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2004 Lincoln Navigator

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2004 Lincoln Navigator do not stand out strongly from the model-year median of 30.

About this comparison →

When problems were reported

Mileage at the reported incident

62 reports with mileage · 24 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.

  • Suspension. Review the 24 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Air Bags. 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.

4 crash reports2 fire reports5 injury reports

Structure complaints

10 reports
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92,000 miles · Jan 16, 2015
Structure

FORD HAS FAILED TO INSTALL INSULATION ON THE UNDERSIDE OF THE LINCOLN NAVIGATOR HOOD THEREFORE THE HEAT HAS CAUSED THE HOOD PAINT AND CLEAR COAT TO BUBBLE AND PEEL. MY HOOD HAS AS MANY SPOTS ON IT AS A HORMONAL TEENAGE BOY HAS ON HIS FACE. THIS ISSUE HAS CAUSED INJURY TO THE VALUE OF MY CAR AND MY PRIDE IN OWNING THIS VEHICLE.…

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FORD HAS FAILED TO INSTALL INSULATION ON THE UNDERSIDE OF THE LINCOLN NAVIGATOR HOOD THEREFORE THE HEAT HAS CAUSED THE HOOD PAINT AND CLEAR COAT TO BUBBLE AND PEEL. MY HOOD HAS AS MANY SPOTS ON IT AS A HORMONAL TEENAGE BOY HAS ON HIS FACE. THIS ISSUE HAS CAUSED INJURY TO THE VALUE OF MY CAR AND MY PRIDE IN OWNING THIS VEHICLE. MANY LAWSUITS HAVE BEEN FILED AND SUCCESSFULLY WON THROUGH SEVERAL STATES, A NATIONWIDE RECALL NEEDS TO HAPPEN FOR THIS ISSUE. *TR

NHTSA ODI #10676159

7,000 miles · Apr 11, 2013
StructureVisibility

THE SUN ROOF LEAKS, TAIL GATE DOES NOT WORK PROPERLY, AND RUNNING BOARD DON'T WORK PROPERLY AS WELL AND THE MY LOCAL FOR CANNOT FIND A PROBLEM:( *TR

NHTSA ODI #10505964

Mileage unknown · Dec 13, 2011
Electrical SystemPower TrainStructure

SHIFTER ASSEMBLY BREAKS AND MAKES IT IMPOSSIBLE TO REMOVE THE KEY FROM THE VEHICLE WHICH COULD RESULT IN THEFT. POWER LIFTGATE WILL NOT WORK CORRECTLY WHICH COULD CAUSE IT TO CLOSE ON TOP IF YOU. DRIVERS SIDE POWER RUNNING BOARDS ARE FAULTY AND BECOME A TRIP HAZARD. *TR

NHTSA ODI #10439761

45,000 miles · Nov 10, 2011
StructureSuspension

ACCORDING TO MY , DECEASED WIFE, THE PROBLEM STARTS ON JULY 14, 2010. THE CAR BECAME BOUNCY IN THE FRONT WHILE IN MOTION, WE ARE STILL UNDER EXTENDED WARRANTY ON AUTO MAINTENANCE. MY WIFE WENT TO THE DEALER FINDLAY LINCOLN HERE HIN SAHARA ST LAS VEGAS REGARDING THIS PROBLEM, SOMEHOW THEY WERE ABLE TO FIX THE PROBLEM BUT AFTER …

