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2003 Ford E-350

Owner reports · Recalls · Investigations

Limited comparison data

There is not enough comparable history to draw a useful model-year comparison.

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How this year compares

Owner complaints by model year

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Counts vary with age, sales and reporting. They are not failure rates.

What owners reported most

All reported categories

Tap a category to read its complaints. One report may name several components.

When problems were reported

Mileage at the reported incident

35 reports with mileage · 11 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Electrical System. Review the 9 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel System, Diesel. Review the 8 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 6 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

4 crash reports4 fire reports3 injury reports

What owners actually said

46 reports
102,375 miles · Apr 18, 2013
Fuel System, Diesel

LOST POWER. FILTER HEAVILY PLUGGED PARTICULATE. DROPPED TANK. BOTTOM OF TANK HAS 1/2" SILVERY FLAKES. FUEL PICK-UP SCREEN PLUGGED. BOILED AND REINSTALLED TANK. FUEL PUMP FAILURE ABOUT 2 MONTHS LATER. NEW PUMP. AT 149000 MILE, NEW TANK AND MAY NEED NEW PUMP. TANK WAS DELAMINATING. *TR

NHTSA ODI #10508712

189,500 miles · Jan 31, 2012
Fuel System, Gasoline

TL* THE CONTACT OWNS A 2003 FORD E 350. THE CONTACT STATED THAT THE VEHICLE WOULD LOSE POWER AND PREVENT HIM FROM ACCELERATING. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC WHO INFORMED THE CONTACT THAT THE FUEL TANK WAS DELAMINATING AND CAUSING THE FUEL PUMP TO FAIL. AS A RESULT, THE FUEL TANK AND TRANSFER PUMP WOULD NEED TO BE …

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TL* THE CONTACT OWNS A 2003 FORD E 350. THE CONTACT STATED THAT THE VEHICLE WOULD LOSE POWER AND PREVENT HIM FROM ACCELERATING. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC WHO INFORMED THE CONTACT THAT THE FUEL TANK WAS DELAMINATING AND CAUSING THE FUEL PUMP TO FAIL. AS A RESULT, THE FUEL TANK AND TRANSFER PUMP WOULD NEED TO BE REPLACED. NO REPAIRS WERE PERFORMED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE BUT DID NOT OFFER ANY ASSISTANCE. THE CURRENT MILEAGE WAS 190,000 AND THE FAILURE MILEAGE WAS 189,500. THE VIN WAS UNAVAILABLE.

NHTSA ODI #10446041

Mileage unknown · Sep 29, 2011
Electrical SystemUnknown Or OtherFire

2003 FORD CUTAWAY VAN WHILE DRIVING VEHICLE DRIVER NOTICED SMELLED A BURNING SMELL AND SAW SMOKE COMING FROM UNDER THE CENTER OF DASH. PULLED VEHICLE OVER AND GOT OUT OF VEHICLE. SMOKE CONTINUED AND FLAMES BEGAN TO CONSUME VEHICLE UNTIL ENTIRE VEHICLE WAS ON FIRE. WE HAVE EXPERIENCED MANY HVAC SWITCH FAILURES(MELTING OF SWITCH A…

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2003 FORD CUTAWAY VAN WHILE DRIVING VEHICLE DRIVER NOTICED SMELLED A BURNING SMELL AND SAW SMOKE COMING FROM UNDER THE CENTER OF DASH. PULLED VEHICLE OVER AND GOT OUT OF VEHICLE. SMOKE CONTINUED AND FLAMES BEGAN TO CONSUME VEHICLE UNTIL ENTIRE VEHICLE WAS ON FIRE. WE HAVE EXPERIENCED MANY HVAC SWITCH FAILURES(MELTING OF SWITCH AND OR HARNESS CONNECTOR) AND NOTICE VERY HOT WIRES TO THE SWITCH AT TIMES. FLEET CONTAINS 85 FORD E350 VEHICLES AND THIS SWITCH HAS BEEN A COMMON FAILURE. *TT

