESEARCH THAT TSB 540103 ISSUED 1/31/03 APPLIES PER CONVERSATION WITH DEALER'S SERVICE ADVISER. TRYING TO GET A COPY OF TSB NOW. ALSO, CALLED ROADSIDE ASSISTANCE ON EVENING OF INCIDENT TO GET ASSISTANCE WITH REMOVING VEHICLE (AND MYSELF, WIFE AND DAUGHTER) FROM THE HIGHWAY MEDIAN. LAND ROVER COULD NOT LOCATE A TOW COMPANY TO ASSIST AND WE WERE FORCED TO CALL CHP AND SEEK THEIR ASSISTANCE IN GETTING A TOW AND PAYING THE SAME - IN OTHER WORDS, NO "ROADSIDE ASSISTANCE" REALLY EXISTED WHEN THIS HAPPENED. *AK

NHTSA ODI #10118373

Official recalls

1

08V635000 · Power Train:driveline:driveshaft

Dec 3, 2008

LAND ROVER IS RECALLING 19,168 MY 2003-2005 RANGE ROVER VEHICLES. THE FRONT DIFFERENTIAL COUPLING SLEEVE AND THE PROPELLER SHAFT MAY BE MISALIGNED, RESULTING IN SPLINE WEAR OVER A PERIOD OF TIME. AS THE WEAR BETWEEN THE PROPELLER SHAFT AND THE DIFFERENTIAL SPLINE COUPLING PROGRESSES, NOISE AND VIBRATION ARE EXPECTED.

Consequence & remedy

Consequence: CONTINUED VEHICLE OPERATION CAN EVENTUALLY RESULT IN THE SPLINES SHEARING AND A LOSS OF DRIVE, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL INSTALL A REVISED DESIGN OF THE PROPELLER SHAFT, THE FLANGE KIT AND HEAT SHIELD KIT. THE RECALL BEGAN ON JANUARY 6, 2009. OWNERS MAY CONTACT LAND ROVER AT 1-800- 637-6837.

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

EA07012 · Front Diff. / Propeller Shaft Failure

Opened Aug 14, 2007 · Closed Dec 10, 2008

Status: closed (inferred from source dates) · Power Train:axle Assembly; Power Train:axle Assembly:axle Shaft; Power Train:driveline; Power Train:driveline:differential Unit; Power Train:driveline:driveshaft

SUMMARY:IN A LETTER DATED DECEMBER 2, 2008, FORD MOTOR COMPANY (FORD) NOTIFIED NHTSA THAT LAND ROVER IS CONDUCTING A SAFETY RECALL OF MODEL YEAR (MY) 2003 THROUGH 2005 RANGE ROVER VEHICLES BUILT AT THE SOLIHULL (UK) ASSEMBLY PLANT FROM JANUARY 3, 2002 THROUGH FEBRUARY 22, 2005, TO REPLACE THE FRONT DRIVESHAFT JOINT (NHTSA RECALL NO. 08V-635, LAND ROVER RECALL NO. P041). THE FRONT DIFFERENTIAL COUPLING SLEEVE AND THE PROPELLER SHAFT MAY BE MISALIGNED RESULTING IN SPLINE WEAR OVER TIME, WHICH MAY EVENTUALLY RESULT IN THE SPLINES SHEARING.THE DEFECT CONDITION CAN RESULT IN A LOSS OF PROPULSION AND SUBSEQUENT VEHICLE DISABLEMENT IN THE ROADWAY OR ON THE SHOULDER OF THE ROADWAY. FURTHERMORE, THE DEFECT CONDITION CAN ALSO CAUSE LOSS OF THE TRANSMISSION LOCK FUNCTION WHEN THE VEHICLE IS SHIFTED INTO THE PARK POSITION.THE LOSS OF THE TRANSMISSION LOCK FUNCTION CAN CAUSE A VEHICLE ROLLAWAY CONDITION IF THE EMERGENCY BRAKE IS NOT APPLIED AND THE VEHICLE IS UNATTENDED BY THE DRIVER. IN JULY 2008, LAND ROVER INITIATED A SERVICE ACTION (Q041) INSTRUCTING DEALERS TO INSTALL A REDESIGNED FRONT PROPELLER SHAFT, FRONT DIFFERENTIAL COUPLING AND HEAT SHIELD KIT TO ADDRESS THE MISALIGNMENT AND SUBSEQUENT SPLINE WEAR.THIS IS THE SAME REPAIR PROCEDURE THAT WILL BE USED IN SAFETY RECALL 08V-635.APPROXIMATELY 48 PERCENT OF THE SUBJECT VEHICLES (18,000) HAVE HAD THE REMEDY PERFORMED UNDER SERVICE ACTION Q041 AS OF DECEMBER 2, 2008. ODI BELIEVES THAT SUDDEN LOSS OF MOTIVE POWER WITHOUT WARNING AND FAILURE OF THE TRANSMISSION LOCK FUNCTION ARE SAFETY CONSEQUENCES THAT, PARTICULARLY IN THE CONTEXT OF THE HIGH FAILURE RATE OF THE SUBJECT COMPONENTS, REPRESENT AN UNREASONABLE RISK TO MOTOR VEHICLE SAFETY AS STATED IN A RECALL REQUEST LETTER SENT TO FORD AND LAND ROVER ON NOVEMBER 6, 2008.LAND ROVER DOES NOT AGREE, BUT IS CHANGING ITS CUSTOMER SATISFACTION PROGRAM TO A SAFETY RECALL AS ODI REQUESTED. LAND ROVER NOTED THAT IT WAS AWARE OF ONE ALLEGED ACCIDENT; HOWEVER, IT WAS UNAWARE OF ANY INJURY OR VEHICLE DAMAGE ASSOCIATED WITH THE ALLEGED ACCIDENT.LAND ROVER'S RECALL RESOLVES THE SAFETY DEFECT CONCERNS PURSUED BY THIS INVESTIGATION. THIS ENGINEERING ANALYSIS IS CLOSED.

