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2003 Mercury Grand Marquis

Owner reports · Recalls · Investigations

More warning signs than most Grand Marquis years

Owner complaints for the 2003 Mercury Grand Marquis are substantially higher than the model-year median of 78.

About this comparison →

When problems were reported

Mileage at the reported incident

289 reports with mileage · 73 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.

  • Exterior Lighting. Review the 207 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 51 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Steering. Review the 28 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

22 crash reports2 fire reports10 injury reports

What owners actually said

362 reports
124,900 miles · Dec 16, 2020
Exterior Lighting

TL* THE CONTACT OWNS A 2003 MERCURY GRAND MARQUIS. THE CONTACT STATED WHILE DRIVING AT VARIOUS SPEEDS, THE HEADLIGHTS BECAME INOPERABLE WITHOUT WARNING. THE VEHICLE WAS TAKEN TO GRIECO FORD OF FORT LAUDERDALE (1333 N FEDERAL HWY, FORT LAUDERDALE, FL 33304, (844) 648-2686) TO BE DIAGNOSED. THE CONTACT WAS INFORMED THAT THE LIGHTI…

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TL* THE CONTACT OWNS A 2003 MERCURY GRAND MARQUIS. THE CONTACT STATED WHILE DRIVING AT VARIOUS SPEEDS, THE HEADLIGHTS BECAME INOPERABLE WITHOUT WARNING. THE VEHICLE WAS TAKEN TO GRIECO FORD OF FORT LAUDERDALE (1333 N FEDERAL HWY, FORT LAUDERDALE, FL 33304, (844) 648-2686) TO BE DIAGNOSED. THE CONTACT WAS INFORMED THAT THE LIGHTING CONTROL MODULE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE VEHICLE WAS PREVIOUSLY REPAIRED UNDER NHTSA CAMPAIGN NUMBER: 15V861000 (EXTERIOR LIGHTING). THE MANUFACTURER WAS CONTACTED HOWEVER, NO FURTHER ASSISTANCE WAS PROVIDED. THE FAILURE MILEAGE WAS 124,900. *BF CONSUMER STATED VEHICLE WAS REPAIRED BUT HAPPENED AGAIN AFTER 3 YEARS.*JB

NHTSA ODI #11383671

101,000 miles · Aug 26, 2020
Exterior Lighting

THE VEHICLE SUDDENLY HAD NO BRAKE LIGHTS OR TAIL LIGHTS, THEN, IT HAD BRAKE LIGHTS AND TAIL LIGHTS, THEN, THE VEHICLE WOULD NOT START, DESPITE HAVING A NEW BATTERY. AFTER MUCH INVESTIGATION AND WORK, OUR CERTIFIED MECHANIC FEELS THAT THE LIGHTING MODULE IS SHORTING OUT, THUS, DRAINING THE BATTERY. THE VEHICLE WAS STATIONARY, IN …

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THE VEHICLE SUDDENLY HAD NO BRAKE LIGHTS OR TAIL LIGHTS, THEN, IT HAD BRAKE LIGHTS AND TAIL LIGHTS, THEN, THE VEHICLE WOULD NOT START, DESPITE HAVING A NEW BATTERY. AFTER MUCH INVESTIGATION AND WORK, OUR CERTIFIED MECHANIC FEELS THAT THE LIGHTING MODULE IS SHORTING OUT, THUS, DRAINING THE BATTERY. THE VEHICLE WAS STATIONARY, IN MOTION ON A CITY STREET AND ON A HIGHWAY, TURNING, ESSENTIALLY ALL ASPECTS OF USAGE, WHEN THESE ISSUES OCCURRED.

