2003 Ford F-250

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.

TWENTY FIVE OF THE ODI FAILURE REPORTS ARE DUPLICATIVE OF FORD COMPLAINTS.TWENTY ODI REPORTS DO NOT CONTAIN A VIN (AND MAY OR MAY NOT BE DUPLICATIVE OF FORD REPORTS).THE 14 ALLEGED CRASHES AND 2 ALLEGED INJURIES WERE ALL MINOR.SUBMITTED DURING PRELIMINARY EVALUATION (PE) 04-070, FORD'S RESPONSE TO ODI'S INFORMATION REQUEST (IR) LETTER CONTAINED ABOUT 5,000 CONSUMER REPORTS (MORS) AND 8,700 FIELD REPORTS (CQIS).FORD REVIEWED THE COMPLAINTS AND CATEGORIZED THEM.THE MANUFACTURER REPORTS SHOWN ABOVE REPRESENT A COUNT OF UNIQUE VEHICLES THAT FORD CATEGORIZED AS ALLEGEDLY STALLING DUE TO A SUBJECT ENGINE COMPONENT ('A' CATEGORY, SEE FORD'S IR RESPONSE LETTER FOR FURTHER DETAIL); SOME OF THESE VEHICLES RECEIVED MULTIPLE REPORTS.ODI HAS NOT YET CONFIRMED FORD'S CATEGORIZATION OF THESE REPORTS, NOR HAS ODI CONFIRMED FORD'S CATEGORIZATION OF THE REMAINING REPORTS (WHICH FORD STATES DO NOT PERTAIN TO THE ALLEGED DEFECT).FORD SUBMITTED NEARLY 19,000 WARRANTY CLAIMS, MANY OF WHICH INVOLVED CLAIMS FOR A TECHNICAL SERVICE BULLETIN (TSB 04-13-08) AND FIELD SERVICE ACTION (FSA 03B05) WHICH FORD IDENTIFIED AS POTENTIAL REMEDIES FOR STALLING COMPLAINTS.ODI HAS NOT CONFIRMED THAT EITHER OF THESE ARE A REMEDY FOR ENGINE STALLING COMPLAINTS.SEVERAL OTHER DEALER COMMUNICATIONS RELATED TO ENGINE STALL WERE ALSO SUBMITTED AS WELL AS OVER 50 PRODUCT MODIFICATIONS, 15 OF WHICH INVOLVE REVISIONS TO THE SOFTWARE FOR THE ELECTRONIC ENGINE CONTROL UNIT.FURTHER INVESTIGATION IS REQUIRED AND ODI IS UPGRADING PE04-070 TO AN ENGINEERING ANALYSIS (EA).DURING THE EA, ODI WILL ESTABLISH AND UPDATE MANUFACTURER FAILURE REPORT COUNTS, FURTHER INVESTIGATE THE FREQUENCY AND TREND OF STALLING COMPLAINTS, AND DETERMINE THE SCOPE AND SAFETY IMPLICATION OF STALLING EVENTS.ODI WILL ALSO INVESTIGATE FORD'S REMEDIES, THEIR EFFECTIVENESS, AND WHETHER FURTHER ACTION IS REQUIRED.

The customer purchased a vehicle from Metro Motors on May 8, 2026, after visiting the dealership three times and speaking with multiple sales representatives. During each visit, the customer specifically stated that the vehicle would be used to tow a trailer and repeatedly asked whether it was safe and suitable for towing. The sales staff consistently represented that the vehicle was in good working condition, had low mileage, showed no significant issues on the Carfax report, and would be an excellent vehicle for towing. The customer was discouraged from test driving the vehicle because it was low on fuel, and sales staff stated that the only reason it had not sold was the snowplow attached to the front. Immediately after taking possession of the vehicle on May 8, the customer experienced a serious issue with the electronic parking brake repeatedly engaging while driving. The customer contacted Metro Motors on the next business day and was instructed by the manager, Nate, to bring the vehicle back. Metro Motors later determined that the parking brake cable was broken and that the brakes were in poor condition. After discussions, the dealership agreed to perform repairs if the customer paid for the parts. After the repairs were completed, the customer noticed smoke coming from the wheels and immediately returned the vehicle to Metro Motors. The dealership retained the vehicle but failed to communicate the nature of the problem or any repair costs until notifying the customer that the vehicle was ready for pickup on June 6, 2026. Before taking possession of the vehicle again, the customer arranged for an independent mechanic to inspect it. Although the dealership manager was initially hesitant to allow the inspection, he ultimately permitted it. The mechanic determined that the vehicle's frame was broken and that it was unsafe to operate, particularly for towing, which was the purpose repeatedly disclosed to Metro Motors before purchase.