Additional source detail variants (5)

Power Train:axle Assembly:axle Shaft

SUMMARY:IN A LETTER DATED DECEMBER 2, 2008, FORD MOTOR COMPANY (FORD) NOTIFIED NHTSA THAT LAND ROVER IS CONDUCTING A SAFETY RECALL OF MODEL YEAR (MY) 2003 THROUGH 2005 RANGE ROVER VEHICLES BUILT AT THE SOLIHULL (UK) ASSEMBLY PLANT FROM JANUARY 3, 2002 THROUGH FEBRUARY 22, 2005, TO REPLACE THE FRONT DRIVESHAFT JOINT (NHTSA RECALL NO. 08V-635, LAND ROVER RECALL NO. P041). THE FRONT DIFFERENTIAL COUPLING SLEEVE AND THE PROPELLER SHAFT MAY BE MISALIGNED RESULTING IN SPLINE WEAR OVER TIME, WHICH MAY EVENTUALLY RESULT IN THE SPLINES SHEARING.THE DEFECT CONDITION CAN RESULT IN A LOSS OF PROPULSION AND SUBSEQUENT VEHICLE DISABLEMENT IN THE ROADWAY OR ON THE SHOULDER OF THE ROADWAY. FURTHERMORE, THE DEFECT CONDITION CAN ALSO CAUSE LOSS OF THE TRANSMISSION LOCK FUNCTION WHEN THE VEHICLE IS SHIFTED INTO THE PARK POSITION.THE LOSS OF THE TRANSMISSION LOCK FUNCTION CAN CAUSE A VEHICLE ROLLAWAY CONDITION IF THE EMERGENCY BRAKE IS NOT APPLIED AND THE VEHICLE IS UNATTENDED BY THE DRIVER. IN JULY 2008, LAND ROVER INITIATED A SERVICE ACTION (Q041) INSTRUCTING DEALERS TO INSTALL A REDESIGNED FRONT PROPELLER SHAFT, FRONT DIFFERENTIAL COUPLING AND HEAT SHIELD KIT TO ADDRESS THE MISALIGNMENT AND SUBSEQUENT SPLINE WEAR.THIS IS THE SAME REPAIR PROCEDURE THAT WILL BE USED IN SAFETY RECALL 08V-635.APPROXIMATELY 48 PERCENT OF THE SUBJECT VEHICLES (18,000) HAVE HAD THE REMEDY PERFORMED UNDER SERVICE ACTION Q041 AS OF DECEMBER 2, 2008. ODI BELIEVES THAT SUDDEN LOSS OF MOTIVE POWER WITHOUT WARNING AND FAILURE OF THE TRANSMISSION LOCK FUNCTION ARE SAFETY CONSEQUENCES THAT, PARTICULARLY IN THE CONTEXT OF THE HIGH FAILURE RATE OF THE SUBJECT COMPONENTS, REPRESENT AN UNREASONABLE RISK TO MOTOR VEHICLE SAFETY AS STATED IN A RECALL REQUEST LETTER SENT TO FORD AND LAND ROVER ON NOVEMBER 6, 2008.LAND ROVER DOES NOT AGREE, BUT IS CHANGING ITS CUSTOMER SATISFACTION PROGRAM TO A SAFETY RECALL AS ODI REQUESTED. LAND ROVER NOTED THAT IT WAS AWARE OF ONE ALLEGED ACCIDENT; HOWEVER, IT WAS UNAWARE OF ANY INJURY OR VEHICLE DAMAGE ASSOCIATED WITH THE ALLEGED ACCIDENT.LAND ROVER'S RECALL RESOLVES THE SAFETY DEFECT CONCERNS PURSUED BY THIS INVESTIGATION. THIS ENGINEERING ANALYSIS IS CLOSED.