NHTSA ODI #10427875

39,895 miles · Sep 27, 2011
Engine And Engine CoolingSteering

TL* THE CONTACT OWNS A 2003 FORD E-350. WHILE DRIVING HIGHWAY SPEEDS, THE CONTACT STATED A BOLT SEPARATED FROM THE ENGINE BLOCK. THIS DEFECT ALSO CAUSED THE SERPENTINE BELT TO FAIL, WHICH CAUSED THE STEERING WHEEL AND POWER STEERING TO FAIL. THE DEALER AND MANUFACTURER DENIED ANY ASSISTANCE WITH REPAIR TO THE FAILURE. THE VEHI…

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TL* THE CONTACT OWNS A 2003 FORD E-350. WHILE DRIVING HIGHWAY SPEEDS, THE CONTACT STATED A BOLT SEPARATED FROM THE ENGINE BLOCK. THIS DEFECT ALSO CAUSED THE SERPENTINE BELT TO FAIL, WHICH CAUSED THE STEERING WHEEL AND POWER STEERING TO FAIL. THE DEALER AND MANUFACTURER DENIED ANY ASSISTANCE WITH REPAIR TO THE FAILURE. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 39,895 AND THE CURRENT MILEAGE WAS 40,395.

NHTSA ODI #10427566

100,000 miles · Sep 8, 2011
Fuel System, Diesel

TL* THE CONTACT OWNS A 2003 FORD E-350. THE CONTACT STATED THE FUEL TANK WAS DETERIORATING WHICH CLOGGED UP THE FUEL PUMP AND FUEL FILTER. THE FAILURE CAUSED THE VEHICLE TO MALFUNCTION WHILE DRIVING UP HILL. THE VEHICLE WAS TAKEN TO A MECHANIC WHO INSPECTED THE VEHICLE AND OBSERVED THAT THE FUEL PUMP AND FILTER WERE CLOGGED UP. …

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TL* THE CONTACT OWNS A 2003 FORD E-350. THE CONTACT STATED THE FUEL TANK WAS DETERIORATING WHICH CLOGGED UP THE FUEL PUMP AND FUEL FILTER. THE FAILURE CAUSED THE VEHICLE TO MALFUNCTION WHILE DRIVING UP HILL. THE VEHICLE WAS TAKEN TO A MECHANIC WHO INSPECTED THE VEHICLE AND OBSERVED THAT THE FUEL PUMP AND FILTER WERE CLOGGED UP. THE MECHANIC WILL REPLACE THE FUEL TANK FOR OVER $1000 AT THE CONTACTS EXPENSE. THE DEALER WAS NOTIFIED AND INFORMED HIM TO CONTACT NHTSA SINCE THERE WERE NO RECALLS OR WARRANTY. THE MANUFACTURER WAS CONTACTED AND ALSO INFORMED HIM THERE WERE NO RECALLS OR WARRANTY. THE FAILURE MILEAGE WAS 100,000. LOW SULFUR DIESEL CAUSES FUEL TANK LINING TO BREAK DOWN. PARTICLES FROM THIS LINING CLOGS UP EVERYTHING DOWN STREAM. FUEL PUMP FILTER CAUSING ENGINE FAILURE AND A THREAT ON ROAD WAYS. UPDATED 11/01/2011 *LN *TR

NHTSA ODI #10424314

23,000 miles · Nov 7, 2010
Fuel System, Gasoline

FAILURE OF FUEL VAPOR VALVE ASSEMBLY PART #F65Z*9B593*DA. GAS VAPORS BUILD UP IN TANK AND ARE RELEASED UNDER PRESSURE WHEN GAS CAP REMOVED FOR REFUELING. VEHICLE OPERATES NORMALLY WITH NO WARNING LIGHT FOR AT LEAST 30 DAYS OR MORE BEFORE CHECK ENGINE LIGHT COMES ON. I THINK IT IS FAIR TO SAY UNDER THE CORRECT CONDITIONS THESE VA…

