NHTSA owner reports · September 18, 2026 snapshot.
Exterior Lighting complaints
207 reportsClear category filter31,000 miles · Aug 17, 2010
Exterior Lighting
FACTS: I OWN A 2003 MERCURY GRAND MARQUIS THAT HAD TOTAL HEADLIGHT FAILURE WHILE DRIVING 55 MPH. ALTHOUGH I RAN OFF THE ROAD I WAS ABLE TO RECOVER WITH NO DAMAGE/INJURY/LOSS OF LIFE BECAUSE I WAS FAMILIAR WITH THE ROAD/THE CAR/AND SADLY, PREVIOUS EXPERIENCE WITH TOTAL HEADLIGHT FAILURE IN A PREVIOUS VEHICLE (2001 DODGE DURANGO)…
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FACTS: I OWN A 2003 MERCURY GRAND MARQUIS THAT HAD TOTAL HEADLIGHT FAILURE WHILE DRIVING 55 MPH. ALTHOUGH I RAN OFF THE ROAD I WAS ABLE TO RECOVER WITH NO DAMAGE/INJURY/LOSS OF LIFE BECAUSE I WAS FAMILIAR WITH THE ROAD/THE CAR/AND SADLY, PREVIOUS EXPERIENCE WITH TOTAL HEADLIGHT FAILURE IN A PREVIOUS VEHICLE (2001 DODGE DURANGO). ONCE I STOPPED I CHECKED ALL OBVIOUS THINGS FOR FAILURE (BATTERY/FUSES/ETC) BUT SOON REALIZED I HAD PARKING LIGHTS/TURN SIGNALS/SIDE MARKER LIGHTS/DASH LIGHTS/TAIL LIGHTS/AND EVEN BRAKE LIGHTS...EVERYTHING EXCEPT HEADLIGHTS. I TRIED THE HIGH-BEAM POSITION AND NO LUCK THERE EITHER - UNTIL I PULLED THE MULTI-FUNCTION SWITCH TOWARD THE STEERING WHEEL TO THE "FLASH" THE HIGH-BEAM POSITION. I CONTINUED TO HOLD THE SWITCH IN THIS POSITION AND DRIVE WITH MY HIGH-BEAMS ON FOR THE FEW MILES I HAD LEFT TO MY DESTINATION. ONCE HOME I TURNED VEHICLE OFF GATHERED MY TEST EQUIPMENT AND BEGAN MY TROUBLESHOOTING JUST TO FIND OUT THAT NOW EVERYTHING WORKED AS ADVERTISED. THAT HELD TRUE FOR APPROX. 1500 MILES ' OR ABOUT 2 MONTHS (WITH INITIAL FAILURE AT APPROX 31,000 MILES) WHEN HEADLIGHTS FAILED AGAIN; AND NOW THEY EVEN FAIL INTERMITTENTLY AT ANY TIME TO INCLUDE DAYLIGHT HOURS. MY TROUBLESHOOTING REVEALED THE LIGHTING CONTROL MODULE (LCM) IS THE CAUSE OF FAILURE, BUT MORE IMPORTANTLY, MY INVESTIGATION REVEALED THIS IS A KNOWN FAILURE...BY LITERALLY HUNDREDS OF PEOPLE...TO INCLUDE YOU PEOPLE OF THE NHTSA. MY ANALYSIS TELLS ME THAT THE FAILURE IS PROBABLY NOT MILES RELATED BUT MORE LIKELY USAGE RELATED SINCE MY 31+ YEARS (AND COUNTING) IN THE MILITARY TAUGHT ME TO DRIVE WITH MY HEADLIGHTS ON 24/7/365 IN THE SEE AND BE SEEN PHILOSOPHY'ADD THE FACT THAT I CURRENTLY HAVE 34,000 MILES WHERE MOST HAVE A LOT MORE. OPINION: A 3RD GRADER COULD HAVE DONE THE RESEARCH TO IDENTIFY THIS IS A SERIOUS PROBLEM AND AN 8TH GRADER COULD MAKE THE DECISION TO RECALL THE CARS FOR TOTAL HEADLIGHT FAILURE. IF YOU CAN'T - TAKE YOUR LOVED ONES FOR A RIDE IN MY CAR AT NIGHT!!! *TR
NHTSA ODI #10350085
128,000 miles · Aug 16, 2010
Electrical SystemExterior Lighting
THE HEAD LIGHTS ON MY MERCURY GRAND MARQUIS GO OUT WHEN I DRIVE AT NIGHT. I HAVE SEARCHED THE WEB FOR SOLUTIONS TO THIS PROBLEM. IT TURNS OUT THIS IS A RECURRING PROBLEM WITH THOUSANDS OF OTHER OWNERS OF THIS MODEL. IT IS A SERIOUS ISSUE WHEN YOU ARE DRIVING ON COUNTRY ROADS OR ON THE INTERSTATE AND YOUR LIGHTS GO OUT AND YOU…