Power Train:axle Assembly

SUMMARY:IN A LETTER DATED DECEMBER 2, 2008, FORD MOTOR COMPANY (FORD) NOTIFIED NHTSA THAT LAND ROVER IS CONDUCTING A SAFETY RECALL OF MODEL YEAR (MY) 2003 THROUGH 2005 RANGE ROVER VEHICLES BUILT AT THE SOLIHULL (UK) ASSEMBLY PLANT FROM JANUARY 3, 2002 THROUGH FEBRUARY 22, 2005, TO REPLACE THE FRONT DRIVESHAFT JOINT (NHTSA RECALL NO. 08V-635, LAND ROVER RECALL NO. P041). THE FRONT DIFFERENTIAL COUPLING SLEEVE AND THE PROPELLER SHAFT MAY BE MISALIGNED RESULTING IN SPLINE WEAR OVER TIME, WHICH MAY EVENTUALLY RESULT IN THE SPLINES SHEARING.THE DEFECT CONDITION CAN RESULT IN A LOSS OF PROPULSION AND SUBSEQUENT VEHICLE DISABLEMENT IN THE ROADWAY OR ON THE SHOULDER OF THE ROADWAY. FURTHERMORE, THE DEFECT CONDITION CAN ALSO CAUSE LOSS OF THE TRANSMISSION LOCK FUNCTION WHEN THE VEHICLE IS SHIFTED INTO THE PARK POSITION.THE LOSS OF THE TRANSMISSION LOCK FUNCTION CAN CAUSE A VEHICLE ROLLAWAY CONDITION IF THE EMERGENCY BRAKE IS NOT APPLIED AND THE VEHICLE IS UNATTENDED BY THE DRIVER. IN JULY 2008, LAND ROVER INITIATED A SERVICE ACTION (Q041) INSTRUCTING DEALERS TO INSTALL A REDESIGNED FRONT PROPELLER SHAFT, FRONT DIFFERENTIAL COUPLING AND HEAT SHIELD KIT TO ADDRESS THE MISALIGNMENT AND SUBSEQUENT SPLINE WEAR.THIS IS THE SAME REPAIR PROCEDURE THAT WILL BE USED IN SAFETY RECALL 08V-635.APPROXIMATELY 48 PERCENT OF THE SUBJECT VEHICLES (18,000) HAVE HAD THE REMEDY PERFORMED UNDER SERVICE ACTION Q041 AS OF DECEMBER 2, 2008. ODI BELIEVES THAT SUDDEN LOSS OF MOTIVE POWER WITHOUT WARNING AND FAILURE OF THE TRANSMISSION LOCK FUNCTION ARE SAFETY CONSEQUENCES THAT, PARTICULARLY IN THE CONTEXT OF THE HIGH FAILURE RATE OF THE SUBJECT COMPONENTS, REPRESENT AN UNREASONABLE RISK TO MOTOR VEHICLE SAFETY AS STATED IN A RECALL REQUEST LETTER SENT TO FORD AND LAND ROVER ON NOVEMBER 6, 2008.LAND ROVER DOES NOT AGREE, BUT IS CHANGING ITS CUSTOMER SATISFACTION PROGRAM TO A SAFETY RECALL AS ODI REQUESTED. LAND ROVER NOTED THAT IT WAS AWARE OF ONE ALLEGED ACCIDENT; HOWEVER, IT WAS UNAWARE OF ANY INJURY OR VEHICLE DAMAGE ASSOCIATED WITH THE ALLEGED ACCIDENT.LAND ROVER'S RECALL RESOLVES THE SAFETY DEFECT CONCERNS PURSUED BY THIS INVESTIGATION. THIS ENGINEERING ANALYSIS IS CLOSED.

