1999 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.

THIS INVESTIGATION WAS OPENED ON CERTAIN FORD PICKUP TRUCKS AND VANS TO EVALUATE THE EFFECTS OF A VALVE STEM EJECTION (WITH RAPID AIR LOSS) AND A SLOW LEAKING VALVE STEM ON VEHICLE HANDING.DURING THE INVESTIGATION, ODI EVALUATED OVER 1,100 COMPLAINTS AND WARRANTY CLAIMS, CONDUCTED VEHICLE DYNAMIC TESTING ON A SUBJECT VEHICLE WITH THE FAILURE MODE REPLICATED, INTERVIEWED OWNERS, AND EXAMINED COMPLAINT VEHICLES IN THE FIELD.THE RESULTS OF THE TEST PROGRAM INDICATES THE EFFECT OF A VALVE STEM EJECTION ON THESE VEHICLES IS EASILY CONTROLLED. FURTHER, WITH A POPULATION OF ALMOST 900,000 VEHICLES, HAVING TWO TO FOUR YEARS OF EXPOSURE, ODI IS AWARE OF ONLY 3 MINOR CRASHES AND IS UNAWARE OF ANY INJURIES.THE SMALL NUMBER OF CRASHES RELATIVE TO THE LARGE POPULATION OF VEHICLES IS CONSISTENT WITH THE TESTING WHICH WAS PERFORMED. THEREFORE, THIS INVESTIGATION IS CLOSED.SEE THE ATTACHED REPORT FOR FULL TECHNICAL DETAILS.

The contact owns a 1999 Ford E-350 Jamboree equipped with Sailun Tires, Tire Line: Terramax H/T, Tire Size: 225/75/R16, DOT Number: (535PLE50). The contact stated that while driving approximately 55 MPH, there were pieces of the driver's side inside dual tire striking the underside of the vehicle and hitting the highway. The contact managed to drive the vehicle back to his residence. The contact stated that the tread had separated leaving only the steel belt and the side wall. The vehicle was not taken to be diagnosed. The dealer was not contacted. The manufacturer was notified of the failure. The approximate vehicle failure mileage was 80,000 and the tire failure mileage was 5,000.

NHTSA ID

11483072

Incident

Aug 31, 2022

Mileage

80,000 mi

I RECENTLY PURCHASED A USED 24' 1999 WINNEBAGO ITASCA SPIRIT WITH VERY LOW MILEAGE AND AT THAT TIME I NOTICED A SHAKING OR VIBRATION PROBLEM POSSIBLY COMING FROM THE TIRES. I OWNED A MOTOR HOME IN THE PAST AND HAVE SOME EXPERIENCE. THIS MOTOR HOME SAT FOR SEVERAL YEARS SO I ATTRIBUTED THE SHAKING TO THE MEMORY IN THE RUBBER OF FLAT SPOTS ON THE BOTTOM FROM SITTING FOR A LONG TIME THAT USUALLY SMOOTH OUT WHEN DRIVEN ESPECIALLY AFTER 30 OR 40 MILES ON A WARM DAY, BUT AFTER A 400 MILE TRIP IT DIDN'T SMOOTH OUT, IN FACT IT SEEMS TO HAVE WORSENED. BEFORE PURCHASING IT FROM A PRIVATE PARTY I RAN AN INSTAVIN AND CARFAX REPORT AND ONLY DISCOVERED AN UNCOMPLETED NHTSA RECALL #05S28 ON THE SPEED CONTROL ONLY. I THEN SEARCHED SEVERAL FORUMS AND DISCOVERED MANY, MANY REPORTS OF THE SAME PROBLEM WITH THE SHAKING AND LEARNED IT IS DUE TO FAULTY WHEELS AND FORD IS NOT MAKING GOOD THE PROBLEM BUT OFFERED AN EXPENSIVE FIX THAT I UNDERSTAND IS ALSO IFFY. I AM VERY CONCERNED ABOUT MY FAMILY'S SAFETY DRIVING ON THESE DEFECTIVE WHEELS AND FIRST LOOKED INTO REPLACING THE TIRES WHICH I LEARNED ISN'T THE PROBLEM BUT THE FAULTY WHEELS THAT WERE AN OEM FORD PART, SO I WANT TO ADD MY COMPLAINT TO THE MANY YOU ALREADY HAVE AND MAYBE FORD WILL FIX THIS POTENTIALLY SERIOUS SAFETY PROBLEM.

