2002 Ford F-250 Sd Engine Problems

TRUCK DIES WHILE DRIVING WITHOUT ANY WARNING, CAN-NOT FIND THE PROBLEM AND FORD WILL NOT ACKNOWLEDGE THAT THERE IS AN ISSUE. *TR

NHTSA ID

10945677

Incident

Sep 1, 2016

Mileage

120,000 mi

AT 102000 MILES ENGINE EJECTED #8 SPARK PLUG WHILE DRIVING, TAKING THREADS WITH IT. LOCAL MECHANIC REPAIRED USING INSERT. AT 125000 MILES ENGINE EJECTED #3 SPARK PLUG IN SAME MANNER. SAME MECHANIC INSPECTED #8 WHILE REPAIRING #3 AND FOUND INSERT NOT HOLDING, PLUS TWO OTHER PLUGS BACKING OUT.

NHTSA ID

10859967

Incident

Apr 8, 2016

Mileage

102,000 mi

TL* THE CONTACT OWNS A 2002 FORD F-250 SD. THE CONTACT STATED THAT WHILE DRIVING 55 MPH, A LOUD ABNORMAL SOUND EMITTED FROM THE ENGINE COMPARTMENT. AFTER INSPECTING THE VEHICLE, THE CONTACT NOTICED THAT THE SPARK PLUG HAD EXPLODED OUT OF THE CYLINDER HEAD. THE FAILURE RECURRED SEVERAL TIMES. THE VEHICLE WAS TAKEN TO THE DEALER WHO ADVISED THAT THE ENGINE NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 84,000.

NHTSA ID

10810751

Incident

Dec 2, 2011

Mileage

84,000 mi

2002 FORD F250 SUPERDUTY. CONSUMER WRITES IN REGARDS TO A STRONG DIESEL FUEL ODOR AND FINDING FUEL ON THE PASSENGER SIDE OF THE ENGINE COMPARTMENT IN THE CAB OF THE VEHICLE. THE DEALER INFORMED THE CONSUMER, THE DIESEL ENGINE WAS DESIGNED WITH COPPER SLEEVES OR CUPS AROUND THE FUEL INJECTORS. THE PURPOSE OF THE CUPS WERE TO SEPARATE THE ENGINE COOLING SYSTEM FROM THE PRESSURIZED FUEL SYSTEM. OVER A PERIOD OF TIME, THE ENGINE COOLANT REACTED WITH THE COPPER CUPS AND CREATED SMALL PIN HOLES OR CRACKS IN THE INJECTOR CUPS. SINCE THE FUEL SYSTEM WAS PRESSURIZED IT INJECTED DIESEL FUEL INTO THE COOLANT CIRCULATING IN THE ENGINE. EVENTUALLY THE DIESEL FUEL CAME OUT OF THE RADIATOR OVERFLOW AND ALL OVER THE PASSENGER SIDE OF THE ENGINE COMPARTMENT. SINCE THERE WAS NO WAY TO TELL, WHICH INJECTOR CUP WAS BAD, ALL OF THEM WOULD HAVE TO BE REPLACED ALONG WITH THE COOLANT HOSES AND THE RADIATOR WOULD NEED TO BE FLUSHED. THE ENGINE WOULD HAVE TO BE TAKEN APART, THE HEADS WOULD HAVE TO BE REMOVED AND THE INJECTOR CUPS REPLACE.*JB UPDATED 02/13/13

NHTSA ID

10495681

Incident

Jan 1, 2013

WHILE DRIVING I BEGAN TO HEAR A LOUD POPPING NOISE COMING FROM THE ENGINE. AFTER STOPPING AND CHECKING THE ENGINE I NOTICE I HAD A BLOWN OUT SPARK PLUG AND BUSTED IGNITION COIL. I HAVE A 2002 FORD F 250 SD. I HAVE ATTEMPTED TO PUT IN A NEW PLUG BUT IT WILL NOT SCREW INTO THE HOLE. DAMAGE ESTIMATES ARE FROM $150.00 ON LABOR FEES AND $75-100 ON A TEMP. FIX HELICOIL OR HEAD REPLACEMENT FOR $2500.00. FORD MECH. SAID IT HAPPENS ALL THE TIME, DUE TO POOR DESIGN. *JS

NHTSA ID

10468123

Incident

Jul 28, 2012

Mileage

150,000 mi

TL*THE CONTACT OWNS A 2002 FORD F250 SD. WHILE DRIVING APPROXIMATELY 50 MPH, THE CONTACT HEARD A LOUD NOISE OUTSIDE OF THE VEHICLE AND SUDDENLY THERE WAS A REDUCTION IN THE ENGINE POWER. THE CONTACT MANEUVERED TO THE SIDE OF THE ROAD AND THEN RESUMED CAUTIOUSLY TO THE RESIDENCE. UPON REACHING THE DESTINATION THE VEHICLE WAS INSPECTED. THE CONTACT DETECTED ONE OF THE SPARK PLUGS EXPLODED FROM THE HEAD. THE VEHICLE HAD NOT BEEN REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 142,000.