Power Train:driveline:differential Unit

SUMMARY:IN A LETTER DATED DECEMBER 2, 2008, FORD MOTOR COMPANY (FORD) NOTIFIED NHTSA THAT LAND ROVER IS CONDUCTING A SAFETY RECALL OF MODEL YEAR (MY) 2003 THROUGH 2005 RANGE ROVER VEHICLES BUILT AT THE SOLIHULL (UK) ASSEMBLY PLANT FROM JANUARY 3, 2002 THROUGH FEBRUARY 22, 2005, TO REPLACE THE FRONT DRIVESHAFT JOINT (NHTSA RECALL NO. 08V-635, LAND ROVER RECALL NO. P041). THE FRONT DIFFERENTIAL COUPLING SLEEVE AND THE PROPELLER SHAFT MAY BE MISALIGNED RESULTING IN SPLINE WEAR OVER TIME, WHICH MAY EVENTUALLY RESULT IN THE SPLINES SHEARING.THE DEFECT CONDITION CAN RESULT IN A LOSS OF PROPULSION AND SUBSEQUENT VEHICLE DISABLEMENT IN THE ROADWAY OR ON THE SHOULDER OF THE ROADWAY. FURTHERMORE, THE DEFECT CONDITION CAN ALSO CAUSE LOSS OF THE TRANSMISSION LOCK FUNCTION WHEN THE VEHICLE IS SHIFTED INTO THE PARK POSITION.THE LOSS OF THE TRANSMISSION LOCK FUNCTION CAN CAUSE A VEHICLE ROLLAWAY CONDITION IF THE EMERGENCY BRAKE IS NOT APPLIED AND THE VEHICLE IS UNATTENDED BY THE DRIVER. IN JULY 2008, LAND ROVER INITIATED A SERVICE ACTION (Q041) INSTRUCTING DEALERS TO INSTALL A REDESIGNED FRONT PROPELLER SHAFT, FRONT DIFFERENTIAL COUPLING AND HEAT SHIELD KIT TO ADDRESS THE MISALIGNMENT AND SUBSEQUENT SPLINE WEAR.THIS IS THE SAME REPAIR PROCEDURE THAT WILL BE USED IN SAFETY RECALL 08V-635.APPROXIMATELY 48 PERCENT OF THE SUBJECT VEHICLES (18,000) HAVE HAD THE REMEDY PERFORMED UNDER SERVICE ACTION Q041 AS OF DECEMBER 2, 2008. ODI BELIEVES THAT SUDDEN LOSS OF MOTIVE POWER WITHOUT WARNING AND FAILURE OF THE TRANSMISSION LOCK FUNCTION ARE SAFETY CONSEQUENCES THAT, PARTICULARLY IN THE CONTEXT OF THE HIGH FAILURE RATE OF THE SUBJECT COMPONENTS, REPRESENT AN UNREASONABLE RISK TO MOTOR VEHICLE SAFETY AS STATED IN A RECALL REQUEST LETTER SENT TO FORD AND LAND ROVER ON NOVEMBER 6, 2008.LAND ROVER DOES NOT AGREE, BUT IS CHANGING ITS CUSTOMER SATISFACTION PROGRAM TO A SAFETY RECALL AS ODI REQUESTED. LAND ROVER NOTED THAT IT WAS AWARE OF ONE ALLEGED ACCIDENT; HOWEVER, IT WAS UNAWARE OF ANY INJURY OR VEHICLE DAMAGE ASSOCIATED WITH THE ALLEGED ACCIDENT.LAND ROVER'S RECALL RESOLVES THE SAFETY DEFECT CONCERNS PURSUED BY THIS INVESTIGATION. THIS ENGINEERING ANALYSIS IS CLOSED.

