2003 Ford Cvpi

FRACTURE (CRACKING) OF THE SUBJECT VEHICLE (SV) WHEEL, WHICH WAS PREVIOUSLY INVESTIGATED UNDER PRELIMINARY EVALUATION PE03-009 (SAFETY RECALL 03V-279), OCCURS IN THE MODEL YEAR (MY) 2003 TO 2005 POLICE INTERCEPTOR VEHICLES ONLY; CIVILIAN SPECIFICATION AND OTHER MY VEHICLES ARE UNAFFECTED BY THIS CONDITION.FOR THE AFFECTED SUBJECT WHEELS, A FATIGUE CRACK OCCURS IN THE HEAT AFFECTED ZONE OF THE RIM MATERIAL ADJACENT TO THE CIRCUMFERENTIAL WELD THAT ATTACHES THE RIM TO THE OUTBOARD WHEEL DISC.THE CRACK INITIATES UNDER THE OUTBOARD TIRE BEAD NEAR THE HEEL (WHERE AIR LEAKAGE CANNOT BE ASSURED) AND SUBSEQUENTLY GROWS CIRCUMFERENTIALLY THROUGH CYCLIC BENDING AS THE WHEELS ROLLS.ALTHOUGH THE VAST MAJORITY OF RIM CRACKS EITHER PRESENTED NO SYMPTOMS OR WERE DETECTED SAFELY VIA RECURRING SLOW AIR LEAKAGE, ODI IDENTIFIED 6 INCIDENTS WHERE RAPID AIR LEAKAGE LEADING TO A FULL OR PARTIAL DEFLATION OF THE TIRE WAS ALLEGED.FOR THESE WHEELS, EVIDENCE INDICATED THAT MULTIPLE CRACKS HAD FORMED IN DIFFERENT AREAS OF THE RIM AND SUBSEQUENTLY GROWN TOGETHER.TWO OF THE INCIDENTS RESULTED IN A CRASH, ONE DURING A HIGH SPEED PURSUIT.ALTHOUGH THE MINORITY OF CASES, FORD?S ASSESSMENTS OF FIELD RETURN WHEELS SHOWED THAT MULTIPLE CRACKS EXIST IN APPROXIMATELY 17 PERCENT OF THE CRACKED WHEELS REPLACED UNDER A FORD EXTENDED WARRANTY PROGRAM.IN A WHEEL WITH MULTIPLE CRACKS, AS THE AREA BETWEEN THE CRACKS IS REDUCED BY GROWTH A HIGH STRESS CONDITION (SUCH AS WOULD OCCUR IN AN AGGRESSIVE VEHICLE MANEUVER DURING A HIGH-SPEED PURSUIT) MAY CAUSE THE CRACKS TO JOIN TOGETHER RAPIDLY.IF THE CRACKS ARE OF SUFFICIENT SIZE, THE STRUCTURAL INTEGRITY OF THE RIM MAY BE COMPROMISED RESULTING IN RAPID AIR LOSS AND RIM DEFORMATION.FOR POLICE VEHICLES USED AT HIGH SPEED, RAPID DEFLATION AND LOSS OF RIM STRUCTURAL INTEGRITY AFFECTS VEHICLE CONTROL AND MAY INCREASE THE RISK OF A CRASH.FATIGUE IS THE FUNDAMENTAL FRACTURE MECHANISM; THEREFORE, WHEEL FRACTURE CAN BE EXPECTED TO OCCUR (AND AT AN INCREASED INCIDENCE LEVEL) AS LONG AS THE AFFECTED WHEELS REMAIN IN SERVICE.IN DECEMBER 2004 (WITHIN MY 2005 SV PRODUCTION) FORD INTRODUCED A SHOT PEEN PROCESS INTO THE MANUFACTURE OF SV WHEELS.SHOT PEEN WHEELS, WHICH ARE IDENTIFIED BY UNIQUE PART NUMBER STAMPINGS, HAVE NOT EXHIBITED FRACTURE IN POLICE SERVICE TO DATE.UNDER 07V-079, FORD WILL INSPECT SVS REGISTERED FOR POLICE USE AND REPLACE EARLIER DESIGN LEVEL WHEELS WITH SHOT PEEN WHEELS.POLICE AGENCIES SHOULD BE ADVISED THAT MY 2005 VEHICLES BUILT AFTER DECEMBER 2004 ARE NOT WITHIN THE SCOPE OF THIS RECALL (SINCE THEY WERE ORIGINALLY MANUFACTURED WITH SHOT PEEN WHEELS).AGENCIES SHOULD BE DILIGENT IN ENSURING THAT NON-SHOT PEEN WHEELS ARE REMOVED FROM OUT-OF-SCOPE VEHICLES OR OTHER WHEEL SUPPLY INVENTORIES.

