The vehicle dossier US · 2001

2001 Ford
F-250 SDProblems & recalls

288 distinct owner reports in the NHTSA snapshot. Engine appears in 99 of them. Explore what was reported—and which official actions are on file.

Snapshot Sep 28, 2026Live NHTSA complaint API How this dossier is compiled

01 / Owner-reported evidence

What owners reported.

Categories attached to 288 distinct reports. A report can mention more than one component, so category totals can overlap.

Engine99 reports
Other components77 reports
Transmission & drivetrain45 reports
Electrical system39 reports
Steering21 reports
Brakes11 reports
Suspension10 reports
Fuel system7 reports
Air bags4 reports
Body & structure4 reports
Visibility4 reports
See original component labels
ENGINE AND ENGINE COOLING:ENGINE29
ENGINE AND ENGINE COOLING29
POWER TRAIN:AUTOMATIC TRANSMISSION27
TIRES:TREAD/BELT25
ELECTRICAL SYSTEM24
ENGINE AND ENGINE COOLING:ENGINE:DIESEL19
TIRES12
STEERING12
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE8
ENGINE8
SEAT BELTS:FRONT:BUCKLE ASSEMBLY7
SEAT BELTS7
POWER TRAIN7
VEHICLE SPEED CONTROL:CRUISE CONTROL6
ELECTRICAL SYSTEM:IGNITION6
WHEELS:HUB5
STEERING:HYDRAULIC POWER ASSIST SYSTEM4
AIR BAGS4
SERVICE BRAKES, HYDRAULIC4
SUSPENSION:FRONT:CONTROL ARM:LOWER BALL JOINT4
POWER TRAIN:AXLE HUBS4
ELECTRICAL SYSTEM:WIRING3
POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER3
SUSPENSION:FRONT3
ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD3
STRUCTURE3
VEHICLE SPEED CONTROL3
FUEL SYSTEM, GASOLINE3
SEATS:FRONT ASSEMBLY:HEAD RESTRAINT2
POWER TRAIN:CLUTCH ASSEMBLY2
VEHICLE SPEED CONTROL:ACCELERATOR PEDAL2
POWER TRAIN:MANUAL TRANSMISSION2
POWER TRAIN:CLUTCH ASSEMBLY:PEDAL/HAND LEVER(MOTORCYCLE)2
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP2
SUSPENSION:FRONT:CONTROL ARM:UPPER BALL JOINT2
TIRES:SIDEWALL2
STEERING:HYDRAULIC POWER ASSIST:PUMP2
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR2
UNKNOWN OR OTHER2
ELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASH2
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE2
SUSPENSION2
ENGINE AND ENGINE COOLING:COOLING SYSTEM2
VISIBILITY/WIPER2
FUEL/PROPULSION SYSTEM2
SERVICE BRAKES2
SUSPENSION:FRONT:WHEEL BEARING1
STEERING:LINKAGES:DRAG:LINK:CONNECTION1
STEERING:LINKAGES:KNUCKLE:SPINDLE:ARM1
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DRUM1
1
ELECTRICAL SYSTEM:WIRING:FUSES AND CIRCUIT BREAKERS1
POWER TRAIN:AXLE ASSEMBLY:AXLE SHAFT:SEAL1
SERVICE BRAKES, HYDRAULIC:POWER ASSIST:HYDRAULIC:HOSES, LINES/PIPING, AND FITTINGS1
ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS1
POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT1
STEERING:GEAR BOX:SHAFT PITMAN1
LATCHES/LOCKS/LINKAGES:DOORS:LATCH1
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CRANKCASE (PCV)1
FUEL SYSTEM, OTHER:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS1
LATCHES/LOCKS/LINKAGES1
VISIBILITY1
EQUIPMENT1
WHEELS1
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM1
FUEL SYSTEM, DIESEL1
VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM1
STRUCTURE:BODY1

These are reports made to NHTSA, not verified diagnoses. More reports can reflect more vehicles, more time on the road, or greater reporting activity.

The reporting timeline

When reports arrived.

Reports by year filed, not by the year a problem occurred. Showing the latest 15 years with reports.

Year filed (last two digits)Latest report: Jun 15, 2019
Mileage, where supplied

74,254 miles is the median among 241 reports with usable mileage. The middle half spans 48,450–110,000 miles.

This describes the submitted reports. It does not predict when a vehicle will fail.

02 / Official safety campaigns

4 recall campaigns on file.