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ACCORDING TO MY , DECEASED WIFE, THE PROBLEM STARTS ON JULY 14, 2010. THE CAR BECAME BOUNCY IN THE FRONT WHILE IN MOTION, WE ARE STILL UNDER EXTENDED WARRANTY ON AUTO MAINTENANCE. MY WIFE WENT TO THE DEALER FINDLAY LINCOLN HERE HIN SAHARA ST LAS VEGAS REGARDING THIS PROBLEM, SOMEHOW THEY WERE ABLE TO FIX THE PROBLEM BUT AFTER 2 WEEKS AGAIN THE BOUNCY PROBLEM STARTED TO APPEAR, AGAIN SHE WENT TO THE DEALER TO HAVE IT FIX, THE PROBLEM WAS AGAIN FIX AND AFTER 3 WEEKS THE PROBLEM AGAIN APPEAR AT THIS POINT MY WIFE HAS BEEN IN AND OUT OF THE HOSPITAL AND WAS NOT ABLE TO BRING THE CAR IN THE DEALERSHIP. WHEN I CAME HOME FROM HAWAII BECAUSE OF MY WIFE ILLNESS THE CAR WAS IN THE GARAGE AND ACCORDING TO MY SON THEY HAVE NOT USED IT BECAUSE OF THE CAR BOUNCE SO HARD THAT ITS DIFFICULT TO CONTROL THE WHEELS. SO ON OCT 13, 2010 I DRIVE IT TO THE DEALER 25 MILES DESPITE OF THE SUSPENSION PROBLEM, SINCE WE ARE NOT UNDER WARRANTY ANYMORE, I WAS CHARGE $912.40 FOR REPLACING AIR SUSPENSION COMPRESSOR, MILEAGE IS 45,076, ITS BEEN A YEAR NOW SINCE I HAVE THAT FIX AND NOW MY FRONT IS SO LOW THAT ITS ALMOST TOUCH MY FRONT TIRES AND WHEN I DRIVE IT IT FEELS THAT MY TIRES ARE UNEVEN LIKE RIDING ON A BIKE. I HAVE CANCELLED MY CAR INSURANCE BECAUSE I CANT DRIVE IT WITH THAT CONDITION AND DEALER WARRANTY IS EXPIRED AND THE MILEAGE IS 53,423. I HAVE FAITH WITH OUR AMERICAN CARS THATS WHY ALL THE CARS I OWN SINCE I STARTED TO DRIVE IS ALL AMERICAN MADE, THIS IS MY FIRST LUXURY CAR I HAVE AND IT COST ME ARM AND A LEG BUT I NEVER GET TO ENJOY IT, I AM UNEMPLOYED RIGHT NOW AND HAVE NO MONEY TO FIX IT, ALSO THE HOOD SUSPENSION WAS OUT 06/2010 I HAVE TO USED A PIECE OF WOOD TO HOLD THE HOOD, IS THERE ANY HELP YOU COULD ADVISE ME TO HAVE THESE PROBLEM TO BE A RECALL FROM THE MANUFACTURING, THANK YOU FOR YOUR TIME ANY HELP WILL BE APPRECIATED. *TR

NHTSA ODI #10435154

54,000 miles · Jul 1, 2010
Structure

TL*THE CONTACT OWNS A 2004 LINCOLN NAVIGATOR. WHILE OPENING THE HOOD OF THE VEHICLE THE CONTACT NOTICED THAT THE HOOD SHOCK ABSORBERS WOULD NO LONGER SUPPORT THE WEIGHT OF THE HOOD. THE VEHICLE WAS TAKEN TO THE DEALER WHO STATED THAT THE SHOCK ABSORBER NEEDED TO BE REPLACED. THERE WERE NO PRIOR WARNINGS. THE VEHICLE WAS NOT REPA…

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TL*THE CONTACT OWNS A 2004 LINCOLN NAVIGATOR. WHILE OPENING THE HOOD OF THE VEHICLE THE CONTACT NOTICED THAT THE HOOD SHOCK ABSORBERS WOULD NO LONGER SUPPORT THE WEIGHT OF THE HOOD. THE VEHICLE WAS TAKEN TO THE DEALER WHO STATED THAT THE SHOCK ABSORBER NEEDED TO BE REPLACED. THERE WERE NO PRIOR WARNINGS. THE VEHICLE WAS NOT REPAIRED. THE CURRENT AND FAILURE MILEAGES WERE 54000. UPDATED 09/24/10. *LJ UPDATED 09/24/10. 8JB

NHTSA ODI #10340927

50,800 miles · Jul 29, 2008
Engine And Engine CoolingEquipmentStructure

NOTICED THE AIR COMPRESSOR RAN ALL OF THE TIME FOR THE AIR RIDE SYSTEM. THE CAR WAS STILL IN WARRANTY TOOK IT TO FORD AND THEY SAID THEY HAD FIXED THE PROBLEM. 800 MILES OUT OF WARRANTY THE RIDE SIDE AIR SHOCK WENT BAD AND BURNED OUT THE COMPRESSOR. LOOKED UP OLD PAPER WORK AND COME TO FIND OUT THAT THEY HAS PUT ON A NOISE …