DURING A SEPTEMBER 23, 2004 MEETING AND IN SUBSEQUENT DISCUSSIONS IN NOVEMBER, FORD ADVISED THE OFFICE OF DEFECTS INVESTIGATION (ODI) OF THEIR PLANS TO INTRODUCE AN IMPROVED STEEL WHEEL FOR MANUFACTURING AND SERVICE COMPONENT USE ON THE SUBJECT VEHICLES, INDICATING THIS WOULD OCCUR IN DECEMBER 2004.THE NEW WHEEL DESIGN INCORPORATES AN ADDITIONAL MANUFACTURING PROCESS (SHOT PEENING) WHICH LOWERS TENSILE STRESS IN THE SURFACE LAYER OF THE RIM MATERIAL ADJACENT TO THE CIRCUMFERENTIAL WELD. THEORETICALLY THIS SHOULD IMPROVE RIM DURABILITY BY REDUCING FATIGUE CRACK INITIATION SITES.INDICATIONS FROM FORD?S ACCELERATED TESTING METHODS SHOW AN IMPROVEMENT IN THE PERFORMANCE OF THE NEW WHEEL.IN ADDITION TO PRIOR SAFETY RECALL 03V279 AND SERVICE ACTION (SA) 03M03, FORD WILL ANNOUNCE A NEW EXTENDED WARRANTY SA FOR VEHICLES BUILT PRIOR TO DECEMBER 2004 THAT SUFFER RIM FRACTURES IN SERVICE.THE NEW WHEEL DESIGN WILL BE USED AS A REMEDY.FORD ADVISES THAT A SA IS SUFFICIENT FOR ADDRESSING FUTURE WHEEL FAILURES (INCLUDING RECALL 03V279 REMEDY WHEEL FAILURES) BECAUSE: 1) FAILURE RATES ARE LOW BASED ON FORD?S ANALYSIS, AND 2) DRIVER WARNINGS (REPETITIVE SLOW AIR LOSS, AND OR STEERING WHEEL VIBRATION) ALLOW EARLY AND SAFE DETECTION OF CRACKED WHEELS.ODI HAS RECEIVED 25 VEHICLE OWNER QUESTIONNAIRE (VOQ) REPORTS (INVOLVING 22 VEHICLES) WHICH ALLEGE A RIM FRACTURE OF ONE OR MORE STEEL WHEELS.ABOUT HALF THE REPORTS INVOLVE VEHICLES BUILT WITH THE REMEDY WHEEL USED FOR RECALL 03V279, AND MOST OF THE REMAINING VEHICLES WERE SUBJECT TO THE RECALL.THE PROCESS OF IDENTIFYING PERTINENT FORD COMPLAINTS IS MADE DIFFICULT BY FORD?S PRIOR RECALL AND WARRANTY PROGRAM ACTIVITIES.THE MANUFACTURER COMPLAINT AND WARRANTY COUNTS, WHICH PRIMARILY INVOLVE FAILURES OF RECALL 03V279 REMEDY WHEELS, ARE BASED ON ANALYSIS CONDUCTED TO DATE AND ARE CONSIDERED TO BE CONSERVATIVE.FURTHER INVESTIGATION IS REQUIRED, THUS ODI IS UPGRADING THIS INVESTIGATION TO AN ENGINEERING ANALYSIS (EA).DURING THE EA, PERTINENT FAILURE REPORTS AND CONSEQUENCES WILL BE IDENTIFIED AND REVIEWED.ODI AND FORD WILL DISCUSS DETAILS FOR CONDUCTING AN AUDIT ANALYSIS OF FAILED WHEELS REPLACED UNDER THE NEW SA.ADDITIONALLY, ODI IS AWAITING FORD?S LAB ANALYSIS OF TWO WHEELS WHICH WERE THE SUBJECT OF VOQ REPORTS, ONE OF WHICH WAS INVOLVED IN THE NOTED CRASH EVENT.A DETERMINATION WILL BE MADE AS TO WHETHER FORD?S SERVICE ACTION IS SUFFICIENT FOR ADDRESSING ONGOING RIM FRACTURES.