A campaign can cover only certain production dates or configurations. The count does not tell you whether an individual car has an open recall.

Oct 13, 2009 Safety recallVEHICLE SPEED CONTROLCampaign 09V399000

Reported concern

FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.

Manufacturer’s stated response

FORD WILL NOTIFY OWNERS THAT DEALERS WILL INSTALL A FUSED WIRING HARNESS IN LINE WITH THE SCDS. ON 1999-2003 WINDSTAR VEHICLES WITH A LEAKING SCDS, DEALERS WILL ALSO INSPECT THE ABS CONTROL MODULE CONNECTOR AND REPAIR AS NECESSARY. REPAIRS WILL BE COMPLETED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 27, 2009. OWNERS MAY CONTACT FORD AT 1-888-222-2751.

Manufacturer campaign: 09S09

Read campaign 09V399000 at NHTSA
Dec 17, 2007 Safety recallWHEELS:HUBCampaign 07E106000

Reported concern

CERTAIN FEDERAL-MOGUL REPLACEMENT WHEEL HUB ASSEMBLIES WITH THE BRAND NAMES: NATIONAL, CARQUEST P/NOS. 515020, 515021, 515025, 515053, 515054, 515059, AND 515060, SHIPPED BETWEEN JANUARY 23, 2006, AND DECEMBER 20, 2007, SOLD FOR LIGHT DUTY AND MEDIUM DUTY TRUCKS. THE INBOARD RETENTION NUT USED TO MAINTAIN HUB BEARING ASSEMBLY CAN LOOSEN RESULTING IN AN ABS LIGHT INDICATION, NOISE, AND/OR WHEEL SEPARATION.

Manufacturer’s stated response

FEDERAL-MOGUL WILL NOTIFY CUSTOMERS AND WILL REPLACE THE HUB ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN ON FEBRUARY 7, 2008. OWNERS CAN CONTACT FEDERAL-MOGUL TOLL-FREE AT 877-489-6659.

Read campaign 07E106000 at NHTSA
Dec 5, 2007 Safety recallENGINE AND ENGINE COOLING:ENGINE:DIESELCampaign 07V553000

Reported concern

ON CERTAIN HEAVY DUTY TRUCKS EQUIPPED WITH 7.3L DIESEL ENGINES, THE CAMSHAFT POSITION SENSOR LOCATED ON THE ENGINE OF THE VEHICLE MAY FUNCTION INTERMITTENTLY, POSSIBLY RESULTING IN AN ENGINE STALL.

Manufacturer’s stated response

DEALERS WILL INSPECT THE SENSOR AND REPLACE IT WITH AN IMPROVED CAMSHAFT POSITION SENSOR FREE OF CHARGE. THE RECALL BEGAN ON DECEMBER 29, 2007. OWNERS MAY CONTACT FORD AT 1-866-436-7332.

Manufacturer campaign: 07S57

Read campaign 07V553000 at NHTSA
Mar 23, 2006 Safety recallEXTERIOR LIGHTINGCampaign 06E026000

Reported concern

CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.

Manufacturer’s stated response

PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.

Read campaign 06E026000 at NHTSA
Check this car’s VIN at NHTSA

03 / The manufacturer’s record

Instructions. Updates. Responses.

33 distinct communications list this model-year. Showing the latest 12. A matching model-year does not establish that every engine, trim or reported symptom is covered.

Jan 13, 2020 Service Bulletin/Repair InstructionsDOR-U2J7Y-02This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for testing and containment. We don't …NHTSA ID 10171326

This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for testing and containment. We don't have evidence that these test results have contributed to a product failure.

Components: EQUIPMENT. Confirm detailed applicability in the original document.

Source record 10171326 at NHTSA
Jan 13, 2020 Service Bulletin/Repair InstructionsDOR-C2C6H-02This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for testing and containment. We don't …NHTSA ID 10171325

This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for testing and containment. We don't have evidence that these test results have contributed to a product failure.

Components: EQUIPMENT. Confirm detailed applicability in the original document.

Source record 10171325 at NHTSA
Oct 2, 2018 Service Bulletin/Repair InstructionsDOR-B8H4Z-11This SKU is a front upper ball joint. The Customer communication requested return of unsold inventory to inspect for ball studs with excessive rotational friction in the ball joint assembly. Excessive friction in the ball joint…NHTSA ID 10148818

This SKU is a front upper ball joint. The Customer communication requested return of unsold inventory to inspect for ball studs with excessive rotational friction in the ball joint assembly. Excessive friction in the ball joint assembly may cause a perceptible increase in steering effort.

