2002 Lincoln Navigator

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.

EA05-005 IS CLOSED WITH FORD?S ACTIONS IN RECALLS 05V-017, 05V-388, AND 06V-286, RECALLING APPROXIMATELY 6.7 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).THE BRAKE SYSTEMS IN THESE RECALLED VEHICLES GENERATE A VACUUM THAT CAN POTENTIALLY CAUSE THE SCDS TO FAIL AND, IN CERTAIN SWITCH INSTALLATION ORIENTATIONS, CATCH FIRE.FORD IS ALSO INCLUDING THE ENTIRE POPULATION OF 1998 EXPLORERS.FORD HAS INFORMED ODI THAT TESTING TO DETERMINE THE CAUSE OF FAILURES IN THE 1998 EXPLORERS WILL CONTINUE AFTER THIS INVESTIGATION IS CLOSED.ODI BELIEVES THAT THE VEHICLES EXHIBITING THE FACTORS CAUSING SCDS FAILURE DESCRIBED IN THIS REPORT CORRELATE WELL WITH THE OBSERVED FAILURE RATES ON THESE VEHICLES BY MODEL AND MODEL YEAR.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE NON-RECALLED VEHICLES MANUFACTURED WITH SCDS THAT ARE NOT INCLUDED IN FORD?S RECALLS.ODI WILL CONTINUE TO MONITOR THE NON-RECALLED POPULATION FOR INCIDENCE OF ENGINE COMPARTMENT FIRES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE ATTACHED CLOSING REPORT FOR DETAILS.

TL* THE CONTACT OWNS A 2002 LINCOLN NAVIGATOR. WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE STALLED WITHOUT WARNING. THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE FUEL GAUGE DID NOT INDICATE THE ACCURATE AMOUNT OF FUEL IN THE VEHICLE. IN ADDITION, THE HAZARD LIGHTS FAILED TO ILLUMINATE PROPERLY AND THE SPEED CONTROL WARNING LIGHT ILLUMINATED. THE CONTACT TOOK THE VEHICLE TO A CERTIFIED MECHANIC WHO DIAGNOSED THAT THE ENGINE FAILED AND THE FUEL PUMP AND FUEL SYSTEM NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED AND THE FAILURE RECURRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURES. THE APPROXIMATE FAILURE MILEAGE WAS 128,000.

NHTSA ID

10894146

Incident

Jul 24, 2016

Mileage

128,000 mi

TL* THE CONTACT OWNS A 2002 LINCOLN NAVIGATOR. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 60 MPH, THE DRIVER'S SIDE REAR PASSENGER'S AIR BAG DEPLOYED INDEPENDENTLY WITHOUT WARNING. ALSO, THE CONTACT MENTIONED THAT THERE WAS AN EXPLOSION UNDERNEATH THE VEHICLE. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 160,000.

NHTSA ID

10639044

Incident

Aug 30, 2014

Mileage

160,000 mi

MY 2002 LINCOLN NAVIGATOR EJECTED A SPARK PLUG CAUSING A SUBSTANTIAL REPAIR BILL. *TR

NHTSA ID

10628210

Incident

Aug 22, 2014

Mileage

120,000 mi

I HAD THE SPARK PLUG BLOW OUT OF THE HOLE CAUSED CAR TO RUN ON LESS COMPRESSION AND IT IS VERY COSTLY TO FIX MECHANIC INFORMED THIS VEHICLE IS KNOWN FOR THIS. *TR

NHTSA ID

10445192

Incident

Jan 7, 2011

Mileage

160,000 mi

ON 12/03/11 WHEN MY HUSBAND STARTED OUR 2002 LINCOLN NAVIGATOR A LOUD BANG HAPPENED, MY SEAT BELT TIGHTENED ACROSS MY CHEST SO TIGHT IT HURT AND I COULDN'T BREATHE, THE CAR STARTED SMOKING SO BAD THAT MY OLDEST DAUGHTER JUMPED OUT OF THE TRUCK BECAUSE IT SCARED HER SO BAD. THE SEAT BELT WAS SO TIGHT IT WOULDN'T COME OFF AT FIRST WHICH SCARED ME BECAUSE THE SMOKE WAS BY THE SIDE OF MY HEAD! NOW THE SEAT BELT WON'T WORK AND I DON'T WANT TO USE MY CAR WITHOUT IT. IN THE PAST YEAR, 2011, MY TRUCK KEEPS BLOWING FUSES ON THE AUTOMATIC LIGHTS AND AIR BAG FOR THE PASSENGER SIDE. I KEEP REPLACING THE FUSE BUT THEY ONLY LAST ABOUT A WEEK AND THEN THEY BLOW OUT. ONCE THE FUSE IS REPLACED THE AUTOMATIC LIGHTS WORK, THE AIRBAG LIGHT GOES OFF. BUT, NO SOONER DO I CHANGE IT, IT BLOWS AGAIN. SO, I HAVEN'T REPLACED IT. IN FEBRUARY I HAVE TO GO FOR EMISSIONS AND I WON'T PASS WITH THIS LIGHT ON. IN THE LAST 6 MONTHS, MY BRIGHT LIGHTS HAVE TURNED ON BY THEMSELVES. I THOUGHT IT ONLY HAPPENED WHEN WE USE THE TURN SIGNALS, BUT MY HUSBAND TOLD ME IT DOES IT ALL THE TIME. I DIDN'T BELIEVE HIM UNTIL THREE DAYS AGO WHEN I HIT A BUMP AND THEY WENT ON. THEN, YESTERDAY I WAS SITTING IN OUR RUNNING, PARKED CAR AND THE BRIGHTS JUST TURNED ON WHILE THE CAR WAS ON AND NOT MOVING. THAT REALLY SCARED ME. WHAT KIND OF ELECTRICAL PROBLEMS DOES THIS VEHICLE HAVE? I HAVE DONE THE ONE RECALL ON MY TRUCK FOR ENGINE FIRE. ARE THERE MORE RECALLS I SHOULD KNOW ABOUT? *TR