AIR LEAKS OUT THE BACK WHEEL EVERY DAY AFTER FILL UP GAS IT SMELLS LIKE GAS INSIDE CAR. *TR

NHTSA ID

10606666

Incident

Jun 25, 2014

Mileage

115,348 mi

I JUST READ ABOUT THE STEERING COLUMN RECALL ON THE CROWN VIC, CVPI, AND GRAND MARQUIS 2005-2011 AND I AM NOT SURE WHY THE 2003-2004 MODELS ARE NOT INCLUDED. THEY HAVE THE SAME ISSUES DESCRIBED IN THIS RECALL. I HAD MY 2003 CVPI IN THE SHOP LESS THAN A MONTH AGO DUE TO SOME STEERING ISSUES I'M HAVING (A LOT OF NOISE DURING DRIVING AND WHILE TURNING) AND THE OUTCOME WAS THAT MY CAR NEEDS A STEERING COLUMN FLEX COUPLER (SHAFT, LOWER) AND THE LOWER BALL JOINT (CONTROL ARM) ALSO NEEDS REPLACED DUE TO EXCESSIVE CORROSION. SO AGAIN, I'M ASKING WHY IT'S NOT PART OF THE RECALL? ALSO, I'M HAVING THE SAME ISSUES WITH MY TIRES THAT A LOT OF OTHER CVPI OWNERS ARE HAVING CONCERNING THE CRACKS IN THE RIMS. MY TIRES ONLY HAVE A FEW THOUSAND MILES ON THEM AND I'M HAVING TO PUT AIR IN THE PASSENGER REAR TIRE ABOUT ONCE A WEEK DUE TO LOSS OF AIR PRESSURE. (I'M LOSING ABOUT 20 PSI A WEEK ON AVERAGE). THE TIRES HAVE BEEN CHECKED AND ARE FINE. *JB

NHTSA ID

10538503

Incident

Aug 19, 2013

Mileage

180,040 mi

I HAVE STEEL WHEELS ON MY 2003 CROWN VIC I RECEIVED A RECALL NOTICE FROM FORD MOTOR COMPANY STATING THAT MY WHEELS WERE PART OF A SAFETY RECALL, THE WHEELS ARE PRONE TO WELDS BREAKING AND RUSTING MAKING THEM LOOSE AIR AND IMPOSSIBLE TO BALANCE WHY STEERING WHEEL SHAKES I HAVE HAD DIFFERENT TIRES AND MULTIPLE SHOPS BALANCE THE WHEELS THEY ARE NOT ABLE TO, ALSO THEY LOOSE AIR ALL THE TIME. I CONTACTED FORD ABOUT THIS ISSUES WHERE I WAS TOLD BECAUSE I AM NOT A POLICE DEPARTMENT THEY WILL NOT BE ABLE TO HONOR THE RECALL, THEY SAY ITS ONLY FOR CARS IN POLICE USE. IM CONCERNED AS THESES WHEELS HAVE BEEN USED BY THE PRIOR OWNER AKA A POLICE FORCE MAKING THE CARS WHEELS UNSAFE FOR ME FOR WANTS ME TO PAY TO GET NEW WHEELS AT A COST OF OVER 500 DOLLARS I JUST WANT THEM TO HONOR THE RECALL AS THE WHEELS ARE CERTAINLY UNSAFE. *TR

NHTSA ID

10447434

Incident

Feb 1, 2011

Mileage

123,000 mi

HEADLIGHTS GO OFF WHILE DRIVING. LCM IS BAD, $500.00 FOR PART. VERY VERY DANGEROUS SITUATION. I WAS EXPECTING TO SEE A RECALL NOTICE. THIS IS THE SECOND LCM FOR ME! *KB

