1998 Ford E350

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.

ODI has received 1 complaint and reports from 4 transportation fleets alleging 182 switch failures.Each fleet operates mini buses built on a Ford E350 or E450 cutaway chassis.The OEM HVAC blower switches have melted, smoked, burned or experienced open flame and become inoperable on vehicles in each fleet.Some drivers have reported a burning smell or smoke coming from the dash.One fleet reported a vehicle fire.No injuries were sustained.However, the bus was carrying special needs children when the driver noticed smoke coming from the dash.The driver was able to evacuate the children prior to the vehicle becoming engulfed in flames.This PE has been upgraded to an Engineering Analysis (EA) to determine if the blower motor switch failures create a situation where a vehicle fire is possible and presents a safety risk to the driver and other passengers.

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

When braking hard, braking power declines after mid peddle range, resulting in crash. Had taken to dealer many years earlier for ABS recall fix.

NHTSA ID

11479119

Incident

Aug 12, 2022

SPARK PLUGS POTENTIALLY EJECT FROM CYLINDER HEADS DUE TO BAD ENGINEERING DESIGN USING ALUMINUM HEADS WITH INSUFFICIENT AMOUNT OF THREADS TO HOLD SPARK PLUGS WHEN IN MOTION. NEWER VEHICLES WERE RE-ENGINEERED TO ELIMINATE THIS HAPPENING. REQUEST RECALL AND REPAIR.

NHTSA ID

11301435

Incident

Jan 1, 2020

Mileage

24,631 mi

TL* THE CONTACT OWNS A 1998 FORD E-350 EQUIPPED WITH STARFIRE SF-510 TIRES, SIZE LT245-75-R16 (NA). WHILE THE VEHICLE WAS AT AN INDEPENDENT MECHANIC FOR A STATE INSPECTION, THE SIDEWALL OF THE REAR DRIVER'S SIDE TIRE WAS FOUND WITH INTERNAL INDENTATIONS. THE MECHANIC STATED THAT THE TIRE NEEDED TO BE REPLACED. THE TIRE WAS NOT REPLACED. THE DEALER AND MANUFACTURER WERE NOT CONTACTED. THE DOT NUMBER WAS UNKNOWN. THE TIRE AND VEHICLE FAILURE MILEAGE WAS 130,000.

NHTSA ID

11140351

Incident

Oct 10, 2018

Mileage

130,000 mi

TL* THE CONTACT OWNS A 1998 FOR E-350. THE CONTACT STATED THAT THE VAN WAS IDLE WHEN HE NOTICED SMOKE COMING FROM THE INSTRUMENT PANEL AND VENTS. THE VEHICLE BECAME ENGULFED IN FLAMES. THE FIRE DEPARTMENT EXTINGUISHED THE FLAMES. A FIRE REPORT WAS NOT FILED. THE MANUFACTURER WAS NOT CONTACTED. THE FAILURE MILEAGE WAS 200,000.

NHTSA ID

10561718

Incident

Jan 23, 2014

Mileage

200,000 mi

I RECENTLY HAD A PROBLEM AND STILL HAVE WITH THE PASSENGER SIDE REAR DOOR OF NOT BEING ABLE TO OPEN IT. I GOT OUT OF THE MY FORD VAN AND WENT AROUND TO THE SIDE DOOR TO OPEN IT UP TO GET MY DOGS OUT OF IT. I COULD NOT OPEN THE SIDE DOOR, I THOUGHT THE DOORS HAD SOMEHOW GOT LOCKED AND I WAS PANICING. IT WAS VERY HOT AND I KNEW I HAD TO GET MY DOGS OUT FAST. I WAS HUNTING FOR SOMETHING TO BREAK THE WINDOW OUT WITH BUT HAD NO LUCK FINDING ANYTHING. AFTER ABOUT 20 OR SO MINUTES I FINALLY NOTICED THAT THE FRONT DOOR LOCKS WERE IN THE UP POSITION INDICATING THAT THE DOORS WERE NOT LOCKED. I WAS ABLE TO OPEN THE FRONT DOOR SAVING ME FROM HAVING TOO BREAK OUT THE GLASS AND THEN I WAS ABLE TO GET INTO THE VAN AND OPEN THE REAR DOOR. I LOVE MY DOGS BUT WHAT IF THIS HAD BEEN A CHILD.AND COULDN'T OPEN THE DOORS IN TIME. LUCKLY I DISCOVERED THAT THE FRONT DOORS WERE NOT LOCKED AND THAT IT WAS A MALFUNCTION OF THE BACK DOOR MAKING IT IMPOSSIBLE TO OPEN THAT DOOR. THE RESULTS COULD HAVE BEEN DISTRASTROUS AND NOT TO MENTION THE COST OF REPAIRING THE WINDOW HAD I BEEN ABLE TO BREAK IT, THINGS TURNED OUT WELL THANK GOODNESS BUT IF IT SHOULD HAPPEN TO SOMEONE ELSE THE RESULTS COULD BE VERY DIFFERENT. THIS IS SUNDAY AND I NOW HAVE TO GET MY VAN TO A FORD DEALER TO FIX THE REAR DOOR SO I CAN OPEN IT UP AS I STILL CAN'T OPEN IT UP FROM THE OUTSIDE.. I THINK THE IS A SERIOUS SAFETY PROBLEM THAT SHOULD BE ADDRESSED. *TR

NHTSA ID

10462882

Incident

Jun 23, 2012

Mileage

113,614 mi

TL*THE CONTACT OWNS A 1998 FORD E-350. WHILE DRIVING THE CONTACT EXPERIENCED A LOSS OF POWER AND THE ENGINE WOULD BEGAN TO MALFUNCTION. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHO CONFIRMED THAT THE FUEL SYSTEM WAS DELAMINATING. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 198,910 AND THE CURRENT MILEAGE WAS 202,300.