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NOTICED THE AIR COMPRESSOR RAN ALL OF THE TIME FOR THE AIR RIDE SYSTEM. THE CAR WAS STILL IN WARRANTY TOOK IT TO FORD AND THEY SAID THEY HAD FIXED THE PROBLEM. 800 MILES OUT OF WARRANTY THE RIDE SIDE AIR SHOCK WENT BAD AND BURNED OUT THE COMPRESSOR. LOOKED UP OLD PAPER WORK AND COME TO FIND OUT THAT THEY HAS PUT ON A NOISE REDUCTION KIT ON THE COMPRESSOR. SO WE COULD NO LONGER HEAR IT RUN. CONTACT THE DEALERSHIP AS WELL AS CUSTOMER SERVICE AT LINCOLN. THEY TOLD US SORRY ABOUT YOUR LUCK IT IS OUT OF WARRANTY. TOOK IT TO A DIFFERENT DEALER AND THEY SAID THAT THE BAGS ON THE AIR RIDE SYSTEM WERE DRY ROTTED (THE TRUCK HAS 50,800 MILES. HE SAID THIS A COMMON PROBLEM WITH FORD AND LINCOLN. THEY REPLACE AT LEAST 8 SETS A WEEK. I HAD THE RIGHT SIDE FIXED, NEW COMPRESSOR. NOW 7 MONTHS LATER THE LEFT SIDE AS DONE THE SAME THING (55,000 MILES). *TR

NHTSA ODI #10236202

65,000 miles · Jun 22, 2008
Structure

REAR TAILGATE PAINT IS BUBBLING. RESEARCH SHOWS THAT THIS IS COMMON FLAW ON FORD/LINCOLN VEHICLES FROM 2000-2005. *TR

NHTSA ODI #10231952

350 miles · Dec 5, 2005
SeatsStructureVisibility

DT: THE CONTACT HAD DIFFICULTY WITH THE POWER SEATS MEMORY SETTING/POWER-FOLDING HEATED EXTERIOR MIRRORS, AND THE POWER-DEPLOYABLE RUNNING BOARDS. THEY WORKED INTERMITTENTLY. THE POWER SEATS WITH MEMORY SETTING HAD A MEMORY FUNCTION THAT SHOULD REMAIN SET AT THE DRIVER'S PREFERENCE. HOWEVER, IT SOMETIMES READJUSTED WITHOUT …

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DT: THE CONTACT HAD DIFFICULTY WITH THE POWER SEATS MEMORY SETTING/POWER-FOLDING HEATED EXTERIOR MIRRORS, AND THE POWER-DEPLOYABLE RUNNING BOARDS. THEY WORKED INTERMITTENTLY. THE POWER SEATS WITH MEMORY SETTING HAD A MEMORY FUNCTION THAT SHOULD REMAIN SET AT THE DRIVER'S PREFERENCE. HOWEVER, IT SOMETIMES READJUSTED WITHOUT WARNING. THE POWER-FOLDING HEATED EXTERIOR MIRRORS WILL NOT IDENTIFY PROGRAMMED POSITIONS. THE POWER-DEPLOYABLE RUNNING BOARDS WILL NOT AUTOMATICALLY DEPLOY WHEN THE DOORS WERE OPENED. THE DEALER REPROGRAMMED THE VEHICLE SEVERAL TIMES IN AN ATTEMPT TO CORRECT THE PROBLEMS. AFTERWARDS, THE AFOREMENTIONED CONTINUED TO WORK INTERMITTENTLY. NO FURTHER REPAIRS HAVE BEEN MADE. *AK

NHTSA ODI #10144436

Mileage unknown · Feb 1, 2005
Structure

CONSUMER DISAPPOINTED IN THE QUALITY AND PERFORMANCE OF 2004 LINCOLN NAVIGATOR. WHILE DRIVING 40 MPH OR HIGHER THE VEHICLE WOULD VIBRATE WHILE THE WINDOWS WERE DOWN. *BF THE VEHICLE WAS TAKEN TO THE DEALER WHO INFORMED THE CONSUMER THAT THE CONDITION WAS NORMAL. *NM

NHTSA ODI #10110963

100 miles · Aug 28, 2004
Electrical SystemSteeringStructure

VIBRATION IN THE FRONT END. HAS BEEN IN THE SHOP THREE TIMES. TWICE THE TIRES CHECKED AND ONE ALIGNMENT. NOTHING HELPED. ALSO THE INTERIOR LIGHTS WENT OUT. BOUGHT BRAND NEW AND HAS ONLY 6,000 MILES.. ALSO THE FRONT BUMPER HAS WATER STREAKS ON IT THAT DEALER SAYS IS MANUFACTURE PROBLEM DUE TO NO CLEAR COAT ON IT. *JB

NHTSA ODI #10088726

Official recalls

0

No recalls in this snapshot.

