NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
487 reports72,251 miles · Jun 5, 2011
Electrical SystemExterior Lighting
MY WIFE AND I WERE PULLING INTO A FOUR LANE HIGHWAY AT 9:30 PM IN THE EVENING, AFTER FINISHING DINNER. ONCE WE HAD APPROACHED HIGHWAY SPEED OF ABOUT 45 TO 50 MPH, OUR FRONT HEAD LIGHTS WENT OUT. IMMEDIATELY MY WIFE PULLED OFF THE HIGHWAY WITH OUR LIGHTS OUT, I GOT OUT OF THE AUTO TO INSURE THE LIGHTS HAD INDEED GONE OUT...YES, …
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MY WIFE AND I WERE PULLING INTO A FOUR LANE HIGHWAY AT 9:30 PM IN THE EVENING, AFTER FINISHING DINNER. ONCE WE HAD APPROACHED HIGHWAY SPEED OF ABOUT 45 TO 50 MPH, OUR FRONT HEAD LIGHTS WENT OUT. IMMEDIATELY MY WIFE PULLED OFF THE HIGHWAY WITH OUR LIGHTS OUT, I GOT OUT OF THE AUTO TO INSURE THE LIGHTS HAD INDEED GONE OUT...YES, THEY WERE OUT BLACK AS MIDNIGHT. I ASKED MY WIFE TO SEE IF THEY WOULD COME BACK JUST FOR THE HECK OF TRYING SOMETHING. YES THE LIGHTS DID COME BACK ON AND REMAINED ON FOR THE REMAINDER OF OUR 25 MINUTE DRIVE. AS MY WIFE AND I WERE DRIVING HOME, SHE INDICATED TO ME THIS WAS NOT THE FIRST TIME, ONLY ONE OF SEVERAL TIMES AS SHE WAS DRIVING, IT MIGHT BE IN THE RAIN DAY OR NIGHT, SHE NEVER KNEW WHEN IT WOULD HAPPEN, HOWEVER AT THIS TIME, THE LIGHTS SEEM TO GO OUT ON A REGULAR BASIC. I'M GOING TO SEE IF THE DEALER CAN REPAIR, WHAT I HAVE BEEN LEAD TO BELIEVE IS THE LCM, AND TO EXPECT A CHARGE UP TO $800.00+, THIS IS A HORRIBLE ACCIDENT WAITING TO OCCUR, AND A EXPENSE THAT I THINK MERC. SHOW ABSORB, WITH ALL OF THE PROBLEMS WITH THE SAME PROBLEM FOR SEVERAL YEARS NOW, I WOULD HOPE A NATION WIDE RECALL SHOULD TAKE PLACE, BEFORE THE IS LOSS OF LIFE. I THANK YOU FOR YOUR TIME, AND I DO APPRECIATE ANY HELP YOU MAY BE ABLE TO OFFER. KIND REGARDS, OWNER OF THE ABOVE AUTO, 2005 MERC. GRAND MARQ. LIGHT CONTROL MODULE, PROBLEM. *TR
NHTSA ODI #10405274
44,300 miles · Jun 3, 2011
Electrical System
WHILE DRIVING THE HEADLIGHTS WENT COMPLETELY OUT. THE HIGH BEAMS WOULD ONLY COME ON IF YOU PULLED THE LEVER FORWARD AND THIS WAS ONLY MOMENTARILY. WAS NOT ABLE TO USE THE SWITCH TO TURN THEM BACK ON. HAD TO PULL OVER IN A PARKING LOT BECAUSE IT WAS DARK. AFTER A FEW MINUTES THE LIGHTS STARTED TO WORK AGAIN BUT SOON FAILED AGAIN.
