2003 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.

To whom it may concern, i recently purchased a 2003 ford econoline e150 vin# [XXX] . from a private party in the state of michigan, im am being refused insurance because the van is coming up as incomplete , the van was sent and finished by Elk automotive Inc , on [XXX] MPV [XXX] they company that manufactured it ,gave it the same vin # [XXX] with completion date as [XXX] the identification sticker from Elk automotive is on the door jam and has been dot approved, i have the michigan title in my name , it says nothing about incomplete on title, but NHTSA website keeps popping up incomplete and my insurance provider wont insure it please contact me or help please. my name is [XXX] , [XXX] or by phone is [XXX] or, my email is : [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11642121

Incident

Feb 10, 2025

TL* THE CONTACT OWNS A 2003 FORD E-350 PULLING A 24-FOOTER AUTO TRAILER. WHILE DRIVING 30 MPH AND ATTEMPTING TO REDUCE SPEED, THE BRAKE PEDAL WAS DEPRESSED AND TRAVELED TO THE FLOORBOARD. THE CONTACT USED THE TRAILER BRAKES TO STOP THE VEHICLE. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE CONTACT MENTIONED THAT THE VEHICLE WAS REPAIRED PER AN UNKNOWN RECALL FOR THE BRAKES IN 2004. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DETERMINED THAT THE AIR BOOSTER, MASTER CYLINDER, AND PRESSURE PUMP NEEDED REPLACEMENT. THE VEHICLE WAS REPAIRED, BUT THE CONTACT STATED THAT THE BRAKE PEDAL WAS STILL SOFT AND STILL ALMOST TRAVELED TO THE FLOORBOARD. THE MANUFACTURER WAS NOTIFIED OF THE FAILURES. THE APPROXIMATE FAILURE MILEAGE WAS 173,000.

NHTSA ID

11109915

Incident

Jun 26, 2018

Mileage

173,000 mi

I WAS STOPPED AT A STOPLIGHT ON A HIGHWAY RAMP IN TOWN BEHIND ANOTHER VEHICLE WAITING FOR THE LIGHT TO TURN GREEN. AS I SAT WAITING, THE VAN SUDDENLY ACCELERATED INTO THE VEHICLE AHEAD OF ME WHILE THE BRAKES WERE STILL FULLY APPLIED! I DID NOT HAVE MY FOOT ON THE GAS PEDAL, JUST ON THE BRAKE. THE ACCELERATION WAS SO SUDDEN AND FAST THAT MY FRONT TIRES LEFT SKID MARKS BECAUSE THE BRAKES WERE FULLY APPLIED. I HAD BEEN USING THE CRUISE CONTROL EARLIER ON THE HIGHWAY, BUT HAD DISENGAGED IT BEFORE GETTING INTO TOWN, WELL BEFORE THE RAMP TO THE STOPLIGHT. THIS IS THE FIRST TIME THIS HAS HAPPEND WITH THIS VAN; HOWEVER, I ALSO OWN A 2001 FORD E350 VAN, AND BEFORE I STOPPED USING IT, I HAD PROBLEMS WITH THE CRUISE CONTROL ENGAGING WHILE I WAS DRIVING, AND REFUSING TO DISENGAGE. I HAVE REPORTED THESE INCIDENTS WITH BOTH OF MY VANS TO THE LOCAL FORD DEALERSHIP, BUT THEY SAID NOTHING WAS WRONG WITH THE VEHICLE.

NHTSA ID

10953892

Incident

Feb 10, 2017

Mileage

160,200 mi

SPARK PLUG BLOWN OUT OF HEAD. *TR

NHTSA ID

10705391

Incident

Apr 10, 2015

Mileage

136,398 mi

SPARK PLUG BLOWN OUT OF HEAD. *TR

NHTSA ID

10705390

Incident

Sep 15, 2014

Mileage

108,458 mi

SPARK PLUGBLOWNOUT OF HEAD. *TR

NHTSA ID

10705382

Incident

Jul 8, 2014

Mileage

106,120 mi

SPARK PLUG BLOWN OUT OF HEAD. *TR

NHTSA ID

10705380

Incident

Jan 2, 2014

Mileage

101,604 mi

A PATIENT, 21 YEAR OLD AMBULANCE DRIVER, HAS BEEN TREATED HERE AT THE UNIVERSITY OF MISSOURI FROM 10/27/14 FOR INJURIES FROM AN AUTO ACCIDENT, SUSTAINED WHEN A VEHICLE PULLED OUT IN FRONT OF THE AMBULANCE SHE WAS DRIVING. HER AIR BAG DEPLOYED, PROTECTING HER APPROPRIATELY. HOWEVER, THERE IS A METAL DISC BENEATH THE AIRBAG ON THE STEERING COLUMN, WHICH WAS QUITE HOT, AND AS SHE WAS TRAPPED IN THE VEHICLE, SHE SUSTAINED BURNS TO HER CHEST AND TO HER CLOTHING. THE BURNS WERE THIRD DEGREE BURNS REQUIRING SURGERY, SMALL AREA, BUT WERE SIGNIFICANT BURNS. I AM UNCERTAIN WHETHER THE HOT DISC AT THE BASE OF THE AIRBAG IS THE RESULT OF A DEFECT, OR IF IT IS PART OF THE DESIGN. I AM NOTIFYING YOU SO YOU WILL BE AWARE OF THIS POTENTIAL HAZARD, AND TO TRACK THE FREQUENCY OF THIS TYPE OF INJURY. ALTHOUGH THERE WAS A DEATH AND ANOTHER INJURY IN THIS ACCIDENT, THEY WERE NOT RELATED IN ANY WAY TO THE HOT DISC ON THE AIRBAG MECHANISM. THE AMBULANCE IS A 2003 FORD E-350. THIS WAS THE DRIVER'S SIDE AIRBAG. *TR

NHTSA ID

10662725

Incident

Oct 27, 2014

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

FORD: RUNS ROUGH, LACKS POWER, HARD START, NO START. SOME VEHICLES AND TRUCKS EQUIPPED WITH 6.0L ENGINE MAY EXHIBIT A RUNS ROUGH, LACKS POWER, HARD TO START, NO START CONCERN WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) P0611 CODE OR VARIOUS INJECTOR CIRCUIT CODES. *PE

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