Power Train:driveline:driveshaft

SUMMARY:IN A LETTER DATED DECEMBER 2, 2008, FORD MOTOR COMPANY (FORD) NOTIFIED NHTSA THAT LAND ROVER IS CONDUCTING A SAFETY RECALL OF MODEL YEAR (MY) 2003 THROUGH 2005 RANGE ROVER VEHICLES BUILT AT THE SOLIHULL (UK) ASSEMBLY PLANT FROM JANUARY 3, 2002 THROUGH FEBRUARY 22, 2005, TO REPLACE THE FRONT DRIVESHAFT JOINT (NHTSA RECALL NO. 08V-635, LAND ROVER RECALL NO. P041). THE FRONT DIFFERENTIAL COUPLING SLEEVE AND THE PROPELLER SHAFT MAY BE MISALIGNED RESULTING IN SPLINE WEAR OVER TIME, WHICH MAY EVENTUALLY RESULT IN THE SPLINES SHEARING.THE DEFECT CONDITION CAN RESULT IN A LOSS OF PROPULSION AND SUBSEQUENT VEHICLE DISABLEMENT IN THE ROADWAY OR ON THE SHOULDER OF THE ROADWAY. FURTHERMORE, THE DEFECT CONDITION CAN ALSO CAUSE LOSS OF THE TRANSMISSION LOCK FUNCTION WHEN THE VEHICLE IS SHIFTED INTO THE PARK POSITION.THE LOSS OF THE TRANSMISSION LOCK FUNCTION CAN CAUSE A VEHICLE ROLLAWAY CONDITION IF THE EMERGENCY BRAKE IS NOT APPLIED AND THE VEHICLE IS UNATTENDED BY THE DRIVER. IN JULY 2008, LAND ROVER INITIATED A SERVICE ACTION (Q041) INSTRUCTING DEALERS TO INSTALL A REDESIGNED FRONT PROPELLER SHAFT, FRONT DIFFERENTIAL COUPLING AND HEAT SHIELD KIT TO ADDRESS THE MISALIGNMENT AND SUBSEQUENT SPLINE WEAR.THIS IS THE SAME REPAIR PROCEDURE THAT WILL BE USED IN SAFETY RECALL 08V-635.APPROXIMATELY 48 PERCENT OF THE SUBJECT VEHICLES (18,000) HAVE HAD THE REMEDY PERFORMED UNDER SERVICE ACTION Q041 AS OF DECEMBER 2, 2008. ODI BELIEVES THAT SUDDEN LOSS OF MOTIVE POWER WITHOUT WARNING AND FAILURE OF THE TRANSMISSION LOCK FUNCTION ARE SAFETY CONSEQUENCES THAT, PARTICULARLY IN THE CONTEXT OF THE HIGH FAILURE RATE OF THE SUBJECT COMPONENTS, REPRESENT AN UNREASONABLE RISK TO MOTOR VEHICLE SAFETY AS STATED IN A RECALL REQUEST LETTER SENT TO FORD AND LAND ROVER ON NOVEMBER 6, 2008.LAND ROVER DOES NOT AGREE, BUT IS CHANGING ITS CUSTOMER SATISFACTION PROGRAM TO A SAFETY RECALL AS ODI REQUESTED. LAND ROVER NOTED THAT IT WAS AWARE OF ONE ALLEGED ACCIDENT; HOWEVER, IT WAS UNAWARE OF ANY INJURY OR VEHICLE DAMAGE ASSOCIATED WITH THE ALLEGED ACCIDENT.LAND ROVER'S RECALL RESOLVES THE SAFETY DEFECT CONCERNS PURSUED BY THIS INVESTIGATION. THIS ENGINEERING ANALYSIS IS CLOSED.