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

NHTSA investigations

1

DP05005 · Spark Plug Ejection From Cylinder Head

Opened Sep 22, 2005 · Closed Jan 4, 2006

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

ON SEPTEMBER 6, 2005, ODI RECEIVED A PETITION REQUESTING THAT THE AGENCY INVESTIGATE ALLEGATIONS OF ENGINE SPARK PLUG EJECTION IN CERTAIN MODEL YEAR 1997 THROUGH 2004 FORD VEHICLES WITH TRITON V-8 AND V-10 ENGINES.ODI RECEIVED A TOTAL OF 474 NON-DUPLICATIVE COMPLAINTS ON THE SUBJECT VEHICLES WHERE THE COMPLAINANT, OR THE DEALER REPAIRING THE VEHICLE, REPORTED THAT A SPARK PLUG DETACHED FROM THE CYLINDER AND/OR EJECTED FROM THE ENGINE.AS OF DECEMBER 8, 2005, ODI IS NOT AWARE OF ANY ALLEGATIONS WHERE THE ALLEGED DEFECT RESULTED IN A LOSS OF VEHICLE CONTROL, A CRASH, AN INJURY, OR A FATALITY IN ANY OF THE 10,319,810 SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF ONLY TWO INCIDENTS WHERE THE VEHICLE STALLED WITHOUT RESTART.INFORMATION CONTAINED IN THE ODI CONSUMER COMPLAINTS AND OBTAINED FROM 72 TELEPHONE INTERVIEWS WITH COMPLAINANTS SHOWED THE FOLLOWING:(1) 99% OF THE COMPLAINTS WERE ON MY 1997 TO 2002 SUBJECT VEHICLES.(2) MOST THE COMPLAINANTS REPORTED HEARING A LOUD POP WHILE DRIVING OR UPON STARTING UP THE VEHICLE FOLLOWED BY A LOUD, REPETITIVE CLICKING OR POPPING SOUND.(3) MANY OF THE COMPLAINANTS REPORTED THAT THE POPPING SOUND WAS ACCOMPANIED BY SOME LOSS OF VEHICLE POWER; HOWEVER, IN 99% OF THE INCIDENTS REPORTED, THE VEHICLE DID NOT STALL.IN THE VERY FEW INCIDENTS WHERE THE VEHICLE DID STALL, MOST VEHICLES COULD BE RESTARTED.(4) ONLY A SMALL PERCENTAGE OF THE COMPLAINANTS CITED THAT THEY SMELLED GAS OR A SLIGHT BURNING SMELL WHEN THE INCIDENT OCCURRED.