← New search

2004 Mercury Mountaineer

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2004 Mercury Mountaineer do not stand out strongly from the model-year median of 117.

About this comparison →

When problems were reported

Mileage at the reported incident

181 reports with mileage · 29 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.

  • Structure. Review the 79 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 64 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Vehicle Speed Control. Review the 21 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

11 crash reports2 fire reports15 injury reports

What owners actually said

210 reports
58,000 miles · Apr 16, 2009
Structure

TL*THE CONTACT OWNS A 2004 MERCURY MOUNTAINEER. WHEN THE CONTACT CLOSED THE REAR LIFTGATE DOOR, IT SUDDENLY CRACKED UNDERNEATH THE WINDOW. THE DEALER STATED THAT IT WAS DUE TO A MANUFACTURER DEFECT, BUT THERE WAS NO RECALL. THE CONTACT BELIEVES THAT THE MANUFACTURER SHOULD BE RESPONSIBLE FOR THE REPAIR COST. THE CURRENT AND …

Read full complaint

TL*THE CONTACT OWNS A 2004 MERCURY MOUNTAINEER. WHEN THE CONTACT CLOSED THE REAR LIFTGATE DOOR, IT SUDDENLY CRACKED UNDERNEATH THE WINDOW. THE DEALER STATED THAT IT WAS DUE TO A MANUFACTURER DEFECT, BUT THERE WAS NO RECALL. THE CONTACT BELIEVES THAT THE MANUFACTURER SHOULD BE RESPONSIBLE FOR THE REPAIR COST. THE CURRENT AND FAILURE MILEAGES WERE 58,000.

NHTSA ODI #10265613

69,449 miles · Mar 11, 2009
Structure

REAR LIFT GATE ON 2004 MERCURY MOUNTAINEER WOULD NOT CLOSE. NOTICED HINGE ATTACHMENT FOR GLASS LOOKED AS THOUGH IT WAS FALLING OFF. GATE WOULD NOT CLOSE AND IS DAMAGED. *TR

NHTSA ODI #10261540

59,000 miles · Mar 9, 2009
Power TrainCrashInjury

TL*THE CONTACT OWNS A 2004 MERCURY MOUNTAINEER. WHILE THE VEHICLE WAS TURNED OFF, THE CONTACT'S TWO YEAR OLD SON GRABBED THE KEY AND PLACED IT IN THE IGNITION. HE ATTEMPTED TO START THE VEHICLE, BUT THE ENGINE NEVER IGNITED. THE CHILD THEN PROCEEDED TO PLACE THE SHIFTER IN EITHER NEUTRAL OR DRIVE AND THE VEHICLE BEGAN TO ROLL…

Read full complaint

TL*THE CONTACT OWNS A 2004 MERCURY MOUNTAINEER. WHILE THE VEHICLE WAS TURNED OFF, THE CONTACT'S TWO YEAR OLD SON GRABBED THE KEY AND PLACED IT IN THE IGNITION. HE ATTEMPTED TO START THE VEHICLE, BUT THE ENGINE NEVER IGNITED. THE CHILD THEN PROCEEDED TO PLACE THE SHIFTER IN EITHER NEUTRAL OR DRIVE AND THE VEHICLE BEGAN TO ROLL APPROXIMATELY 350 FEET DOWN A HILL. THE VEHICLE CRASHED INTO A BRUSH-HOG AND A HONDA VEHICLE BEFORE FINALLY COMING TO A STOP WHEN IT CRASHED INTO A BUILDING. THE CHILD SUSTAINED A CONTUSION AND LACERATIONS TO HIS HEAD, CHEST, AND LEGS. THE VEHICLE WAS TOWED AND IS CURRENTLY AT A SALVAGE YARD. THE POLICE STATED THAT EVEN THOUGH THE VEHICLE WAS NOT STARTED, THE GEARS WERE ABLE TO BE SHIFTED, WHICH SHOULD NOT HAVE OCCURRED. A POLICE REPORT WAS FILED. THE CONTACT BELIEVES THAT THE FAILURE WAS DUE TO A MANUFACTURER DEFECT AND THEY SHOULD BE HELD ACCOUNTABLE. THE SPEED WAS UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 59,000.

