1997 Ford F Super Duty

IN A DECEMBER 3, 2007 LETTER, FORD ADVISED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL TO REPLACE THE CAM POSITION SENSOR (CPS) IN APPROXIMATELY 1.2 MILLION SUBJECT VEHICLES TO ADDRESS REPORTS OF ENGINE STALLING.A NEW DESIGN CPS WITH IMPROVED PERFORMANCE AND DURABILITY WILL BE INSTALLED AS A REMEDY.OWNER NOTIFICATIONS WILL BEGIN IN DECEMBER 2007. THE SUBJECT VEHICLES ARE DURABLE, FULL-SIZED, MEDIUM DUTY TRUCKS COMMONLY USED FOR COMMERCIAL PURPOSES, RESCUE/EMERGENCY RESPONSE, AND COMMERCIAL OR RECREATIONAL TOWING.CPS FAILURE IS COMPARABLE TO UNEXPECTEDLY TURNING THE KEY OFF SINCE THE SIGNAL IT PRODUCES IS VITAL TO THE ELECTRONIC ENGINE CONTROL SYSTEM.CPS SIGNAL LOSS TERMINATES FUEL INJECTION RESULTING IN AN ENGINE STALL.ONCE STALLED, THE ENGINE MAY RESTART RIGHT AWAY, OR MAY RESTART AFTER A DELAY (TYPICALLY 5 TO 10 MINUTES), OR MAY NOT RESTART AT ALL.IN ADDITION TO EXPOSING THE DRIVER AND OTHER MOTORISTS TO CRASH RISK DUE TO LOSS OF MOTIVE POWER OR VEHICLE DISABLEMENT, ENGINE STALLING ALSO EFFECTS THE POWER ASSISTED STEERING AND BRAKING. THROUGH CONSUMER INTERVIEWS, ODI DETERMINED THAT CPS FAILURES OCCURRED WITHOUT ANY FORM OF WARNING, AT ANY VEHICLE SPEED (50% AT HIGHWAY SPEEDS), AND UNDER ANY DRIVING CONDITION, SUCH AS ACCELERATING.CONSUMERS REPORTED THAT ABOUT A THIRD OF THE VEHICLES FAILED TO RESTART, WITH ANOTHER THIRD REPORTING DELAYED RESTARTING.HALF THE VEHICLES THAT DID RESTART EXPERIENCED ANOTHER STALL ON THE SAME OR A SUBSEQUENT DRIVE CYCLE (BEFORE CPS REPLACEMENT) RE-EXPOSING THOSE CONSUMERS TO THE RISKS ASSOCIATED WITH A STALLING EVENT.IN THEIR VOQ REPORTS, HALF OF THE ODI COMPLAINANTS DESCRIBED DIFFICULTY CONTROLLING THE VEHICLE DUE TO LOSE OF POWER ASSIST SYSTEMS, ESPECIALLY THOSE WHO WERE TOWING AT THE TIME OF THE INCIDENT. THE ONE ALLEGED INJURY INCIDENT OCCURRED IN AN INTERSECTION WHEN A SUBJECT VEHICLE STALLED WHILE TURNING ACROSS ONCOMING LANES OF TRAFFIC.ALTHOUGH UNSUBSTANTIATED, THE COMPLAINANT ALLEGED AN INJURY TO A CHILD OCCUPANT DURING ODI'S INTERVIEW.THE OTHER CRASH ALLEGATIONS MOSTLY INVOLVED LOW SPEED, LOSS OF CONTROL INCIDENTS OFTEN CAUSED BY LACK OF POWER ASSIST; NO INJURIES ARE REPORTED IN THESE INCIDENTS, AND PROPERTY DAMAGE, IF ANY, WAS MINIMAL.CONSUMERS ALSO REPORTED OTHER INCIDENTS WITH SIGNIFICANT SAFETY RISKS, SUCH AS DISABLEMENT IN A LANE OR ON A SHOULDER OF A HIGH-SPEED ROADWAY OR INTERSTATE, OR EXTENDED DISABLEMENT IN REMOTE AREAS DURING SEVERE WEATHER CONDITIONS. THE POPULATION ABOVE IS FORD'S ESTIMATE OF THE 1.4 MILLION SUBJECT VEHICLES PRODUCED THAT ARE CURRENTLY REGISTERED.THE FORD COMPLAINT AND WARRANTY COUNTS NOTED ABOVE ARE CURRENT AS OF FORD'S LAST SUBMISSION DATED JUNE 21, 2007; THEY DO NOT INCLUDE F-450, F-550, OR ECONOLINE COUNTS AS THESE PRODUCTS WERE NOT FORMALLY WITHIN SCOPE OF THE INVESTIGATION WHEN FAILURE INFORMATION WAS REQUESTED.WARRANTY DATA ANALYSIS INDICATES THAT ABOUT HALF THE CLAIMS INVOLVED A STALL WHILE DRIVING EVENT ( FORD'S ASSESSMENT) AND THAT POOR CPS DURABILITY WAS A LONGSTANDING CONCERN.FORD REPORTED THAT THE NEW CPS DESIGN SHOULD MEET OR EXCEED THEIR 10 YEAR, 150K MILE LIFE EXPECTANCY DESIGN REQUIREMENT.

