2002 Ford Econoline

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.

LEFT HOUSE FOR VACATION, GOT 75 MILES AWAY AT 60 MPH ON THE FREEWAY, AND ENGINE STARTED MAKING A POPPING SOUND. PULLED OFF ROAD AND CALLED A NEARBY MOBILE REPAIR COMPANY. THEY SENT OUT A MECHANIC, HE DIAGNOSED A BLOWN OUT SPARK PLUG, AND SAID THIS WAS COMMON FOR THE FORD V-10. MADE IT TO HIS SHOP, AND THAT'S WHERE IT SITS. ESTIMATES ARE OVER $4000 TO REPAIR.

NHTSA ID

11033338

Incident

Oct 12, 2017

Mileage

150,000 mi

DRIVING VAN ON HIGHWAY WHEN VAN BEGAN SMOKING. THEN FIRE. EVERYTHING WAS COMPLETELY DESTROYED. *TR

NHTSA ID

10614804

Incident

Oct 15, 2013

Mileage

280,000 mi

TL* THE CONTACT OWNS A 2002 FORD ECONOLINE E-150. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 30 MPH, HE HEARD A LOUD, ABNORMAL NOISE FROM THE VEHICLE. AFTER STOPPING THE VEHICLE FOR FURTHER INSPECTION, THE CONTACT DISCOVERED THAT THE REAR END OF THE FUEL TANK HAD DETACHED FROM THE VEHICLE. IN ADDITION, ONE OF THE FUEL TANK STRAPS HAD BECOME COMPLETELY CORRODED. THE VEHICLE WAS DRIVEN CAUTIOUSLY AND WAS LATER TAKEN TO THE DEALER. THE DEALER CONFIRMED THE FAILURE OF THE FUEL TANK STRAPS AND INSTALLED A TEMPORARY STRAP FOR THE FUEL TANK. THE MANUFACTURER WAS NOT CONTACTED. THE FAILURE AND THE CURRENT MILEAGES WERE APPROXIMATELY 76,000.

NHTSA ID

10480958

Incident

Oct 8, 2012

Mileage

76,000 mi

TOOK THE VAN TO THE STORE. UPON RETURNING FROM STORE STARTED THE VAN, THERE WAS A LOUD EXPLOSION AS IF A BOMB WENT OFF. EVERYONE LOOKED BECAUSE IT WAS SO LOUD. TURNED THE VAN OFF AND RESTARTED IT. IT SOUNDED LIKE A DRAG CAR AT THE TRACK, NO EXHAUST SYSTEM AT ALL. TOOK COW OFF AND LOOKED INSIDE, FOUND THE SPARK PLUG WITH THE BOOT LAYING ON TOP OF THE VALVE COVER OR INTAKE, NOT SURE THERE IS NO ROOM AND JUST ENOUGH TO GET TWO FINGERS IN TO RETRIEVE IT. I HAD NOTICED A LITTLE TICKING EARLIER IN THE DAY LIKE AN EXHAUST LEAK, BUT DID NOT FIND ONE. HAD VEHICLE TOWED TO REPAIR SHOP, WHERE IT IS NOW. NOT SURE WHAT WILL HAPPEN NEXT. *TR

