2005 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.

The contact owned a 2005 Ford E-350. The contact stated while driving approximately 45 MPH he smelled a burning odor and saw that the vehicle was trailing a large white cloud. The contact stated no warning light was illuminated. The contact pulled over and as soon as he exited the vehicle it had become engulfed in flames. The contact stated that the flames came from under the rear of the vehicle. The vehicle burned, the contact stated the fire department was not able to locate his vehicle and later the police had called him and left a voice message advising him that the vehicle had been towed to an impound lot. The manufacturer had not been informed of the failure. The contact had researched online and related the failure to NHTSA Campaign Number: 11E047000 (Fuel System, Gasoline). The failure mileage was approximately 145,000.

NHTSA ID

11553413

Incident

Nov 2, 2023

Mileage

145,000 mi

ONLY 87000 MILES AND THE FUEL TANK IS SHEDDING SILVER PAINT FLAKES, INTO THE FUEL SYSTEM.. HAVE NOW REPLACED ALL THE FILTERS TWICE, PUMP ONCE.. AND THE TANK PRE FILTER HAS TO BE CLOGGED AS NO FUEL WILL EVEN COME OUT.. HAD BEEN A VERY GOOD TRUCK, BUT THIS ENGINEERING CAUSES THE VAN TO JUST DIE!! ON THE ROAD. THIS IS APPARENTLY A COMMON PROBLEM AND ONE THAT FORD AND THEIR ENGINEERS ARE NOT BEING RESPONSIBLE FOR.. REALLY... PAINT INSIDE AT FUEL TANK? WTF ARE THEY THINKING...

NHTSA ID

11355011

Incident

Sep 2, 2020

Mileage

87,000 mi

TL* THE CONTACT OWNS A 2005 FORD E-350. WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE SUDDENLY STALLED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL INJECTION CONTROL MODULE FAILED. THE CONTACT REPLACED THE CONTROL MODULE, BUT THE FAILURE CONTINUED. UPON INSPECTION, THE CONTACT DETERMINED THAT THE FUEL INJECTION CONTROL MODULE WIRE HARNESS FAILED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE CONTACT WAS INFORMED THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 05V270000 (ELECTRICAL SYSTEM). THE FAILURE MILEAGE WAS 90,000.

NHTSA ID

10913614

Incident

Jun 1, 2016

Mileage

90,000 mi

TL* THE CONTACT OWNS A 2005 FORD E-350. THE CONTACT STATED THAT THE HEATER BOX FAILED TO CHANGE SETTINGS AFTER THE INITIAL SETTING. THE VEHICLE WAS TAKEN TO A DEALER WHO DIAGNOSED THAT THE HEATER BOX NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 42,900.

NHTSA ID

10763509

Incident

Jun 5, 2015

Mileage

42,900 mi

TL* THE CONTACT OWNS A 2005 FORD E-350. THE CONTACT STATED THAT THE GEAR SHIFTER FAILED TO SHIFT. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 243,000.

NHTSA ID

10706285

Incident

Apr 16, 2015

Mileage

243,000 mi

WHILE DRIVE ON HIGHWAY,VEHICLE BEGAN TO LOSE POWER WHEN I ENCOUNTERED A HILL. IT BOGGED DOWN AND STRUGGLED TO MAKE IT TO TOP OF HILL AND LOST SPEED DOWN TO 30 MPH OR LESS AND THEN DIED. IT WOULD NOT START RIGHT AWAY, BUT AFTER LETTING IT SIT FOR 15 MINUTES, IT STARTED AND HAD REGAINED POWER AND I DROVE IT TILL I GOT TO THE NEST HILL AND DID THE SAME THING SEVERAL TIMES TILL I MADE IT HOME 3 HOURS LATER FOR A 10 MILE TRIP. I CHECKED ONLINE ON THE VEHICLE FOR FORD OWNERS FORUM AND SAW THAT SEVERAL PEOPLE ENCOUNTERED THIS PROBLEM BEFORE AND DESCRIBED IT AS BOGGING DOWN AND LOSING POWER. SOME ONE SUGGESTED CHANGING THE EGR VALVE WHICH I HAD DONE, AND THE FUEL FILTERS AS WELL AS AIR FILTER. WHEN I REMOVED THE BOTTOM FUEL FILTER UNDER THE VAN, I CAPTURED THE FUEL IN THE FILTER AND LINE AND IT HAD WHAT LOOKED LIKE SILVER PAINT. I KEPT THE SAMPLE AND IT IS SOFT AND PLIABLE. I ASSUMED IT WAS A PROTECTIVE COATING LINING THE FUEL TANK. I DON'T BELIEVE THIS SHOULD BE HAPPENING,BECAUSE IT COULD DO DAMAGE TO THE INJECTORS AND OTHER THINGS. *TR

NHTSA ID

10659991

Incident

Oct 17, 2014

Mileage

141,008 mi

TL* THE CONTACT OWNS A 2005 FORD E-350. WHILE DRIVING 40 MPH, THE ENGINE STALLED WITHOUT WARNING. THE CONTACT WAS ABLE TO RESTART THE VEHICLE AFTER REPEATED ATTEMPTS. THE FAILURE OCCURRED MULTIPLE TIMES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 45,000.