NHTSA ID

10436535

Incident

Nov 20, 2011

Mileage

142,000 mi

SPARK PLUG IN THE #8 CYLINDER WAS BLOWN OUT BREAKING THE COIL PACK AND MESSING THE THREADS UP INSIDE THE HEAD ON THE TRITON 5.4 V8. *KB

NHTSA ID

10429430

Incident

Oct 10, 2011

Mileage

183,595 mi

ON SUNDAY MAY 1ST. I WAS DRIVING MY FORD F250 ON THE FREEWAY AND NOTICED THAT SMOKE WAS COMING OUT OF THE DASHBOARD, AND OUT OF THE AC VENTS. I PULLED OVER TO THE EMERGENCY LANE OF THE FREEWAY AND OPENED THE HOOD, WE SAW NO SMOKE NOR FIRE UNDER THE HOOD BUT JUST TO BE ON THE SAFE SIDE I DISCONNECTED THE BATTERY. THE SMOKE CONTINUED COMING OUT THROUGH THE DASHBOARD I THEN PROCEEDED TO CALL AAA AND THEY CALLED THE POLICE. MY SON THEN CALLED 911, AND BEFORE THE FIRE DEPARTMENT ARRIVED TO THE SCENE THAT TRUCK CAUGHT FIRE AND KEPT BURNING UNTIL THE FIRE DEPT. TURNED IT OFF. THE TRUCK IS NOW A TOTAL LOSS, ASIDE FROM MY TRUCK BURNING UP I HAD ALOT OF WORK TOOLS THAT BURNED IN THE FIRE AS WELL. *TR

NHTSA ID

10399949

Incident

May 1, 2011

THERE WAS NO EVENT LEADING UP TO THIS FAILURE IT JUST HAPPENED THE SPARK PLUG AND COIL BLEW OUT OF THE CYL HEAD OF THE ENGINE CAUSING A LOUD NOISE AND SEVERE LOST OF POWER. THE TRUCK HAD TO BE TOWED TO THE REPAIR SHOP TO REPAIR THE HEAD AND RETHREAD THE SPARK PLUG HOLE. LOOKING ON THE INTERNET FOR THIS SAME PROBLEM AND FOUND HUNDREDS OF COMPLAINTS WITH THE SAME PROBLEM. *TR

NHTSA ID

10395690

Incident

Apr 4, 2011

Mileage

106,390 mi

TL*THE CONTACT OWNS A 2002 FORD F250 SUPER DUTY. WHILE THE CONTACT WAS DRIVING APPROXIMATELY 35 MPH, THE VEHICLE BEGAN TO SHAKE WITH A VIBRATION. THE VEHICLE WAS TAKEN TO A LOCAL INDEPENDENT MECHANIC WHO STATED THAT ONE OF THE SPARK PLUGS EJECTED FROM THE ENGINE. THE VEHICLE WAS IN THE PROCESS OF BEING TOWED TO A DIFFERENT MECHANIC TO BE REPAIRED. THE FAILURE MILEAGE WAS 86,000.

NHTSA ID

10367232

Incident

Nov 22, 2010

Mileage

86,000 mi

2002 FORD F-250 5.4L TRITON MOTOR. 95,950 MILES ON ENG. SPARK PLUG BLOW OUT. JUST COST ME $775 DOLLARS TO HAVE SPARK PLUG INSERT,NEW SPARK PLUG, AND SPARK PLUG COIL REPLACED. I DID NOT GET THE OLD PARTS BACK. *TR

NHTSA ID

10358363

Incident

Sep 27, 2010

Mileage

95,988 mi

2002 F250 SUPER DUTY LARIAT WITH 80,350 MILES AND ORIGINAL FACTORY INSTALLED PLUGS LOST A SPARKPLUG ON PASSENGER SIDE OF MOTOR ON 8/22/2010, 183 MILES FROM DEALER(WHO SOLD ME AN AFTER MARKET "EXTENDED" WARRANTY. I PAID $300.00 PLUS TO HAVE TRUCK TRAILERED BACK TO THE DEALER AND HAVE INCURRED OTHER EXPENSES NOW THAT WE ARE GOING ON OVER A WEEK SINCE THE PROBLEM! I DON'T HAVE ANY FAITH IN THE VEHICLE NOW AND AM NOT GOING TO BE OVERLY SURPRISED AT WHAT THIS SITUATION HAS DONE TO THE TRADE-IN VALUE OF, WHAT WAS, A BEAUTIFUL TRUCK. FORD SAYS "WON'T HELP" AND WARRANTY PEOPLE SAY "WON'T HELP; NOT A LUBRICATED PART". ASKING FOR LETTERS TO THAT EFFECT FROM BOTH COMPANY'S FOR MY "PERSONAL USE"!!! *TR