NHTSA ODI #10261351

91,000 miles · Mar 9, 2009
Engine And Engine Cooling

I STARTED MY 2004 MERCURY MOUNTAINEER THE OTHER DAY, AND THE ENGINE STARTED MAKING A HORRIBLE NOISE, LIKE A LAWN MOWER, RIGHT WHEN IT STARTED. I SHUT IT OFF IMMEDIATELY AND EVENTUALLY HAD TO GET A TOW TRUCK TO BRING ME TO THE FORD DEALER. LUCKILY I WASN'T DRIVING THIS TIME WHEN IT HAPPENED. IT TURNS OUT THAT THE ENGINE …

Read full complaint

I STARTED MY 2004 MERCURY MOUNTAINEER THE OTHER DAY, AND THE ENGINE STARTED MAKING A HORRIBLE NOISE, LIKE A LAWN MOWER, RIGHT WHEN IT STARTED. I SHUT IT OFF IMMEDIATELY AND EVENTUALLY HAD TO GET A TOW TRUCK TO BRING ME TO THE FORD DEALER. LUCKILY I WASN'T DRIVING THIS TIME WHEN IT HAPPENED. IT TURNS OUT THAT THE ENGINE SPAT OUT A SPARK PLUG. THIS SEEMS TO BE A CHRONIC PROBLEM WITH FORD MOTOR COMPANY SUV'S AND PICK-UPS. THE TEMPORARY SOLUTION IS TO PLUG THE SOCKET BECAUSE THE THREADS WORE OUT. HOWEVER THE SPARK PLUG WAS FACTORY-INSTALLED AND THE ISSUE IS DEFINITELY A FORD PROBLEM. THE NEXT TIME, IT COULD BE EITHER LEAD TO A TERRIBLE ACCIDENT OR THOUSANDS OF DOLLARS TO REPAIR, OR BOTH. *TR

NHTSA ODI #10261334

71,000 miles · Mar 7, 2009
Power Train

MY VEHICLES TRANSMISSION HAD SLIPPED ONCE AND TOOK IT IN AS SOON AS IT HAPPENED TO A MERCURY DEALER FOR SERVICE AND THEY CHANGED FLUID AND FILTER NOW IT DON'T HAVE REVERSE OR FORWARD GEARS UNLESS I SHIFT IT MANUALLY THE DEALER SAID IF THEY CHANGE FLUID IT WILL GET WORSE AND IT DID SO THEY ARE AWARE OF THE PROBLEM WHY WASN'T A RE…

Read full complaint

MY VEHICLES TRANSMISSION HAD SLIPPED ONCE AND TOOK IT IN AS SOON AS IT HAPPENED TO A MERCURY DEALER FOR SERVICE AND THEY CHANGED FLUID AND FILTER NOW IT DON'T HAVE REVERSE OR FORWARD GEARS UNLESS I SHIFT IT MANUALLY THE DEALER SAID IF THEY CHANGE FLUID IT WILL GET WORSE AND IT DID SO THEY ARE AWARE OF THE PROBLEM WHY WASN'T A RECALL GIVEN FOR THIS VEHICLES TRANSMISSION PLUS THERE IS NO DIP STICK ON THE TRANSMISSION TO CHECK THE FLUID NOW I HAVE A VEHICLE THAT NEEDS A TRANSMISSION THAT HAS TO BE REPLACED AT A COST OF 3500 DOLLARS AND IS OUT OF WARRANTY I AM VERY DISAPPOINTED THAT A CAR COMPANY CAN GET AWAY WITH THIS. *TR

NHTSA ODI #10261035

66,000 miles · Feb 23, 2009
Power TrainFire

OUR VEHICLE WAS PURCHASED IN JUNE 2008 AT DEALERSHIP NEARBY. WE WERE DRIVING HOME AND THERE WAS A GRINDING AND POPPING SOUND IN THE REAREND OF THE VEHICLE. IT WAS ME , MY HUSBAND, 3 MTH OLD AND 2 YR OLD OCCUPYING THE CAR. MY HUSBAND GOT OUT OF THE CAR AND STATED TO GET THE BABIES OUT OF THE CAR IN A HURRY IT WAS ON FIRE. WE GOT…

