2000 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.

TL* THE CONTACT OWNS A 2000 FORD E-350. WHILE DRIVING 70 MPH, THE VEHICLE ACCELERATED WITHOUT WARNING. THE BRAKE PEDAL WAS DEPRESSED, BUT THE VEHICLE FAILED TO DECELERATE. THE CONTACT PLACED THE GEAR SHIFTER INTO NEUTRAL TO STOP THE VEHICLE. THE CONTACT COASTED THE VEHICLE OVER TO THE SIDE OF THE ROAD AND POWERED OFF THE ENGINE TWICE. WHEN THE VEHICLE WAS RESTARTED, IT OPERATED NORMALLY AND WAS DRIVEN TO THE CONTACT'S RESIDENCE. IN ADDITION, WHILE DEPRESSING THE BRAKE PEDAL, SMOKE APPEARED FROM THE BRAKE PEDAL. THE VEHICLE WAS NOT TAKEN TO A DEALER OR AN INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 169,000.

NHTSA ID

11186525

Incident

Mar 12, 2019

Mileage

169,000 mi

TL* THE CONTACT OWNS A 2000 FORD E-350. THE CONTACT HEARD A LOUD, BOOMING NOISE FROM THE FRONT OF THE VEHICLE. THE CONTACT DISCOVERED THAT A SPARK PLUG EXPLODED AND DISLODGED FROM THE ENGINE, WHICH SHATTERED THE ENGINE COIL PACK. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE LOCAL DEALER (TOM HOLZER FORD, 39300 W. 10 MILE RD, FARMINGTON HILLS, MI) WAS NOTIFIED OF THE FAILURE. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS 151,000.

NHTSA ID

11155207

Incident

Nov 19, 2018

Mileage

151,000 mi

THE SPARK PLUG NO.7 BLOW OUT WITH THE IGNITION COIL. *TR

NHTSA ID

10695515

Incident

Mar 17, 2015

Mileage

213,723 mi

2000 FORD E-350. CONSUMER WRITES IN REGARDS TO VEHICLE FIRE. *SMD THE CONSUMER STATED THE FIRE DAMAGED HIS HOUSE AND THE VAN WAS DESTROYED. THE CONSUMER BELIEVED THE CRUISE CONTROL WAS THE CAUSE OF THE FIRE. *JB

NHTSA ID

10644036

Incident

Apr 28, 2014

TL* THE CONTACT OWNS A 2000 FORD E350 EQUIPPED WITH RUNWAY ENDURO HT TIRES, SIZE LT 225-75-R16 DOT NUMBER (5WTM0408). THE CONTACT STATED THAT UPON INSPECTION, IT WAS NOTICED THAT THE TREAD ON THE PASSENGER REAR TIRE WAS EXTREMELY WORN AND NEEDED TO BE REPLACED. THE TIRE WAS REPLACED BEFORE THE STEEL BELTS FAILED. THE MANUFACTURER WAS NOT NOTIFIED. THE TIRE MILEAGE WAS 18,478. THE FAILURE MILEAGE WAS 76,544. ... UPDATED 02/28/13 *BF THE CONSUMER STATED THE TIRE WAS ABNORMALLY WORN IN ONE SPOT. THE CONSUMER IS IN POSSESSION OF THE TIRE. UPDATED 03/27/2013 *JS

NHTSA ID

10492936

Incident

Dec 11, 2012

Mileage

76,544 mi

MY FUEL TANK INTERIOR FLAKED SO SEVERELY IT CAUSED THE ENGINE TO BUCK VIOLENTLY AND DRAMATICALLY LOOSE POWER. THIS WAS CAUSED BY THE ALMOST COMPLETE BLOCKAGE OF THE FUEL TANK PICKUP SCREEN/FILTER. SINCE THAT TIME I HAVE HAD TO DISASSEMBLE AND THOROUGHLY CLEAN THE FUEL PICKUP OF THE FLAKES 4 TIMES INCLUDING TODAY. EACH TIME THE PICKUP WAS PACKED WITH SILVER FLAKES FROM THE DETERIORATING LINING OF THE FUEL TANK. THE PROBLEM OCCURRED EACH TIME WHILE TRAILERING MY RV DOWN THE INTERSTATE. IT IS EXTREMELY SCARY AND THE ALMOST COMPLETE LOSS OF POWER MAKES IT VERY DIFFICULT TO GET TO THE NEXT EXIT. THE PROBLEM IS SO PERSISTENT THAT I HAVE PUT A DOOR IN THE FLOOR OF MY VAN SO THAT I NO LONGER HAVE TO DROP THE TANK FOR ACCESS. I PURCHASED THIS FORD E-350 DIESEL NEW IN 2000. *TR

