1997 Ford E-250

This investigation was opened based on one complaint and reports from four transportation fleets alleging 182 blower motor control switch failures.ODI was concerned that these melting and burning switches could lead to an open flame that could spread throughout the vehicle.After a comprehensive review of all data related to overheating blower motor control switches in the subject vehicles, ODI did not identify the existence of a safety defect trend.ODI reviewed 1,036 complaints, claims, and field reports of failed blower motor control switches and determined that only two fires were likely to have been caused by a failing subject blower motor control switch.This represents a failure rate of 0.2 R/100K on a population of 1,076,975 vehicles that have been in service for up to 14 years.ODI has found that when the subject switches do fail and begin to melt, they are constructed in a manner that typically prevents the failing switch from igniting and developing into an open flame.Ford Motor Company has agreed to take two actions to further reduce the likelihood an overheated blower motor switch in the subject vehicles.Ford informed ODI that it has implemented a series of design changes to the subject switch that will help prevent it from developing internal high resistance short circuits.Ford has also informed ODI that it would release a Technical Service Bulletin (TSB-11-11-21) instructing subject vehicle owners to replace the electrical connector at the same time a failed switch is replaced.In light of the low rate of failure resulting in open flame and fire spread on the subject vehicles, and Ford's actions to reduce the likelihood of a switch failure through switch design changes and a TSB, further use of agency resources does not appear to be warranted.The closing of this investigation does not constitute a finding by NHTSA that no safety-related defect exists.The agency reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following (ODI) numbers: 10427875, 10114393, 10257890For additional information, see the attached closing report.

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.

There is no summary currently available

TL* THE CONTACT OWNS A 1997 FORD E-250. WHILE DRIVING AT APPROXIMATELY 55 MPH, THE FAN SWITCH THAT CONTROLS THE FAN SPEED MELTED AND BURNED. THE CONTACT COASTED TO THE SIDE OF THE ROAD, PULLED THE COVER FOR THE DASHBOARD, AND REMOVED THE WIRES THAT WERE CONNECTED TO THE SWITCH. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THAT THE BURNED WIRES SWITCH NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 236,092.

NHTSA ID

10732449

Incident

Jun 28, 2015

Mileage

236,092 mi

SPARK PLUG EJECTION. POSSIBLE FIRE HAZARD. *TR

NHTSA ID

10260335

Incident

Feb 28, 2009

Mileage

97,000 mi

I HAVE MICHELIN XPS 235-83/R16 TIRES ON MY MOTORHOME, LESS THAN 2 YEARS OLD. FOR NO REASON, I HAVE HAD 3 FAILURES OUT OF 4 TIRES. THE LAST FAILURE WAS IN THE RV LOT, WHERE I HAVE BEEN PARKED FOR THE LAST 5 MONTHS, AND THE TIRE JUST BLEW OUT, SAME WITH THE OTHER 3 TIRES. THERE ARE MANY COMPLAINTS FILED ON THE INTERNET. PLEASE RECALL ALL OF THE DEFECTIVE TIRES.. *TR

NHTSA ID

10235732

Incident

Jul 5, 2008

FORD MOTOR COMPANY HAS FAILED TO PROVIDE THE NECESSARY SERVICE TO REMEDY THE CRUISE CONTROL RECALL SPECIFIED IN ODI ID NUMBER : 10056190. I HAVE CONTACTED THE DEALERSHIPS IN ASHEVILLE, NORTH CAROLINA & BLACK MOUNTAIN, NORTH CAROLINA MONTHLY SINCE I WAS ADVISED OF THE RECALL AUGUST, 2007. EACH TIME I HAVE BEEN TOLD THAT THE REPAIR KIT IS UNAVAILABLE FROM FORD. *TR

NHTSA ID

10216762

Incident

Aug 30, 2007

SPARK PLUG EJECTED FROM CYLINDER HEAD AND REPEATEDLY STRUCK PRESSURIZED FUEL RAIL. *JB

NHTSA ID

10150288

Incident

Dec 18, 2005

Mileage

150,000 mi

FORD ECONOLINE ( 25V) 1997, ENGINE BURST INTO FLAMES WHILE DRIVING. *BF PRIOR TO THE FIRE THE CONSUMER HAD OTHER WORK PERFORMED ON THE VEHICLE. THE ALTERNATOR WAS REPLACED, THE OVERDRIVE LIGHT WAS ON AND IT WAS DIFFICULT TO SHIFT INTO 2ND GEAR. THE CONSUMER WANTED TO KNOW IF THE FIRE HAD ANYTHING TO DO WITH THE FAULTY CRUISE CONTROL SWITCH THAT ARE IN FORD VEHICLE. *JB

NHTSA ID

10115614

Incident

Jan 21, 2005

HEATER TEMP CONTROL FAILS. *AK

NHTSA ID

10108332

Incident

Dec 20, 2004

Mileage

35,975 mi

CRUISE CONTROL FAILURE, ENGINE SPED UP, LOSS OF BRAKES

NHTSA ID

10056190

Incident

Sep 16, 2003

Mileage

134,511 mi

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.

VIBRATION/HARSHNESS ABOVE 45 MPH (72 KM/H) AFTER TIRE BALANCE. *TT

A BUMP STEER STEERING FEELING, NOTED WHEN THE VEHICLE'S FRONT WHEELS/TIRES CONTACT ROAD SURFACE IRREGULARITIES. *TT

SOME VEHICLES EQUIPPED WITH 4R70W TRANSMISSION (DRIVESHAFT >70 INCH) MAY EXHIBIT A VIBRATION / ROUGHNESS ON ACCELERATION OR UNDER LOAD AT ABOUT 50-55 MPH. *TT

CONCERNS WITH BUMP STEER STEERING FEELING NOTED WHEN FRONT WHEELS / TIRES CONTACT ROAD SURFACE IRREGULARITIES. *TT

SOME VEHICLES MAY EXHIBIT A FUEL FILL VALVE SEALING CONDITION. *YD