Read full complaint

OUR VEHICLE WAS PURCHASED IN JUNE 2008 AT DEALERSHIP NEARBY. WE WERE DRIVING HOME AND THERE WAS A GRINDING AND POPPING SOUND IN THE REAREND OF THE VEHICLE. IT WAS ME , MY HUSBAND, 3 MTH OLD AND 2 YR OLD OCCUPYING THE CAR. MY HUSBAND GOT OUT OF THE CAR AND STATED TO GET THE BABIES OUT OF THE CAR IN A HURRY IT WAS ON FIRE. WE GOT THE BABIES OUT AND RAN IN TO CALL 911 AND THE FIRE DEPT. THE FIRE WAS CONTAINED AND TOOK TO A LOCAL GARAGE AT THAT TIME I CONTACTED MY AUTO INSURANCE TO SEE IF THIS WAS SOMETHING THAT WOULD BE COVERED. THEY SENT AN AUTO ADJUSTER OUT TO LOOK AT IT. OUR INSURANCE DID HELP TO REPAIR THE REAR DIFFERENTIAL. THE REAR DIFFERENTIAL HAD GOT SO HOT IT EXPLODED CAUSING THE FIRE. THEN AFTER THE CAR WAS REPAIRED WE BEGAN TO HAVE PROBLEMS AGAIN AT THAT TIME I CONTACTED FORD MOTOR COMPANY. THEY EXPLAINED THEY COULD NOT REPLACE THE CAR BUT IF I TOOK TO A LOCAL FORD DEALER FOR DIAGNOSTIC THEY MAY CONSIDER REPAIRING. SO I DID AND THE WHOLE TRANSFER CASE HAS TO BE REPLACED AND FORD IS NOT PAYING FOR THE COST. I JUST DON'T WANT THIS EXPERIENCE TO HAPPEN TO ANYONE ELSE AND TO RISK THEIR LIVES JUST DRIVING THIS CAR AS A RESULT TO A FIRE. THE FIRE WAS CLOSE TO THE FUEL TANK. I DON'T THINK THIS CAR IS SAFE FOR US TO DRIVE I ALWAYS HAVE THAT FEAR IN MY MIND AND WORRYING ABOUT MY BABIES. NOW I HAVE THIS NEW PROBLEM WITH THE VEHICLE TO DEAL WITH. I HAVE TALKED TO SEVERAL PEOPLE AND ONE PARTICULAR COMPANY THAT HAS THE SAME TYPE OF VEHICLES WITH THE SAME PROBLEMS. SOMETHING REALLY NEEDS TO BE DONE ABOUT THIS. *TR

NHTSA ODI #10259704

60,000 miles · Feb 9, 2009
Structure

TL*THE CONTACT OWNS A 2004 MERCURY MOUNTAINEER. THE CONTACT NOTICED A CRACK IN THE REAR LIFTGATE PANEL OF HER VEHICLE. THE CRACK CURVES AROUND THE MERCURY LOGO LOCATED ON THE REAR PANEL. THE CONTACT CALLED THE DEALER AND THE MANUFACTURER AND WAS INFORMED THAT THEY WOULD GIVE HER 20% OFF THE REPAIR SINCE HER VEHICLE WAS OUT OF…

Read full complaint

TL*THE CONTACT OWNS A 2004 MERCURY MOUNTAINEER. THE CONTACT NOTICED A CRACK IN THE REAR LIFTGATE PANEL OF HER VEHICLE. THE CRACK CURVES AROUND THE MERCURY LOGO LOCATED ON THE REAR PANEL. THE CONTACT CALLED THE DEALER AND THE MANUFACTURER AND WAS INFORMED THAT THEY WOULD GIVE HER 20% OFF THE REPAIR SINCE HER VEHICLE WAS OUT OF WARRANTY. THE FAILURE MILEAGE WAS 60,000. UPDATED 03/12/09. *LJ UPDATED 03/13/09. *JB