NHTSA ODI #10405106
99,983 miles · Jun 2, 2011
Exterior Lighting
LIGHTING CONTROL MODULE FAILED. FORTUNATELY, I WAS NOT DRIVING IN TRAFFIC OR ON THE FREEWAY AS MANY OF THE COMPLAINTS I FOUND ON THE INTERNET. THIS IS A SERIOUS DEFECT AND A RECALL SHOULD BE ISSUED AS THIS ISSUE OCCURS NORMALLY BETWEEN 50,000 AND 100,000 MILES. THE PROBLEM IS SO LARGE THAT JUNK YARD OPERATORS TOLD ME THAT ALL…
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LIGHTING CONTROL MODULE FAILED. FORTUNATELY, I WAS NOT DRIVING IN TRAFFIC OR ON THE FREEWAY AS MANY OF THE COMPLAINTS I FOUND ON THE INTERNET. THIS IS A SERIOUS DEFECT AND A RECALL SHOULD BE ISSUED AS THIS ISSUE OCCURS NORMALLY BETWEEN 50,000 AND 100,000 MILES. THE PROBLEM IS SO LARGE THAT JUNK YARD OPERATORS TOLD ME THAT ALL THE WRECKED 2005 MODELS HAVE BEEN STRIPPED OF THIS ITEM. THIS IS THE FIRST COMPLAINT I HAVE EVER REGISTERED BECAUSE IT IS SUCH A SERIOUS SAFETY ISSUE AND MUST BE ADDRESSED BEFORE TRAFFIC DEATHS OCCUR OR HAVE OCCURRED. THANK YOU FOR YOUR PROMPT ASSISTANCE IN THE CRUCIAL MATTER. P.S. A FORD DEALER TOLD ME THEY SELL MANY OF THESE ITEMS AND ARE AWARE OF THE PROBLEM. *TR
NHTSA ODI #10404976
75,000 miles · May 17, 2011
Power Train
I DID OWNED A 2005 FREESTAR VAN UNTIL I TRADED IT OFF, WHILE DRIVING THE MOTOR JUST QUIT RUNNING AFTER GETTING THE VAN RESTARTED WITH NO TROUBLE THE TRANNY WOULD NOT GO FORWARD OR IN REVERSE. THE TRANNY LIGHT CAME ON SO I HAD TO HAVE THE TRANNY REBUILT AT MY COST PLUS THE TOLL BILL. FORD SHOULD TAKE OF THIS PROBLEM BEFORE SOME…
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I DID OWNED A 2005 FREESTAR VAN UNTIL I TRADED IT OFF, WHILE DRIVING THE MOTOR JUST QUIT RUNNING AFTER GETTING THE VAN RESTARTED WITH NO TROUBLE THE TRANNY WOULD NOT GO FORWARD OR IN REVERSE. THE TRANNY LIGHT CAME ON SO I HAD TO HAVE THE TRANNY REBUILT AT MY COST PLUS THE TOLL BILL. FORD SHOULD TAKE OF THIS PROBLEM BEFORE SOMEONE GETS A FATAL ACCIDENT AND REIMBURSE OUT OF POCKET MONEY TO ALL THAT FILE A COMPLAINT. *TR
NHTSA ODI #10401294
50,000 miles · May 5, 2011
Exterior Lighting
TL* THE CONTACT OWNS A 2005 MERCURY GRAND MARQUIS. WHILE DRIVING AN UNKNOWN SPEED, THE HEADLIGHTS FAILED. THE VEHICLE WAS PARKED AND AFTER COOLING OFF, THE HEADLIGHTS BEGAN OPERATING AS NORMAL. THE FAILURE RECURRED WHENEVER THE VEHICLE WAS OPERATED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS TOLD THAT T…