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.

TL*- THE CONTACT OWNS A1997 FORD F SUPER DUTY. HE RECEIVED A RECALL NOTICE ON THE CAMSHAFT POSITION SENSOR, WHICH CAN CAUSE ENGINE STALLING. HE HAD BEEN EXPERIENCING THAT PROBLEM WHENEVER HE APPROACHED LOWER SPEEDS IN HIS VEHICLE. HE TOOK THE VEHICLE TO THE DEALERSHIP THEY REPLACED THE SENSOR WITH A NEWER AND NON-DEFECTED SENSOR. AFTER THEY REPLACED THE SENSOR THE VEHICLE WOULD NOT START. THEY TRIED SEVERAL SENSORS AND NONE OF THEM WOULD START THE ENGINE. THE MECHANIC THEN PLACED THE OLD SENSOR BACK INTO THE VEHICLE AND THE ENGINE WAS ABLE TO TURN ON. THE MECHANIC TOLD HIM TO BRING THE VEHICLE BACK IN THE FOLLOWING DAY. WHEN HE TOOK THE VEHICLE BACK IN THE NEXT DAY, THEY REPLACED THE SENSOR ONCE AGAIN AND THE VEHICLE WOULD NOT START. THEY PLACED THE OLDER SENSOR BACK INTO THE VEHICLE AND HE WAS ABLE TO DRIVE AWAY. MINUTES AFTER DRIVING AWAY THE CHECK ENGINE LIGHT STARTED TO COME ON AND OFF RANDOMLY IN THE VEHICLE, WHICH IS A PROBLEM NOT PREVIOUSLY EXPERIENCED. HE TOOK THE VEHICLE BACK INTO THE DEALERSHIP AND THEY WERE NOT ABLE TO REPAIR THE PROBLEM. THE CURRENT AND FAILURE MILEAGE WAS 287,000. UPDATED 04/23/08 *BF

NHTSA ID

10222481

Incident

Mar 26, 2008

Mileage

287,000 mi

1997 FORD F-SUPER DUTY WITH SPEED CONTROL RECALL. CONSUMER STATES THAT DEALER PUT HIM ON A WAITING LIST FOR THE REPLACEMENT PARTS. HE STATES THAT THE DEALER KEEPS TELLING HIM THE PARTS ARE NOT IN AND THEY DO NOT KNOW WHEN THEY WILL BE IN. *KB

NHTSA ID

10215048

Incident

Jan 1, 1901

TL*THE CONTACT OWNS A 1997 FORD F-530 SUPER DUTY. THE CONTACT RECEIVED A RECALL NOTICE FOR NHTSA CAMPAIGN ID NUMBER 07V336000 (VEHICLE SPEED CONTROL). THE DEALER STATED THAT THE PARTS WERE UNAVAILABLE AND COULD NOT PROVIDE AN ESTIMATED DATE OF ARRIVAL. THE CONTACT FELT THAT THE WAIT TIME FOR THE RECALLED PART WAS UNACCEPTABLE. THERE HAD BEEN NO FAILURE TO DATE. THE CURRENT MILEAGE WAS 40,000. UPDATED 01-10-08. *KB UPDATED 12/31/07 *TR