NHTSA ID

10352626

Incident

Aug 22, 2010

Mileage

80,350 mi

LEAKING HEAD GASKETS ON 2002 FORD F250 TRUCK WITH 5.4L ENGINE ALLOWS OIL TO LEAK ONTO STARTER AND EXHAUST MANIFOLD CREATING SAFETY HAZARD. THIS IS A KNOWN PROBLEM WITH THIS TYPE ENGINE. *TR

NHTSA ID

10335960

Incident

May 15, 2010

Mileage

78,000 mi

FORD F-250 SPARK PLUG CAME OUT OF HEAD, BROKE OFF COIL PACK, CANT GET NEW PLUG BACK IN. THIS SHOULD NOT BE ABLE TO HAPPEN. I GUESS I AM GOING TO TRY HELICOIL,IT HAPPENED ON THE 3RD CYL BACK FROM THE FRONT ON RIGHT SIDE SO ITS KIND OF UNDER THE WINDSHIELD ALL READY, NOT MUCH ROOM FOR DRILL. *TR

NHTSA ID

10330098

Incident

May 10, 2010

Mileage

60,560 mi

TL*THE CONTACT OWNS A 2002 FORD F-250 SUPER DUTY. WHILE DRIVING AT 50 MPH, THE CONTACT HEARD A HISSING NOISE AND THE VEHICLE SUDDENLY LOST POWER. THE CONTACT PULLED OVER AND NOTICED A SPARK PLUG HAD FALLEN OUT OF THE VEHICLE. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALERSHIP WHERE IT WAS REPAIRED. THE FAILURE MILEAGE WAS 70,142. THE CURRENT MILEAGE WAS APPROXIMATELY 79,000.

NHTSA ID

10329326

Incident

Jul 8, 2008

Mileage

70,142 mi

WELL GUESS WHAT, IT'S ME AGAIN WITH F250 4X4 WITH THE TRITON MOTOR. GOT IN IT MADE IT ABOUT 1/10 OF A MILE, IT STARTED SHIMMING AND RUNNING ROUGH AGAIN AND IT DIED. I'M AFRAID TO START IT BECAUSE OF THE SPARK PLUG EJECTING ALREADY ONCE AND I'M AFRAID IT'S GOING TO DO IT AGAIN AND CATCH FIRE. FORD IF THIS KEEPS UP U WILL HAVE A LAWSUIT AND YOU CAN BRING IN YOUR BIG LAWYERS BUT I GUARANTEE YOU WILL NOT WIN. *TR

NHTSA ID

10328448

Incident

May 2, 2010

Mileage

160,000 mi

I HAD TO REPLACE EXHAUST MANIFOLD BOLTS AT 75,000 MILES AND NOW I AM REPLACING THEM AGAIN ALSO. I HAVE READ ALL THESE COMPLAINTS ABOUT THE SPARKPLUGS AND THE BOLTS BURNING INTO AND I HAVE HAD FORDS SINCE I'VE BEEN DRIVING AT AGE 16 WHICH IS OVER 30 YEARS AGO AND I MIGHT BE CHANGING MY BRAND BECAUSE I AM SICK OF THE TROUBLE. FORD YOU NEED TO STEP UP TO THE PLATE, THESE ARE HARD TIMES FOR EVERYONE BUT YOU NEED TO TAKE RESPONSIBILITY OF THESE PROBLEMS. *TR

NHTSA ID

10328385

Incident

Aug 19, 2005

Mileage

75,000 mi

SPARKPLUG EJECTED OUT OF MOTOR ON RIGHT SIDE AND ANOTHER SPARKPLUG ON THE LEFT SIDE KEEPS MISSING OUT BECAUSE OF OIL IN IT. I CAN'T KEEP FIGHTING REPAIRS I'M STILL PAYING ON IT. FROM WHAT I'M HEARING THERE IS SEVERAL MOTORS DOING THIS. I WOULD LIKE TO SEE THIS PROBLEM SOLVED PLEASE OR FORD CAN PAY MY TOW BILLS. MY CRUISE CONTROL QUIT WORKING. I HAVE A RUMBLE IN REAR END WHEN TURNING CORNERS. I HAVE HAD IT LOOKED AT, DIFFERENT THINGS FIXED AND NO REPAIR FACILITY CAN FIGURE IT OUT. I WORK 60 MINUTES AWAY AND I CAN'T KEEP GETTING STRANDED IN IT AND I'M VERY TIRED OF IT. *TR