NHTSA ID

10438466

Incident

Dec 3, 2011

Mileage

150,000 mi

TL* THE CONTACT OWNS A 2002 LINCOLN NAVIGATOR. THE CONTACT WAS DRIVING 50 MPH WHEN THE SIDE IMPACT AIR BAG DEPLOYED WITHOUT WARNING. AS A RESULT, THE CONTACT SUSTAINED AN INJURY TO THE EAR DRUM. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSTICS BUT THE DEALER WAS UNABLE TO DETERMINE WHY THE AIR BAGS HAD DEPLOYED WITHOUT THE VEHICLE BEING INVOLVED IN A CRASH. THE CONTACT CALLED THE MANUFACTURER AND THE MANUFACTURER SENT A SPECIALIST TO INSPECT THE VEHICLE. THE SPECIALIST ADVISED THAT A FAULTY COMPONENT IN THE AIR BAG CAUSED THE DEPLOYMENT. THE MANUFACTURER STATED THAT THEY WOULD NOT PROVIDE ANY ASSISTANCE FOR THE REPAIR. THE CONTACT STATED VEHICLE WAS UNSAFE TO DRIVE. THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

10425095

Incident

Aug 31, 2011

TL* THE CONTACT OWNS A 2002 LINCOLN NAVIGATOR. THE CONTACT STATED THE AIR BAG DEPLOYED IMMEDIATELY AFTER THE VEHICLE WAS TURNED ON. THE CONTACT TOOK THE VEHICLE TO THE DEALER WHO STATED THAT EITHER SOMETHING WAS PLACED UNDER THE SEAT OR THE SEAT COVER WAS WORN EXCESSIVELY. THE AIR BAG DEPLOYED FROM UNDER THE SEAT. THE CONTACTS LEFT ARM WAS SEVERELY INJURED. THE MANUFACTURER STATED THE AIR BAGS ARE NOT COVERED BY THE WARRANTY. THE AIR BAGS WERE NOT REPLACED. THE VIN WAS REJECTED FROM THE SYSTEM. THE FAILURE AND CURRENT MILEAGE WAS 180,000.

NHTSA ID

10412104

Incident

Jul 1, 2011

Mileage

180,000 mi

I THINK THIS IS A COMMON TACTIC BY FORD AND THE JUSTICE DEPARTMENT SHOULD LOOK INTO IT. I LEASED A NEW 2002 NAVIGATOR AND HAD A SIMILAR SITUATION. ON A ROAD TRIP IN 2004 WITH 32000 MILES, THE ENGINE SEIZED. THE DEALER CLAIMED THERE WAS SLUDGE IN THE ENGINE AND FORD WOULD NOT HONOR THE WARRANTY. APPARENTLY, THE LEASE INCLUDED FREE OIL CHANGES AT THE DEALER, WHICH I WAS NOT AWARE OF. I PRODUCED ALL OF THE RECEIPTS TO SHOW THAT I HAD THE OIL CHANGED EVERY 3000 MILES (MORE FREQUENTLY THAN REQUIRED) BUT WAS TOLD IT WAS IRRELEVANT SINCE I DIDN'T HAVE THE DEALER DO THE OIL CHANGES. I WAS TOLD THE ENGINE REPLACEMENT WOULD COST $12,000. THE FORD DEALER WAS SO UPSET BY THIS HE OFFERED TO DO IT FOR COST, ABOUT $4500, BUT I JUST WALKED AWAY, EVEN THOUGH THEY SUED AND PUT A $15,000 BLOT ON MY CREDIT RATING.THIS WAS MY THIRD NAVIGATOR LEASE, INCLUDING A 1998 AND 2000 MODEL BEFORE THIS. I PAID TOP DOLLAR FOR THEIR MOST EXPENSIVE VEHICLE AND THIS IS HOW THEY TREAT GOOD CUSTOMERS. NOT TO MENTION BEING STRANDED IN THE DESERT WITH MY WIFE AND FIVE KIDS. I WILL NEVER BUY ANOTHER FORD AGAIN. ONE LAST POINT - I HAD JUST HAD THE OIL CHANGED BEFORE I LEFT AND HAD LESS THAN 1000 MILES ON THE CAR WHEN IT BROKE DOWN. I CHECKED THE OIL AND IT WAS MORE THAN 1/2 QUART DOWN. CLEARLY THE CAR WAS USING OIL AT JUST 32000 MILES. FUNNY THING IS, I HAVE A 97 EXPLORER WITH ROUGHLY THE SAME ENGINE, AND IT FINALLY THREW A ROD AT 250,000 MILES OF EXCELLENT SERVICE. *TR

NHTSA ID

10404430

Incident

Jul 3, 2004

Mileage

32,000 mi

This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended.

Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition

Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition

ENGINE MISFIRE WITH DIAGNOSTIC TROUBLE CODE (DTC) PEWEE, P0302, P0303, P0304, P0305, P0306, P0307, P0308, AND P0316. *TT

WDS COP KIT DIAGNOSTIC TIP - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING. *TT

SAFETY BELT RETRACTION SPEED. *TT