NHTSA ODI #11351425

200,000 miles · Jun 10, 2020
Electrical SystemSeat BeltsSuspension

1.REAR SEATBELTS OFTEN JAM AND HAVE TO BE UNLOCKED BY A PROFESSIONAL. 2. BLEND DOOR SWITCH THAT CONTROLS HEAT AND AIR CONDITIONING GETS STUCK ON HEAT AND BLOWS EXTREMELY HOT AIR YEAR ROUND EVEN IF THE UNIT IS TURNED OFF. VEHICLE IS IN MOTION ON HIGHWAYS AND CITY STREETS. 3. VEHICLE SQUEAKS WHILE IN MOTION DUE TO FAULTY BALL …

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1.REAR SEATBELTS OFTEN JAM AND HAVE TO BE UNLOCKED BY A PROFESSIONAL. 2. BLEND DOOR SWITCH THAT CONTROLS HEAT AND AIR CONDITIONING GETS STUCK ON HEAT AND BLOWS EXTREMELY HOT AIR YEAR ROUND EVEN IF THE UNIT IS TURNED OFF. VEHICLE IS IN MOTION ON HIGHWAYS AND CITY STREETS. 3. VEHICLE SQUEAKS WHILE IN MOTION DUE TO FAULTY BALL BEARINGS. *TR

NHTSA ODI #11328203

173,000 miles · Jan 27, 2020
Exterior Lighting

TL* THE CONTACT OWNS A 2003 MERCURY GRAND MARQUIS. THE CONTACT STATED THAT THE FRONT HEAD LIGHT ASSEMBLY HAD MALFUNCTIONED AND THE FRONT PASSENGER SIDE AND DRIVER SIDE HEAD LIGHTS WERE INOPERABLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE HEAD LIGHT ASSEMBLY NEEDED TO THE BE REPLACED. THE VEHICLE WA…

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TL* THE CONTACT OWNS A 2003 MERCURY GRAND MARQUIS. THE CONTACT STATED THAT THE FRONT HEAD LIGHT ASSEMBLY HAD MALFUNCTIONED AND THE FRONT PASSENGER SIDE AND DRIVER SIDE HEAD LIGHTS WERE INOPERABLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE HEAD LIGHT ASSEMBLY NEEDED TO THE BE REPLACED. THE VEHICLE WAS NOT YET REPAIRED. THE MANUFACTURER AND LOCAL DEALER PUNDMANN FORD (2727 W. CLAY ST. ST. CHARLES, MO.) WERE NOTIFIED BUT NO ASSISTANCE WAS OFFERED. THE FAILURE MILEAGE WAS 173,000.

NHTSA ODI #11302180

130,212 miles · Dec 27, 2019
Exterior Lighting

TL* THE CONTACT OWNS A 2003 MERCURY GRAND MARQUIS. WHILE OPERATING THE VEHICLE WITH THE EXTERIOR LIGHTING SWITCH IN AUTO MODE, BOTH THE FRONT AND REAR EXTERIOR LIGHTING WOULD NOT ILLUMINATE. WHILE IN MANUAL MODE, THE TAIL LIGHTS WOULD NOT ILLUMINATE. THE VEHICLE WAS TAKEN TO TOM HOLZER FORD (39300 W. 10 MILE RD, FARMINGTON HILLS…

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TL* THE CONTACT OWNS A 2003 MERCURY GRAND MARQUIS. WHILE OPERATING THE VEHICLE WITH THE EXTERIOR LIGHTING SWITCH IN AUTO MODE, BOTH THE FRONT AND REAR EXTERIOR LIGHTING WOULD NOT ILLUMINATE. WHILE IN MANUAL MODE, THE TAIL LIGHTS WOULD NOT ILLUMINATE. THE VEHICLE WAS TAKEN TO TOM HOLZER FORD (39300 W. 10 MILE RD, FARMINGTON HILLS, MI) WHERE IT WAS DIAGNOSED THAT THE LIGHTING CONTROL MODULE WAS FAULTY AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURES AND DID NOT ASSIST. THE CONTACT INDICATED THAT THE VEHICLE WAS PREVIOUSLY REPAIRED PER NHTSA CAMPAIGN NUMBER: 15V861000 (EXTERIOR LIGHTING); HOWEVER, THE FAILURE RECURRED. THE FAILURE MILEAGE WAS 130,212.