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THE HEAD LIGHTS ON MY MERCURY GRAND MARQUIS GO OUT WHEN I DRIVE AT NIGHT. I HAVE SEARCHED THE WEB FOR SOLUTIONS TO THIS PROBLEM. IT TURNS OUT THIS IS A RECURRING PROBLEM WITH THOUSANDS OF OTHER OWNERS OF THIS MODEL. IT IS A SERIOUS ISSUE WHEN YOU ARE DRIVING ON COUNTRY ROADS OR ON THE INTERSTATE AND YOUR LIGHTS GO OUT AND YOU CAN'T SEE ANYTHING. THE LIGHTS USUALLY REMAIN OFF FOR ABOUT TEN MINUTES OR SO. MERCURY NEEDS TO BE RESPONSIBLE FOR THIS ISSUE BEFORE A SERIOUS ACCIDENT HAPPENS (IF ONE HASN'T ALREADY). *TR
NHTSA ODI #10349568
65,000 miles · Jul 21, 2010
Exterior Lighting
HELLO, WE HAVE A 2003 MERCURY GRAND MARQUIS THAT HAS A PROBLEM WITH THE HEAD LIGHTS SHUTTING OFF AT RANDOM TIMES. NOTHING GAVE WARNING TO THIS PROBLEM HAPPENING, WE BOUGHT THE CAR USED, AND WAS JUST FINE FOR A YEAR, THEN ALL OF A SUDDEN ONE DAY THE HEADLIGHTS JUST GO OUT. THE FIRST TIME IT HAPPENED WAS ABOUT 6 MONTHS AGO(3-1-10)…
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HELLO, WE HAVE A 2003 MERCURY GRAND MARQUIS THAT HAS A PROBLEM WITH THE HEAD LIGHTS SHUTTING OFF AT RANDOM TIMES. NOTHING GAVE WARNING TO THIS PROBLEM HAPPENING, WE BOUGHT THE CAR USED, AND WAS JUST FINE FOR A YEAR, THEN ALL OF A SUDDEN ONE DAY THE HEADLIGHTS JUST GO OUT. THE FIRST TIME IT HAPPENED WAS ABOUT 6 MONTHS AGO(3-1-10). NOW EVERYTIME IT IS DRIVEN WITH THE HEADLIGHTS ON, IT IS GUARANTEED TO HAPPEN AT LEAST ONCE AND SOMETIMES UP TO 5 TIMES JUST IN 3 MILES OF DRIVING ON MY WIFE'S WAY HOME FROM WORK. THE ONLY WAY TO GET THE LIGHTS BACK ON AFTER THEY GO OUT IS TO PULL OVER TO THE SIDE OF THE ROAD, SHUT THE CAR OFF, LET SIT FOR A FEW MIN, THEN START AND THEY WORK AGAIN FOR A BIT. THIS IS OVERALL VERY DANGEROUS AND SURPRISING THAT WE HAVE NOT BEEN IN AN ACCIDENT OR RECEIVED A TICKET YET! I AM A ACTIVE MEMBER ON A CROWN VICTORIA FORUM, AND WITH LITTLE SEARCHING ON THAT SITE OR GOOGLE YOU WILL SEE TONS OF REPORTS OF THIS BEING A VERY COMMON PROBLEM ON THE 2003-2005 CROWN VICTORIA, GRAND MARQUIS, AND MERCURY MARAUDER. WITH THE HELP OF OTHER MEMBERS ON THAT FORUM IT WAS FOUND TO BE A FAULTY LCM(LIGHTING CONTROL MODULE) WHICH HAS A PROBLEM WITH OVERHEATING LIGHTING RELAYS. THE ONLY WAY TO REMEDY THIS PROBLEM IS TO PURCHASE A NEW LCM FOR ANYWHERE BETWEEN $250 AND $600 WITH NO GUARANTEE HOW LONG THAT PART WILL LAST. I ACTUALLY PURCHASED A NEW ONE TODAY. VERY EXPENSIVE FIX JUST FOR THE USE OF HEADLIGHTS, BUT I VALUE MY FAMILIES SAFETY MORE. I WILL BE KEEPING MY OLD LCM TO POSSIBLY HAVE IT REPAIRED FOR WHEN MY NEW PART FAILS AGAIN. THANKS SO MUCH. *TR
NHTSA ODI #10344514
62,127 miles · Jul 1, 2010
Exterior Lighting
MY 2003 MERCURY GRAND MARQUIS BEGAN EXPERIENCING HEADLIGHT FAILURE OVER A PERIOD OF MONTHS, WITH BOTH LOWER BEAMS RANDOMLY GOING OFF AND THEN AFTER SEVERAL MINUTES OR HOURS COMING BACK ON. OTHER INTERNAL LIGHTS AND LIGHT SENSORS CONTINUED TO WORK NORMALLY. THIS HAPPENED SEVERAL TIMES WHILE DRIVING ON AN UNLIGHTED ROAD AT NIGHT…
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MY 2003 MERCURY GRAND MARQUIS BEGAN EXPERIENCING HEADLIGHT FAILURE OVER A PERIOD OF MONTHS, WITH BOTH LOWER BEAMS RANDOMLY GOING OFF AND THEN AFTER SEVERAL MINUTES OR HOURS COMING BACK ON. OTHER INTERNAL LIGHTS AND LIGHT SENSORS CONTINUED TO WORK NORMALLY. THIS HAPPENED SEVERAL TIMES WHILE DRIVING ON AN UNLIGHTED ROAD AT NIGHT, CREATING A DANGEROUS SITUATION, UNABLE TO SEE THE ROAD AHEAD OR OTHER CARS SEEING ME COMING. NHTSA ACTION NUMBER PE08066 DESCRIBES A SIMILAR