(5) IN ALL BUT A VERY FEW INCIDENTS, VEHICLE DAMAGE WAS LIMITED TO THE ENGINE.IN ONE INCIDENT, THE COMPLAINT REPORTED THAT THE FUEL RAIL WAS DAMAGED AND REPLACED AFTER ONE OF THE SPARK PLUGS EJECTED FROM THE ENGINE; HOWEVER, THE COMPLAINANT REPORTED THAT THE DAMAGE DID NOT RESULT IN ANY TYPE OF FUEL LEAK OR FIRE.IN ANOTHER INCIDENT, THE ONLY INCIDENT WHERE A FIRE WAS ALLEGED, THE COMPLAINANT REPORTED THAT NO FLUID LEAK WAS OBSERVED, BUT THAT A FIRE RESULTED AFTER THE SPARK PLUG HAD EJECTED FROM THE ENGINE AND HE HAD RESTARTED THE VEHICLE AND DRIVEN TO ANOTHER LOCATION.NONE OF THE COMPLAINANTS REPORTED ANY DAMAGE TO THE VEHICLE HOOD.(6) ONLY TWO COMPLAINANTS REPORTED THAT THEY OBSERVED WHAT APPEARED TO BE SOME DROPS OF FUEL COMING FROM THE CYLINDER WHERE THE SPARK PLUG HAD FAILED OR ON THE SPARK PLUG ITSELF; HOWEVER, EACH OF THESE COMPLAINANTS REPORTED THAT THERE WAS NO SMOKE OR FLAMES AS A RESULT OF HIS INCIDENT.AS THE PETITIONER NOTED, AND ODI?S ANALYSIS SHOWED, IT IS POSSIBLE FOR A SPARK PLUG TO DETACH FROM THE ENGINE CYLINDER THREADS IN THE SUBJECT VEHICLES.HOWEVER, ODI?S ANALYSIS OF 474 COMPLAINTS DESCRIBING SUCH INCIDENTS FOUND ONLY A VERY FEW ALLEGED ANY SAFETY-RELATED CONSEQUENCES.NONE OF THESE SHOWED ANY EVIDENCE OF A SERIOUS SAFETY CONSEQUENCE.GIVEN THE LARGE POPULATION AND RELATIVELY LONG EXPOSURE TIME OF THE SUBJECT VEHICLES, THE COMPLAINT ANALYSIS INDICATES THAT THE RISK TO MOTOR VEHICLE SAFETY FROM THE ALLEGED DEFECT IS VERY LOW.IN VIEW OF THE FOREGOING, IT IS UNLIKELY THAT NHTSA WOULD ISSUE AN ORDER FOR THE NOTIFICATION AND REMEDY OF THE ALLEGED DEFECT AT THE CONCLUSION OF THE INVESTIGATION REQUESTED IN THE PETITION.THEREFORE, IN VIEW OF THE NEED TO ALLOCATE AND PRIORITIZE NHTSA?S LIMITED RESOURCES TO BEST ACCOMPLISH THE AGENCY?S SAFETY MISSION, THE PETITION IS DENIED.