NHTSA ID

10328383

Incident

Mar 11, 2010

Mileage

150,000 mi

I HAVE 2002 FORD F250 WITH A 5.4L TRITON ENGINE. THE EXHAUST MANIFOLD STUDS ARE RUSTING AND BREAKING OFF. I HAVE CONTACTED MY DEALER AND HAVE BEEN TOLD IT IS COMMON PROBLEM. THIS IS AN $850 TO $1000 FIX. I AM AFRAID THAT THE EXHAUST GASES MAY START SOMETHING BURNING IN THE ENGINE COMPARTMENT AND THAT THE LEAKING EXHAUST IS NOT BEING CLEANED BY THE CATALYTIC CONVERTER. IF THIS IS A COMMON PROBLEM, WHY ISN'T THERE A RECALL? THE REPLACEMENT STUDS ARE STAINLESS STEEL AND ARE BIGGER SO FORD MUST KNOW OF THIS PROBLEM. *TR

NHTSA ID

10326157

Incident

Oct 6, 2009

Mileage

80,000 mi

SPARK PLUG BLOWOUT WHILE DRIVING ON 5.4 LITER TRITON MOTOR WITH 48,000 MILES FACTORY INSTALLED SPARK PLUGS. FORD MOTOR DEALER CONTACTED. REFUSED TO ACCEPT RESPONSIBILITY. MECHANIC MADE SHOP REPAIR BY PULLING INTAKE AND INSTALLING INSERT TO NUMBER 3 CYLINDER. $1000.00 DOLLAR REPAIR, POTENTIAL FUEL IGNITION FROM MOTOR, ESCAPING FUEL MIX COMBINED WITH COIL SPARK PRESENT DURING FAILURE. *TR

NHTSA ID

10325525

Incident

Apr 7, 2010

Mileage

48,000 mi

I HAD A SPARK PLUG BLOW OUT OF MY CYLINDER HEAD OF MY FORD F250 2002 WITH 79,000 MILES ON IT.

NHTSA ID

10321664

Incident

Mar 10, 2010

Mileage

79,000 mi

2002 FORD F-250 V-10 I HAVING THE ISSUE OF THE SPARK PLUG BLOWING OUT THIS IS THE SECOND ONE IN ABOUT A YEARS TIME. LUCKILY THE FIRST TIME SPARK PLUG WENT BACK IN THIS TIME IT ISN'T GOING TO HAPPEN THAT WAY. IF ITS A FORD ISSUE THEY NEED TO FIX IT INSTEAD OF US HAVING TO FIX THERE PROBLEMS. *TR

NHTSA ID

10321293

Incident

Mar 21, 2010

Mileage

123,000 mi

I HAVE A 2002 FORD F250 WITH A TRITON V* ENGINE. TO THIS DATE, IT HAS BLOWN OUT 5 SPARK PLUGS! SO FAR, THE REPAIRS HAVE RUN OVER $1000 TO FIX THIS, AND WITH THREE MORE TO GO, I CAN FORESEE AT LEAST ANOTHER $750, WHICH I CAN ILL AFFORD. *TR

NHTSA ID

10319012

Incident

Mar 11, 2010

Mileage

97,625 mi

FORD F250 V-10 SPIT SPARK PLUG, CAUSED SMALL FIRE UNDER THE HOOD. BROKE THE COP. IF A SPARK PLUG BLOWS OUT AND COULD INJURE A PERSON WORKING ON THE VEHICLE, WHY IS THAT DIFFERENT FROM THIS THAT IS CLASSIFIED AS A SAFETY RECALL? (ENGINE COOLING FAN BLADES THAT BREAK UNEXPECTEDLY CAUSING INJURY TO PERSONS WORKING ON A VEHICLE). *TR

NHTSA ID

10315784

Incident

Aug 15, 2009

Mileage

145,000 mi

I OWN A 2002 F250 V10 WITH APPROX 84,000 MILES. I WAS JUST DRIVING ALONG AND THE SPARK PLUG FROM THE # 8 CYLINDER BLEW OUT. I HAD TO RETAP IT AND PUT A HELICOIL IN IT. THE SPARK PLUGS WERE THE ORIGINAL SPARK PLUGS AND HAVE NEVER BEEN REPLACED. I HAVE SEEN NUMEROUS COMPLAINTS OF THE SAME PROBLEM ON KLINE. IT IS DEFINITELY A MANUFACTURING DEFECT. ALSO I NEED TO REPLACE THE EXHAUST MANIFOLD BOLTS ON THE SAME CYLINDER HEADS. THIS IS ANOTHER PROBLEM I HAVE FOUND NUMEROUS COMPLAINTS ABOUT ONLINE. *TR

NHTSA ID

10311728

Incident

Jan 15, 2010

Mileage

84,000 mi