NHTSA ODI #10258061

56,000 miles · Jan 26, 2009
Air Bags

MY 2004 MERCURY MOUNTAINEER HAS A CRACK IN THE LIFT GATE THAT APPEARED A YEAR AFTER I BROUGHT IT FROM THE DEALERSHIP. AT FIRST I THOUGHT IT WAS SOMETHING I MIGHT HAVE DONE BUT EVERY ONE I RAN ACROSS HAS THE SAME IDENTICAL CRACK IN THE SAME AREA. PEOPLE I SPOKE WITH SAID IT JUST SHOWED UP ONE DAY. IS THERE A RECALL ON THIS DEFECT…

Read full complaint

MY 2004 MERCURY MOUNTAINEER HAS A CRACK IN THE LIFT GATE THAT APPEARED A YEAR AFTER I BROUGHT IT FROM THE DEALERSHIP. AT FIRST I THOUGHT IT WAS SOMETHING I MIGHT HAVE DONE BUT EVERY ONE I RAN ACROSS HAS THE SAME IDENTICAL CRACK IN THE SAME AREA. PEOPLE I SPOKE WITH SAID IT JUST SHOWED UP ONE DAY. IS THERE A RECALL ON THIS DEFECT? *TR

NHTSA ODI #10256331

85,000 miles · Dec 13, 2008
Power Train

TRANSMISSION IS SLIPPING. I NOTICED WHEN PUTTING VEHICLE IN REVERSE IT JERKS REAL HARD INTO GEAR. ALSO COMING TO A STOP AND WHEN TAKING OFF FROM A STOP THE TRUCK WILL JERK. *TR

NHTSA ODI #10251697

50,000 miles · Dec 1, 2008
Structure

THE FAILURE IS FOR A 2004 MERCURY MOUNTAINEER AND THE FAILURE IS A CRACK IN THE LIFT GATE THAT OCCURS RIGHT ALONGSIDE THE MERCURY EMBLEM OR LOGO ON THE BACK OF THE TAILGATE OR LIFT GATE. THIS CRACK HAS BEEN REPORTED NUMEROUS TIMES ON ONLINE FORUMS AND TO ME SEEMS LIKE A DEFICIENCY IN THE MATERIAL THAT MAKES UP THE LIFT GATE OR …

Read full complaint

THE FAILURE IS FOR A 2004 MERCURY MOUNTAINEER AND THE FAILURE IS A CRACK IN THE LIFT GATE THAT OCCURS RIGHT ALONGSIDE THE MERCURY EMBLEM OR LOGO ON THE BACK OF THE TAILGATE OR LIFT GATE. THIS CRACK HAS BEEN REPORTED NUMEROUS TIMES ON ONLINE FORUMS AND TO ME SEEMS LIKE A DEFICIENCY IN THE MATERIAL THAT MAKES UP THE LIFT GATE OR TAILGATE. (I.E. - THE LOGO IS SO BIG AND THE MATERIAL AROUND THE LOGO EMBLEM SO THIN THAT IT CRACKS UNDER PRESSURE AND CHANGE IN TEMPERATURE) I WOULD ALSO LIKE TO ADD THAT I HAVE BEEN TOLD THAT THE FORD EXPLORER HAS A RECALL FOR THIS EXACT TYPE OF PROBLEM, YET MERCURY HAS YET TO ISSUE A RECALL FOR THE MOUNTAINEER. THE VEHICLES THAT HAVE INCURRED THIS TYPE OF PROBLEM HAVE BEEN AROUND THE SAME YEARS (2004-2006 MODELS - OR AT LEAST THE VEHICLES THAT I HAVE SEEN THIS PROBLEM OCCUR IN.) 1. THE EVENTS THAT HAVE LED UP TO THIS FAILURE INCLUDES: MERCURY AND FORD ARE SOLELY TO BLAME FOR PRODUCING A FAULTY TAILGATE OR LIFT GATE ON THESE VEHICLES AND SHOULD RECALL THEM. THE CHANGE IN TEMPERATURE ALONG WITH AVERAGE USAGE OF SHUTTING OR CLOSING THE TAILGATE WOULD CAUSE A VIBRATION TO PROMOTE THE TAILGATE TO CRACK. I NOTICED MY FAILURE OR CRACK IN MID-AUGUST OF 2008, I'VE OWNED MY VEHICLE SINCE 2004 BUT IT HAS BEEN GARAGED ALL OF THOSE YEARS EXCEPT FOR LAST YEAR, WHICH COULD EXPLAIN WHY IT HAPPENED LAST YEAR (CHANGE IN TEMPERATURE MORE SEVERE). 2. I HAVE NOTED HOW THE FAILURE OCCURS, ITS CONSEQUENCES INCLUDE A CRACK IN THE LIFT GATE OF THE VEHICLE, WHICH IS AESTHETICALLY NON-APPEALING, AND THIS COULD LEAD TO A LARGER CRACK IN THE LIFT GATE THAT COULD EVENTUALLY CAUSE MAJOR PROBLEMS FOR THE VEHICLE. THIS CRACK (WHICH IS NOT MINOR, 3 - 5 INCHES USUALLY) COULD ALSO REDUCE OR LEAD TO COMPROMISING THE VEHICLES STRUCTURAL INTEGRITY AND REDUCE CRASH TEST RATINGS. THIS IS A BIG CONCERN FOR YOUR SAFETY. 3. I PERSONALLY SPENT OVER $400 TO REPLACE THE ENTIRE LIFT GATE. I SHOULD BE REIMBURSED AND MERCURY SHOULD RECALL THIS PROBLEM. *TR

