2001 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.

SPARK PLUG - I'M REALLY SHOCKED THIS HASN'T BEEN RECALLED! PURCHASED THIS 2001 FORD E-350 FROM THE ORIGINAL OWNER WHO WAS A MECHANIC AND KEPT ALL SERVICE RECORDS OF THIS VEHICLE. IT IS IN EXCELLENT CONDITION. HAD THE VAN SERVICED AND LOOKED OVER BEFORE TAKING IT ON A LONGER TRIP. AT 2 AM AND ONLY AFTER 5 HOURS OF DRIVING (ALL HIGHWAY) WE HEARD A LOUD BANG FOLLOWED BY EVEN LOUDER RUMBLING AND INTENSE GAS SMELL. THIS HAPPENED WHILE DRIVING AND THE VAN WAS IN MOTION ON THE HIGHWAY. WE WERE ABLE TO EXIT THE HIGHWAY AND WAIT UNTIL THE MORNING. THE NEXT MORNING WE TOOK THE ENGINE APART AND FOUND THE SPARK PLUG COMPLETELY BLOWN OUT OF THE ENGINE. AFTER BUYING THE REPAIR KIT FROM THE PARTS STORE AND PUTTING IN A NEW SPARK PLUG WE WERE ABLE TO LIMP OUR WAY HOME. DUE TO THE FORCE CAUSED BY THE FIRST SPARK PLUG BEING SHOT OUT, THE ENGINE NOW SOUNDS LIKE SOME OTHER SPARK PLUGS ARE VERY LOOSE AND READY TO GO. NOT SURE THE TOTAL DAMAGE UNTIL IT CAN BE REPAIRED BY A MECHANIC.

NHTSA ID

11354066

Incident

Sep 7, 2020

Mileage

119,000 mi

THE DRIVER'S SIDE SEAT BELT RANDOMLY COMES UNLATCHED. THIS HAS HAPPENED BEFORE THIS DATE AND HAPPENS MULTIPLE TIMES EACH TIME IT IS DRIVEN. IT DOES NOT MATTER IF THE VEHICLE IS IN MOTION OR NOT. IT HAS HAPPENED SITTING STILL IN THE DRIVEWAY AND AT HIGHWAY SPEEDS. THIS IS A TRW 33012760 PART.

NHTSA ID

11092628

Incident

May 8, 2018

Mileage

153,700 mi

MY 2001 FORD E350 SUPER DUTY VAN BLEW OUT A SPARK PLUG WHILE DRIVING 40 MPH AND COST ME $900 FOR DEALERSHIP TO REPAIR....WITH ONLY 117,000 MILES ON IT. FORD NEEDS TO DO A RECALL ON THIS. *TR

NHTSA ID

10917209

Incident

Oct 14, 2016

Mileage

117,000 mi

SPARK PLUG WAS EJECTED FROM ENGINE. NO ADVANCED WARNING OR UNUSUAL SOUNDS OF ANY KIND. ENGINE HAD BEEN RUNNING PERFECTLY AND RELIABLY UP UNTIL THIS EVENT.

NHTSA ID

10763386

Incident

Sep 13, 2015

Mileage

159,693 mi

TL* THE CONTACT OWNS A 2001 FORD E-350. THE CONTACT STATED THAT WHILE DRIVING VARIOUS SPEEDS, THE CONTACT LOST CONTROL OF THE STEERING WHEEL. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN DIAGNOSED THAT THERE WAS EXCESSIVE CORROSION ON THE SUB FRAME, UNDER CARRIAGE AND THE TIE RODS. THE TECHNICIAN ADDED THAT THE VEHICLE WAS NOT ABLE TO BE REPAIR. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 70,000. UPDATED 10/31/14*LJ UPDATED 7/9/2015*JS

NHTSA ID

10636951

Incident

Jan 1, 2009

Mileage

70,000 mi

WHILE DRIVING VEHICLE STARTED RUNNING ROUGH/MISSING LOST ENGINE POWER. HAD TO HAVE THE VEHICLE TOWED HOME REPLACED THE FUEL FILTER AND PUMP. STILL HAD PROBLEMS. TOWED TO THE DEALER WHO FINALLY ADVISED FUEL TANK LAMINATE WAS FLAKING. FOUND 4 OTHER COMPLAINTS ON THIS SITE FOR THE SAME PROBLEM. ONLINE FOUND THAT THIS IS HAPPENING IN MULTIPLE YEARS/DIESEL TYPES FROM FORD. *TR

NHTSA ID

10456780

Incident

Apr 21, 2012

Mileage

143,000 mi

SPARK PLUG BLOW OUT OF 5.4L ENGINE CAUSING GAS FUMES IN PASSENGER AREA. *TR

NHTSA ID

10441215

Incident

Dec 8, 2011

Mileage

148,028 mi

I PARKED MY F 350 DIESEL IN FRONT OF MY HOUSE FOR THE NIGHT. NEXT MORNING ,BEFORE 6 A.M., I WOKE TO THE NOISES OUTSIDE:CRACKING, POPPING, AND EXPLOSIONS. THE FRONT OF MY TRUCK WAS ON FIRE. IT WAS COMING AROUND ALL SIDES OF THE HOOD AND AROUND THE FRONT WHEEL AREA,ALSO THROUGH THE DASH AND STEERING AREA. I CALLED THE FIRE DEPT. AND STARTED PUTTING THE FIRE OUT USING THE GARDEN HOSE. FOUR MORE EXPLOSIONS HAPPENED,AND TWO FRONT TIRES EXPLODED AS WELL. I FOUGHT THE FLAMES UNTIL FIRE TRUCKS SET UP AND TOOK OVER. THEY PUT IT OUT JUST IN TIME TO SAVE $ 4,000 CASH AND AMMO INSIDE THE CAB. *TR

NHTSA ID

10426450

Incident

Jun 25, 2011

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