PROBLEMS CAUSED BY A DEFECTIVE PRINTED CIRCUIT BOARD IN THE LIGHT CONTROL MODULE (LCM), RESULTING IN SEVERAL THOUSAND WARRANTY CLAIMS. IN FACT, THIS HAS BEEN DETERMINED TO BE THE DEFECTIVE PART ON MY CAR, WHICH HAS NOW BEEN REPLACED BY A FORD DEALER AT A COST OF $511.07 FOR THE LCM PLUS $184.97 LABOR AND TAX. FORD ADVISES ME THAT MY CAR WAS NOT IN THE RECALL CAMPAIGN, BUT OBVIOUSLY IT HAS DEVELOPED THE SAME PROBLEM. AN UPGRADED PART LCM HAS BEEN DEVELOPED BY FORD FOR REPLACEMENT. I BELIEVE I SHOULD HAVE BEEN NOTIFIED OF THIS EARLIER FOR REPLACEMENT SO I WOULD NOT HAVE EXPERIENCED THIS DANGEROUS SITUATION. THE ODI INVESTIGATION WAS CLOSED 3/24/09. I BELIEVE IT SHOULD BE REOPENED AS DEALERS TELL ME THAT THEY REPLACE "LOTS" OF THESE MODULES. I HAVE RETAINED THE DEFECTIVE LCM FOR ANALYSIS. *TR
NHTSA ODI #10340989
76,000 miles · Jun 26, 2010
Exterior Lighting
WHILE DRIVING MY 2003 MERCURY MARQUIS ONE EVENING, MY HEADLIGHTS WENT OUT. I TRIED TURNING THE SWITCH ON THE DASHBOARD TO THE HEADLIGHT POSITION BECAUSE ORIGINALLY IT WAS ON THE SENSOR POSITION, BUT THEY DIDN'T COME BACK ON. NO MATTER WHAT I DID, THEY REMAINED OFF. FROM THAT NIGHT ON, MY HEADLIGHTS WORK SPORADICALLY. SOMETIM…
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WHILE DRIVING MY 2003 MERCURY MARQUIS ONE EVENING, MY HEADLIGHTS WENT OUT. I TRIED TURNING THE SWITCH ON THE DASHBOARD TO THE HEADLIGHT POSITION BECAUSE ORIGINALLY IT WAS ON THE SENSOR POSITION, BUT THEY DIDN'T COME BACK ON. NO MATTER WHAT I DID, THEY REMAINED OFF. FROM THAT NIGHT ON, MY HEADLIGHTS WORK SPORADICALLY. SOMETIMES THEY'LL COME ON RIGHT AWAY AND THEN GO OUT WHILE DRIVING. SOMETIMES THEY'LL COME ON IN THE DAYLIGHT WITH THE SWITCH IN THE OFF POSITION. IT'S VERY SCARY WHEN YOU'RE DRIVING DOWN A BACK COUNTRY ROAD WHERE THERE'S NO STREET LIGHTS AND YOUR HEADLIGHTS GO OUT. THE ONLY WAY I COULD GET LIGHT WAS TO HOLD BACK ON THE HIGH BEAM LEVER. THAT WAS WEIRD TOO BECAUSE THE HIGH BEAMS WOULDN'T WORK WHEN I PUT THE LEVER IN THE ON POSITION, ONLY WHEN I PULLED BACK ON THE LEVER WHICH PUTS THE HIGH BEAMS ON FOR AS LONG AS YOU HOLD THE LEVER. ONE NIGHT I DROVE FOR ABOUT 5 MILES AND THE HEADLIGHTS STAYED ON THE WHOLE TIME. THERE'S JUST NO KNOWING WHEN THEY'RE GOING TO WORK, AND IF THEY DO, HOW LONG THEY'LL STAY ON. I UNDERSTAND IT'S GOING TO BE VERY EXPENSIVE TO FIX THE PROBLEM, BUT I DON'T HAVE $800 SO HAVEN'T HAD IT REPAIRED YET. I JUST DON'T DRIVE AFTER DARK, WHICH IS VERY INCONVENIENT! *TR
NHTSA ODI #10340234
58,000 miles · Jun 25, 2010
Exterior Lighting
TL* THE CONTACT OWNS A 2003 MERCURY GRAND MARQUIS. THE CONTACT STATED THE HEADLIGHTS WOULD SHUT OFF WITHOUT WARNING. THE CONTACT STATED HE WAS ADVISED BY A CERTIFIED MECHANIC THAT THE LIGHT CONTROL MODULE WAS DEFECTIVE AND CAUSING THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 58,000 AND THE CURRENT MILEAGE…
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TL* THE CONTACT OWNS A 2003 MERCURY GRAND MARQUIS. THE CONTACT STATED THE HEADLIGHTS WOULD SHUT OFF WITHOUT WARNING. THE CONTACT STATED HE WAS ADVISED BY A CERTIFIED MECHANIC THAT THE LIGHT CONTROL MODULE WAS DEFECTIVE AND CAUSING THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 58,000 AND THE CURRENT MILEAGE WAS 58,500.