NHTSA ODI #11291473

113,000 miles · Oct 24, 2019
Steering

FORD PANTHER VEHICLES HAD RECIRCULATING BALL STEERING UNTIL 2002, REDESIGNED TO RACK AND PINION STEERING IN 2003. FORD ISSUED RECALL 13S08 FOR SEVERE CORROSION THAT CAN SEIZE THE LOWER INTERMEDIATE STEERING SHAFT WHICH MAY CAUSE THE UPPER INTERMEDIATE SHAFT TO COLLAPSE AND THE STEERING COLUMN LOWER BEARING TO SEPARATE, COVERING…

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FORD PANTHER VEHICLES HAD RECIRCULATING BALL STEERING UNTIL 2002, REDESIGNED TO RACK AND PINION STEERING IN 2003. FORD ISSUED RECALL 13S08 FOR SEVERE CORROSION THAT CAN SEIZE THE LOWER INTERMEDIATE STEERING SHAFT WHICH MAY CAUSE THE UPPER INTERMEDIATE SHAFT TO COLLAPSE AND THE STEERING COLUMN LOWER BEARING TO SEPARATE, COVERING 2005-2012 VEHICLES BUT NOT 2003 AND 2004 VEHICLES HAVING SAME PARTS AND SYMPTOMS. STEERING HAS BECOME EXTREMELY STIFF, STEERING WHEEL NOT RETURNING TO STRAIGHT AHEAD ON ITS OWN, AND DIFFICULT TO STEER AT ALL SPEEDS. FORD DEALER LUBRICATED LOWER STEERING SHAFT 2 MONTHS AGO, BUT SYMPTOMS RETURNED IN 2,000 MILES. THESE SYMPTOMS ARE CONCERN FOR REAL DANGER OF COMPLETE LOSS OF STEERING.

NHTSA ODI #11270699

110,000 miles · Aug 15, 2019
Steering

LOSS OF POWER STEERING. DIFFICULT TO STEER. CORROSION RELATED DEFECT IN THE LOWER INTERMEDIATE SHAFT.

NHTSA ODI #11244174

Mileage unknown · May 23, 2019
Exterior Lighting

TL* THE CONTACT OWNS A 2003 MERCURY GRAND MARQUIS. THE CONTACT STATED THAT THE MANUFACTURER FAILED TO PROVIDE THE PART WITHIN A REASONABLE TIME FRAME CONCERNING NHTSA CAMPAIGN NUMBER: 15V861000 (EXTERIOR LIGHTING). WILMES CHEVROLET BUICK GMC (2215 E BROADWAY ST, ALTUS, OK 73521, 580-301-7169) AND THE MANUFACTURER WERE CONTACTED …

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TL* THE CONTACT OWNS A 2003 MERCURY GRAND MARQUIS. THE CONTACT STATED THAT THE MANUFACTURER FAILED TO PROVIDE THE PART WITHIN A REASONABLE TIME FRAME CONCERNING NHTSA CAMPAIGN NUMBER: 15V861000 (EXTERIOR LIGHTING). WILMES CHEVROLET BUICK GMC (2215 E BROADWAY ST, ALTUS, OK 73521, 580-301-7169) AND THE MANUFACTURER WERE CONTACTED AND CONFIRMED THAT THE PART WAS NOT AVAILABLE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. VIN TOOL CONFIRMS PARTS NOT AVAILABLE.

NHTSA ODI #11209524

92,500 miles · Apr 18, 2019
Fuel/propulsion System

TL* THE CONTACT OWNS A 2003 MERCURY GRAND MARQUIS. WHILE DRIVING AT ANY SPEED, FUEL SPILLED ALL OVER THE ENGINE WITHOUT WARNING. THERE WAS NO SMOKE PRESENT. THE FAILURE RECURRED SEVERAL TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO PLACED O-RINGS IN THE FUEL INJECTORS, BUT THE FAILURE RECURRED. THE VEHICLE WAS TAKE…

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TL* THE CONTACT OWNS A 2003 MERCURY GRAND MARQUIS. WHILE DRIVING AT ANY SPEED, FUEL SPILLED ALL OVER THE ENGINE WITHOUT WARNING. THERE WAS NO SMOKE PRESENT. THE FAILURE RECURRED SEVERAL TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO PLACED O-RINGS IN THE FUEL INJECTORS, BUT THE FAILURE RECURRED. THE VEHICLE WAS TAKEN TO HILBISH FORD (704-938-3121, LOCATED AT 2600 S CANNON BLVD, KANNAPOLIS, NC 28083) WHERE THE O-RINGS AND THE FUEL INJECTORS WERE REPLACED, BUT THE FAILURE RECURRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 92,500.

