2003 Ford Explorer Sport

IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), FORD STATED CONSUMER REPORTS OF HIGHER THAN EXPECTED EFFORTS WHEN SHIFTING INTO AND OUT OF PARK COULD BE A RESULT OF A GROOVE BEING WORN INTO THE SWING ARM RAMP OF THE STEERING COLUMN. THE SWING ARM IS A COMPONENT BOLTED TO THE STEERING COLUMN THAT ASSISTS IN SHIFTING THROUGH THE TRANSMISSION GEARS.AN ENGINEERING EVALUATION CONDUCTED BY FORD OF RETURNED STEERING COLUMNS FOUND THE GROOVE COULD BE CREATED OVER TIME IF CONSUMER SHIFT MORE QUICKLY FROM THE DRIVE OR REVERSE TO PARK THAN THE BRAKE SHIFT INTERLOCK (BSI) SOLENOID PIN RETRACTS AFTER THE BRAKE PEDAL IS APPLIED. IN NOVEMBER OF 2004, FORD RELEASED A REDESIGNED BSI SOLENOID WITH A SHORTER PIN RETRACTING TIME AS A SERVICEABLE COMPONENT. FORD HAS NOTED THE SHORTER RETRACTION TIME SIGNIFICANTLY LESSENS THE LIKELIHOOD OF BSI SOLENOID PIN TO SWING ARM CONTACT EVEN WITH RAPID CONSUMER SHIFTS.FORD ALSO ISSUED A TECHNICAL SERVICE BULLETIN, TSB 04-22-12, TO INSTRUCT SERVICE TECHNICIANS ON THE PROPER DIAGNOSIS AND VEHICLE REPAIR. REVIEWING COMPLAINTS TO ODI AND DATA SUBMITTED BY FORD, ODI HAS IDENTIFIED 200 ALLEGED INCIDENTS OF UNINTENDED VEHICLE MOVEMENT AFTER CONSUMERS BELIEVE THEY HAVE SHIFTED THE VEHICLE INTO PARK, RESULTING IN 85 ALLEGED CRASHES AND 32 ALLEGED INJURIES.IN ADDITION TO THE REPORTS OF ALLEGED INCIDENTS OF UNINTENDED VEHICLE MOVEMENT, ODI HAS ALSO IDENTIFIED 883 REPORTS OF CONSUMERS ALLEGING DIFFICULTY OR THE INABILITY TO SHIFT THE VEHICLE INTO PARK.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA09-013) TO FURTHER ASSESS THE SCOPE, FREQUENCY AND RISK TO MOTOR VEHICLE SAFETY OF THE ALLEGED DEFECT IN THE SUBJECT VEHICLES.

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.

WAS CLOSING BACK HATCH AND GLASS WINDOW LITERALLY EXPLODED! VEHICLE WAS PARKED IN MY YARD.

NHTSA ID

11385770

Incident

Dec 30, 2020

Mileage

137,800 mi

THE TRANSMISSION IS SHOT I CANT PUT IT IN GEAR AND ME AND MY HUSBAND WERE ALMOST KILLED BUT WERE ABLE TO PUT IT IN 2ND GEAR TO ROLL IT TO THE SHOP. THE 4WHEEL DRIVE GOT STUCK IN 4 WHEEL LOW AND WOULD NOT SHIFT AT ALL. WHEN WE TURNED THE CAR ON IT WOULD REV UP TO 5 BUT ONLY GO 2 MILES AN HOUR.

NHTSA ID

11289611

Incident

Dec 15, 2019

Mileage

133,000 mi

"TAKATA RECALL" AIRBAG LIGHT KEEPS BLINKING WITH THE SEAT BELT NOISE. CHANGED THE LIGHT BULB FROM THE DASH BOARD AND NOW THE AIRBAG LIGHT STAYS ON BUT WILL NOT CONNECT WITH MILEAGE.

NHTSA ID

11230012

Incident

Jul 1, 2019

BODY MOUNTS DETERIORATED CRUMPLED.BODY DOWN ON FRAME CAUSING IRREGULAR RIDE CONTROL

NHTSA ID

11143472

Incident

Sep 1, 2018

Mileage

77,000 mi

CAR HAS AN INTERMITTENT PROBLEM AND WILL STALL AND BOTH HIGH AND LOW SPEEDS, OR WHEN IDLING. WHEN THIS HAPPENS AND POWER ASSIST FAILS, IT'S ALMOST IMPOSSIBLE TO STEER OR TO BRAKE POSING A SERIOUS RISK TO SAFETY. THIS FIRST STARTING HAPPENING ABOUT ONCE A WEEK LAST NOVEMBER, AND NOW IT'S PRETTY OFTEN. STOPPED DRIVING THE CAR, EXCEPT TO TEST DRIVE AS WE'RE TRYING TO FIND THE SOURCE OF THE PROBLEM. WE THINK IT'S EITHER THE FUEL OR VACUUM SYSTEM AND ARE CONTINUING TO NARROW DOWN THE PROBLEM. I AM NOT SURE IF BRAKING WILL WORK AT ALL WHEN IT FAILS, AS FORTUNATELY IT HASN'T STALLED GOING DOWNHILL. I PUT ALL MY STRENGTH INTO BOTH BRAKING AND STEERING (I'M A PRETTY STRONG WOMAN) TO GET IT TO SAFETY. IT MAY SIMPLY BE STOPPING DUE TO INERTIA.

NHTSA ID

11063921

Incident

Nov 22, 2017

Mileage

167,000 mi

TL* THE CONTACT OWNS A 2003 FORD EXPLORER SPORT. WHILE DRIVING 50 MPH, A LOUD NOISE WAS HEARD WHEN THE SUN ROOF EXPLODED WITHOUT WARNING. THERE WERE NO INJURIES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 130,000. THE VIN WAS NOT AVAILABLE.

NHTSA ID

10946504

Incident

Jan 19, 2017

Mileage

130,000 mi

REAR LIFTGATE WINDOW ON MY 2003 FORD EXPLORER SPORT EXPLODED INTO A MILLION PIECES. THE VEHICLE WAS PARKED IN MY DRIVEWAY AND I WENT TO OPEN THE DOOR AND IT JUST EXPLODED.

NHTSA ID

10934774

Incident

Dec 12, 2016

Mileage

84,500 mi

TL* THE CONTACT OWNS A 2003 FORD EXPLORER SPORT. WHILE DRIVING APPROXIMATELY 25 MPH, A NOISE EMERGED FROM THE REAR HATCH WINDOW. THE CONTACT PULLED THE VEHICLE OVER TO THE SIDE OF THE ROAD AND NOTICED THAT THE PIECE THAT HELD THE WINDOW IN PLACE WAS FRACTURED. THE VEHICLE WAS REPAIRED FOR THE SAME FAILURE IN MARCH OF 2015. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 159,149.

NHTSA ID

10886191

Incident

Jul 18, 2016

Mileage

159,149 mi

STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE. *TT

MALFUNCTION INDICATOR LAMP COMING ON WITH DIAGNOSTIC TROUBLE CODES (DTCS) P0171, P0172, P0174 AND/OR P0175 (FUEL SYSTEM TOO RICH OR LEAN). *TT

SAFETY BELT RETRACTION SPEED. *TT

FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD. *TT

SAFETY BELT WEB STOP BUTTON SERVICE. *EH

REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR. *TT