Additional source detail variants (3)

Engine And Engine Cooling:engine

ON SEPTEMBER 6, 2005, ODI RECEIVED A PETITION REQUESTING THAT THE AGENCY INVESTIGATE ALLEGATIONS OF ENGINE SPARK PLUG EJECTION IN CERTAIN MODEL YEAR 1997 THROUGH 2004 FORD VEHICLES WITH TRITON V-8 AND V-10 ENGINES.ODI RECEIVED A TOTAL OF 474 NON-DUPLICATIVE COMPLAINTS ON THE SUBJECT VEHICLES WHERE THE COMPLAINANT, OR THE DEALER REPAIRING THE VEHICLE, REPORTED THAT A SPARK PLUG DETACHED FROM THE CYLINDER AND/OR EJECTED FROM THE ENGINE.AS OF DECEMBER 8, 2005, ODI IS NOT AWARE OF ANY ALLEGATIONS WHERE THE ALLEGED DEFECT RESULTED IN A LOSS OF VEHICLE CONTROL, A CRASH, AN INJURY, OR A FATALITY IN ANY OF THE 10,319,810 SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF ONLY TWO INCIDENTS WHERE THE VEHICLE STALLED WITHOUT RESTART.INFORMATION CONTAINED IN THE ODI CONSUMER COMPLAINTS AND OBTAINED FROM 72 TELEPHONE INTERVIEWS WITH COMPLAINANTS SHOWED THE FOLLOWING:(1) 99% OF THE COMPLAINTS WERE ON MY 1997 TO 2002 SUBJECT VEHICLES.(2) MOST THE COMPLAINANTS REPORTED HEARING A LOUD POP WHILE DRIVING OR UPON STARTING UP THE VEHICLE FOLLOWED BY A LOUD, REPETITIVE CLICKING OR POPPING SOUND.(3) MANY OF THE COMPLAINANTS REPORTED THAT THE POPPING SOUND WAS ACCOMPANIED BY SOME LOSS OF VEHICLE POWER; HOWEVER, IN 99% OF THE INCIDENTS REPORTED, THE VEHICLE DID NOT STALL.IN THE VERY FEW INCIDENTS WHERE THE VEHICLE DID STALL, MOST VEHICLES COULD BE RESTARTED.(4) ONLY A SMALL PERCENTAGE OF THE COMPLAINANTS CITED THAT THEY SMELLED GAS OR A SLIGHT BURNING SMELL WHEN THE INCIDENT OCCURRED.(5) IN ALL BUT A VERY FEW INCIDENTS, VEHICLE DAMAGE WAS LIMITED TO THE ENGINE.IN ONE INCIDENT, THE COMPLAINT REPORTED THAT THE FUEL RAIL WAS DAMAGED AND REPLACED AFTER ONE OF THE SPARK PLUGS EJECTED FROM THE ENGINE; HOWEVER, THE COMPLAINANT REPORTED THAT THE DAMAGE DID NOT RESULT IN ANY TYPE OF FUEL LEAK OR FIRE.IN ANOTHER INCIDENT, THE ONLY INCIDENT WHERE A FIRE WAS ALLEGED, THE COMPLAINANT REPORTED THAT NO FLUID LEAK WAS OBSERVED, BUT THAT A FIRE RESULTED AFTER THE SPARK PLUG HAD EJECTED FROM THE ENGINE AND HE HAD RESTARTED THE VEHICLE AND DRIVEN TO ANOTHER LOCATION.NONE OF THE COMPLAINANTS REPORTED ANY DAMAGE TO THE VEHICLE HOOD.(6) ONLY TWO COMPLAINANTS REPORTED THAT THEY OBSERVED WHAT APPEARED TO BE SOME DROPS OF FUEL COMING FROM THE CYLINDER WHERE THE SPARK PLUG HAD FAILED OR ON THE SPARK PLUG ITSELF; HOWEVER, EACH OF THESE COMPLAINANTS REPORTED THAT THERE WAS NO SMOKE OR FLAMES AS A RESULT OF HIS INCIDENT.AS THE PETITIONER NOTED, AND ODI?S ANALYSIS SHOWED, IT IS POSSIBLE FOR A SPARK PLUG TO DETACH FROM THE ENGINE CYLINDER THREADS IN THE SUBJECT VEHICLES.HOWEVER, ODI?S ANALYSIS OF 474 COMPLAINTS DESCRIBING SUCH INCIDENTS FOUND ONLY A VERY FEW ALLEGED ANY SAFETY-RELATED CONSEQUENCES.NONE OF THESE SHOWED ANY EVIDENCE OF A SERIOUS SAFETY CONSEQUENCE.GIVEN THE LARGE POPULATION AND RELATIVELY LONG EXPOSURE TIME OF THE SUBJECT VEHICLES, THE COMPLAINT ANALYSIS INDICATES THAT THE RISK TO MOTOR VEHICLE SAFETY FROM THE ALLEGED DEFECT IS VERY LOW.IN VIEW OF THE FOREGOING, IT IS UNLIKELY THAT NHTSA WOULD ISSUE AN ORDER FOR THE NOTIFICATION AND REMEDY OF THE ALLEGED DEFECT AT THE CONCLUSION OF THE INVESTIGATION REQUESTED IN THE PETITION.THEREFORE, IN VIEW OF THE NEED TO ALLOCATE AND PRIORITIZE NHTSA?S LIMITED RESOURCES TO BEST ACCOMPLISH THE AGENCY?S SAFETY MISSION, THE PETITION IS DENIED.