Power Train:driveline

SUMMARY:IN A LETTER DATED DECEMBER 2, 2008, FORD MOTOR COMPANY (FORD) NOTIFIED NHTSA THAT LAND ROVER IS CONDUCTING A SAFETY RECALL OF MODEL YEAR (MY) 2003 THROUGH 2005 RANGE ROVER VEHICLES BUILT AT THE SOLIHULL (UK) ASSEMBLY PLANT FROM JANUARY 3, 2002 THROUGH FEBRUARY 22, 2005, TO REPLACE THE FRONT DRIVESHAFT JOINT (NHTSA RECALL NO. 08V-635, LAND ROVER RECALL NO. P041). THE FRONT DIFFERENTIAL COUPLING SLEEVE AND THE PROPELLER SHAFT MAY BE MISALIGNED RESULTING IN SPLINE WEAR OVER TIME, WHICH MAY EVENTUALLY RESULT IN THE SPLINES SHEARING.THE DEFECT CONDITION CAN RESULT IN A LOSS OF PROPULSION AND SUBSEQUENT VEHICLE DISABLEMENT IN THE ROADWAY OR ON THE SHOULDER OF THE ROADWAY. FURTHERMORE, THE DEFECT CONDITION CAN ALSO CAUSE LOSS OF THE TRANSMISSION LOCK FUNCTION WHEN THE VEHICLE IS SHIFTED INTO THE PARK POSITION.THE LOSS OF THE TRANSMISSION LOCK FUNCTION CAN CAUSE A VEHICLE ROLLAWAY CONDITION IF THE EMERGENCY BRAKE IS NOT APPLIED AND THE VEHICLE IS UNATTENDED BY THE DRIVER. IN JULY 2008, LAND ROVER INITIATED A SERVICE ACTION (Q041) INSTRUCTING DEALERS TO INSTALL A REDESIGNED FRONT PROPELLER SHAFT, FRONT DIFFERENTIAL COUPLING AND HEAT SHIELD KIT TO ADDRESS THE MISALIGNMENT AND SUBSEQUENT SPLINE WEAR.THIS IS THE SAME REPAIR PROCEDURE THAT WILL BE USED IN SAFETY RECALL 08V-635.APPROXIMATELY 48 PERCENT OF THE SUBJECT VEHICLES (18,000) HAVE HAD THE REMEDY PERFORMED UNDER SERVICE ACTION Q041 AS OF DECEMBER 2, 2008. ODI BELIEVES THAT SUDDEN LOSS OF MOTIVE POWER WITHOUT WARNING AND FAILURE OF THE TRANSMISSION LOCK FUNCTION ARE SAFETY CONSEQUENCES THAT, PARTICULARLY IN THE CONTEXT OF THE HIGH FAILURE RATE OF THE SUBJECT COMPONENTS, REPRESENT AN UNREASONABLE RISK TO MOTOR VEHICLE SAFETY AS STATED IN A RECALL REQUEST LETTER SENT TO FORD AND LAND ROVER ON NOVEMBER 6, 2008.LAND ROVER DOES NOT AGREE, BUT IS CHANGING ITS CUSTOMER SATISFACTION PROGRAM TO A SAFETY RECALL AS ODI REQUESTED. LAND ROVER NOTED THAT IT WAS AWARE OF ONE ALLEGED ACCIDENT; HOWEVER, IT WAS UNAWARE OF ANY INJURY OR VEHICLE DAMAGE ASSOCIATED WITH THE ALLEGED ACCIDENT.LAND ROVER'S RECALL RESOLVES THE SAFETY DEFECT CONCERNS PURSUED BY THIS INVESTIGATION. THIS ENGINEERING ANALYSIS IS CLOSED.

PE07019 · Front Differential/driveshaft Failure

Opened Apr 4, 2007 · Closed Aug 15, 2007

Status: closed (inferred from source dates) · Power Train:axle Assembly:axle Shaft; Power Train:driveline:differential Unit; Power Train:driveline:driveshaft

IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), FORD STATED THAT THE PRIMARY CAUSE FOR THE MAJORITY OF THE REPORTED FRONT DIFFERENTIAL/DRIVE SHAFT FAILURES IS A MISALIGNMENT OF THE JOINT BETWEEN THE TWO COMPONENTS.CERTAIN LEVELS OF MISALIGNMENT MAY OVER TIME CAUSE AN UNEVEN WEAR OF THE SPLINES.CONTINUED WEAR OF THE SPLINES MAY RESULT IN A SHEARING OF THE SPLINES AND THE INABILITY OF THE DRIVESHAFT TO TRANSFER TORQUE TO THE FRONT DIFFERENTIAL. TO ADDRESS THE ISSUE IN THE FIELD, FORD INITIATED A SERVICE CAMPAIGN IN JUNE 2003 TO CORRECT THE MISALIGNMENT ISSUE AND, IF NECESSARY, REPLACE THE FRONT DRIVE SHAFT AND/OR DIFFERENTIAL.THE SERVICE CAMPAIGN COVERED MODEL YEAR (MY) 2003 AND MY 2004 VEHICLES BUILT FROM APRIL 18, 2002 THROUGH JULY 3, 2003.IN PRODUCTION, FORD INTRODUCED A CHANGE TO THE LUBRICATING GREASE OF THE JOINT IN FEBRUARY 2003 AND A CHANGE TO THE ASSEMBLY PLANT ALIGNMENT PROCESS IN JULY 2003 TO ADDRESS THE MISALIGNMENT AND WEAR ISSUE. ODI IDENTIFIED ONE CRASH RELATED TO THE ALLEGED DEFECT.THE CRASH INVOLVED A SUBJECT VEHICLE BEING STRUCK IN THE REAR AFTER BECOMING DISABLED BY A FRONT DIFFERENTIAL/DRIVESHAFT FAILURE AND PULLING TO THE SIDE OF THE ROAD. THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-012) TO FURTHER ASSESS THE SCOPE, FREQUENCY AND SAFETY CONSEQUENCES OF FRONT DIFFERENTIAL/DRIVESHAFT FAILURES IN THE SUBJECT VEHICLE POPULATION.

Additional source detail variants (3)

Power Train:axle Assembly:axle Shaft

IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), FORD STATED THAT THE PRIMARY CAUSE FOR THE MAJORITY OF THE REPORTED FRONT DIFFERENTIAL/DRIVE SHAFT FAILURES IS A MISALIGNMENT OF THE JOINT BETWEEN THE TWO COMPONENTS.CERTAIN LEVELS OF MISALIGNMENT MAY OVER TIME CAUSE AN UNEVEN WEAR OF THE SPLINES.CONTINUED WEAR OF THE SPLINES MAY RESULT IN A SHEARING OF THE SPLINES AND THE INABILITY OF THE DRIVESHAFT TO TRANSFER TORQUE TO THE FRONT DIFFERENTIAL. TO ADDRESS THE ISSUE IN THE FIELD, FORD INITIATED A SERVICE CAMPAIGN IN JUNE 2003 TO CORRECT THE MISALIGNMENT ISSUE AND, IF NECESSARY, REPLACE THE FRONT DRIVE SHAFT AND/OR DIFFERENTIAL.THE SERVICE CAMPAIGN COVERED MODEL YEAR (MY) 2003 AND MY 2004 VEHICLES BUILT FROM APRIL 18, 2002 THROUGH JULY 3, 2003.IN PRODUCTION, FORD INTRODUCED A CHANGE TO THE LUBRICATING GREASE OF THE JOINT IN FEBRUARY 2003 AND A CHANGE TO THE ASSEMBLY PLANT ALIGNMENT PROCESS IN JULY 2003 TO ADDRESS THE MISALIGNMENT AND WEAR ISSUE. ODI IDENTIFIED ONE CRASH RELATED TO THE ALLEGED DEFECT.THE CRASH INVOLVED A SUBJECT VEHICLE BEING STRUCK IN THE REAR AFTER BECOMING DISABLED BY A FRONT DIFFERENTIAL/DRIVESHAFT FAILURE AND PULLING TO THE SIDE OF THE ROAD. THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-012) TO FURTHER ASSESS THE SCOPE, FREQUENCY AND SAFETY CONSEQUENCES OF FRONT DIFFERENTIAL/DRIVESHAFT FAILURES IN THE SUBJECT VEHICLE POPULATION.