NHTSA ID

11747388

Incident

May 8, 2026

The contact owned a 2003 Ford F-250. The contact stated that while her husband was driving home, there was black smoke coming from the exhaust, with the check engine warning light illuminated. The vehicle was driven to the residence and turned off. The contact stated that while attempting to restart the vehicle, the vehicle failed to start. The vehicle was towed to an independent mechanic where the vehicle was diagnosed, and the contact was informed that the engine was faulty and needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 171,000.

NHTSA ID

11658268

Incident

Jul 31, 2010

Mileage

171,000 mi

Truck had no check engine light then caught on fire going down the road and burned to ground within seconds Incident report 46-24-05039 08_30-74 US-30 - PA 74 30 W

NHTSA ID

11618329

Incident

Sep 24, 2024

Speed control sensor allows brake fluid leak through the plug connector and run down the wiring harness, allowing brake fluid to splash on the exhaust manifold and cause a fire.

NHTSA ID

11572268

Incident

Feb 13, 2024

The contact owns a 2003 Ford F-250. The contact stated that both turn signals and the windshield wipers would intermittently fail to operate as needed. Over time, the failure worsened and the components failed to operate. The dealer and the manufacturer were notified of the failure and informed him that there were no recalls on the vehicle. the contact was referred to the NHTSA Hotline for assistance. The vehicle was not repaired. The failure mileage was approximately 140,000.

NHTSA ID

11487100

Incident

Aug 31, 2022

Mileage

140,000 mi

Fuel tank straps corrode causing fuel tank to fall off A recall was issued for other similar ford trucks, but this model was not included

NHTSA ID

11471677

Incident

Jun 15, 2022

When the truck accelerates and reaches about 40-5mph the truck begins to wobble sideways. This wobbling sensation shakes the steering wheel violently and as the speed increases so does the shake. I have not had the truck over 65mph as it becomes unmanageable and is very hard to keep in its lane. The tyres are wearing funny as a result. All 4 wheels are wearing a band around both the inside and outside of the tyres.

NHTSA ID

11461337

Incident

Mar 2, 2022

I have been trying to get the exhaust manifold bolts replaced by several machine shops and did my own checking on the Ford F-250 Web site and everyone tells me the same thing! Ford knows about the problem but is doing nothing to correct! I have finally found a shop that will fix the broken exhaust manifold blots ! But I would like to know what ford truly knows about this problem . To get it fixed they have to replace all the bolts do to the bolts being so rusted ! Now I only have 121, + miles on my2003 and with the bolts broken it starts admitting gas fumes into the cab . I did check your site and could only find but 1 complaint , so if this is an issue with the exhaust manifold bolts braking and all the ford forums are full of complaints where are they being filed at on your site ? And I do believe it is an issue because I have spoken to 5 different shoppes and 1 ford dealer , they all say the same thing SORRY but it is your problem ! ford knows but will not do anything about it ! I am having mine put in the shop for repairs on the week of 7 Feb 2022 , now that I found someone I could afford! I had quotes from I will not do the work because it is a V10 to $1000.00 per bolt please address this ! It won’t help me but maybe it will hold ford accountable for the product !

NHTSA ID

11450126

Incident

Feb 3, 2018

LACK OF POWER, SURGE, AND/OR DIAGNOSTIC TROUBLE CODES P2263 OR P0299. *TT

SERVICE TIPS BEFORE ARC WELDING ON THE FRAME OR BODY OF A UNIT. *TT

A COLD WEATHER REVERSE ENGAGEMENT STALL. *TT

WARNING INDICATORS-PARKING AID-REVERSE SENSING SYSTEM (RSS) AND FORWARD SENSING SYSTEM (FSS)-FALSE ACTIVATION OF WARNING TONE-SERVICE TIPS. *MJ UPDATE. *TT

MEMONTARY RETURN TO IDLE DURING AGGRESSIVE ACCELERATION - DIAGNOSTIC TROUBLE CODE (DTC) P0123. *TT

GENERAL (PCM) POWER TRAIN CONTROL MODULE PROGRAMMING PROCEDURES. *TT