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TL* THE CONTACT OWNS A 2005 MERCURY GRAND MARQUIS. WHILE DRIVING AN UNKNOWN SPEED, THE HEADLIGHTS FAILED. THE VEHICLE WAS PARKED AND AFTER COOLING OFF, THE HEADLIGHTS BEGAN OPERATING AS NORMAL. THE FAILURE RECURRED WHENEVER THE VEHICLE WAS OPERATED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS TOLD THAT THE LIGHTING CONTROL MODULE FAILED. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 50,000 AND THE CURRENT MILEAGE WAS 53,000. UPDATED 06/14/11
NHTSA ODI #10399222
60,000 miles · Apr 7, 2011
Electrical System
I HAVE A 2005 MERCURY GRAND MARQUIS. I WAS DRIVING AND SUDDENLY MY HEADLIGHTS WENT OUT WITHOUT WARNING. THIS IS A VERY SCARING SITUATION AT NIGHT. I HAVE BEEN LOOKING ONLINE TO SEE IF THERE HAS BEEN A RECALL, AND ALSO I TOOK IT TO THE FORD DEALER WHERE I PURCHASED THE VEHICLE AND THEY TOLD ME IT WAS A ELECTRICAL MODULE AND THE C…
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I HAVE A 2005 MERCURY GRAND MARQUIS. I WAS DRIVING AND SUDDENLY MY HEADLIGHTS WENT OUT WITHOUT WARNING. THIS IS A VERY SCARING SITUATION AT NIGHT. I HAVE BEEN LOOKING ONLINE TO SEE IF THERE HAS BEEN A RECALL, AND ALSO I TOOK IT TO THE FORD DEALER WHERE I PURCHASED THE VEHICLE AND THEY TOLD ME IT WAS A ELECTRICAL MODULE AND THE COST IS ENORMOUS. I DON'T THINK THAT ME THE CONSUMER SHOULD HAVE TO BEAR THE COST OF A DEFECT THAT IS SUCH A SAFETY HAZARD. WHY HAVEN'T THIS MATTER BEEN RECALLED? SOMEONE COULD LOSE THEIR LIFE, TRAVELING DOWN A DARK TWO LANE HIGHWAY AND SUDDENLY YOU HAVE NO LIGHTS. THIS IS VERY FRIGHTENING. AND WHAT'S MORE FRIGHTENING IS THAT NOTHING IS BEING DONE ABOUT. BUT I WILL NOT STOP UNTIL I SEE SOMETHING DONE.[XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #10395206
52,000 miles · Apr 5, 2011
Exterior Lighting
TL* THE CONTACT OWNS A 2005 MERCURY GRAND MARQUIS. WHILE DRIVING APPROXIMATELY 55-60 MPH, THE LOW BEAM HEADLIGHTS FAILED AND THE CONTACT HAD TO UTILIZE THE HIGH BEAM HEADLIGHTS. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS ADVISED THAT THE LOW BEAM MODULAR FAILED AND WOULD NEED TO BE REPLACED. THE VEHICLE …
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TL* THE CONTACT OWNS A 2005 MERCURY GRAND MARQUIS. WHILE DRIVING APPROXIMATELY 55-60 MPH, THE LOW BEAM HEADLIGHTS FAILED AND THE CONTACT HAD TO UTILIZE THE HIGH BEAM HEADLIGHTS. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS ADVISED THAT THE LOW BEAM MODULAR FAILED AND WOULD NEED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 52,000 AND THE CURRENT MILEAGE WAS 52,500.