Components: STEERING. Confirm detailed applicability in the original document.

Source record 10148818 at NHTSA
Feb 1, 2014 Service Bulletin/Repair InstructionsASI-44408FORD: THE RESTRAINT CONTROL MODULE (RCM) WHEN USING VCM II, WOULD HAVE AN ERROR CODE 35 AND DIAGNOSTIC TROUBLE CODE (DTC) B1035, AND DIFFICULTY ATTEMPTING PROGRAMMABLE MODULE INSTALLATION (PMI). MODEL 2001-2004 F-SUPER DUTY. *PENHTSA ID 10055648

FORD: THE RESTRAINT CONTROL MODULE (RCM) WHEN USING VCM II, WOULD HAVE AN ERROR CODE 35 AND DIAGNOSTIC TROUBLE CODE (DTC) B1035, AND DIFFICULTY ATTEMPTING PROGRAMMABLE MODULE INSTALLATION (PMI). MODEL 2001-2004 F-SUPER DUTY. *PE

Components: EQUIPMENT ADAPTIVE/MOBILITY. Confirm detailed applicability in the original document.

Source record 10055648 at NHTSA
Dec 1, 2013 Service Bulletin/Repair InstructionsLP-09L02FORD TRUCKS SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. VEHICLES HAVE EXPERIENCED SEVERE STEERING WHEEL AND FRONT WHEEL VIBRATIONS AND OSCILLATIONS AFTER TRAVELING OVER A BUMP OR DIP IN THE ROAD. MODELS 2006 …NHTSA ID 10028404

FORD TRUCKS SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. VEHICLES HAVE EXPERIENCED SEVERE STEERING WHEEL AND FRONT WHEEL VIBRATIONS AND OSCILLATIONS AFTER TRAVELING OVER A BUMP OR DIP IN THE ROAD. MODELS 2006 F-250/350 SUPER DUTY 4X4. *PE UPDATED 7/22/09. CSC LETTER WAS RECEIVED. *PE

Components: STEERING: STEERING WHEEL/HANDLE BAR · TIRES. Confirm detailed applicability in the original document.

Source record 10028404 at NHTSA
Apr 1, 2008 Service Bulletin/Repair Instructions202281999-2008 7.3L/6.0L/6.4L/4.5L DIESEL F-SUPER DUTY - CLEAN THE CHARGE AIR COOLER (CAC) SYSTEM AFTER CERTAIN TURBO OR ENGINE FAILURES - SERVICE TIP. *NJNHTSA ID 10024865

1999-2008 7.3L/6.0L/6.4L/4.5L DIESEL F-SUPER DUTY - CLEAN THE CHARGE AIR COOLER (CAC) SYSTEM AFTER CERTAIN TURBO OR ENGINE FAILURES - SERVICE TIP. *NJ

Components: ENGINE AND ENGINE COOLING:ENGINE:OTHER FUEL TYPES:TURBO/SUPERCHARGER. Confirm detailed applicability in the original document.

Source record 10024865 at NHTSA
Nov 1, 2007 Service Bulletin/Repair Instructions200521999-2008 F250-F550 SUPER DUTY 4X4 WITH ELECTRONIC SHIFT TRANSFER CASE NOT ENGAGING 4X4. *NJNHTSA ID 10023653

1999-2008 F250-F550 SUPER DUTY 4X4 WITH ELECTRONIC SHIFT TRANSFER CASE NOT ENGAGING 4X4. *NJ

Components: POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE). Confirm detailed applicability in the original document.

Source record 10023653 at NHTSA
Apr 3, 2007 Service Bulletin/Repair Instructions07216.8L ENGINES. POWERTRAIN CONTROL MODULE (PCM) RECALIBRATION. SAMPLE CONSUMER LETTER ATTACHED. *KBNHTSA ID 10022289

6.8L ENGINES. POWERTRAIN CONTROL MODULE (PCM) RECALIBRATION. SAMPLE CONSUMER LETTER ATTACHED. *KB

Components: POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM). Confirm detailed applicability in the original document.