NHTSA ID

11280548

Incident

Oct 7, 2019

Mileage

27,500 mi

I WAS IN AN ACCIDENT AND MY AIR BAGS DID NOT WORK I HAVE DAMAGE TO FRONT END AND REAR END

NHTSA ID

10979428

Incident

Apr 15, 2017

Mileage

125,000 mi

TL* THE CONTACT OWNS A 1999 FORD E-350 EQUIPPED WITH NEXEN TIRES, TIRE LINE: ROADIAN HT, TIRE SIZE: LT225/ 75R16 (N/A), AND DOT NUMBER: BEAKBAMR3312. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE STEERING WHEEL STARTED VIOLENTLY SHAKING WITHOUT WARNING. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE FRONT PASSENGER SIDE TIRE STEEL BELT WAS FRACTURED AND NEEDED TO BE REPLACED. THE TIRE WAS NOT REPLACED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE VEHICLE FAILURE MILEAGE WAS 91,012 AND THE APPROXIMATE TIRE FAILURE MILEAGE WAS 14,913.

NHTSA ID

10807189

Incident

Oct 12, 2015

Mileage

91,012 mi

THE VEHICLE STALLS ON NUMEROUS OCCASIONS DUE TO LACK OF FUEL. INVESTIGATION PROVED THAT THE INTERIOR PAINT OF THE GAS TANK PEALS BLOCKING THE FUEL PUMP. RESEARCH SHOWS THAT DELAMINATION OF THE GAS TANK IS FREQUENT IN THIS MODEL CAUSING A VERY UNSAFE CONDITION AS THE VAN CAN STOP AT ANYTIME AS IT LOOSES POWER AND PROPULSION DUE TO THE PAINT FLAKES BLOCKING THE FUEL. *TR

NHTSA ID

10705496

Incident

Jan 24, 2014

Mileage

87,000 mi

TL* THE CONTACT OWNS A 1999 FORD F350. THE CONTACT STATED THAT WHILE DRIVING 60 MPH, THE CONTACT NOTICED THAT THE FUEL TANK WAS DANGLING FROM THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS WHERE IT WAS STATED THAT THE FUEL TANK SUPPORT STRAPS WERE RUSTED. THE VEHICLE WAS REPAIRED AND THE MANUFACTURER WAS NOT NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 150,000.

NHTSA ID

10546674

Incident

Jun 15, 2013

Mileage

150,000 mi

TL* THE CONTACT OWNS A 1999 FORD E-350 EQUIPPED WITH UNICORN CREATION LT TIRES, LINE SIZE 225/75/R16. THE CONTACT STATED THAT SHE HEARD A LOUD NOISE OUTSIDE THE VEHICLE AND NOTICED THAT THE PASSENGER SIDE REAR OUTER TIRE BLEW OUT. THE TIRE WAS TAKEN TO A TIRE SHOP AND THEY STATED THAT THE STEEL BELT SEPARATED. THE FAILURE MILEAGE WAS 73,498.

NHTSA ID

10474112

Incident

Aug 24, 2012

Mileage

73,498 mi

TL* THE CONTACT OWNS 1999 FORD E-350 EQUIPPED WITH RUNWAY ENDURO HT TIRES, LINE SIZES LT225/75/R16. THE CONTACT STATED THAT AFTER INSPECTING THE DRIVER SIDE REAR OUTER TIRE SHE NOTICED THAT IT HAD BECOME DEFLATED. THE TIRE WAS TAKEN TO A TIRE SHOP WHO STATED THAT CRACKS HAD DEVELOPED IN THE TIRE WALLS AND THE STEEL BELT SEPARATED. THE FAILURE MILEAGE WAS 73,000.

NHTSA ID

10474110

Incident

Aug 23, 2012

Mileage

73,000 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.

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

CLUNK FROM FRONT SUSPENSION. *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