NHTSA ID

10392628

Incident

Dec 15, 2010

Mileage

198,910 mi

POWERSTROKE 7.3 DIESEL. THE CAMSHAFT POSITIONING SENSOR (CPS) FAILURE IS A SERIOUS PROBLEM THAT FORD WILL HAVE TO DEAL WITH. I HAVE HAD THREE INSTANCES OF THE UNIT FAILING ON ME SINCE THIS FIRST ONE ON DEC 13TH, 2007. IN THE FIRST CASE, I WAS TAKING MY SON TO SCHOOL. THE VAN WAS SPUTTERING THE WHOLE WAY AND I EVENTUALLY HAD TO HAVE IT TOWED TO A REPAIR SHOP AFTER A COMPLETE ENGINE FAILURE. FORD HAD JUST ISSUED THE RECALL ON DEC 6TH, 2007, AND THEY HONORED THE REPAIR. THE SECOND CPS INCIDENT HAPPENED ON FEB 23RD, 2010. THE VEHICLE WOULD NOT START; I HAD IT TOWED TO A REPAIR SHOP AFTER GETTING A PARKING TICKET. I CANNOT FIND PROOF THAT FORD HONORED THE REPAIR. THE 3RD CPS INCIDENT HAPPENED ON SUNDAY FEB 27TH, 2011, ONE YEAR AFTER THE 2ND INCIDENT. I WAS IN FLAGSTAFF, AZ DURING A SNOWSTORM, AND THE VEHICLE WAS FAILING ON ME ON ROUTE 66. IT STALLED TWICE ON THE MAIN HIGHWAY AS THE SNOWPLOWS WHIPPED AROUND ME. I GOT BACK TO WHERE I WAS STAYING, AND WAITED UNTIL MONDAY MORNING WHEN I HAD IT TOWED TO A REPAIR SHOP AND HAD THE CPS UNIT REPLACED. THIS ENGINE IS UNSAFE AND UNRELIABLE. THE CPS UNIT CAN FAIL AT ANYTIME, ANYWHERE, AND MAYBE AT ANY SPEED, THOUGH MY ISSUES WERE AT LOW SPEED OR AT STARTUP. FORD WILL NOT HONOR THIS LATEST INCIDENT BECAUSE THEY SAY AFTER MY FIRST REPLACEMENT IN DEC 2007 THAT MY "CASE WAS CLOSED IN 2007".

NHTSA ID

10388028

Incident

Dec 13, 2007

Mileage

411,637 mi

1998 FORD E 350 POWERSTROKE 7.3 DIESEL. THE CAMSHAFT POSITIONING SENSOR (CPS) FAILURE IS A SERIOUS PROBLEM THAT FORD WILL HAVE TO DEAL WITH. I HAVE HAD THREE INSTANCES OF THE UNIT FAILING ON ME SINCE THIS FIRST ONE ON DEC 13TH, 2007. IN THE FIRST CASE, I WAS TAKING MY SON TO SCHOOL. THE VAN WAS SPUTTERING THE WHOLE WAY AND I EVENTUALLY HAD TO HAVE IT TOWED TO A REPAIR SHOP AFTER A COMPLETE ENGINE FAILURE. FORD HAD JUST ISSUED THE RECALL ON DEC 6TH, 2007, AND THEY HONORED THE REPAIR. THE SECOND CPS INCIDENT HAPPENED ON FEB 23RD, 2010. THE VEHICLE WOULD NOT START; I HAD IT TOWED TO A REPAIR SHOP AFTER GETTING A PARKING TICKET. I CANNOT FIND PROOF THAT FORD HONORED THE REPAIR. THE 3RD CPS INCIDENT HAPPENED ON SUNDAY FEB 27TH, 2011, ONE YEAR AFTER THE 2ND INCIDENT. I WAS IN FLAGSTAFF, AZ DURING A SNOWSTORM, AND THE VEHICLE WAS FAILING ON ME ON ROUTE 66. IT STALLED TWICE ON THE MAIN HIGHWAY AS THE SNOWPLOWS WHIPPED AROUND ME. I GOT BACK TO WHERE I WAS STAYING, AND WAITED UNTIL MONDAY MORNING WHEN I HAD IT TOWED TO A REPAIR SHOP AND HAD THE CPS UNIT REPLACED. THIS ENGINE IS UNSAFE AND UNRELIABLE. THE CPS UNIT CAN FAIL AT ANYTIME, ANYWHERE, AND MAYBE AT ANY SPEED, THOUGH MY ISSUES WERE AT LOW SPEED OR AT STARTUP. FORD WILL NOT HONOR THIS LATEST INCIDENT BECAUSE THEY SAY AFTER MY FIRST REPLACEMENT IN DEC 2007 THAT MY 'CASE WAS CLOSED'. *TR

NHTSA ID

10386300

Incident

Dec 13, 2007

Mileage

411,637 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.

CRACKS IN THE LEFT OR RIGHT SPRING TOWER FLANGE. *TT SPRING TOWER WELD REPAIR AND REPLACEMENT PROCEDURE. *TT

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

MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATION WITH NO HARD FAULT. *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