NHTSA ODI #10394315
78,000 miles · Mar 20, 2011
Exterior Lighting
I OWN A 2005 MERCURY GRAND MARQUIS, WHILE DRIVING, THE HEADLIGHTS WILL GO OUT WITHOUT WARNING. ALL OTHER OUTSIDE LIGHTS STAY ON AND PASSING LIGHTS WORK. I HAVE RESEARCHED THIS AND FOUND ALL SOURCES SAY IT IS A FAILED LCM, LIGHT CONTROL MODULE. I HAVE NOT FOUND A SAFETY RECALL FOR THIS PROBLEM, BUT HAVE FOUND SEVERAL COMPLAINTS. …
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I OWN A 2005 MERCURY GRAND MARQUIS, WHILE DRIVING, THE HEADLIGHTS WILL GO OUT WITHOUT WARNING. ALL OTHER OUTSIDE LIGHTS STAY ON AND PASSING LIGHTS WORK. I HAVE RESEARCHED THIS AND FOUND ALL SOURCES SAY IT IS A FAILED LCM, LIGHT CONTROL MODULE. I HAVE NOT FOUND A SAFETY RECALL FOR THIS PROBLEM, BUT HAVE FOUND SEVERAL COMPLAINTS. OF ALL THE COMPLAINTS ON THIS PARTICULAR VEHICLE, FAILED HEADLIGHTS IS NUMBER ONE. THIS SHOULD BE A SAFETY RECALL. OWNERS SHOULD NOT BE REQUIRED TO PAY TO HAVE A SAFETY ISSUE LIKE THIS REPAIRED. I HAVE CONTACTED FORD AND MERCURY DEALERS CONCERNING THIS, AND HAVE BEEN TOLD THERE ARE NO RECALLS ON THIS VEHICLE. THIS PROBLEM KEEPS HAPPENING MORE OFTEN AND MAKES IT NEARLY IMPOSSIBLE TO DRIVE THE CAR AT NIGHT. YOU CAN USE THE PASSING LIGHTS, BUT THAT IS VERY DANGEROUS, BECAUSE IT BLINDS OTHER DRIVERS. *TR
NHTSA ODI #10392247
75,000 miles · Mar 11, 2011
Exterior Lighting
TL*THE CONTACT OWNS A 2005 MERCURY GRAND MARQUIS LS. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS THE HEADLIGHTS WOULD SUDDENLY SHUT OFF AND ON AN INTERMITTENTLY. IN ORDER TO KEEP THE LIGHTS ON HE HAD TO HOLD CONTINUE HOLDING THE HIGH BEAM SWITCH, UNTIL HE DROVE ONTO THE EMERGENCY LANE AND RESTARTED THE VEHICLE. THE V…
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TL*THE CONTACT OWNS A 2005 MERCURY GRAND MARQUIS LS. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS THE HEADLIGHTS WOULD SUDDENLY SHUT OFF AND ON AN INTERMITTENTLY. IN ORDER TO KEEP THE LIGHTS ON HE HAD TO HOLD CONTINUE HOLDING THE HIGH BEAM SWITCH, UNTIL HE DROVE ONTO THE EMERGENCY LANE AND RESTARTED THE VEHICLE. THE VEHICLE WAS INSPECTED BY AN INDEPENDENT MECHANIC WHO ADVISED HIM THAT THE FAILURE MAY BE CAUSED BY THE LIGHT CONTROL MODULE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED AND ADVISED HIM THAT THEY WOULD CONFIRM WHETHER OR NOT THERE WERE ANY BULLETINS REGARDING THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 75,000. UPDATED 04/15/11*LJ THE CONSUMERS HAS SINCE SOLD THE VEHICLE. UPDATED 05/02/11
NHTSA ODI #10389838
52,087 miles · Mar 3, 2011
Exterior Lighting
WHILE TRAVELING IN HEAVY TRAFFIC AT NIGHT WITH MY 2005 MERCURY GRAND MARQUIS SUDDENLY AND WITHOUT WARNING MY HEADLIGHTS TURN OFF AND I WAS SCARRED TO DEATH,I"M A 65 YEAR OLD LADY AND I HAVE NEVER BEEN SO SCARED!I PULLED TO THE SIDE OF THE ROAD AND AFTER 5 MINS THEY COME BACK ON I MAKE IT HOME BUT IN A 15 MILE TIME THEY TURNED OF…
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WHILE TRAVELING IN HEAVY TRAFFIC AT NIGHT WITH MY 2005 MERCURY GRAND MARQUIS SUDDENLY AND WITHOUT WARNING MY HEADLIGHTS TURN OFF AND I WAS SCARRED TO DEATH,I"M A 65 YEAR OLD LADY AND I HAVE NEVER BEEN SO SCARED!I PULLED TO THE SIDE OF THE ROAD AND AFTER 5 MINS THEY COME BACK ON I MAKE IT HOME BUT IN A 15 MILE TIME THEY TURNED OFF EVERY COUPLE OF MINUTES. *TR
NHTSA ODI #10386379
Official recalls
4Dec 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.
