2004 Ford Crown Victoria

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.

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.

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.

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.

Taillight failure and corner light failure likely caused by faulty wiring as mentioned in 2015 lcm recall

NHTSA ID

11483992

Incident

Sep 7, 2022

I was informed by my mechanic that my steering column shaft needs to be replaced on my 2004 primary vehicle. Ford says they do not have a recall and will not cover the service. I have a recall for THE SAME ISSUE for my (not currently driving) 2005 Ford Crown Victoria Interceptor made in the SAME LOCATION (St. Thomas). 2005 Manufacturer Recall Number 13S08, NHTSA Recall Number 13V385000). The recall includes cars originally sold in NH (both of mine) and says: 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. Safety Risk: IF THE LOWER BEARING SEPARATES, THE VEHICLE MAY EXPERIENCE A LOSS OF STEERING, INCREASING THE RISK OF A CRASH. How can Ford say there is no issue when there is an active recall for it on model years 2005-2011? Have there been reported issues/crashes of 2004 cars with this defect? Is there anything I can do to have Ford cover this? Or are they not bothering because there probably aren't many 2004s still on the road? Is it possible to get Ford to provide the manufacturer lot/date codes of the defective steering parts? As my 2004 & 2005 were built in the same location, I would bet my 2004 was built with the same steering part manufacturer lot as my 2005- they probably don't turn out the volume of police Interceptors as commercial cars. Thank you

NHTSA ID

11450920

Incident

Feb 1, 2022

THE GOOD YEAR EAGLE SPORT TIRES TORE APART ON A SHORT TRIP TO THE GROCERY STORE AND CAUSED THE CAR TO BE UNSAFE TO DRIVE. THE TIRES WERE MANUFACTURED ON JUNE 2019 AND PURCHASED OCTOBER 2019 AND BY JANUARY 3RD OF 2021 THEY WERE FLAT AND CHEWED UP WITH ONLY AROUND 13,000 MILES ON THEM EVEN THOUGH THEY WERE 50,000 MILE TIRES. THIS COMPLAINT IS INVOLVING THE GOODYEAR TIRES THAT WERE ON THE CAR AND THE ONE THAT FAILED AND WAS CHEWED UP DESPITE LOW MILES AND RECENTLY MANUFACTURED/MADE WITHIN THE LAST 19 MONTHS PRIOR TO THIS HAPPENING. IT SHOULD BE NOTED THAT AFTER THE TIRE WAS DISCOVERED CHEWED UP THE BRAKE SYSTEM WAS IN NEED OF REPAIR AS THE TIRE CAUSED DAMAGE. THE BRAKES WERE NOT RESPONSIVE TO STOPPING AFTER THE TIRE WAS CHEWED UP EVEN THOUGH THERE WAS SOME BRAKING POWER WHEN BRAKE PEDAL WAS PUSHED DOWN TO THE FLOOR, THE BRAKING POWER WAS REDUCED AND THE BRAKE LIGHT ON THE CAR CAME ONE. THAT IS TO SAY THAT THE TIRE FAILURE DAMAGED SOME OF THE BRAKING COMPONENETS IN THE VEHICLE. DOT C0X3 2E1R 0619

NHTSA ID

11386905

Incident

Jan 3, 2021

Mileage

109,000 mi

THE NEAD LIGHTS SHUT OFF WHILE DRIVING AT NIGHT AT 65 MILES A HOUR STOPED ON THE SIDE OF THE HIWAY SHUT OFF THE CAR PLAYED WITH THE HEADLIGHT SWITCH THE LIGHTS CAME BACK ON BUT NOW THEY WILL NOT SHUT OFF SO THE BATTERY MUST BE DICONECTED WHEN NOT IN USE WORKING ON FINDING A REPAIR SHOP T FIX IT

NHTSA ID

11377413

Incident

Nov 30, 2020

Mileage

117,000 mi

2004 FORD CROWN VIC HEADLIGHTS STOPPED WORKING. I ORDERED AND REPLACED THE HEADLIGHT SWITCH AND MY HEADLIGHTS STILL DON'T WORK. I CAN'T DRIVE AT NIGHT ANYMORE. I HAVE CONTACTED FORD DEALERSHIP ABOUT A RECALL AND HAVE NOT RECEIVED A CALL BACK.

NHTSA ID

11372311

Incident

Oct 3, 2020

Mileage

124,000 mi

TL* THE CONTACT OWNS A 2004 FORD CROWN VICTORIA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 15V861000 (EXTERIOR LIGHTING) HOWEVER, THE PART TO DO THE RECALL REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. NEITHER THE DEALER NOR THE MANUFACTURER WERE MADE AWARE OF THE ISSUE. THE CONTACT STATED THAT THE HEADLIGHTS FAILED TO ILLUMINATE PROPERLY WITHOUT WARNING. THE CONTACT MANUALLY ADJUSTED THE LIGHT SWITCH AND THE HEADLIGHTS OPERATED AS INTENDED. THE FAILURE MILEAGE WAS APPROXIMATELY 120,000. VIN TOOL CONFIRMS PARTS NOT AVAILABLE.

NHTSA ID

11361504

Incident

Sep 8, 2020

Mileage

120,000 mi

WHAT HAPPENED IS THAT I GOT THE VIN REPORT ONLINE AND ASKED ABOUT RECALLS, FOUND 5 RECALLS, AND WENT TO THE NHTSA AND NOW YOU DO NOT TELL ME IF THE RECALLS WERE MADE OR THE PROBLEMS FIXED. *TR

NHTSA ID

11328516

Incident

May 22, 2020

Mileage

55,600 mi

TL* THE CONTACT OWNS A 2004 FORD CROWN VICTORIA. WHILE DRIVING VARIOUS SPEEDS, THE STEERING WHEEL SEIZED WHILE TURNING RIGHT OR LEFT. THE CONTACT MENTIONED THAT THE FAILURE OCCURRED PERIODICALLY. THE VEHICLE WAS NOT TAKEN TO A DEALER OR INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING OR REPAIRS. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND INFORMED THE CONTACT THAT THERE WAS NO RECALL ON THE VEHICLE. THE FAILURE MILEAGE WAS 96,000.

NHTSA ID

11245836

Incident

Mar 1, 2017

Mileage

96,000 mi

This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended.

Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition

Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition

The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate when reading these PIDs and cannot display quickly enough to validate a concern. The PCM automatically monitors these inputs more accurately and will set diagnostic trouble codes (DTCs) when appropriate. Using these PIDs for diagnostics will lead to inaccurate results and improper ETB replacements. If a concern is intermittent and no DTCs are present, refer to historical DTCs and the PC/ED, Section 3 No DTCs Present Index chart for further information.

SUMMARY TO BE PROVIDED ON A FUTURE DATE.

FORD: THE LIGHTING CONTROL MODULE HAS EXTENDED WARRANTY COVERAGE, ON CERTAIN VEHICLES, DUE TO A POSSIBLE CRACK ON SOLDER JOINT THAT CONNECTS RELAY TO CIRCUIT BOARD. MODEL 2003-2005 CROWN VICTORIA, GRAND MARQUIS. *PE