NHTSA ODI #10339963
45,000 miles · Jun 9, 2010
Exterior Lighting
TL* THE CONTACT OWNS A 2003 MERCURY GRAND MARQUIS. THE CONTACT STATED THAT WHILE DRIVING, THE HEADLIGHTS SUDDENLY TURNED OFF. THE LIGHTS ON THE INSTRUMENT PANEL STAYED LIT BUT THE HEADLIGHTS AND HIGH BEAMS TURNED OFF COMPLETELY. THE VEHICLE WAS TAKEN TO A REPAIR SHOP WHERE A MODULE LOCATED INSIDE A BLACK BOX NEAR THE ACCELERATO…
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TL* THE CONTACT OWNS A 2003 MERCURY GRAND MARQUIS. THE CONTACT STATED THAT WHILE DRIVING, THE HEADLIGHTS SUDDENLY TURNED OFF. THE LIGHTS ON THE INSTRUMENT PANEL STAYED LIT BUT THE HEADLIGHTS AND HIGH BEAMS TURNED OFF COMPLETELY. THE VEHICLE WAS TAKEN TO A REPAIR SHOP WHERE A MODULE LOCATED INSIDE A BLACK BOX NEAR THE ACCELERATOR PEDAL WAS REPLACED. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 45,000.
NHTSA ODI #10335422
54,834 miles · Jun 7, 2010
Exterior Lighting
I HAVE A 2003 GRAND MARQUIS GS, THE HEADLIGHTS STARTED TURNING OFF FOR NO PARTICULAR REASON. THIS IS EXTREMELY DANGEROUS; ONE TIME I HAD A CAR FULL OF CHILDREN AND THE LIGHTS WENT OUT ON A BACK ROAD, I ALMOST DROVE INTO A TREE. I HAD TO RIDE HOME WITH THE HIGHBEAMS ON. IT TURNS OUT THAT ITS AN EXPENSIVE PART AND A VERY COMMON CO…
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I HAVE A 2003 GRAND MARQUIS GS, THE HEADLIGHTS STARTED TURNING OFF FOR NO PARTICULAR REASON. THIS IS EXTREMELY DANGEROUS; ONE TIME I HAD A CAR FULL OF CHILDREN AND THE LIGHTS WENT OUT ON A BACK ROAD, I ALMOST DROVE INTO A TREE. I HAD TO RIDE HOME WITH THE HIGHBEAMS ON. IT TURNS OUT THAT ITS AN EXPENSIVE PART AND A VERY COMMON COMPLAINT FOR THIS MODEL; WHY IS THERE NOT A RECALL, WE COULD HAVE BEEN INJURED AND IF SO MANY COMPLAINTS ARE BEING FILED WHY IS NOTHING BEING DONE? *TR
NHTSA ODI #10335006
Mileage unknown · May 15, 2010
Exterior Lighting
I OWN A MERCURY GRAND MARQUIS 03 AT APPROX. 65,000 MILES I WAS DRIVING IN TAMPA AND THE LIGHTS WENT OUT. IT DIDN'T DO IT FOR A WHILE THEN THEY WENT OUT AGAIN AND NOW THEY GO OUT OFTEN. I TOOK CAR TO DEALERSHIP AT 72K HOWEVER WARRANTY WAS UP AND THEY WOULD CHARGE ME LIKE %800 FOR PARTS AND LABOR. THIS IS VERY DANGEROUS AFTER R…
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I OWN A MERCURY GRAND MARQUIS 03 AT APPROX. 65,000 MILES I WAS DRIVING IN TAMPA AND THE LIGHTS WENT OUT. IT DIDN'T DO IT FOR A WHILE THEN THEY WENT OUT AGAIN AND NOW THEY GO OUT OFTEN. I TOOK CAR TO DEALERSHIP AT 72K HOWEVER WARRANTY WAS UP AND THEY WOULD CHARGE ME LIKE %800 FOR PARTS AND LABOR. THIS IS VERY DANGEROUS AFTER READING IT APPEARS THAT IS A COMMON DEFECT IN THESE CARS. *TR
NHTSA ODI #10330527
83,400 miles · May 3, 2010
Exterior Lighting
2003 GRAND MARQUIS HEADLIGHT FAILURE. THE HEADLIGHTS ON THE CAR JUST GO OUT AT INOPPORTUNE TIMES. THIS IS A COMMON PROBLEM ON THIS MODEL. WHY HASN'T THERE BEEN A RECALL FOR THIS EXTREMELY DANGEROUS ISSUE. SEVENTY MILES AN HOUR AND LOSING THE HEADLIGHTS IS A SERIOUS PROBLEM. *TR
NHTSA ODI #10328627
NHTSA investigations
6PE15028 · Loss Of Headlights
Opened Aug 10, 2015 · Closed Jan 8, 2016
Status: closed (inferred from source dates) · Exterior Lighting; Exterior Lighting:headlights
The Office of Defects Investigation (ODI) opened an investigation concerning the loss of headlights in model year (MY) 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles. The subject vehicles share the same architecture and major components.ODI has received 636 unique reports (for all submission dates) related to the alleged defect, with owners describing a loss of both low and/or high beam headlights occurring while driving.ODI identified 4 Vehicle Owner Questionnaire ( VOQ) reports alleging minor crash or loss of control incidents due to headlight failures.Drivers alleged running off of the road due to a lack of headlights and one driver reportedly struck a deer.No injuries were indicated in the VOQ crashes.In response to ODI's Information Request (IR) letter, Ford Motor Company (Ford) responded with 4173 unique reports related to the alleged problem.There were a total of 11 crashes reported within that group as well as one injury that occurred when the vehicle struck an unseen object on the side of the road when the headlights failed. Ford also submitted 49,843 warranty claims related to headlight failures.Most reports indicate that the headlights failed without warning leaving the driver with no forward lighting, however some noted the headlights flickered or dimmed prior to turning off.Consumers also noted they were able to hold the flash to pass lever on the steering column mounted stalk to activate the high beams however this is only effective as long as the lever is physically actuated.On December 21st, 2015 Ford notified ODI that it would