NHTSA ODI #11197120

50,000 miles · Mar 26, 2019
Steering

WHEN DRIVING THE CAR AND MAKING A TURN IN EITHER DIRECTION, AT THE POINT THE STEERING WHEEL HAS TURNED 180 DEGREES AND IS NOW UPSIDE DOWN FROM "NORMAL POSITION", IT FEELS AS THOUGH THE STEERING WHEEL IS GOING TO COME OFF!!! IT ROCKS BACK AND FORTH IN THE UPSIDE DOWN POSITION. ALSO.... AT TIMES IT FEELS HARD TO TURN THE WHEEL IN…

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WHEN DRIVING THE CAR AND MAKING A TURN IN EITHER DIRECTION, AT THE POINT THE STEERING WHEEL HAS TURNED 180 DEGREES AND IS NOW UPSIDE DOWN FROM "NORMAL POSITION", IT FEELS AS THOUGH THE STEERING WHEEL IS GOING TO COME OFF!!! IT ROCKS BACK AND FORTH IN THE UPSIDE DOWN POSITION. ALSO.... AT TIMES IT FEELS HARD TO TURN THE WHEEL IN EITHER DIRECTION. THIS PROBLEM APPARENTLY COMES FROM THE UPPER AND LOWER STEERING SHAFTS WHERE THE U-JOINT CONNECTS THE TWO STEERING SHAFTS. IF I SLATHER GREASE ON THE SHAFTS AND WORK THE STEERING WHEEL BACK AND FORTH ABOUT 30 TIMES, THE "TOUGH STEERING" OR THE FEELING OF NO POWER STEERING SUBSIDES, BUT COMES BACK IN ANYWHERE FROM 1 WEEK TO A MONTH! I CAN BE DRIVING ON THE INTERSTATE AND ALL AT ONCE I CAN NOT CHANGE LANES, WHICH IS VERY SCARY AT TIMES!!! WHEN THIS HAPPENS AT 65 MPH IT IS ALMOST TIMPOSSIBLE TO STEER THE CAR!!! IT IS ALSO VERY DANGEROUS MAKING A TURN AT 10-20 MPH AS ON NUMEROUS OCCASIONS, THE POWER STEERING QUITS WORKING AND I ALMOST RAM THE CAR SITTING AT THE STOP LIGHT BECAUSE THE CAR WON'T MAKE THE COMPLETE TURN!!! MANY TIMES, I HAVE HAD TO STOP DEAD TO KEEP FROM HITTING THE CAR AS I AM TRYING TO TURN RIGHT, AND THEN WITH ALL MY STRENGTH, CRANK AND MUSCLE THE STEERING WHEEL TO COMPLETE MY RIGHT TURN! ( AND I AM A 6', 245 LB. MAN IN PRETTY GOOD SHAPE!!!) I HAD HEARD FROM OTHER GRAND MARQUIS OWNERS THAT THERE WAS A RECALL ON EARLIER MODELS OF THE GRAND MARQUIS (2000-2002 MODELS) FOR THE SAME PROBLEM, BUT FOR SOME REASON, THE 2003 GRAND MARQUIS LS MODEL WAS EXCLUDED FROM THIS RECALL!!!. BOTH PROBLEMS THAT I HAVE LISTED APPARENTLY ORIGINATE FROM THE UPPER AND LOWER STEERING SHAFTS AND ARE COMPLETELY UNSAFE!!! THERE IS NO WARNING AS TO WHEN THE STEERING PROBLEM PRESENTS ITSELF. IN THE WINTER, HERE IN ILLINOIS, THE PROBLEM COMPOUNDS IMMENSELY!!!! THIS PROBLEM NEED TO BE ADDRESSED BEFORE SOMEONE IS KILLED!!! THANK YOU!

NHTSA ODI #11191754

Official recalls

1

15V861000 · Exterior Lighting:headlights

Dec 22, 2015

Ford Motor Company (Ford) is recalling certain model year 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles manufactured October 3, 2001, to August 2, 2005. The affected vehicles have a lighting control module (LCM) that may fail, resulting in a loss of headlights.

Consequence & remedy

Consequence: A loss of headlights can reduce driver visibility and increase the risk of a crash.

Remedy: Ford will notify owners, and dealers will replace the LCM, free of charge. The recall began April 14, 2017. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S39.

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

6

PE15028 · 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.