NHTSA ODI #10250359

Official recalls

0

No recalls in this snapshot.

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

NHTSA investigations

3

EA09013 · Vehicle Rollaway Allegations

Opened Aug 18, 2009 · Closed Feb 12, 2013

Status: closed (inferred from source dates) · Power Train:automatic Transmission:gear Position Indication (prndl); Power Train:automatic Transmission:lever And Linkage:column Shift; Steering; Steering:column; Steering:column LOCKING:ANTI-THEFT Device

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.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.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.

Additional source detail variants (5)

Power Train:automatic Transmission:gear Position Indication (prndl)

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.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.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.

Power Train:automatic Transmission:lever And Linkage:column Shift

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.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.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.

Steering:column

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.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.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.

Steering:column LOCKING:ANTI-THEFT Device

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.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.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.

Steering

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.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.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.

RQ08003 · Rear Liftgate Glass Hatch Failure

Opened Jun 23, 2008 · Closed Oct 24, 2008

Status: closed (inferred from source dates) · Structure:body:hatchback/liftgate; Structure:body:hatchback/liftgate:hinge And Attachments; Structure:body:hatchback/liftgate:support Device/strut; Visibility:glass, Side/rear

THIS INVESTIGATION WAS OPENED ON JUNE 23, 2008, BASED ON 34 COMPLAINTS INVOLVING EIGHT INJURIES IN WHICH THE REAR LIFTGATE GLASS HATCH ON MODEL YEAR 2004 FORD EXPLORERS OR MERCURY MOUNTAINEERS BROKE OFF AND FELL, USUALLY WHILE INDIVIDUALS WERE OPERATING THE GLASS HATCH OR LOADING OR UNLOADING ITEMS FROM THE REAR OF THE VEHICLE.FORD CONDUCTED RECALL 04V-442 IN 2004 TO ADDRESS SIMILAR PROBLEMS ON MODEL YEAR 2002 AND CERTAIN MODEL YEAR 2003 FORD EXPLORERS AND MERCURY MOUNTAINEERS.THE INFORMATION FORD PROVIDED IN RESPONSE TO ODI'S INFORMATION REQUEST LETTER INDICATED THAT FAILURES WITH 2004 VEHICLES WERE PRIMARILY LIFTGATE GLASS HATCH HINGE FAILURES RELATED TO CORROSION AT THE HINGE PIN, WHEREAS THE FAILURES THAT PROMPTED THE RECALL WITH THE EARLIER MODELS WERE PRIMARILY RELATED TO PROBLEMS WITH THE GLASS HATCH'S STRUTS OR FRACTURE OF A PRIOR HINGE DESIGN AT THE BOSS/BOLT CONNECTION AT THE GLASS.ODI'S REVIEW OF FORD'S WARRANTY, COMPLAINT, AND INJURY DATA FOR THE 2004 VEHICLES INDICATES THAT THESE RATES ARE SIGNIFICANTLY LOWER THAN THOSE FOR THE RECALLED POPULATION.A POTENTIAL DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME.ODI WILL CONTINUE TO MONITOR COMPLAINTS AND TAKE APPROPRIATE ACTION AS NECESSARY.THIS INVESTIGATION IS CLOSED.

