2003 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.

TIRE BRAND AND SIZE: PATHFINDER SPORT S A/T 245/75-16 PUT ON REAR OF 2003 FORD E250 EXTENDED LENGTH WORK VAN. BOUGHT NEW FROM DISCOUNT TIRE. AS SOON AS I GOT ON THE INTERSTATE I NOTICED THE VEHICLE FELT UNSTABLE. WAS WANDERING IN REAR. WHEN MAKING A LANE CHANGE IS WAS REALLY BAD AND FELT UNSAFE AS THE REAR SWAYED FROM SIDE TO SIDE. HAD THEM TAKE THESE TIRES OFF AND REPLACE WITH A MAJOR BRAND AND THIS PROBLEM WENT AWAY. I HIGHLY RECOMMEND SOME ONE LOOKS INTO THESE TIRES AS I THINK THE POTENTIAL IS THERE FOR CAUSING A SPIN OUT OR ROLL OVER.

NHTSA ID

10907234

Incident

Sep 14, 2016

TL* THE CONTACT OWNS A 2003 FORD E-250. THE CONTACT STATED THAT THE ENGINE TEMPERATURE GAUGE FAILED. THE CONTACT TOOK THE VEHICLE TO THE DEALER AND WAS TOLD THAT THE INSTRUMENT PANEL WOULD NEED TO BE REPLACED. THE FAILURE PREVENTED THE CONTACT FROM KNOWING IF THE VEHICLE WAS OVERHEATING. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 60,000. *TR

NHTSA ID

10531554

Incident

Jul 10, 2013

Mileage

60,000 mi

TL* THE CONTACT OWNED A 2003 FORD E-250. THE CONTACT STATED THAT UPON STARTING, THE VEHICLE SURGED IN REVERSE AND CRASHED INTO A BUILDING. THE VEHICLE WAS DESTROYED AND TOWED TO AN INDEPENDENT REPAIR SHOP. THE FAILURE WAS NOT DIAGNOSED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 170,000. THE VIN WAS UNAVAILABLE.

NHTSA ID

10454526

Incident

Mar 19, 2012

Mileage

170,000 mi

TL* THE CONTACT OWNS 2003 FORD E-250. THE CONTACT STATED WHILE DRIVING 2 MPH, PRESSURE WAS APPLIED TO THE BRAKE PEDAL AND IT DEPRESSED TO THE FLOOR. THE CONTACT ENGAGED THE EMERGENCY BRAKE IN ORDER TO STOP THE VEHICLE. AN INDEPENDENT MECHANIC EXAMINED THE VEHICLE AND STATED THAT THERE WAS A SMALL PINHOLE IN THE BRAKE LINES THAT DEVELOPED DUE TO CORROSION. AS A RESULT, BRAKE FLUID WAS LEAKING FROM THE BRAKE LINES. THE VEHICLE WAS IN THE PROCESS OF BEING REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE, BUT OFFERED NO ASSISTANCE. THE FAILURE AND CURRENT MILEAGES WAS 93,636.

NHTSA ID

10419442

Incident

Aug 3, 2011

Mileage

93,636 mi

LOSS OF INSTRUMENTS IN 2003 F250 DIESEL WITH 50,153 MILES. FUSE REPLACED BY SERVICE CENTER AND INSTRUMENTS CAME ON. 3 DAYS LATER THEY WENT OFF WHILE IN 4 WHEEL LOW AND THE THE ENGINE STOPPED (BATTERY'S DEAD). I HAD NO CONTROL OVER STEERING AND WENT OFF THE ROAD. REPAIR OF DAMAGED WIRING IN STEERING COLUMN FIXED PROBLEM. THIS IS A WELL DOCUMENTED PROBLEM ON THE WEB AND KNOWN TO THE SERVICE CENTERS I HAVE CONTACTED. IF WIRING IS WORN IN A 50,000 MILE TRUCK I WOULD THINK IT PROBABLY WILL OCCUR IN SIMILAR MODELS. THE TRUCK COULD HAVE SUSTAINED SEVERE DAMAGE AND POSSIBLY RESULTED IN INJURY. WHY NO RECALL OR AT LEAST NOTIFICATION OF OWNERS. *KB

NHTSA ID

10413775

Incident

Jul 20, 2011

Mileage

50,103 mi

TL*THE CONTACT OWNS A 2003 FORD E-250. THE CONTACT NOTICED THE ABS WARNING LIGHT WAS ILLUMINATED ON THE INSTRUMENT PANEL AND THE GEARS WOULD NOT ENGAGE. THE CONTACT RESTARTED THE VEHICLE AND IT BEGAN TO FUNCTION NORMALLY; HOWEVER, THE ABS LIGHT CONTINUED TO ILLUMINATE. THE DEALER WAS CONTACTED AND STATED THERE WAS A FEE TO DIAGNOSE THE FAILURE. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING. THE VEHICLE WAS NOT REPAIRED. THERE WAS A RECALL UNDER NHTSA CAMPAIGN ID NUMBER: 04V444000 (ELECTRICAL SYSTEM:WIRING) THAT MAY BE RELATED TO THE FAILURE BUT THE VIN WAS NOT INCLUDED. THE APPROXIMATE FAILURE MILEAGE WAS 84,000.

NHTSA ID

10407294

Incident

Jun 1, 2011

Mileage

84,000 mi

TL*THE CONTACT OWNS A 2003 FORD E-250. THE VEHICLE HAS TRAIL KING A/S MUD N SNOW LOAD RANGE E TIRES, SIZE LT235 85 R1. THE CONTACT NOTICED PULSATION AND VIBRATION IN THE FRONT END OF HIS VEHICLE WHILE DRIVING 75 MPH. A WEEK LATER, WHILE DRIVING APPROXIMATELY 75 MPH AGAIN, THE VIBRATION WORSENED. ALMOST IMMEDIATELY, THE TREAD SEPARATED AND THE FRONT PASSENGER SIDE TIRE EXPLODED, WHICH RESULTED IN $1,900 WORTH OF DAMAGE TO THE VEHICLE. THE MANUFACTURER HAS NOT BEEN NOTIFIED. THE CURRENT MILEAGE WAS APPROXIMATELY 115,000 AND FAILURE MILEAGE WAS APPROXIMATELY 114,800.

NHTSA ID

10265082

Incident

Apr 1, 2009

Mileage

114,800 mi

TL*THE CONTACT OWNS A 2003 FORD E250. WHILE DRIVING 35 MPH IN INCLEMENT WEATHER CONDITIONS, THE CONTACT CRASHED INTO A LIGHTPOLE AND SEVERAL TREES. THE VEHICLE WAS COMPLETELY DESTROYED AND NONE OF THE AIR BAGS DEPLOYED. A POLICE REPORT WAS FILED. THE VEHICLE HAS NOT BEEN INSPECTED TO DETERMINE THE CAUSE OF THE FAILURE. THE MANUFACTURER AND DEALER HAVE NOT BEEN NOTIFIED. THE FAILURE AND CURRENT MILEAGES WERE 27,000. UPDATED 03/04/09. *LJ UPDATED 03/04/09. *JB

NHTSA ID

10255999

Incident

Nov 17, 2008

Mileage

27,000 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.

FORD: WHEN SHIFTING BETWEEN PARK, REVERSE AND/OR DURING 2-3 SHIFT, AN INTERMITTENT CLUNK OCCURS WITH A TORQSHIFT TRANSMISSION. MODEL 2003-2014 F-SUPER DUTY, E SERIES, EXCURSION, F-53 MOTORHOME CHASSIS, LOW CAB FORWARD. *PE

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