Power Train:driveline:differential Unit

IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), FORD STATED THAT THE PRIMARY CAUSE FOR THE MAJORITY OF THE REPORTED FRONT DIFFERENTIAL/DRIVE SHAFT FAILURES IS A MISALIGNMENT OF THE JOINT BETWEEN THE TWO COMPONENTS.CERTAIN LEVELS OF MISALIGNMENT MAY OVER TIME CAUSE AN UNEVEN WEAR OF THE SPLINES.CONTINUED WEAR OF THE SPLINES MAY RESULT IN A SHEARING OF THE SPLINES AND THE INABILITY OF THE DRIVESHAFT TO TRANSFER TORQUE TO THE FRONT DIFFERENTIAL. TO ADDRESS THE ISSUE IN THE FIELD, FORD INITIATED A SERVICE CAMPAIGN IN JUNE 2003 TO CORRECT THE MISALIGNMENT ISSUE AND, IF NECESSARY, REPLACE THE FRONT DRIVE SHAFT AND/OR DIFFERENTIAL.THE SERVICE CAMPAIGN COVERED MODEL YEAR (MY) 2003 AND MY 2004 VEHICLES BUILT FROM APRIL 18, 2002 THROUGH JULY 3, 2003.IN PRODUCTION, FORD INTRODUCED A CHANGE TO THE LUBRICATING GREASE OF THE JOINT IN FEBRUARY 2003 AND A CHANGE TO THE ASSEMBLY PLANT ALIGNMENT PROCESS IN JULY 2003 TO ADDRESS THE MISALIGNMENT AND WEAR ISSUE. ODI IDENTIFIED ONE CRASH RELATED TO THE ALLEGED DEFECT.THE CRASH INVOLVED A SUBJECT VEHICLE BEING STRUCK IN THE REAR AFTER BECOMING DISABLED BY A FRONT DIFFERENTIAL/DRIVESHAFT FAILURE AND PULLING TO THE SIDE OF THE ROAD. THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-012) TO FURTHER ASSESS THE SCOPE, FREQUENCY AND SAFETY CONSEQUENCES OF FRONT DIFFERENTIAL/DRIVESHAFT FAILURES IN THE SUBJECT VEHICLE POPULATION.

Power Train:driveline:driveshaft

IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), FORD STATED THAT THE PRIMARY CAUSE FOR THE MAJORITY OF THE REPORTED FRONT DIFFERENTIAL/DRIVE SHAFT FAILURES IS A MISALIGNMENT OF THE JOINT BETWEEN THE TWO COMPONENTS.CERTAIN LEVELS OF MISALIGNMENT MAY OVER TIME CAUSE AN UNEVEN WEAR OF THE SPLINES.CONTINUED WEAR OF THE SPLINES MAY RESULT IN A SHEARING OF THE SPLINES AND THE INABILITY OF THE DRIVESHAFT TO TRANSFER TORQUE TO THE FRONT DIFFERENTIAL. TO ADDRESS THE ISSUE IN THE FIELD, FORD INITIATED A SERVICE CAMPAIGN IN JUNE 2003 TO CORRECT THE MISALIGNMENT ISSUE AND, IF NECESSARY, REPLACE THE FRONT DRIVE SHAFT AND/OR DIFFERENTIAL.THE SERVICE CAMPAIGN COVERED MODEL YEAR (MY) 2003 AND MY 2004 VEHICLES BUILT FROM APRIL 18, 2002 THROUGH JULY 3, 2003.IN PRODUCTION, FORD INTRODUCED A CHANGE TO THE LUBRICATING GREASE OF THE JOINT IN FEBRUARY 2003 AND A CHANGE TO THE ASSEMBLY PLANT ALIGNMENT PROCESS IN JULY 2003 TO ADDRESS THE MISALIGNMENT AND WEAR ISSUE. ODI IDENTIFIED ONE CRASH RELATED TO THE ALLEGED DEFECT.THE CRASH INVOLVED A SUBJECT VEHICLE BEING STRUCK IN THE REAR AFTER BECOMING DISABLED BY A FRONT DIFFERENTIAL/DRIVESHAFT FAILURE AND PULLING TO THE SIDE OF THE ROAD. THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-012) TO FURTHER ASSESS THE SCOPE, FREQUENCY AND SAFETY CONSEQUENCES OF FRONT DIFFERENTIAL/DRIVESHAFT FAILURES IN THE SUBJECT VEHICLE POPULATION.