Additional source detail variants (4)

Structure:body:hatchback/liftgate

THIS INVESTIGATION WAS OPENED ON JUNE 23, 2008, BASED ON 34 COMPLAINTS INVOLVING EIGHT INJURIES IN WHICH THE REAR LIFTGATE GLASS HATCH ON MODEL YEAR 2004 FORD EXPLORERS OR MERCURY MOUNTAINEERS BROKE OFF AND FELL, USUALLY WHILE INDIVIDUALS WERE OPERATING THE GLASS HATCH OR LOADING OR UNLOADING ITEMS FROM THE REAR OF THE VEHICLE.FORD CONDUCTED RECALL 04V-442 IN 2004 TO ADDRESS SIMILAR PROBLEMS ON MODEL YEAR 2002 AND CERTAIN MODEL YEAR 2003 FORD EXPLORERS AND MERCURY MOUNTAINEERS.THE INFORMATION FORD PROVIDED IN RESPONSE TO ODI'S INFORMATION REQUEST LETTER INDICATED THAT FAILURES WITH 2004 VEHICLES WERE PRIMARILY LIFTGATE GLASS HATCH HINGE FAILURES RELATED TO CORROSION AT THE HINGE PIN, WHEREAS THE FAILURES THAT PROMPTED THE RECALL WITH THE EARLIER MODELS WERE PRIMARILY RELATED TO PROBLEMS WITH THE GLASS HATCH'S STRUTS OR FRACTURE OF A PRIOR HINGE DESIGN AT THE BOSS/BOLT CONNECTION AT THE GLASS.ODI'S REVIEW OF FORD'S WARRANTY, COMPLAINT, AND INJURY DATA FOR THE 2004 VEHICLES INDICATES THAT THESE RATES ARE SIGNIFICANTLY LOWER THAN THOSE FOR THE RECALLED POPULATION.A POTENTIAL DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME.ODI WILL CONTINUE TO MONITOR COMPLAINTS AND TAKE APPROPRIATE ACTION AS NECESSARY.THIS INVESTIGATION IS CLOSED.

Structure:body:hatchback/liftgate:hinge And Attachments

THIS INVESTIGATION WAS OPENED ON JUNE 23, 2008, BASED ON 34 COMPLAINTS INVOLVING EIGHT INJURIES IN WHICH THE REAR LIFTGATE GLASS HATCH ON MODEL YEAR 2004 FORD EXPLORERS OR MERCURY MOUNTAINEERS BROKE OFF AND FELL, USUALLY WHILE INDIVIDUALS WERE OPERATING THE GLASS HATCH OR LOADING OR UNLOADING ITEMS FROM THE REAR OF THE VEHICLE.FORD CONDUCTED RECALL 04V-442 IN 2004 TO ADDRESS SIMILAR PROBLEMS ON MODEL YEAR 2002 AND CERTAIN MODEL YEAR 2003 FORD EXPLORERS AND MERCURY MOUNTAINEERS.THE INFORMATION FORD PROVIDED IN RESPONSE TO ODI'S INFORMATION REQUEST LETTER INDICATED THAT FAILURES WITH 2004 VEHICLES WERE PRIMARILY LIFTGATE GLASS HATCH HINGE FAILURES RELATED TO CORROSION AT THE HINGE PIN, WHEREAS THE FAILURES THAT PROMPTED THE RECALL WITH THE EARLIER MODELS WERE PRIMARILY RELATED TO PROBLEMS WITH THE GLASS HATCH'S STRUTS OR FRACTURE OF A PRIOR HINGE DESIGN AT THE BOSS/BOLT CONNECTION AT THE GLASS.ODI'S REVIEW OF FORD'S WARRANTY, COMPLAINT, AND INJURY DATA FOR THE 2004 VEHICLES INDICATES THAT THESE RATES ARE SIGNIFICANTLY LOWER THAN THOSE FOR THE RECALLED POPULATION.A POTENTIAL DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME.ODI WILL CONTINUE TO MONITOR COMPLAINTS AND TAKE APPROPRIATE ACTION AS NECESSARY.THIS INVESTIGATION IS CLOSED.