NHTSA ID

10617117

Incident

Oct 9, 2013

Mileage

45,000 mi

THIS BUS IS OWNED BY FIRST BAPTIST CHURCH OF GRANT, AL. ABOUT ONE YEAR AGO WE STARTED HAVING TIMES WHEN THE BUS WOULD CRANK BUT NOT START. OUR MECHANIC HAS CHECKED IT FOUR DIFFERENT TLIMES, HOWEVER, EVERY TIME EXCEPT THIS TIME (5TH TIME) IT STARTED WHEN HE WENT TO CHECK IT. THIS TIME WE WERE TAKING OUR SENIORS ON A TRIP, BUT WHEN WE WENT TO CRANK IT, IT CRANKED BUT WOULD NOT START. WE HAD IT TOWED TO WOODY ANDERSON FORD IN HUNTSVILLE, AL. I SPOKE WITH THE TRUCK SERVICE MANAGER TODAY AND HE TOLD ME THE ENGINE WIRING HARNESS WAS BAD. THIS BUS ONLY HAS 30,000 MILES ON IT. IT HAS BEEN AT WOODY ANDERSON FORD 4 DAYS. I KNOW RECALLS ARE BASED ON THE VIN NUMBER PRIMARILY. THIS IS A LIKE NEW BUS AND ALREADY HAD TO REPLACE THE FUEL INJECTORS, TURBO CHARGER, AND A COUPLE OF DIFFERENT SENSORS. ANYONE WITH ANY COMMON SENSE KNOWS THAT IT IS NOT NORMAL FOR AN ENGINE WIRING HARNESS TO GO BAD. FORD MOTOR COMPANY NEEDS TO BE HELD ACCOUNTABLE AND RESPONSIBLE FOR REPLACING AN ENGINE COMPONENT THAT SHOULD LAST AS LONG AS YOU OWN THE VEHICLE. THERE IS A RECALL ON SOME VEHICLES WITH A 6.0L DIESEL ENGINE WITH PROBLEMS LIKE OURS, IT IS RECALL # 05S34. THE FORD DEALERSHIP SAID IT WOULD COST $3000.00 TO REPLACE THE WIRING HARNESS. THIS SHOULD BE A FORD MOTOR COMPANY PROBLEM. THANKS FOR READING AND CONSIDERING MY COMPLAINT. ANY HELP WOULD BE GREATLY APPRECIATED. MY NAME IS STEVE STANFIELD. I AM THE PASTOR. MY EMAIL IS [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10553482

Incident

Nov 11, 2013

Mileage

30,000 mi

When performing any transmission fluid changes or topoffs involving MERCON SP, MERCON LV has replaced all versions of MERCON SP and can be used going forward. Mixing MERCON LV and MERCON SP in the same transmission is acceptable. After 30-Jun-2023, MERCON SP ATF will no longer be manufactured and will only be available until inventory depletes.

These SKUs are Trailer Brake Control Modules. The customer communication requested return of unsold inventory due to an internal software issue. The internal software issue leads to a false check trailer brake message and Trailer Brake Controller fault whenever the brake pedal is pressed. This will cause the part to be replaced, due to repetitive dashboard warning light, even though it sends signals to the trailer brakes properly.

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: ON SOME TRUCKS, THERE IS A NO CRANK SITUATION AND IF VOLTAGE ON TRANSMISSION RANGE SENSOR AT PIN 21, IS LESS THAN 5 VOLTS, DISCONNECT THE ENGINE COOLING FAN CLUTCH, ELECTRONICALLY, AND RECHECK VOLTAGE. MODEL 2003-2007 F SUPER DUTY, 2004-2010 E SERIES, 2003-2005 EXCURSION.

FORD: THERE MAY BE A LACK OF RPM, HESITATION, OR ROUGH RUNNING CONCERNS WHEN THE VEHICLE IS IN IDLE. THERE MAY BE TWO TROUBLE CODES STORED. THE PROBLEM MAY BE CAUSED BY AFTERMARKET GENERATORS INSTALLED OR MODIFICATIONS TO THE FRONT END DRIVE. E-350/450. *RM

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