2002 Ford F Series

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.

I was driving my truck and it began vibrating; shortly thereafter it was running as if half the engine was working , with a loss of power. I pulled the fuel filter and there was trash all in the filter. I bought another filter and replaced it and ran the truck again and it was working fine. Shortly thereafter the same thing happened again, loss of power, running like half the engine was working and then stalled. After a few minutes it started up but ran terrible. I got it home. I pulled the fuel filter and it was loaded with trash again. I called the Ford dealer and spoke to a mechanic and he advised he has fixed numerous trucks like mine and the gas tank was deteriorating from the inside and clogging my fuel filter. He said there is a recall for the truck and that the fuel tank needs to be replaced. Please help me as this truck only has 75,000 miles and is like brand new, garage kept and well taken care of. Thank you for your time in this matter and I look forward to hearing from you soon.

NHTSA ID

11462328

Incident

Apr 11, 2022

DRIVING ON THE FREEWAY A SPARK PLUG CAME OUT OF THE ENGINE CAUSING THE VEHICLE TO SHAKE AND LOOSE POWER. THE DEALER AND A SHOP I TOOK THE VEHICLE TO STATED THAT THIS IS A FREQUENT PROBLEM WITH THIS ENGINE. *TR

NHTSA ID

10672488

Incident

Dec 30, 2014

Mileage

119,000 mi

WHILE BACKING INTO MY TRUCK STARTED MAKING A LOAD NOISE, IT WAS OBVIOUS IT WAS IN THE FRONT END. TRYING TO TURN THE STEERING WHEEL, IT WAS STUCK. STOPPED THE TRUCK, LOOKED UNDER THE FRONT OF TRUCK AT STEERING, I NOTICED THAT THERE WAS A HOLE IN THE FRAME, IT WAS THEN THAT I SAW THE STEERING LINK, AGAINST THE RIGHT CV AXLE. THE IDLER ARM HAD SOME HOW RIPPED OFF THE FRAME, LEAVING NA HOLE WHERE THE IDLER ARM WAS, THE FRAME OF THE TRUCK HAD WEAKENED, CAUSING THE METAL TO WEAKEN AND SEPARATE, THANK AGAIN FORD. *TR

NHTSA ID

10639169

Incident

Sep 2, 2014

Mileage

134,549 mi

FAILURE OF THE ABS MODULE HAS LED TO A NEAR MISS ACCIDENT THAT WAS AVOIDED VIA STEERING AROUND THE OBSTRUCTION INSTEAD OF BRAKING. THE OBDII MODULE IS THROWING CODE C1185 AS A PART OF THE FAILURE OF THE ABS CONTROLLER.. *TR

NHTSA ID

10627892

Incident

Aug 18, 2014

Mileage

190,000 mi

GAS PETAL STICKS AND WHEN PUSHED ON TRUCK ACCELERATES RAPIDLY, THIS HAPPENS WHEN STARTING OUT FROM A STOP AND DURING ALL DRIVING. *JS

NHTSA ID

10585196

Incident

Apr 26, 2014

Mileage

212,003 mi

WAS DRIVING DOWN THE ROAD AT 35 MPH AND HEARD A POP THEN THE ENGINE STARTED TO RUN ROUGH. TOOK TO THE MECHANIC SAID THAT I HAD A BLOWN SPARK PLUG. *TR

NHTSA ID

10574581

Incident

Mar 24, 2014

Mileage

206,000 mi

THROTTLE BODY LINKAGE "PLASTIC COVER CLAMSHELL" CRACKED IN HALF AT PLASTIC HINGE (OXIDIZED PLASTIC) . LOOSE PLASTIC COVER WEDGED OPEN THROTTLE FULLY CAUSING "DANGEROUS LIFE THREATENING" DRIVING STUCK AT FULL THROTTLE. I HAVE THE COVER AND PHOTOS IF YOU WANT ME TO SEND THEM. *TR

NHTSA ID

10566358

Incident

Feb 26, 2014

Mileage

154,000 mi

A SPARK PLUG EJECTED FROM THE RIGHT SIDE HEAD OF THE ENGINE HEAD WHILE RUNNING DOWN THE HWY AT 60 MPH. THE HEAD MIGHT BE DAMAGED. I HAVEN'T HAD A CHANCE TO GET IT FIXED. BEEN A FORD TRUCK GUY ALL MY LIFE & I CAN'T BELIEVE FORD HASN'T ACCEPTED ANY RESPONSIBILITY OF ANY PORTION OR KIND FOR THIS. MY ESTIMATED EXPENSE TO REPAIR THIS IS $1,000 TO $3,000 DEPENDING ON ANY DAMAGE TO THE HEAD ETC.. I PAID $4200 FOR THE TRUCK IN APRIL OF 2013...IT IS IN VERY GOOD CONDITION & TO GOOD TO JUNK IN MY OPINION. BESIDES I CAN'T AFFORD TO BUY ANOTHER TRUCK SO I HAVE TO TRY TO FIX IT. THIS IS BEYOND DISAPPOINTING, IT IS A MAJOR BLOW TO THE BUDGET ETC. ETC. ETC...... *TR

NHTSA ID

10562084

Incident

Jan 4, 2014

Mileage

180,000 mi

JERR-DAN: ANTI STALL FEATURE FOR FORD F SERIES LIGHT DUTY CHASSIS WITH V10 GAS ENGINE AND AN ENGINE DRIVE CLUTCH PUMP. MODEL YEARS UNKNOWN. *PE

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

CUSTOMER SATISFACTION PROGRAM 02M01 SUPPLEMENT #4. CERTAIN FORD 2000 THROUGH 2003 VEHICLES EQUIPPED WITH A TUBE-MOUNTED EGR PRESSURE SENSOR - ADDITIONAL EGR PRESSURE SENSOR WARRANTY COVERAGE. *TT SUPPLEMENT #3. *MJ SUPPLEMENT #6. *TT

REMOTE KEYLESS ENTRY (RKE) - SERVICE TIPS. *TT

CLEAR GEL-LIKE SUBSTANCE IN THE HYDRAULIC BRAKE MASTER CYLINDER RESERVOIR. THIS SUBSTANCE IS A SILICONE BASE LUBRICANT USED DURING ASSEMBLY OF THE MASTER CYLINDER. *TT

FALSE FAILURE OF THE VAPOR MANAGEMENT VALVE (VMV). *TT *JB