Source record 10022289 at NHTSA
Apr 1, 2007 Service Bulletin/Repair Instructions19728LACK OF POWER DUE TO LOW FUEL PRESSURE - FUEL TANK LINER SEPERATION. *KBNHTSA ID 10022243

LACK OF POWER DUE TO LOW FUEL PRESSURE - FUEL TANK LINER SEPERATION. *KB

Components: ENGINE AND ENGINE COOLING:ENGINE:DIESEL. Confirm detailed applicability in the original document.

Source record 10022243 at NHTSA
Feb 1, 2007 Service Bulletin/Repair Instructions19621LACK OF POWER DUE TO LOW FUEL PRESSURE, FUEL TANK LINER SEPERATION. *KBNHTSA ID 10021621

LACK OF POWER DUE TO LOW FUEL PRESSURE, FUEL TANK LINER SEPERATION. *KB

Components: FUEL SYSTEM, GASOLINE. Confirm detailed applicability in the original document.

Source record 10021621 at NHTSA
Oct 7, 2005 Service Bulletin/Repair Instructions05174VACUUM PUMP INOPERATIVE OR RUNS CONTINUOUSLY - CLIMATE CONTROL DEFAULTS TO DEFROST MODE. *TTNHTSA ID 10018067

VACUUM PUMP INOPERATIVE OR RUNS CONTINUOUSLY - CLIMATE CONTROL DEFAULTS TO DEFROST MODE. *TT

Components: VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM. Confirm detailed applicability in the original document.

Source record 10018067 at NHTSA
Oct 7, 2005 Service Bulletin/Repair Instructions04227DRIVE AWAY SHUDDER OR VIBRATION. *EHNHTSA ID 10013402

DRIVE AWAY SHUDDER OR VIBRATION. *EH

Components: POWER TRAIN. Confirm detailed applicability in the original document.

Source record 10013402 at NHTSA
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Records below contain the NHTSA bulk summary unless a document-reviewed explainer is linked. A service bulletin is not a safety recall or a promise of a free repair. Records may be revised or superseded; verify the current document with the manufacturer.

04 / Agency investigations

Official inquiries.

An investigation is an inquiry into a potential concern. Its presence does not establish a defect, and a closed case does not certify a car’s condition.