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FAILURE OF FUEL VAPOR VALVE ASSEMBLY PART #F65Z*9B593*DA. GAS VAPORS BUILD UP IN TANK AND ARE RELEASED UNDER PRESSURE WHEN GAS CAP REMOVED FOR REFUELING. VEHICLE OPERATES NORMALLY WITH NO WARNING LIGHT FOR AT LEAST 30 DAYS OR MORE BEFORE CHECK ENGINE LIGHT COMES ON. I THINK IT IS FAIR TO SAY UNDER THE CORRECT CONDITIONS THESE VAPORS COULD IGNITE AT GAS PUMP WHEN REFUELING. I HAVE COMPLETE RECORDS OF LETTERS, PHONE CALLS AND VISITS TO FORD DEALERSHIP, ALSO DEFECTIVE VALVE WAS SENT TO FORD MOTOR COMPANY AND RETURNED TO ME WITH A LETTER SAYING IN PART "RETURNING PART AS WE DO NOT HAVE FACILITIES FOR INSPECTING OR EVALUATION" I WAS ALSO INFORMED MY REQUEST WITH SERVICE MANAGER AT GATOR FORD TO MEET WITH MYSELF AND REP. FROM FORD IS NOT POSSIBLE. I AM ORIGINAL OWNER AND VEHICLE HAS LOW MILEAGE AND WELL MAINTAINED. PARTS LETTERS AND ANY OTHER INFORMATION YOU MAY NEED TO INVESTIGATE THIS MATTER WILL BE PROVIDED FROM ME AT YOUR REQUEST. CORDIALLY YOURS, DANIEL TRZASKA

NHTSA ODI #10364911

97,000 miles · Oct 8, 2010
Engine And Engine Cooling

HAVE A 2003 FORD E-350 VAN CNG GAS CONVERSION. AT 97,000 MILES A SPARK PLUG BLEW COMPLETELY OUT OF THE CYLINDER HEAD AND BROKE OFF THE IGNITION COIL THAT WAS BOLTED TO THE HEAD. THE CNG GAS COULD HAVE POSSIBLY IGNITED AND CAUSED A FIRE SINCE THE FUEL WAS STILL BEING SENT TO THAT PARTICULAR CYLINDER AND THE SPARK WAS STILL SPA…

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HAVE A 2003 FORD E-350 VAN CNG GAS CONVERSION. AT 97,000 MILES A SPARK PLUG BLEW COMPLETELY OUT OF THE CYLINDER HEAD AND BROKE OFF THE IGNITION COIL THAT WAS BOLTED TO THE HEAD. THE CNG GAS COULD HAVE POSSIBLY IGNITED AND CAUSED A FIRE SINCE THE FUEL WAS STILL BEING SENT TO THAT PARTICULAR CYLINDER AND THE SPARK WAS STILL SPARKING EVENTHOUGH IT WAS BLOWN OUT OF THE HOLE. I HAVE NEVER HEARD OF THIS HAPPENING BEFORE UNTIL I RESEARCHED IT AFTER IT OCCURRED. THIS SEEMS TO BE VERY COMMON IN FORD ENGINES THAT ARE 5.4 LITER. THE REPAIR IS AROUND $2500. TO PULL THE ENGINE AND REPAIR THE HEAD. THIS COULD HAVE BEEN VERY DANGEROUS IF WE HAD CONTINUE DRIVING THE VAN. THIS OCCURRED 9/27/2010. *TR

NHTSA ODI #10359622

78,000 miles · Sep 1, 2010
Seat Belts

TL*THE CONTACT OWNS A 2003 FORD E-350. THE VEHICLE WAS INCLUDED IN THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER 07V069000, SEAT BELTS:FRONT:ANCHORAGE. THE MANUFACTURER WAS NOTIFIED AND HE WAS INFORMED THE PARTS NEEDED WERE ON BACK ORDER. THIS PROCESS HAS BEEN ONGOING FOR APPROXIMATELY 9 MONTHS WITH NO RESOLUTION. THE V…

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TL*THE CONTACT OWNS A 2003 FORD E-350. THE VEHICLE WAS INCLUDED IN THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER 07V069000, SEAT BELTS:FRONT:ANCHORAGE. THE MANUFACTURER WAS NOTIFIED AND HE WAS INFORMED THE PARTS NEEDED WERE ON BACK ORDER. THIS PROCESS HAS BEEN ONGOING FOR APPROXIMATELY 9 MONTHS WITH NO RESOLUTION. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 78,000 AND THE CURRENT MILEAGE WAS 80,079.