Nov 5, 2014
Ford Motor Company (Ford) is recalling certain model year 2005-2011 Ford Crown Victoria, 2005-2011 Mercury Grand Marquis vehicles manufactured March 23, 2004, to August 30, 2011, and 2005-2011 Lincoln Town Car vehicles manufactured March 8, 2004, to August 30, 2011, and on which the upper intermediate shaft was serviced during the course of safety recall 13V-385. The prior repairs may not have been correctly performed.
Consequence & remedy
Consequence: Improper servicing of the upper intermediate shaft could cause the shaft to separate, which can then result in a loss of steering control, and increasing the risk of a crash.
Remedy: Ford will notify the owners of vehicles whose repair records reflect that the upper intermediate steering shaft was repaired during the course of the prior recall 13V-385. Dealers will inspect and replace the upper immediate shaft if necessary free of charge. The recall began November 17, 2014. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 14S25.
Aug 29, 2013
Ford is recalling certain model year 2005-2011 Ford Crown Victoria (including Crown Victoria Police Interceptors), Mercury Grand Marquis, and Lincoln Town Car vehicles. The affected vehicles are currently registered or were originally sold in Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, and Wisconsin. Severe corrosion can seize the lower intermediate shaft which may cause the upper intermediate shaft to collapse and the steering column lower bearing to separate.
Consequence & remedy
Consequence: If the lower bearing separates, the vehicle may experience a loss of steering, increasing the risk of a crash.
Remedy: Ford will notify owners and dealers will replace the lower intermediate shaft, free of charge. The upper intermediate shaft and steering column lower bearing will be inspected to identify any damage that may have occurred as a result of lower intermediate shaft corrosion, and repaired or replaced as necessary. If the steering column lower bearing has separated, a retainer clip will be installed. The recall began on October 23, 2013. Owners may contact Ford at 1-866-436-7332. Ford's recall number is 13S08.
Nov 9, 2005
ON CERTAIN PASSENGER VEHICLES, THE BATTERY CABLE INCLUDES A FUSIBLE LINK THAT MAY CONTACT AND SUBSEQUENTLY CHAFE ON A #2 CROSS MEMBER ATTACHING BOLT.
Consequence & remedy
Consequence: THIS CONDITION MAY RESULT IN HEAT DAMAGE AND COULD LEAD TO A FIRE.
Remedy: DEALERS WILL INSPECT THE FUSIBLE LINK AND POSITION IT AWAY FROM THE CROSS MEMBER BOLT. IF THE FUSIBLE LINK HAS ALREADY CHAFED AND COPPER WIRES HAVE BEEN EXPOSED, THE FUSIBLE LINK WILL BE REPLACED. THE RECALL BEGAN ON NOVEMBER 18, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673, OR LINCOLN/MERCURY AT 1-800-521-4140.
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
4PE15028 · 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.