NHTSA ID

10209350

Incident

Sep 1, 2007

TL*THE CONTACT OWNS A 1997 FORD F SUPER DUTY. THE VEHICLE HAS FIRESTONE STEELTEX RADIAL TIRES. WHILE DRIVING 50 MPH, THE CONTACT HEARD A LOUD POUNDING NOISE COMING FROM THE REAR OF THE VEHICLE. HE NOTICED THE TREAD HAD SEPARATED ON THE REAR PASSENGER SIDE TIRE. A TIRE SHOP INSPECTED THE TIRE AND STATED THAT THEY WERE UNABLE TO DETERMINE THE REASON FOR THE FAILURE. APPROXIMATELY ONE WEEK LATER, WHILE DRIVING 60 MPH, THE VEHICLE BEGAN VIBRATING. THE CONTACT NOTICED THE TREAD ON THE REAR DRIVER SIDE TIRE HAD SEPARATED. THE TIRE HAS NOT BEEN INSPECTED. THE CURRENT MILEAGE IS 38,000 AND FAILURE MILEAGE WAS 37,000.

NHTSA ID

10195171

Incident

Jun 13, 2007

Mileage

37,000 mi

THE BRAKES FAILED WHILE DRIVING. THE CONSUMER FOUND THE BRAKES RESERVOIR EMPTY, THEN INSPECTED THE BRAKE LINES AND SAW A HOLE IN THE REAR BRAKE LINE. *NM CONSUMER LOST CONTROL OF VEHICLE WHEN BRAKES WENT OUT AND WENT OVER A CURB, OVER PARKING LOTS, INTO A PARKING LOT, AND CAUSED FUEL TANK AND STRAP DAMAGE, FRONT END AND REAR TAD AXLE OUT OF THE ALIGNMENT. CONSUMER FOUND WEAR HOLE IN REAR BRAKE LINE, EGR TUBE CORRODED, BURNT ENGINE COVER, AND CARPET. *SB *NM

NHTSA ID

10127908

Incident

Aug 25, 2000

THE RV VIBRATED AT SPEED OFF 55 MPH AND HIGHER. IT WAS LATER DETERMINED THAT THE DRIVELINE WAS UNDER COATED AND OUT OF ROUND. THE CONSUMER REQUESTED REIMBURSEMENT FOR THE PARTS REPLACED/REPAIRS THAT DID NOT SOLVE THE VIBRATION PROBLEM. *PH *NLM

NHTSA ID

10011494

HAD TREAD SEPARATION OCCUR AT 60 MPH ON RIGHT REAR INBOARD DULEY. AIR TEMPERATURE WAS 90 F.*AK

NHTSA ID

764359

Incident

Jul 9, 2002

WHILE DECELLERATING, BRAKE PEDAL WENT SOFT, BRAKE WARNING LIGHT ACTIVATED, AND VEHICLE WAS STOPPED WITH FRONT BRAKES ONLY, NEARLY CAUSING AN ACCIDENT. INSPECTION REVEALED LEFT REAR BRAKE HOSE (FLEXIBLE) HAD BEEN ABRADED BY AFTERMARKET MODIFICATION BY THE MOTORHOME MANUFACTURER, FLEETWOOD ENTERPRISES. TAG AXLE LINKAGE ADDED BY FLEETWOOD ADJACENT TO BRAKE HOSE CAUSED HOSE TO BE ABRADED IN TWO LOCATIONS, ONE OF WHICH WORE THROUGH CAUSING BRAKE FLUID LOSS AND FAILURE.

NHTSA ID

755202

Incident

Nov 30, 2001

A DRIVELINE CLUNK OR BUMP WHEN STARTING FROM A STOP. *TT

LOW RPM, NO START, RUNS POORLY, STALL. 7.3L DIT ENGINE. *TT

7.3L DIT GLOW PLUG START-UP ON-TIME DURING COLD TEMPERATURE - SERVICE TIP. *TT

A NO-START OR REDUCED POWER CONDITION MAY OCCUR INTERMITTENTLY. *TT

LOSS OF POWER AND MALFUNCTION INDICATOR LAMP MAY ALSO ILLUMINATE WITH DIAGNOSTIC TROUBLE CODES 128 AND 845 OR P0236 AND P0238 STORED IN MEMORY. *TT

A HIGH NUMBER OF HIGH PRESSURE REXROTH PUMPS AND INJECTION PRESSURE REGULATORS (IPR) ARE BEING REPLACED DUE TO OIL LEAKING, WHEN ALL THAT IS REQUIRED IS A NEW GASKET OR SEAL ON EITHER THE PUMP OR IPR. *TT