2002 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.

BOTH FRONT TIRES MERELY DEVELOPED TREAD BULGES , LESS THAN 15K MILES, NEVER HAD A FLAT, BEEN OVERLOADED ,OVERINFLATED , ECT.. THEY JUST BECAME VERY POOR DRIVING AND VIBRATED BADLY TO FIND THEY BOTH HAVE BULGES IN THE TREAD. THEY SEEMED FINE ABOUT TWO WEEKS AGO AND WHEN I WENT TO DRIVE IT A COUPLE DAYS AGO THE PROBLEM BECAME APPARENT. *TR

NHTSA ID

11331209

Incident

Jun 24, 2020

Mileage

282,952 mi

TL* THE CONTACT OWNS A 2002 FORD E-250. THE CONTACT STATED THAT WHILE DRIVING AT 60 MPH, THE FUEL TANK STRAP DETACHED FROM THE VEHICLE AND CAUSED THE FUEL TANK TO NEARLY TOUCH THE GROUND. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE WAS 160,000.

NHTSA ID

10763125

Incident

Jun 3, 2015

Mileage

160,000 mi

I OWN A FORD F-250 WITH A 5.4 MOTOR. THIS TRUCK BLEW A SPARK PLUG OUT OF THE MOTOR ON 4-15 -2008 AND IT BLEW A DIFFERENT SPARK PLUG OUT OF THE MOTOR ON 5-13-2009. FORD NEEDS TO RECALL THIS TRUCK AND OTHER VEHICLES AND CORRECT THIS DEFECT. I WILL BE TALKING WITH A LAWYER IN THE NEXT FEW DAYS IN HOPES OF GETTING MY TRUCK REPAIRED AND TO RECOVER THE MONEY I HAVE ALREADY SPENT FOR REPAIRS.I F SAFERCAR.GOV WILL CHECK WITH PARTS HOUSES SUCH AS AUTO ZONE AND REPAIR SHOPS YOU WILL FIND THIS IS A VERY BIG PROBLEM, A VERY VERY BIG PROBLEM. I PULL A HORSE TRAILER AND IF THIS SPARK WOULD HAVE BLEW OUT WHILE PULLING OUT INTO TRAFFIC ME OR MY DAUGHTER COULD HAVE BEEN KILLED !!!!!! *TR WALTER GLENN JOHNSON BYRAM,MS

NHTSA ID

10268892

Incident

May 13, 2009

Mileage

117,715 mi

FAILURE OF CAM POSITION SENSOR ON 2002 FORD F250 DIESEL. MOTOR STOPS WORKING LOST OF POWER STEERING AND ALL POWER,AS IF KEY WAS TURNED OFF. IF PULLING TRAILER THIS WAS AN EXTREMLY DANGERIOS CONDITIONIN IN THE FORD 2002 F250 TRUCK WITH THE 7.3 DIESEL MOTOR. JUST CHECK THE INTERNET TO SEE HOW MANY PEOPLLE WERE HAVING TROUBLE. *AK

NHTSA ID

10195390

Incident

Jun 28, 2007

Mileage

40,000 mi

4R70W TRANSMISSION FAILURE. PLANETARY GEAR SHATTERED RESULTING IN A TRANSMISSION FAILURE. REQUIRING THE TRANSMISSION TO BE REBUILT. *NM

NHTSA ID

10183496

Incident

Feb 14, 2007

Mileage

75,000 mi

TOTAL CATALYTIC CONVERTER FAILURE AT 51,000 MILES. SAT AT DEALERSHIP FROM JAN 3,2006 TO APRIL 7, 2005 WAITING FOR DEALER ONLY PART. NO CAUSE FOUND. TRUCK WAS IN EXCELLENT RUNNING CONDITION. *NM

NHTSA ID

10183494

Incident

Jan 3, 2005

Mileage

51,000 mi

FORD HAS RECALLS ON 1994-2002 FORD TRUCK 8500 GVW AND UNDER I HAVE A 2002 F250 FORD 8600 GVW THAT USES SAME CRUISE CONTROL PARTS AS THE OTHER TRUCKS. THIS UNIT WAS SITTING IN GARAGE WHEN NOT RUNNING WHEN THE SAME PARTS THAT ARE BEING REPLACED ON OTHER VEHICLES IGNITED ON FIRE. FORD WILL NOT REPLACE THE PARTS. *JB

NHTSA ID

10138296

Incident

Sep 5, 2005

Mileage

90,000 mi

TIRE SEPARATION, GOODYEAR LT245/75R16E TIRES. AT APPROXIMATELY 30000 MILES, THE TIRE BEGAN TO BOUNCE DUE TO A TREAD SEPARATION, CREATING AN UNSAFE SITUATION. *AK

NHTSA ID

10114525

Incident

Mar 20, 2005

Mileage

30,000 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.

HEADLIGHT ADJUSTMENT NEEDED. *KB

MALFUNCTION INDICATOR LAMP ON WITH DIAGNOSTIC TROUBLE CODE P1131 AND/OR P1151 - 4.2L ENGINE. *TT

HEADLIGHT ADJUSTMENT - CHASSIS CAB INCOMPLETE VEHICLES. *TT

DIAGNOSTIC TROUBLE CODE B1876, B1880, B1915 AND/OR B1920 IN THE ECS MODULE - VEHICLES EQUIPPED WITH AFTERMARKET HIGH CURRENT DEVICES. *TT

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