conduct a safety recall (15V-861) to remedy headlight failures on (MY) 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles.According to Ford, the headlights of the vehicle are controlled by the Lighting Control Module (LCM) located in the engine compartment of the vehicle.The LCM uses an internal relay, mounted to a circuit board, to control power to the headlights. The headlight relay is soldered to the circuit board at six different terminals. The original equipment LCMs were manufactured in a manner that resulted in the solder joints fatiguing and/or cracking as a result of repeated thermal cycling and/or vibration, a defect condition. The condition could be exacerbated by manufacturing quality issues such as an insufficient amount of solder, effecting the continuity between the circuit board and the relay terminal, and resulting in loss of headlights while driving.Other lighting functions are unaffected by this condition.The LCM manufacturing processes were revised to address the defect condition and Ford has been conducting a warranty extension program to cover defective LCMs since late 2013.Under the recall Ford will replace any remaining defective LCMs in recalled vehicles with remedy LCMs once they become available.See NHTSA recall 15V-861 for further details on the safety recall.The recall action initiated by Ford addresses the safety risks of concern to ODI.Accordingly, the investigation is closed.The ODI reports cited above can be reviewed at SaferCar.gov under the identification (ODI) numbers found in the attached list.
Additional source detail variants (2)
Exterior Lighting
The Office of Defects Investigation (ODI) opened an investigation concerning the loss of headlights in model year (MY) 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles. The subject vehicles share the same architecture and major components.ODI has received 636 unique reports (for all submission dates) related to the alleged defect, with owners describing a loss of both low and/or high beam headlights occurring while driving.ODI identified 4 Vehicle Owner Questionnaire ( VOQ) reports alleging minor crash or loss of control incidents due to headlight failures.Drivers alleged running off of the road due to a lack of headlights and one driver reportedly struck a deer.No injuries were indicated in the VOQ crashes.In response to ODI's Information Request (IR) letter, Ford Motor Company (Ford) responded with 4173 unique reports related to the alleged problem.There were a total of 11 crashes reported within that group as well as one injury that occurred when the vehicle struck an unseen object on the side of the road when the headlights failed. Ford also submitted 49,843 warranty claims related to headlight failures.Most reports indicate that the headlights failed without warning leaving the driver with no forward lighting, however some noted the headlights flickered or dimmed prior to turning off.Consumers also noted they were able to hold the flash to pass lever on the steering column mounted stalk to activate the high beams however this is only effective as long as the lever is physically actuated.On December 21st, 2015 Ford notified ODI that it would conduct a safety recall (15V-861) to remedy headlight failures on (MY) 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles.According to Ford, the headlights of the vehicle are controlled by the Lighting Control Module (LCM) located in the engine compartment of the vehicle.The LCM uses an internal relay, mounted to a circuit board, to control power to the headlights. The headlight relay is soldered to the circuit board at six different terminals. The original equipment LCMs were manufactured in a manner that resulted in the solder joints fatiguing and/or cracking as a result of repeated thermal cycling and/or vibration, a defect condition. The condition could be exacerbated by manufacturing quality issues such as an insufficient amount of solder, effecting the continuity between the circuit board and the relay terminal, and resulting in loss of headlights while driving.Other lighting functions are unaffected by this condition.The LCM manufacturing processes were revised to address the defect condition and Ford has been conducting a warranty extension program to cover defective LCMs since late 2013.Under the recall Ford will replace any remaining defective LCMs in recalled vehicles with remedy LCMs once they become available.See NHTSA recall 15V-861 for further details on the safety recall.The recall action initiated by Ford addresses the safety risks of concern to ODI.Accordingly, the investigation is closed.The ODI reports cited above can be reviewed at SaferCar.gov under the identification (ODI) numbers found in the attached list.