PE14021 · Steering Column Shaft Obstruction
Opened Jul 7, 2014 · Closed Nov 21, 2014
Status: closed (inferred from source dates) · Engine And Engine Cooling:exhaust System; Steering
On July 7, 2014 the Office of Defects Investigation (ODI) opened a preliminary evaluation based on five complaints (VOQs) alleging incidents ofinterference between dislodged exhaust manifold heat shields and the lower steering shaft/knuckle, including one alleging the interference resulted in a crash on a highway entrance ramp. Since opening this investigation, ODI has received four additional owner complaints.One indicated that the shield was removed before binding could occur.The other three occurred at low speed and produced some momentary steering binding that was overcome by the driver when additional steering effort was applied.Once the shield was repaired or removed, the steering returned to normal.The single incident ODI identified as a possible crash (VOQ No. 10578715) related to this condition could not be verified and the description of the crash in the complaint was not supported by the police accident report.No additional crash allegations have been identified related to the alleged defect condition.Information provided by Ford in its September 10, 2014 response to ODI's information request letter identified 10 additional incidents resulting in a low rate of 1.6 incidents per 100,000 vehicles sold in vehicles ranging from 7 to 11 years in service.Six of these incidents were reported by a single source, a state police fleet that corrected the problems in March 2011 and has not reported any additional failures since.Ford also reported 5 warranty claims, but these incidents occurred at very low mileages and appeared to be caused by loose or missing heat shield attachment hardware rather than the corrosion condition that was the cause of the more recent incidents and the focus of this investigation.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 continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted.The following VOQs are associated with this investigation:10643753, 10615584, 10611362, 10610451, 10578715, 10479681, 10471833, 10317493.
Additional source detail variants (2)
Engine And Engine Cooling:exhaust System
On July 7, 2014 the Office of Defects Investigation (ODI) opened a preliminary evaluation based on five complaints (VOQs) alleging incidents ofinterference between dislodged exhaust manifold heat shields and the lower steering shaft/knuckle, including one alleging the interference resulted in a crash on a highway entrance ramp. Since opening this investigation, ODI has received four additional owner complaints.One indicated that the shield was removed before binding could occur.The other three occurred at low speed and produced some momentary steering binding that was overcome by the driver when additional steering effort was applied.Once the shield was repaired or removed, the steering returned to normal.The single incident ODI identified as a possible crash (VOQ No. 10578715) related to this condition could not be verified and the description of the crash in the complaint was not supported by the police accident report.No additional crash allegations have been identified related to the alleged defect condition.Information provided by Ford in its September 10, 2014 response to ODI's information request letter identified 10 additional incidents resulting in a low rate of 1.6 incidents per 100,000 vehicles sold in vehicles ranging from 7 to 11 years in service.Six of these incidents were reported by a single source, a state police fleet that corrected the problems in March 2011 and has not reported any additional failures since.Ford also reported 5 warranty claims, but these incidents occurred at very low mileages and appeared to be caused by loose or missing heat shield attachment hardware rather than the corrosion condition that was the cause of the more recent incidents and the focus of this investigation.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 continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted.The following VOQs are associated with this investigation:10643753, 10615584, 10611362, 10610451, 10578715, 10479681, 10471833, 10317493.
Steering
On July 7, 2014 the Office of Defects Investigation (ODI) opened a preliminary evaluation based on five complaints (VOQs) alleging incidents ofinterference between dislodged exhaust manifold heat shields and the lower steering shaft/knuckle, including one alleging the interference resulted in a crash on a highway entrance ramp. Since opening this investigation, ODI has received four additional owner complaints.One indicated that the shield was removed before binding could occur.The other three occurred at low speed and produced some momentary steering binding that was overcome by the driver when additional steering effort was applied.Once the shield was repaired or removed, the steering returned to normal.The single incident ODI identified as a possible crash (VOQ No. 10578715) related to this condition could not be verified and the description of the crash in the complaint was not supported by the police accident report.No additional crash allegations have been identified related to the alleged defect condition.Information provided by Ford in its September 10, 2014 response to ODI's information request letter identified 10 additional incidents resulting in a low rate of 1.6 incidents per 100,000 vehicles sold in vehicles ranging from 7 to 11 years in service.Six of these incidents were reported by a single source, a state police fleet that corrected the problems in March 2011 and has not reported any additional failures since.Ford also reported 5 warranty claims, but these incidents occurred at very low mileages and appeared to be caused by loose or missing heat shield attachment hardware rather than the corrosion condition that was the cause of the more recent incidents and the focus of this investigation.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 continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted.The following VOQs are associated with this investigation:10643753, 10615584, 10611362, 10610451, 10578715, 10479681, 10471833, 10317493.
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.
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