Engine And Engine Cooling:engine:gasoline

ON SEPTEMBER 6, 2005, ODI RECEIVED A PETITION REQUESTING THAT THE AGENCY INVESTIGATE ALLEGATIONS OF ENGINE SPARK PLUG EJECTION IN CERTAIN MODEL YEAR 1997 THROUGH 2004 FORD VEHICLES WITH TRITON V-8 AND V-10 ENGINES.ODI RECEIVED A TOTAL OF 474 NON-DUPLICATIVE COMPLAINTS ON THE SUBJECT VEHICLES WHERE THE COMPLAINANT, OR THE DEALER REPAIRING THE VEHICLE, REPORTED THAT A SPARK PLUG DETACHED FROM THE CYLINDER AND/OR EJECTED FROM THE ENGINE.AS OF DECEMBER 8, 2005, ODI IS NOT AWARE OF ANY ALLEGATIONS WHERE THE ALLEGED DEFECT RESULTED IN A LOSS OF VEHICLE CONTROL, A CRASH, AN INJURY, OR A FATALITY IN ANY OF THE 10,319,810 SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF ONLY TWO INCIDENTS WHERE THE VEHICLE STALLED WITHOUT RESTART.INFORMATION CONTAINED IN THE ODI CONSUMER COMPLAINTS AND OBTAINED FROM 72 TELEPHONE INTERVIEWS WITH COMPLAINANTS SHOWED THE FOLLOWING:(1) 99% OF THE COMPLAINTS WERE ON MY 1997 TO 2002 SUBJECT VEHICLES.(2) MOST THE COMPLAINANTS REPORTED HEARING A LOUD POP WHILE DRIVING OR UPON STARTING UP THE VEHICLE FOLLOWED BY A LOUD, REPETITIVE CLICKING OR POPPING SOUND.(3) MANY OF THE COMPLAINANTS REPORTED THAT THE POPPING SOUND WAS ACCOMPANIED BY SOME LOSS OF VEHICLE POWER; HOWEVER, IN 99% OF THE INCIDENTS REPORTED, THE VEHICLE DID NOT STALL.IN THE VERY FEW INCIDENTS WHERE THE VEHICLE DID STALL, MOST VEHICLES COULD BE RESTARTED.(4) ONLY A SMALL PERCENTAGE OF THE COMPLAINANTS CITED THAT THEY SMELLED GAS OR A SLIGHT BURNING SMELL WHEN THE INCIDENT OCCURRED.(5) IN ALL BUT A VERY FEW INCIDENTS, VEHICLE DAMAGE WAS LIMITED TO THE ENGINE.IN ONE INCIDENT, THE COMPLAINT REPORTED THAT THE FUEL RAIL WAS DAMAGED AND REPLACED AFTER ONE OF THE SPARK PLUGS EJECTED FROM THE ENGINE; HOWEVER, THE COMPLAINANT REPORTED THAT THE DAMAGE DID NOT RESULT IN ANY TYPE OF FUEL LEAK OR FIRE.IN ANOTHER INCIDENT, THE ONLY INCIDENT WHERE A FIRE WAS ALLEGED, THE COMPLAINANT REPORTED THAT NO FLUID LEAK WAS OBSERVED, BUT THAT A FIRE RESULTED AFTER THE SPARK PLUG HAD EJECTED FROM THE ENGINE AND HE HAD RESTARTED THE VEHICLE AND DRIVEN TO ANOTHER LOCATION.NONE OF THE COMPLAINANTS REPORTED ANY DAMAGE TO THE VEHICLE HOOD.(6) ONLY TWO COMPLAINANTS REPORTED THAT THEY OBSERVED WHAT APPEARED TO BE SOME DROPS OF FUEL COMING FROM THE CYLINDER WHERE THE SPARK PLUG HAD FAILED OR ON THE SPARK PLUG ITSELF; HOWEVER, EACH OF THESE COMPLAINANTS REPORTED THAT THERE WAS NO SMOKE OR FLAMES AS A RESULT OF HIS INCIDENT.AS THE PETITIONER NOTED, AND ODI?S ANALYSIS SHOWED, IT IS POSSIBLE FOR A SPARK PLUG TO DETACH FROM THE ENGINE CYLINDER THREADS IN THE SUBJECT VEHICLES.HOWEVER, ODI?S ANALYSIS OF 474 COMPLAINTS DESCRIBING SUCH INCIDENTS FOUND ONLY A VERY FEW ALLEGED ANY SAFETY-RELATED CONSEQUENCES.NONE OF THESE SHOWED ANY EVIDENCE OF A SERIOUS SAFETY CONSEQUENCE.GIVEN THE LARGE POPULATION AND RELATIVELY LONG EXPOSURE TIME OF THE SUBJECT VEHICLES, THE COMPLAINT ANALYSIS INDICATES THAT THE RISK TO MOTOR VEHICLE SAFETY FROM THE ALLEGED DEFECT IS VERY LOW.IN VIEW OF THE FOREGOING, IT IS UNLIKELY THAT NHTSA WOULD ISSUE AN ORDER FOR THE NOTIFICATION AND REMEDY OF THE ALLEGED DEFECT AT THE CONCLUSION OF THE INVESTIGATION REQUESTED IN THE PETITION.THEREFORE, IN VIEW OF THE NEED TO ALLOCATE AND PRIORITIZE NHTSA?S LIMITED RESOURCES TO BEST ACCOMPLISH THE AGENCY?S SAFETY MISSION, THE PETITION IS DENIED.