Opened Jun 22, 2006 ClosedENGINE STALLINGEA06012

IN A DECEMBER 3, 2007 LETTER, FORD ADVISED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL TO REPLACE THE CAM POSITION SENSOR (CPS) IN APPROXIMATELY 1.2 MILLION SUBJECT VEHICLES TO ADDRESS REPORTS OF ENGINE STALLING.A NEW DESIGN CPS WITH IMPROVED PERFORMANCE AND DURABILITY WILL BE INSTALLED AS A REMEDY.OWNER NOTIFICATIONS WILL BEGIN IN DECEMBER 2007. THE SUBJECT VEHICLES ARE DURABLE, FULL-SIZED, MEDIUM DUTY TRUCKS COMMONLY USED FOR COMMERCIAL PURPOSES, RESCUE/EMERGENCY RESPONSE, AND COMMERCIAL OR RECREATIONAL TOWING.CPS FAILURE IS COMPARABLE TO UNEXPECTEDLY TURNING THE KEY OFF SINCE THE SIGNAL IT PRODUCES IS VITAL TO THE ELECTRONIC ENGINE CONTROL SYSTEM.CPS SIGNAL LOSS TERMINATES FUEL INJECTION RESULTING IN AN ENGINE STALL.ONCE STALLED, THE ENGINE MAY RESTART RIGHT AWAY, OR MAY RESTART AFTER A DELAY (TYPICALLY 5 TO 10 MINUTES), OR MAY NOT RESTART AT ALL.IN ADDITION TO EXPOSING THE DRIVER AND OTHER MOTORISTS TO CRASH RISK DUE TO LOSS OF MOTIVE POWER OR VEHICLE DISABLEMENT, ENGINE STALLING ALSO EFFECTS THE POWER ASSISTED STEERING AND BRAKING. THROUGH CONSUMER INTERVIEWS, ODI DETERMINED THAT CPS FAILURES OCCURRED WITHOUT ANY FORM OF WARNING, AT ANY VEHICLE SPEED (50% AT HIGHWAY SPEEDS), AND UNDER ANY DRIVING CONDITION, SUCH AS ACCELERATING.CONSUMERS REPORTED THAT ABOUT A THIRD OF THE VEHICLES FAILED TO RESTART, WITH ANOTHER THIRD REPORTING DELAYED RESTARTING.HALF THE VEHICLES THAT DID RESTART EXPERIENCED ANOTHER STALL ON THE SAME OR A SUBSEQUENT DRIVE CYCLE (BEFORE CPS REPLACEMENT) RE-EXPOSING THOSE CONSUMERS TO THE RISKS ASSOCIATED WITH A STALLING EVENT.IN THEIR VOQ REPORTS, HALF OF THE ODI COMPLAINANTS DESCRIBED DIFFICULTY CONTROLLING THE VEHICLE DUE TO LOSE OF POWER ASSIST SYSTEMS, ESPECIALLY THOSE WHO WERE TOWING AT THE TIME OF THE INCIDENT. THE ONE ALLEGED INJURY INCIDENT OCCURRED IN AN INTERSECTION WHEN A SUBJECT VEHICLE STALLED WHILE TURNING ACROSS ONCOMING LANES OF TRAFFIC.ALTHOUGH UNSUBSTANTIATED, THE COMPLAINANT ALLEGED AN INJURY TO A CHILD OCCUPANT DURING ODI'S INTERVIEW.THE OTHER CRASH ALLEGATIONS MOSTLY INVOLVED LOW SPEED, LOSS OF CONTROL INCIDENTS OFTEN CAUSED BY LACK OF POWER ASSIST; NO INJURIES ARE REPORTED IN THESE INCIDENTS, AND PROPERTY DAMAGE, IF ANY, WAS MINIMAL.CONSUMERS ALSO REPORTED OTHER INCIDENTS WITH SIGNIFICANT SAFETY RISKS, SUCH AS DISABLEMENT IN A LANE OR ON A SHOULDER OF A HIGH-SPEED ROADWAY OR INTERSTATE, OR EXTENDED DISABLEMENT IN REMOTE AREAS DURING SEVERE WEATHER CONDITIONS. THE POPULATION ABOVE IS FORD'S ESTIMATE OF THE 1.4 MILLION SUBJECT VEHICLES PRODUCED THAT ARE CURRENTLY REGISTERED.THE FORD COMPLAINT AND WARRANTY COUNTS NOTED ABOVE ARE CURRENT AS OF FORD'S LAST SUBMISSION DATED JUNE 21, 2007; THEY DO NOT INCLUDE F-450, F-550, OR ECONOLINE COUNTS AS THESE PRODUCTS WERE NOT FORMALLY WITHIN SCOPE OF THE INVESTIGATION WHEN FAILURE INFORMATION WAS REQUESTED.WARRANTY DATA ANALYSIS INDICATES THAT ABOUT HALF THE CLAIMS INVOLVED A STALL WHILE DRIVING EVENT ( FORD'S ASSESSMENT) AND THAT POOR CPS DURABILITY WAS A LONGSTANDING CONCERN.FORD REPORTED THAT THE NEW CPS DESIGN SHOULD MEET OR EXCEED THEIR 10 YEAR, 150K MILE LIFE EXPECTANCY DESIGN REQUIREMENT.