Exterior Lighting:headlights
The Office of Defects Investigation (ODI) opened an investigation concerning the loss of headlights in model year (MY) 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles. The subject vehicles share the same architecture and major components.ODI has received 636 unique reports (for all submission dates) related to the alleged defect, with owners describing a loss of both low and/or high beam headlights occurring while driving.ODI identified 4 Vehicle Owner Questionnaire ( VOQ) reports alleging minor crash or loss of control incidents due to headlight failures.Drivers alleged running off of the road due to a lack of headlights and one driver reportedly struck a deer.No injuries were indicated in the VOQ crashes.In response to ODI's Information Request (IR) letter, Ford Motor Company (Ford) responded with 4173 unique reports related to the alleged problem.There were a total of 11 crashes reported within that group as well as one injury that occurred when the vehicle struck an unseen object on the side of the road when the headlights failed. Ford also submitted 49,843 warranty claims related to headlight failures.Most reports indicate that the headlights failed without warning leaving the driver with no forward lighting, however some noted the headlights flickered or dimmed prior to turning off.Consumers also noted they were able to hold the flash to pass lever on the steering column mounted stalk to activate the high beams however this is only effective as long as the lever is physically actuated.On December 21st, 2015 Ford notified ODI that it would conduct a safety recall (15V-861) to remedy headlight failures on (MY) 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles.According to Ford, the headlights of the vehicle are controlled by the Lighting Control Module (LCM) located in the engine compartment of the vehicle.The LCM uses an internal relay, mounted to a circuit board, to control power to the headlights. The headlight relay is soldered to the circuit board at six different terminals. The original equipment LCMs were manufactured in a manner that resulted in the solder joints fatiguing and/or cracking as a result of repeated thermal cycling and/or vibration, a defect condition. The condition could be exacerbated by manufacturing quality issues such as an insufficient amount of solder, effecting the continuity between the circuit board and the relay terminal, and resulting in loss of headlights while driving.Other lighting functions are unaffected by this condition.The LCM manufacturing processes were revised to address the defect condition and Ford has been conducting a warranty extension program to cover defective LCMs since late 2013.Under the recall Ford will replace any remaining defective LCMs in recalled vehicles with remedy LCMs once they become available.See NHTSA recall 15V-861 for further details on the safety recall.The recall action initiated by Ford addresses the safety risks of concern to ODI.Accordingly, the investigation is closed.The ODI reports cited above can be reviewed at SaferCar.gov under the identification (ODI) numbers found in the attached list.
DP15002 · Loss Of Headlamp/exterior Lighting
Opened Apr 1, 2015 · Closed Aug 11, 2015
Status: closed (inferred from source dates) · Exterior Lighting; Exterior Lighting:headlights
In a letter dated October 2, 2014 the Office of Defects Investigation (ODI) was initially petitioned by the North Carolina Consumers Council, Inc. requesting a defect investigation of an alleged defect condition resulting in headlight and/or exterior lighting failure on 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles.ODI analyzed Vehicle Owner Questionnaire (VOQ) complaints received from consumers and identified a total of 605 reports (for all submission dates) alleging headlight failure.The complaints indicate failures of both low beam headlights typically while driving, a defect condition that was evaluated under a prior ODI investigation (PE08066).Most consumer VOQs indicate that the headlights failed suddenly and without warning leaving the driver with no forward lighting, however some report the headlights flickered or dimmed prior to turning off.In some cases drivers were able to turn the headlights back on after a period of time while others reported the headlights would not come back on at all.Consumers noted they were able to hold the flash to pass lever on the steering column mounted stalk to activate the high beams however this is only effective as long as the lever is actuated.ODI identified 4 VOQ reports alleging minor crash or loss of control incidents due to headlight failures.Drivers indicated running off of the road due to a lack of headlights and one driver reportedly struck a deer.No injuries were indicated in the VOQ crashes.In response to ODI's April 7, 2015 Information Request letter, Ford provided data indicating it has received 3,092 complaints of failed headlights related to the Lighting Control Module (LCM), a device that controls the headlights and other lighting functions.This number includes the complaints Ford reviewed and classified as headlight failure due specifically to the LCM.Within Ford's complaints, there are 11 reports alleging a crash occurred.These drivers reported hitting objects, including other vehicles after the headlights failed causing damage to the affected vehicles.One driver was injured when their car struck an unseen object in the road, jerking the steering wheel from their hands and injuring their shoulder.In total 15 crash allegations were identified, all of which have occurred since ODI's prior evaluation of this issue.This petition has been granted.Preliminary Evaluation PE15-028 has been opened to assess the scope, frequency, and safety-related consequences of the alleged defect.The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SarchNHTSAID under the identification (ODI) numbers found in the attached list.