Structure:body:hatchback/liftgate:support Device/strut

THIS INVESTIGATION WAS OPENED ON JUNE 23, 2008, BASED ON 34 COMPLAINTS INVOLVING EIGHT INJURIES IN WHICH THE REAR LIFTGATE GLASS HATCH ON MODEL YEAR 2004 FORD EXPLORERS OR MERCURY MOUNTAINEERS BROKE OFF AND FELL, USUALLY WHILE INDIVIDUALS WERE OPERATING THE GLASS HATCH OR LOADING OR UNLOADING ITEMS FROM THE REAR OF THE VEHICLE.FORD CONDUCTED RECALL 04V-442 IN 2004 TO ADDRESS SIMILAR PROBLEMS ON MODEL YEAR 2002 AND CERTAIN MODEL YEAR 2003 FORD EXPLORERS AND MERCURY MOUNTAINEERS.THE INFORMATION FORD PROVIDED IN RESPONSE TO ODI'S INFORMATION REQUEST LETTER INDICATED THAT FAILURES WITH 2004 VEHICLES WERE PRIMARILY LIFTGATE GLASS HATCH HINGE FAILURES RELATED TO CORROSION AT THE HINGE PIN, WHEREAS THE FAILURES THAT PROMPTED THE RECALL WITH THE EARLIER MODELS WERE PRIMARILY RELATED TO PROBLEMS WITH THE GLASS HATCH'S STRUTS OR FRACTURE OF A PRIOR HINGE DESIGN AT THE BOSS/BOLT CONNECTION AT THE GLASS.ODI'S REVIEW OF FORD'S WARRANTY, COMPLAINT, AND INJURY DATA FOR THE 2004 VEHICLES INDICATES THAT THESE RATES ARE SIGNIFICANTLY LOWER THAN THOSE FOR THE RECALLED POPULATION.A POTENTIAL DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME.ODI WILL CONTINUE TO MONITOR COMPLAINTS AND TAKE APPROPRIATE ACTION AS NECESSARY.THIS INVESTIGATION IS CLOSED.

Visibility:glass, Side/rear

THIS INVESTIGATION WAS OPENED ON JUNE 23, 2008, BASED ON 34 COMPLAINTS INVOLVING EIGHT INJURIES IN WHICH THE REAR LIFTGATE GLASS HATCH ON MODEL YEAR 2004 FORD EXPLORERS OR MERCURY MOUNTAINEERS BROKE OFF AND FELL, USUALLY WHILE INDIVIDUALS WERE OPERATING THE GLASS HATCH OR LOADING OR UNLOADING ITEMS FROM THE REAR OF THE VEHICLE.FORD CONDUCTED RECALL 04V-442 IN 2004 TO ADDRESS SIMILAR PROBLEMS ON MODEL YEAR 2002 AND CERTAIN MODEL YEAR 2003 FORD EXPLORERS AND MERCURY MOUNTAINEERS.THE INFORMATION FORD PROVIDED IN RESPONSE TO ODI'S INFORMATION REQUEST LETTER INDICATED THAT FAILURES WITH 2004 VEHICLES WERE PRIMARILY LIFTGATE GLASS HATCH HINGE FAILURES RELATED TO CORROSION AT THE HINGE PIN, WHEREAS THE FAILURES THAT PROMPTED THE RECALL WITH THE EARLIER MODELS WERE PRIMARILY RELATED TO PROBLEMS WITH THE GLASS HATCH'S STRUTS OR FRACTURE OF A PRIOR HINGE DESIGN AT THE BOSS/BOLT CONNECTION AT THE GLASS.ODI'S REVIEW OF FORD'S WARRANTY, COMPLAINT, AND INJURY DATA FOR THE 2004 VEHICLES INDICATES THAT THESE RATES ARE SIGNIFICANTLY LOWER THAN THOSE FOR THE RECALLED POPULATION.A POTENTIAL DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME.ODI WILL CONTINUE TO MONITOR COMPLAINTS AND TAKE APPROPRIATE ACTION AS NECESSARY.THIS INVESTIGATION IS CLOSED.

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.