Recorded closure: Dec 7, 2007

Campaign reference in the source: 07V553000

Find investigation EA06012
Opened Feb 27, 2006 ClosedENGINE STALLINGPE06011

THE CAM POSITION SENSOR (CPS) PROVIDES A CRITICAL SIGNAL TO THE SUBJECT VEHICLE (SV) ENGINE MANAGEMENT SYSTEM, THE LOSS OF WHICH RESULTS IN AN ENGINE STALL.DURING PE06-011, FORD STATED IN THEIR RESPONSE TO ODI THAT IT IS CONTINUING TO INVESTIGATE ALLEGATIONS OF CPS RELATED ENGINE STALL AND FURTHER ADVISED THAT AN UPDATE WILL BE PROVIDED UPON COMPLETION OF THE INVESTIGATION.FORD DATA SHOWS THAT 20% OF THE 716,000 SVS ARE EQUIPPED WITH MANUAL TRANSMISSIONS WHICH ARE CAPABLE OF BACK-DRIVING THE ENGINE WHEN A STALL OCCURS; POWER ASSISTED STEERING AND BRAKING ARE NOT LOST DURING ENGINE BACK-DRIVE.FORD DATA ALSO INDICATES THAT BACK-DRIVE OCCURS IN AUTOMATIC TRANSMISSION VEHICLES ABOVE CERTAIN ROAD SPEEDS.THE MANUFACTURER REPORTS NOTED REFERENCE 755 UNIQUE VEHICLES; 2 ARE DUPLICATIVE OF ODI REPORTS.IN ITS REVIEW OF CUSTOMER AND FIELD REPORTS, FORD IDENTIFIED SOME 800 REPORTS ALLEGING ONE OR MORE ENGINE STALLS POTENTIALLY RELATED TO A CPS FAILURE IN THESE 755 VEHICLES (FORD?S ?A? CATEGORY REPORTS).ODI HAS NOT COMPLETED ITS REVIEW OF THESE OR OTHER FORD REPORTS, NOR HAS IT CONFIRMED THIS COUNT.ALL BUT ONE OF THE 9 CRASH ALLEGATIONS APPEAR TO BE MINOR IN NATURE ALTHOUGH ODI IS STILL INVESTIGATING THESE CRASH/INJURY ALLEGATIONS AND WHETHER OR NOT THEY INVOLVE A CPS FAILURE.BASED ON EARLY ASSESSMENT OF THE APPROXIMATELY 166,000 SUBJECT VEHICLE WARRANTY CLAIMS FORD PAID, THERE APPEARS TO BE VARIABILITY IN CLAIM RATES BETWEEN CERTAIN SV PRODUCTION PERIODS; AN EXPLANATION FOR THIS HAS NOT BEEN IDENTIFIED.FORD REVIEWED A SAMPLE OF THE WARRANTY CLAIMS AND INDICATED THAT ABOUT HALF MAY INVOLVE A STALL DUE TO CPS FAILURE; ODI HAS YET TO CONFIRM THIS ASSESSMENT.THE INVESTIGATION IS THEREFORE UPGRADED TO ENGINEERING ANALYSIS EA06-012 SO THAT ODI CAN CONTINUE TO INVESTIGATE THE SCOPE, FREQUENCY AND CONSEQUENCES OF CPS RELATED ENGINE STALLING.

Recorded closure: Jun 23, 2006

Find investigation PE06011
Opened Sep 22, 2005 ClosedSPARK PLUG EJECTION FROM CYLINDER HEADDP05005

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.

Recorded closure: Jan 4, 2006

Find investigation DP05005
Opened Mar 22, 2005 ClosedENGINE COMPARTMENT FIRESEA05005

EA05-005 IS CLOSED WITH FORD?S ACTIONS IN RECALLS 05V-017, 05V-388, AND 06V-286, RECALLING APPROXIMATELY 6.7 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).THE BRAKE SYSTEMS IN THESE RECALLED VEHICLES GENERATE A VACUUM THAT CAN POTENTIALLY CAUSE THE SCDS TO FAIL AND, IN CERTAIN SWITCH INSTALLATION ORIENTATIONS, CATCH FIRE.FORD IS ALSO INCLUDING THE ENTIRE POPULATION OF 1998 EXPLORERS.FORD HAS INFORMED ODI THAT TESTING TO DETERMINE THE CAUSE OF FAILURES IN THE 1998 EXPLORERS WILL CONTINUE AFTER THIS INVESTIGATION IS CLOSED.ODI BELIEVES THAT THE VEHICLES EXHIBITING THE FACTORS CAUSING SCDS FAILURE DESCRIBED IN THIS REPORT CORRELATE WELL WITH THE OBSERVED FAILURE RATES ON THESE VEHICLES BY MODEL AND MODEL YEAR.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE NON-RECALLED VEHICLES MANUFACTURED WITH SCDS THAT ARE NOT INCLUDED IN FORD?S RECALLS.ODI WILL CONTINUE TO MONITOR THE NON-RECALLED POPULATION FOR INCIDENCE OF ENGINE COMPARTMENT FIRES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE ATTACHED CLOSING REPORT FOR DETAILS.