NHTSA ID

10413990

Incident

Jul 5, 2011

Mileage

150,229 mi

I JUST PURCHASES AND TOOK POSSESSION OF A 2003 FORD CROWN VICTORIA POLICE INTERCEPTOR. I DROVE THE VEHICLE FOR A COUPLE DAYS DURING DAYLIGHT HOURS WITH NO ISSUES. HOWEVER, ON THE FIRST NIGHT I DROVE THE VEHICLE (WELL AFTER SUNSET) I EXPERIENCED NUMEROUS OCCURRENCES OF THE HEADLIGHTS GOING OUT COMPLETELY FOR EXTENDED PERIODS OF TIME (RANGING FROM SEVERAL SECONDS TO SEVERAL MINUTES). THE ONLY WAY I WAS ABLE TO CONTINUE DRIVING THE VEHICLE WAS TO HOLD THE HIGH/LOW BEAM SWITCH IN THE HIGH BEAM POSITION. IF I WERE ON AN UNLIT ROAD THIS SITUATION COULD HAVE EASILY RESULTED IN A VEHICLE CRASH, POTENTIALLY DAMAGING OR DESTROYING THE VEHICLE AND INJURING OR KILLING MYSELF AND/OR ANY NEARBY PEDESTRIANS. I HAVE SEEN THE CLOSED INVESTIGATION #PE08066, WHICH STATES THAT THE REASON THIS ISSUE WAS CLOSED IS BECAUSE IT HAS NOT RESULTED IN A DEATH. BEING A VOLUNTEER FIRE FIGHTER AND EMERGENCY MEDICAL RESPONDER, I DO NOT CONSIDER THIS TO BE AN ACCEPTABLE REASON FOR CLOSING SUCH AN OBVIOUS SAFETY ISSUE. I HAVE LEARNED THAT THE COST TO REPLACE THE DEFECTIVE CIRCUITRY IS UPWARDS OF $500+ FOR THE PART ALONE, NOT INCLUDING LABOR COSTS. *TR

NHTSA ID

10401308

Incident

May 16, 2011

Mileage

72,200 mi

2003 CROWN VICTORIA, HEADLIGHTS STOP WORKING WHILE DRIVING. IT APPEARS I NEED TO REPLACE THE LIGHTING CONTROL MODULE (LCM). I SEE FROM INTERNET SEARCHES THAT MANY MANY HAVE HAD THIS SAME PROBLEM.THIS PART IS ALMOST $600 FROM FORD. IT APPEARS THAT FORD HAS A SAFETY ISSUE HERE THAT THEY ARE AVOIDING. I'M SURPRISED THAT NO RECALL IS IN EFFECT. AT LEAST FORD SHOULD OFFER SOME GOODWILL SUPPORT TO THEIR CUSTOMERS BY LOWERING THE PRICE OF THIS PART.... *TR

NHTSA ID

10369070

Incident

Dec 3, 2010

Mileage

134,799 mi

THE VEHICLE'S HEADLIGHTS SHUT THEMSELVES OFF RANDOMLY WHILE THE HEADLIGHTS ARE IN USE. INTERMITTENTLY, THE LIGHTS WILL FAIL TO TURN ON WHEN THE SWITCH IS TURNED ON. THESE EVENTS HAVE BECOME INCREASINGLY FREQUENT TO THE POINT THAT NOW THE LIGHTS WILL FAIL SEVERAL TIMES ON EVERY NIGHT TRIP. HITTING A BOX CALLED THE "LIGHTING CONTROL MODULE" MAY ENCOURAGE THE LIGHTS TO TURN BACK ON TEMPORARILY. *TR

NHTSA ID

10366542

Incident

Nov 16, 2010

Mileage

134,414 mi

TL*THE CONTACT OWNS A 2003 FORD CROWN VICTORIA CVPI. WHILE DRIVING 10 TO 60 MPH THE HEADLIGHTS WOULD SHUT OFF INTERMITTENTLY AT NIGHT. THERE WERE NO WARNING LIGHTS ILLUMINATING BEFORE THE HEADLIGHTS FAILED. AS THE VEHICLE WAS BEING DRIVEN ONTO THE SIDE OF THE ROAD SOMETIME THE LIGHTS WOULD COME BACK ON WITHIN 5 TO 10 MINUTES. THE VEHICLE WAS TOWED TO A REPAIR FACILITY. THE DEALER STATED THAT HE HAD TO PAY $418 IN ORDER TO REPLACE THE LIGHTING CONTROL MODULE SINCE THERE WERE NO RECALLS OR RELATED WARRANTIES. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT CONTACTED. THE FAILURE MILEAGE WAS 282,000.

NHTSA ID

10353579

Incident

Jan 4, 2009

Mileage

282,000 mi