Engine And Engine Cooling

ON SEPTEMBER 6, 2005, ODI RECEIVED A PETITION REQUESTING THAT THE AGENCY INVESTIGATE ALLEGATIONS OF ENGINE SPARK PLUG EJECTION IN CERTAIN MODEL YEAR 1997 THROUGH 2004 FORD VEHICLES WITH TRITON V-8 AND V-10 ENGINES.ODI RECEIVED A TOTAL OF 474 NON-DUPLICATIVE COMPLAINTS ON THE SUBJECT VEHICLES WHERE THE COMPLAINANT, OR THE DEALER REPAIRING THE VEHICLE, REPORTED THAT A SPARK PLUG DETACHED FROM THE CYLINDER AND/OR EJECTED FROM THE ENGINE.AS OF DECEMBER 8, 2005, ODI IS NOT AWARE OF ANY ALLEGATIONS WHERE THE ALLEGED DEFECT RESULTED IN A LOSS OF VEHICLE CONTROL, A CRASH, AN INJURY, OR A FATALITY IN ANY OF THE 10,319,810 SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF ONLY TWO INCIDENTS WHERE THE VEHICLE STALLED WITHOUT RESTART.INFORMATION CONTAINED IN THE ODI CONSUMER COMPLAINTS AND OBTAINED FROM 72 TELEPHONE INTERVIEWS WITH COMPLAINANTS SHOWED THE FOLLOWING:(1) 99% OF THE COMPLAINTS WERE ON MY 1997 TO 2002 SUBJECT VEHICLES.(2) MOST THE COMPLAINANTS REPORTED HEARING A LOUD POP WHILE DRIVING OR UPON STARTING UP THE VEHICLE FOLLOWED BY A LOUD, REPETITIVE CLICKING OR POPPING SOUND.(3) MANY OF THE COMPLAINANTS REPORTED THAT THE POPPING SOUND WAS ACCOMPANIED BY SOME LOSS OF VEHICLE POWER; HOWEVER, IN 99% OF THE INCIDENTS REPORTED, THE VEHICLE DID NOT STALL.IN THE VERY FEW INCIDENTS WHERE THE VEHICLE DID STALL, MOST VEHICLES COULD BE RESTARTED.(4) ONLY A SMALL PERCENTAGE OF THE COMPLAINANTS CITED THAT THEY SMELLED GAS OR A SLIGHT BURNING SMELL WHEN THE INCIDENT OCCURRED.(5) IN ALL BUT A VERY FEW INCIDENTS, VEHICLE DAMAGE WAS LIMITED TO THE ENGINE.IN ONE INCIDENT, THE COMPLAINT REPORTED THAT THE FUEL RAIL WAS DAMAGED AND REPLACED AFTER ONE OF THE SPARK PLUGS EJECTED FROM THE ENGINE; HOWEVER, THE COMPLAINANT REPORTED THAT THE DAMAGE DID NOT RESULT IN ANY TYPE OF FUEL LEAK OR FIRE.IN ANOTHER INCIDENT, THE ONLY INCIDENT WHERE A FIRE WAS ALLEGED, THE COMPLAINANT REPORTED THAT NO FLUID LEAK WAS OBSERVED, BUT THAT A FIRE RESULTED AFTER THE SPARK PLUG HAD EJECTED FROM THE ENGINE AND HE HAD RESTARTED THE VEHICLE AND DRIVEN TO ANOTHER LOCATION.NONE OF THE COMPLAINANTS REPORTED ANY DAMAGE TO THE VEHICLE HOOD.(6) ONLY TWO COMPLAINANTS REPORTED THAT THEY OBSERVED WHAT APPEARED TO BE SOME DROPS OF FUEL COMING FROM THE CYLINDER WHERE THE SPARK PLUG HAD FAILED OR ON THE SPARK PLUG ITSELF; HOWEVER, EACH OF THESE COMPLAINANTS REPORTED THAT THERE WAS NO SMOKE OR FLAMES AS A RESULT OF HIS INCIDENT.AS THE PETITIONER NOTED, AND ODI?S ANALYSIS SHOWED, IT IS POSSIBLE FOR A SPARK PLUG TO DETACH FROM THE ENGINE CYLINDER THREADS IN THE SUBJECT VEHICLES.HOWEVER, ODI?S ANALYSIS OF 474 COMPLAINTS DESCRIBING SUCH INCIDENTS FOUND ONLY A VERY FEW ALLEGED ANY SAFETY-RELATED CONSEQUENCES.NONE OF THESE SHOWED ANY EVIDENCE OF A SERIOUS SAFETY CONSEQUENCE.GIVEN THE LARGE POPULATION AND RELATIVELY LONG EXPOSURE TIME OF THE SUBJECT VEHICLES, THE COMPLAINT ANALYSIS INDICATES THAT THE RISK TO MOTOR VEHICLE SAFETY FROM THE ALLEGED DEFECT IS VERY LOW.IN VIEW OF THE FOREGOING, IT IS UNLIKELY THAT NHTSA WOULD ISSUE AN ORDER FOR THE NOTIFICATION AND REMEDY OF THE ALLEGED DEFECT AT THE CONCLUSION OF THE INVESTIGATION REQUESTED IN THE PETITION.THEREFORE, IN VIEW OF THE NEED TO ALLOCATE AND PRIORITIZE NHTSA?S LIMITED RESOURCES TO BEST ACCOMPLISH THE AGENCY?S SAFETY MISSION, THE PETITION IS DENIED.