NHTSA ODI #10353299

98,000 miles · Aug 11, 2010
Fuel System, Diesel

TL*THE CONTACT OWNS A 2003 FORD E350. THE CONTACT STATED THAT THE FUEL TANK LINING CAME OFF CAUSING THE FUEL TANK TO RUST, CLOGGING THE FUEL FILTER AND FUEL INJECTORS. THE FUEL ENTERING THE INJECTORS WAS MINIMAL WHICH MADE THE TRUCK VERY HARD TO ACCELERATE WHILE DRIVING. THE VEHICLE WAS TAKEN TO THE DEALER WHO STATED THAT IT WAS…

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TL*THE CONTACT OWNS A 2003 FORD E350. THE CONTACT STATED THAT THE FUEL TANK LINING CAME OFF CAUSING THE FUEL TANK TO RUST, CLOGGING THE FUEL FILTER AND FUEL INJECTORS. THE FUEL ENTERING THE INJECTORS WAS MINIMAL WHICH MADE THE TRUCK VERY HARD TO ACCELERATE WHILE DRIVING. THE VEHICLE WAS TAKEN TO THE DEALER WHO STATED THAT IT WAS A CLOGGED INJECTOR THAT NEEDED TO BE REPLACED. ONE FUEL INJECTOR WAS REPLACED FOR $970 WHICH CAUSE THE IDENTICAL FAILURE TO RECUR. THE FORD MANUFACTURER WAS CONTACTED AND STATED THAT THEY COULD NOT HELP HIM SINCE THERE WERE NO RECALLS. THE FAILURE MILEAGE WAS 98,000 AND THE CURRENT MILEAGE WAS 105,000.

NHTSA ODI #10348628

84,000 miles · Feb 26, 2010
Fuel System, Diesel

SUDDEN FUEL LEAK FROM THE FUEL FILTER MOUNTING HOUSING ON THE ENGINE. RESULTING IN SIGNIFICANT DOWN TIME AND EXPENSE. *TR

NHTSA ODI #10314673

Official recalls

6

09V399000 · Vehicle Speed Control

Oct 13, 2009

FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.

Consequence & remedy

Consequence: A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING.

Remedy: FORD WILL NOTIFY OWNERS THAT DEALERS WILL INSTALL A FUSED WIRING HARNESS IN LINE WITH THE SCDS. ON 1999-2003 WINDSTAR VEHICLES WITH A LEAKING SCDS, DEALERS WILL ALSO INSPECT THE ABS CONTROL MODULE CONNECTOR AND REPAIR AS NECESSARY. REPAIRS WILL BE COMPLETED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 27, 2009. OWNERS MAY CONTACT FORD AT 1-888-222-2751.

08V478000 · Equipment Adaptive/mobility

Sep 18, 2008

AROUND TOWN IS RECALLING 6 MY 2003 FORD E-350 AND MY 2006 E-250 WHEELCHAIR CONVERSION VANS EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 404, "PLATFORM LIFT INSTALLATIONS IN MOTOR VEHICLES." THE THRESHOLD WARNING SYSTEM MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER IN A CERTAIN SPOT WITHIN THE DEFINED THRESHOLD AREA.

Consequence & remedy

Consequence: THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.

Remedy: AROUND TOWN IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E095). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR AROUND TOWN AT 1-678-364-8594.

08V051000 · Vehicle Speed Control:cruise Control

Feb 4, 2008

FORD IS RECALLING 225,000 MY 1992-2003 ECONOLINE, MY 1993-1995 TAURUS SHO, MY 1992-1998 CROWN VICTORIA, MY 1993 BRONCO, F-SERIES, MY 1995-1997 F-SERIES SUPER DUTY STRIPPED CHASSIS, MY 1992-1998 MERCURY GRAND MARQUIS, AND MY 1992-1995 LINCOLN TOWN CAR VEHICLES. THE AFFECTED VEHICLES WERE PREVIOUSLY REPAIRED USING A WIRING HARNESS THAT IS NOT COMPATIBLE WITH THE VEHICLE CIRCUIT POLARITY.