Additional source detail variants (2)
Exterior Lighting
In a letter dated October 2, 2014 the Office of Defects Investigation (ODI) was initially petitioned by the North Carolina Consumers Council, Inc. requesting a defect investigation of an alleged defect condition resulting in headlight and/or exterior lighting failure on 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles.ODI analyzed Vehicle Owner Questionnaire (VOQ) complaints received from consumers and identified a total of 605 reports (for all submission dates) alleging headlight failure.The complaints indicate failures of both low beam headlights typically while driving, a defect condition that was evaluated under a prior ODI investigation (PE08066).Most consumer VOQs indicate that the headlights failed suddenly and without warning leaving the driver with no forward lighting, however some report the headlights flickered or dimmed prior to turning off.In some cases drivers were able to turn the headlights back on after a period of time while others reported the headlights would not come back on at all.Consumers noted they were able to hold the flash to pass lever on the steering column mounted stalk to activate the high beams however this is only effective as long as the lever is actuated.ODI identified 4 VOQ reports alleging minor crash or loss of control incidents due to headlight failures.Drivers indicated running off of the road due to a lack of headlights and one driver reportedly struck a deer.No injuries were indicated in the VOQ crashes.In response to ODI's April 7, 2015 Information Request letter, Ford provided data indicating it has received 3,092 complaints of failed headlights related to the Lighting Control Module (LCM), a device that controls the headlights and other lighting functions.This number includes the complaints Ford reviewed and classified as headlight failure due specifically to the LCM.Within Ford's complaints, there are 11 reports alleging a crash occurred.These drivers reported hitting objects, including other vehicles after the headlights failed causing damage to the affected vehicles.One driver was injured when their car struck an unseen object in the road, jerking the steering wheel from their hands and injuring their shoulder.In total 15 crash allegations were identified, all of which have occurred since ODI's prior evaluation of this issue.This petition has been granted.Preliminary Evaluation PE15-028 has been opened to assess the scope, frequency, and safety-related consequences of the alleged defect.The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SarchNHTSAID under the identification (ODI) numbers found in the attached list.
Exterior Lighting:headlights
In a letter dated October 2, 2014 the Office of Defects Investigation (ODI) was initially petitioned by the North Carolina Consumers Council, Inc. requesting a defect investigation of an alleged defect condition resulting in headlight and/or exterior lighting failure on 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles.ODI analyzed Vehicle Owner Questionnaire (VOQ) complaints received from consumers and identified a total of 605 reports (for all submission dates) alleging headlight failure.The complaints indicate failures of both low beam headlights typically while driving, a defect condition that was evaluated under a prior ODI investigation (PE08066).Most consumer VOQs indicate that the headlights failed suddenly and without warning leaving the driver with no forward lighting, however some report the headlights flickered or dimmed prior to turning off.In some cases drivers were able to turn the headlights back on after a period of time while others reported the headlights would not come back on at all.Consumers noted they were able to hold the flash to pass lever on the steering column mounted stalk to activate the high beams however this is only effective as long as the lever is actuated.ODI identified 4 VOQ reports alleging minor crash or loss of control incidents due to headlight failures.Drivers indicated running off of the road due to a lack of headlights and one driver reportedly struck a deer.No injuries were indicated in the VOQ crashes.In response to ODI's April 7, 2015 Information Request letter, Ford provided data indicating it has received 3,092 complaints of failed headlights related to the Lighting Control Module (LCM), a device that controls the headlights and other lighting functions.This number includes the complaints Ford reviewed and classified as headlight failure due specifically to the LCM.Within Ford's complaints, there are 11 reports alleging a crash occurred.These drivers reported hitting objects, including other vehicles after the headlights failed causing damage to the affected vehicles.One driver was injured when their car struck an unseen object in the road, jerking the steering wheel from their hands and injuring their shoulder.In total 15 crash allegations were identified, all of which have occurred since ODI's prior evaluation of this issue.This petition has been granted.Preliminary Evaluation PE15-028 has been opened to assess the scope, frequency, and safety-related consequences of the alleged defect.The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SarchNHTSAID under the identification (ODI) numbers found in the attached list.