Recorded closure: Aug 2, 2006

Campaign reference in the source: 08V025000

Find investigation EA05005
Opened Feb 17, 2005 ClosedFRONT SEAT BELT BUCKLE ASSEMBLYEA05004

DURING THE INITIAL RECALL CAMPAIGN IN 2001, THE SUBJECT VEHICLES WERE INSPECTED BY FORD DEALERSHIPS USING A TEST TOOL THAT WOULD DETECT A DEFECTIVE FRONT SEAT OUTBOARD SEAT BELT BUCKLE ASSEMBLY.APPROXIMATELY ONE MILLION VEHICLES PASSED THE INSPECTION TEST FOR ONE OR BOTH FRONT BUCKLES.SUBSEQUENT TO THE RECALL SERVICE ACTION, ODI RECEIVED 15 CONSUMER REPORTS ALLEGING THAT A PASSED INSPECTION BUCKLE SUBSEQUENTLY FAILED TO LATCH OR INADVERTENTLY UNLATCHED DURING USE.IN ADDITION, FORD HAS IDENTIFIED 543 OWNER AND FIELD REPORTS ALLEGING BUCKLE FAILURE SUBSEQUENT TO PASSING THE INSPECTION TEST.FORD TESTED AND EXAMINED OVER 100 WARRANTY-RETURNED BUCKLES AND FOUND THAT 44% OF THE BUCKLES HAD NO PROBLEM OR A CONDITION NOT RELATED TO THE RECALL INSPECTION (NON-LATCH RELATED BUCKLE DAMAGE OR FOREIGN CONTAMINATION).WARRANTY CLAIMS WERE HIGHEST DURING THE 18-MONTH PERIOD AFTER THE START OF THE RECALL (JULY 2001) AND HAVE BEEN DECLINING DURING THE PAST 24 MONTHS.OVER THE PAST 12 MONTHS, FORD HAS RECEIVED APPROXIMATELY 12 WARRANTY CLAIMS PER MONTH OUT OF A VEHICLE POPULATION OF ABOUT ONE MILLION.COMPLAINTS COUNTS ARE ALSO DECREASING.DURING THE PAST SEVEN MONTHS, ODI HAS RECEIVED ONLY TWO COMPLAINTS. 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 RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

Recorded closure: Jul 6, 2005

Find investigation EA05004
Opened Oct 22, 2004 ClosedFRONT SEAT BELT BUCKLE ASSEMBLYRQ04011

UNDER RECALL CAMPAIGN (01V227), FORD RECALLED APPROXIMATELY 1.3 MILLION VEHICLES TO INSPECT AND IF NECESSARY REPLACE THE FRONT DRIVER AND/OR PASSENGER SEAT BELT BUCKLE.APPROXIMATELY 1.1 MILLION OWNERS RESPONDED BY TAKING THEIR VEHICLES TO A DEALER FOR INSPECTION OF THE BUCKLE USING A SPECIALIZED BUCKLE TEST TOOL.FORD REPORTED THAT 829,927 VEHICLES HAD BOTH BUCKLES PASS THE TOOL TEST AND ANOTHER 167,336 VEHICLES HAD ONE BUCKLE PASS.ODI AND FORD RECEIVED COMPLAINTS ALLEGING SEAT BELT BUCKLE FAILURE SHORTLY AFTER PASSING THE ORIGINAL RECALL INSPECTION SERVICE.COMPLAINANTS ALLEGED THAT THE BUCKLE FAILED BY EITHER NOT LATCHING OR FALSE-LATCHING (PARTIAL ENGAGEMENT OF THE LATCH TO THE LATCH PLATE).A FALSE-LATCHED BUCKLE MAY RELEASE WITH MINOR MOVEMENT OR IMPACT AGAINST THE BUCKLE HOUSING INCLUDING INADVERTENT RELEASE WHILE THE VEHICLE IS IN MOTION.ODI IS UPGRADING THIS RECALL QUERY TO AN ENGINEERING ANALYSIS (EA05-004) TO FURTHER ANALYZE THE FIELD PERFORMANCE OF THOSE VEHICLES THAT FORD DEALERS PASSED (ONE OR BOTH BUCKLES) USING FORD'S INSPECTION TEST (997,263 VEHICLES).

Recorded closure: Feb 17, 2005

Find investigation RQ04011
Opened Feb 23, 2004 ClosedACCELERATOR PEDAL SENSOR (ETC)EA04006