Consequence & remedy

Consequence: AS A RESULT, THE FUSE IS LOCATED IN THE OUTPUT CIRCUIT RATHER THAN IN THE INTENDED INPUT POWER FEED CIRCUIT, AND MAY NOT OFFER THE INTENDED PROTECTION IN THE EVENT OF AN ELECTRICAL SHORT TO GROUND.

Remedy: DEALERS WILL INSTALL A NEW WIRING HARNESS, OR REPLACE THE MATING ELECTRICAL COMPONENT. THE RECALL BEGAN ON FEBRUARY 18, 2008. OWNERS MAY CONTACT FORD AT 1-800-392-3673.

07V336000 · Vehicle Speed Control

Aug 3, 2007

ON CERTAIN PICKUP TRUCKS, PASSENGER VEHICLES, SPORT UTILITY VEHICLES, AND MOTOR HOMES CHASSIS, THE SPEED CONTROL DEACTIVATION SWITCH MAY, UNDER CERTAIN CONDITIONS, LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.

Consequence & remedy

Consequence: THIS COULD RESULT IN AN UNDERHOOD FIRE.

Remedy: DEALERS WILL INSTALL A FUSED WIRING HARNESS. OWNERS OF THE PASSENGER CARS INCLUDED IN THIS CAMPAIGN WILL BE INSTRUCTED TO RETURN THEIR VEHICLES TO THEIR DEALERS TO HAVE THE SPEED CONTROL DEACTIVATION SWITCH DISCONNECTED AS AN INTERIM REPAIR. AS SOON AS REPAIR PARTS ARE AVAILABLE (EXPECTED OCTOBER 2007), OWNERS WILL BE INSTRUCTED TO RETURN TO THE DEALERS FOR INSTALLATION OF A FUSED WIRING HARNESS. THE RECALL BEGAN ON AUGUST 13, 2007, AND MAILING COMPLETED BY SEPTEMBER 19, 2007. OWNERS MAY CONTACT FORD AT 1-888-222-2751.

04V444000 · Electrical System:wiring

Sep 13, 2004

ON CERTAIN VANS, A DIODE IN THE ANTI-LOCK BRAKING SYSTEM (ABS) MODULE MAY EXPERIENCE AN ELECTRICAL SHORT.

Consequence & remedy

Consequence: THE ELECTRICAL SHORT MAY CAUSE AN ABS MALFUNCTION THAT WOULD ILLUMINATE THE ABS WARNING LIGHT, OR THE MODULE MAY OVERHEAT RESULTING IN A BURNING ODOR, SMOKE, AND/OR FIRE. THIS CONDITION MAY OCCUR WHILE THE VEHICLE IS BEING DRIVEN OR UNATTENDED.

Remedy: DEALERS WILL INSTALL A NEW FUSE IN THE ABS CIRCUIT AND INSTALL A HEAT SHIELD OVER THE ABS MODULE. THE RECALL BEGAN ON OCTOBER 15, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673. ALSO FORD IS EXTENDING THE LIMITED WARRANTY (FOR A ONE TIME REPLACEMENT) OF THE ABS MODULE FOR A TOTAL OF 10 YEARS OR 150,000 MILES FROM THE WARRANTY START DATE, WHICHEVER OCCURS FIRST. IF YOUR VEHICLE HAS ALREADY ACCUMULATED MORE THAN 150,000 MILES, THIS COVERAGE WILL LAST UNTIL SEPTEMBER 30, 2005.

04V445000 · Engine And Engine Cooling

Sep 13, 2004

ON CERTAIN VANS, THE AIR FILTER ELEMENT MATERIAL PROCESS RESULTED IN AN AIR FILTER PAPER ELEMENT THAT CAN SMOLDER OR BURN. THIS CHANGE IN FILTER PAPER COMPOSITION COMBINED WITH THE CONFIGURATION OF THE AIR INDUCTION SYSTEM, MAY ALLOW HOT CARBON PARTICLES TO CONTACT THE AIR FILTER ELEMENT DURING CERTAIN DRIVING CONDITIONS THAT CREATE HOT PARTICLES.