NHTSA ID

10465883

Incident

Jul 12, 2012

Mileage

98,000 mi

FUEL PUMP FAILED WHILE DRIVING VEHICLE AT FREEWAY SPEEDS ON 101 SOUTH ON THE WALDO GRADE APPROACHING THE GOLDEN GATE BRIDGE. VEHICLE LOST POWER HALF WAY UP THE GRADE AND SLOWED TO 10 MPH. LIMPED VEHICLE TO OFF RAMP. I AM AN ASE CERTIFIED MASTER MECHANIC, I ALSO HOLD MY CALIFORNIA SMOG LICENSE. I'VE WORKED AS A MECHANIC FOR 30 YEARS. UPON GETTING THE VEHICLE HOME I DIAGNOSED THE CONCERN I FOUND THE FUEL TANK FULL OF METAL THAT HAD FLAKED FROMT HE WALLS OF THE FUEL TANK. I FOUND THE FUEL PICKUP IN THE TANK PLUGGED WITH FILINGS, THE FUEL PUMP RUINED, AND THE FUEL FILTER FULL OF METAL AND RUST. I SENT THE TANK TO WHO COATED THE FUEL TANK FOR ME. STATED THAT HE CONTINUOUSLY SEES THESE FORD TANK COMING FROM ALL THE DEALERSHIPS IN THE AREA. UPON DOING SOME RESEARCH ON THE INTERNET I FOUND THAT THIS IS A WIDESPREAD PROBLEM WITH FORD FUEL TANKS. MY TOTAL COST FOR THIS REPAIR IN PARTS AND REPAIRS TO THE FUEL TANK HAS COME TO $1,200.00 WHOLESALE COST, NOT INCLUDING MY LABOR OR ANY PARTS RETAIL MARKUP. I HAVE OWNED THIS VEHICLE SINCE NEW AND ALWAYS RUN GOOD QUALITY FUEL IN MY VEHICLE AND TOPPED UP THE TANK WEEKLY OR MORE OFTEN TO REDUCE THE POSSIBILITY OF MOISTURE IN MY FUEL SYSTEM. I HAVE NOT FILLED UP THE FUEL TANK AND RUN THE ENGINE YET, AND HOPE THAT THERE IS NO FURTHER DAMAGE TO MY FUEL INJECTORS OR FUEL SYSTEM. IF THERE IS I COULD BE OUT ANOTHER $4,000 TO 5,000 JUST IN PARTS. I AM CURIOUS AS TO WHY IF THERE SEEMS TO BE SUCH A WIDESPREAD PROBLEM OUR GOVERNMENT HAS NOT RECALLED THESE VEHICLES? IT IS CLEAR TO ME THAT FORD IS PRODUCING VEHICLES WITH SUBSTANDARD FUEL SYSTEMS AND THAT THERE IS A KNOWN DEFECT THAT FORD IS NOT OWNING. THE PUBLIC SHOULD NOT BE HELD LIABLE OFR FORD'S DESIGN FLAWS. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6) *TT

NHTSA ID

10459094

Incident

May 6, 2012

Mileage

96,517 mi

2002 FORD VAN - BLOWN SPARK PLUG. *TR

NHTSA ID

10406082

Incident

Jun 10, 2011

Mileage

141,058 mi

2002 FORD VAN - BLOWN SPARK PLUG. *TR

NHTSA ID

10406081

Incident

Jun 11, 2010

Mileage

123,005 mi

2002 FORD VAN - BLOWN SPARK PLUG. *TR

NHTSA ID

10406079

Incident

Mar 12, 2010

Mileage

117,519 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.

FORD: VEHICLES MISTAKENLY CHARGED $100 POWERTRAIN WARRANTY DEDUCTIBLE FOR FUEL INJECTOR REPAIR OR REPAIRS. NO MODEL OR MODEL YEARS PROVIDED. *PE ECONOLINE, EXCURSION AND F-SERIES SUPER DUTY VEHICLES, MODEL YEARS 2002-2005. UPDATED 10/24/08. *PE CSC LETTER WAS RECEIVED. UPDATED 10/27/08. *PE

MERLIN MULTIPLEX SYSTEM WHEN A PROER/GROUND LUG IS NOT CORRECTLY TIGHTENED OR BECOMES LOOSE FOR ANY REASON; ERRATIC SYSTEM OPERATION IS POSSIBLE.

ENGINE OR FUEL SYSTEM CONCERNS WHEN USING FUEL WITH GREATER THAN 5% BIODIESEL CONCENTRATION. *TT

MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - SYSTEM LEAN DIAGNOSTIC TROUBLE CODES (DTC'S) - SERVICE TIPS. VARIOUS MODELS INCLUDING 2004 F-SERIES. *TT

LOW POWER, POOR FUEL ECONOMY, FUEL GELLING COLD, EXCESSIVE WHITE SMOKE COLD, OR HARD START. *MJ THIS OASIS UPDATES PREVIOUS OASIS DATED 12/01/03. *TT