NHTSA ID

10470853

Incident

Jan 8, 2007

I WAS DRIVING A FORD DIESEL VAN NORTH ON HIGHWAY 31 TOWARDS PENNINGTON, NJ, WHEN THE TRUCK STARTED ACTING UP. ULTIMATELY, IT STALLED - RIGHT THERE ON THE HIGHWAY; 4 LANES, SEMI TRUCKS COMING AROUND A BEND @ 40 + MPH, AND NO SHOULDER. I TOLD MY HELPER TO LEAVE THE TRUCK BECAUSE I WAS SURE WE WERE GOING TO GET HIT. NO WAY A TRACTOR TRAILER, AT THOSE SPEEDS, COULD STOP IN TIME. SEVERAL SEMI'S HAD TO CUT OFF CARS IN THE LEFT LANE TO AVOID US. I THOUGHT FOR SURE I WAS DEAD. AFTER SWEATING IT OUT, I FINALLY GOT THE TRUCK STARTED AND GOT TO A SIDE STREET, AT ABOUT 5 MPH. THAT'S WHEN I CALLED AAA & GOT THE TRUCK TOWED TO MY FORD DEALER, WHERE THEY WANT $2500 TO REPAIR WHAT THEY CALL " FUEL TANK DELAMINATION". I NEVER HEARD OF SUCH A THING AND NEITHER DID ANYONE I SPOKE WITH IN THE AUTO REPAIR INDUSTRY SO I GOOGLED IT: FORD DIESEL FUEL TANK PROBLEMS, AND AS IT TURNS OUT, THERE ARE THOUSANDS OF VEHICLES OUT THERE WITH THE EXACT SAME PROBLEM. I"M SURPRISED NO ONE HAS DIED YET, BUT I GUESS THAT'S WHAT IT WILL TAKE, MAYBE WHEN A COUPLE OF KIDS DIE, FORD WILL DO SOMETHING ABOUT IT, IF IT DOESN'T COST TOO MUCH - OF COURSE. TO ALLEVIATE THIS "PROBLEM," THE FORD DEALER IS, IN EFFECT, GOING TO REPLACE THE ENTIRE FUEL DELIVERY SYSTEM, AT THE CONSUMERS COST. NEW FUEL TANK, NEW FUEL TRANSFER PUMP, CLEAN OUT THE FUEL LINES, REPLACE FUEL FILTER, CLEAN INJECTORS, SO, BEND OVER. PS REALLY HOPE NOBODY HAS TO DIE - BUT THAT'S YOUR CALL. *TR

NHTSA ID

10360720

Incident

Oct 14, 2010

Mileage

198,000 mi

2000 FORD V8 TRITON ENGINE SPARK PLUG POPPED OUT AND ENGINE MISFIRE HAD THE COIL REPLACED AND HAD MECHANIC TAP OUT THE SPARK PLUG HOLE AND RE SET THE PLUG AND THEN IT HAPPENED AGAIN ON SATURDAY JULY 3RD 2010. *TR

NHTSA ID

10341387

Incident

Jun 26, 2010

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

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

HEADLIGHT ADJUSTMENT - CHASSIS CAB INCOMPLETE VEHICLES. *TT

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

INTERMITTENT CLUNK ON 3-2 DOWNSHIFT DURING COASTDOWN/TIP-IN. OASIS. TO INCLUDE 2005 F-150, E-SERIES AND EXPEDITION. *TT