PE08066 · Loss Of Headlight Function
Opened Nov 26, 2008 · Closed Mar 24, 2009
Status: closed (inferred from source dates) · Exterior Lighting:headlights
THE AGENCY HAS CLOSED THIS INVESTIGATION BASED ON ITS REVIEW OF COMPLAINT REPORTS, FIELD AND TECHNICAL DATA PROVIDED BY FORD AND COMPLAINANT INTERVIEWS. FORD FOUND THAT SOME LIGHTING CONTROL MODULES (LCM) IN THE SUBJECT VEHICLES CONTAINED DEFECTIVE SOLDER JOINTS ON THE PRINTED CIRCUIT BOARD.THIS CONDITION CAN LEAD TO POOR HEADLIGHT PERFORMANCE RANGING FROM INTERMITTENT OUTAGE AND DIMMING TO EVENTUAL HEADLIGHTS FAILURE.THE FAILURE DOES NOT AFFECT OTHER LIGHTING FUNCTIONS (PARK, EMERGENCY FLASHER, BRAKE AND FLASH TO PASS LIGHTS).THE AGENCY IS AWARE OF A TOTAL OF 306 CONSUMERS COMPLAINTS AND NO REPORT OF CRASH, INJURY OR FATALITY.FORD REPORTS 2,074 WARRANTY CLAIMS RELATED TO HEADLIGHT FAILURE LINKED TO THE LCM DURING THE FIRST THREE YEARS OF OPERATION.ABOUT 12% (247) OF THESE CLAIMS ARE SPECIFIC TO HEADLIGHT FAILURE WHILE DRIVING.THE AVERAGE WARRANTY RATE FOR HEADLIGHT FAILING WHILE DRIVING IS LOW (0.05%).FORD REPORTS A SLIGHTLY HIGHER WARRANTY RATE EXPERIENCED FOR THE CROWN VICTORIA POLICE INTERCEPTOR VEHICLES AND THIS IS ATTRIBUTED TO THE HIGHER DUTY CYCLE OF THESE VEHICLES (HEADLIGHTS ON FOR LONGER PERIODS).A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL MONITOR THIS ISSUE AND RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
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.
PE04010 · Rear Axle Fracture
Opened Jan 22, 2004 · Closed Jul 8, 2004
Status: closed (inferred from source dates) · Power Train:axle Assembly:axle Shaft
THIS PE WAS OPENED AFTER ODI BECAME AWARE OF TWO ALLEGATIONS CONCERNING REAR AXLE FRACTURE AND PARTIAL WHEEL SEPARATION INVOLVING MY 2003 FORD CROWN VICTORIA POLICE INTERCEPTORS (CVPI).INITIALLY, THE PE'S SCOPE INVOLVED ALL MY 2003 GRAND MARQUIS, CROWN VICTORIA, AND LINCOLN TOWN CARS (I.E., PANTHER PLATFORM) PRODUCED THROUGH JANUARY 2003.WHILE GATHERING INFORMATION ABOUT THIS ISSUE, IT BECAME EVIDENT THAT THE FAILURES WERE CONFINED TO LONG-WHEELBASE LINCOLN TOWN CARS AND THE CVPI'S DUE TO THEIR UNIQUE WEIGHT DISTRIBUTION AND USAGE PROFILES.FORD'S RECALL ADDRESSES THESE VEHICLES.BOTH THE COMPANY AND ODI ARE CONTINUING TO MONITOR THE FIELD PERFORMANCE OF THE AXLES AND WILL TAKE APPROPRIATE ACTION AS REQUIRED.
PE03009 · Fracture Of The Steel Wheel Rim
Opened Feb 25, 2003 · Closed Aug 8, 2003
Status: closed (inferred from source dates) · Wheels
THE SUBJECT WHEEL (NEW FOR MY 2003) IS USED ON CROWN VICTORIA (CV) AND GRAND MARQUIS.COMPLAINT DATA INDICATES THAT WHEEL FAILURE AFFECTS PRIMARILY THE COMMERCIAL SPECIFICATION CV MODEL (POLICE AND TAXI) WHICH HAS UNIQUE DESIGN CHARACTERISTICS AND IS GENERALLY SUBJECTED TO HIGHER USAGE DEMANDS.DURING FORD'S ANALYSIS, IT WAS DETERMINED THAT CYCLIC BENDING MOMENT FATIGUE COULD CAUSE RIM CRACKS TO OCCUR IN THE HEAT AFFECTED ZONE ADJACENT TO THE CIRCUMFERENTIAL WELD.FORD IMPLEMENTED CHANGES IN WHEEL MANUFACTURE IN SEPTEMBER 2002 AND INTRODUCED A NEW WHEEL DESIGN WITH A THICKER RIM IN APRIL 2003.ODI FOUND EVIDENCE THAT INDICATED RAPID CRACK PROPOGATION MIGHT HAVE OCCURRED IN SEVEN WHEEL FAILURE INCIDENTS, TWO OF WHICH LEAD TO TIRE DEBEADING.FORD HAS ANNOUNCED THAT 29,946 COMMERCIAL SPEC CV VEHICLES, MANUFACTURED PRIOR TO THE SEPTEMBER CHANGE, WILL BE RECALLED TO HAVE THE APRIL 2003 DESIGN WHEEL INSTALLED.ODI WILL CONTINUE TO MONITOR FOR WHEEL FAILURES IN THE SUBJECT VEHICLES NOT COVERED BY THE RECALL.