Consequence & remedy

Consequence: THESE HOT PARTICLES MAY IGNITE THE AIR FILTER ELEMENT WITH THE POTENTIAL FOR AIR INDUCTION SYSTEM DAMAGE OR UNDERHOOD FIRE.

Remedy: DEALERS WILL INSPECT AND REPLACE THE AIR FILTER ELEMENT. THE RECALL BEGAN SEPTEMBER 27, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673. ALSO FORD IS EXTENDING THE LIMITED WARRANTY (FOR A ONE TIME REPLACEMENT) OF THE ABS MODULE FOR A TOTAL OF 10 YEARS OR 150,000 MILES FROM THE WARRANTY START DATE, WHICHEVER OCCURS FIRST. IF YOUR VEHICLE HAS ALREADY ACCUMULATED MORE THAN 150,000 MILES, THIS COVERAGE WILL LAST UNTIL SEPTEMBER 30, 2005.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

3

EA10003 · Hvac Switch Failures

Opened Apr 13, 2010 · Closed Mar 5, 2012

Status: closed (inferred from source dates) · Electrical System:wiring:interior/under Dash

This investigation was opened based on one complaint and reports from four transportation fleets alleging 182 blower motor control switch failures.ODI was concerned that these melting and burning switches could lead to an open flame that could spread throughout the vehicle.After a comprehensive review of all data related to overheating blower motor control switches in the subject vehicles, ODI did not identify the existence of a safety defect trend.ODI reviewed 1,036 complaints, claims, and field reports of failed blower motor control switches and determined that only two fires were likely to have been caused by a failing subject blower motor control switch.This represents a failure rate of 0.2 R/100K on a population of 1,076,975 vehicles that have been in service for up to 14 years.ODI has found that when the subject switches do fail and begin to melt, they are constructed in a manner that typically prevents the failing switch from igniting and developing into an open flame.Ford Motor Company has agreed to take two actions to further reduce the likelihood an overheated blower motor switch in the subject vehicles.Ford informed ODI that it has implemented a series of design changes to the subject switch that will help prevent it from developing internal high resistance short circuits.Ford has also informed ODI that it would release a Technical Service Bulletin (TSB-11-11-21) instructing subject vehicle owners to replace the electrical connector at the same time a failed switch is replaced.In light of the low rate of failure resulting in open flame and fire spread on the subject vehicles, and Ford's actions to reduce the likelihood of a switch failure through switch design changes and a TSB, further use of agency resources does not appear to be warranted.The closing of this investigation does not constitute a finding by NHTSA that no safety-related defect exists.The agency reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following (ODI) numbers: 10427875, 10114393, 10257890For additional information, see the attached closing report.

PE09055 · Hvac Switch Failures

Opened Dec 7, 2009 · Closed Apr 21, 2010

Status: closed (inferred from source dates) · Electrical System:wiring:interior/under Dash

ODI has received 1 complaint and reports from 4 transportation fleets alleging 182 switch failures.Each fleet operates mini buses built on a Ford E350 or E450 cutaway chassis.The OEM HVAC blower switches have melted, smoked, burned or experienced open flame and become inoperable on vehicles in each fleet.Some drivers have reported a burning smell or smoke coming from the dash.One fleet reported a vehicle fire.No injuries were sustained.However, the bus was carrying special needs children when the driver noticed smoke coming from the dash.The driver was able to evacuate the children prior to the vehicle becoming engulfed in flames.This PE has been upgraded to an Engineering Analysis (EA) to determine if the blower motor switch failures create a situation where a vehicle fire is possible and presents a safety risk to the driver and other passengers.

DP05005 · Spark Plug Ejection From Cylinder Head

Opened Sep 22, 2005 · Closed Jan 4, 2006

Status: closed (inferred from source dates) · Engine And Engine Cooling; Engine And Engine Cooling:engine; Engine And Engine Cooling:engine:gasoline

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.

Additional source detail variants (3)

Engine And Engine Cooling:engine

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.

Engine And Engine Cooling:engine:gasoline

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.

Engine And Engine Cooling

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.