FAILURE COUNTS FROM ODI?S ANALYSIS ARE STATED ABOVE; SEE THE ADDITIONAL PROBLEM EXPERIENCE DISCUSSION IN THE SUMMARY REPORT.FORD DATA CONTAINED DUPLICATIVE REPORTS FOR 4 ODI COMPLAINTS AND 1 CRASH.THREE CRASHES WERE ALLEGEDLY DUE TO INTERMITTENT OPERATION OF THE ELECTRONIC THROTTLE CONTROL (ETC) PEDAL, ONE CRASH OCCURRED WHEN AN ETC DISABLED VEHICLE WAS STRUCK BY ANOTHER MOTORIST, ONE REPORT CONTAINED NO DETAIL.THE INJURIES WERE MINOR.AN ISSUE INVOLVING FIXED ETC PEDALS WAS INVESTIGATED ALSO, HOWEVER FAILURE REPORTS AND POPULATIONS ARE NOT SHOWN ABOVE; SEE SUMMARY REPORT FOR DETAIL.ALTHOUGH FORD HAS USED ETC BASED THROTTLE CONTROL SYSTEMS FOR MANY YEARS, THE PAP FEATURE WAS NEW FOR MY 2002.THE SUBJECT ETC SENSOR PRODUCES TWO OUTPUT SIGNALS WHICH THE ENGINE MANAGEMENT SYSTEM (EMS) UTILIZES TO:1) DETERMINE FUELING REQUIREMENTS; AND 2) PERFORM SENSOR DIAGNOSTICS.ONE SIGNAL IS LINEARLY PROPORTIONAL TO THROTTLE PEDAL POSITION; THE SECOND IS A DIGITAL SIGNAL.BY DESIGN, THE DETECTION OF A SENSOR FAULT RESULTS IN THE ENGINE RETURNING TO (OR REMAINING AT) THE IDLE STATE.FORD IDENTIFIED A DEFECT IN THE PAP ETC SENSOR WHICH PREMATURELY AFFECTED AN OUTPUT SIGNAL; THE MIGRATION OF INTERNAL SENSOR LUBRICANT CAUSED A LOSS OF PROPORTIONAL SIGNAL.THE FAILURE MECHANISM IS PROGRESSIVE AND AS THE SENSOR DETERIORATES, THE EMS WILL DETECT A FAULT, STORE A FAULT CODE, ILLUMINATE A WARNING LAMP, AND THE ENGINE MAY REMAIN AT/RETURN TO IDLE.IN THE EARLY STAGES, NORMAL OPERATION CAN BE REGAINED BY PEDAL RE-APPLICATION.THE FAILURE PROGRESSES UNTIL THE ENGINE REMAINS AT IDLE.THE ENGINE DOES NOT STALL, POWER ASSISTED STEERING AND BRAKING SYSTEMS ARE UNAFFECTED. FORD CORRECTED THE ETC SENSOR DEFECT AND CONDUCTED FIELD SERVICE ACTION (FSA) 03B03 TO REPLACE ETC PEDALS, ADDRESSING 50% OF VEHICLES.AT AGENCY REQUEST TO IMPROVE COMPLETION RATE, FORD EXTENDED FSA 03B03 FOR 6 MONTHS.BASED ON ODI'S ANALYSIS OF AVAILABLE DATA, FORD'S ACTION HAS APPROPRIATELY RESOLVED THE ETC SENSOR PROPLEM IN THE SUBJECT VEHICLES.THE CLOSING OF THE INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST, AND SHOULD NOT BE CONSIDERED AS HAVING ANY PRECEDENTIAL VALUE OR EFFECT BINDING THE AGENCY IN FUTURE DEFECT INVESTIGATIONS. SEE THE ATTACHED SUMMARY REPORT FOR ADDITIONAL INFORMATION.

Recorded closure: Feb 10, 2005

Find investigation EA04006
Opened Mar 2, 2001 ClosedSECTOR SHAFT FRACTURESEA01009

THIS EA WAS OPENED BASED ON A RESPONSE RECEIVED FROM FORD MOTOR COMPANY TO AN INFORMATION REQUEST (IR) SUBMITTED DURING SQ00-018.FORD STATED IN AN INTERNAL SERVICE MESSAGE THAT IT HAD CHANGED THE STEERING GEAR SECTOR SHAFTS AND PITMAN ARMS INSTALLED 1999 MODEL YEAR F-SERIES SUPER DUTY VEHICLES ON MARCH 22, 1999.FORD STATED THAT THESE DESIGN CHANGES WERE IMPLEMENTED TO MAKE IMPROVEMENTS IN VEHICLE STEERING AND HANDLING, AND THAT VIRTUALLY ALL OF THE REPORTED FRACTURED SECTOR SHAFTS WERE THE RESULT OF EXTRAORDINARY, POSSIBLY MULTIPLE, IMPACTS.AN ENGINEERING ANALYSIS CLOSING REPORT IS ATTACHED.

Recorded closure: Aug 19, 2003

Find investigation EA01009

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