IllustrationVEHICLE CUTS OUT DURING DRIVING . *TR
2004 Ford E-350
Owner reports · Recalls · Investigations
Limited comparison data
There is not enough comparable history to draw a useful model-year comparison.
About this comparison →How this year compares
Owner complaints by model year
Compare all E-350 years →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
90–25K
725–50K
650–75K
375–100K
5100–150K
3150K+
33 reports with mileage · 13 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.
- Fuel System, Diesel. Review the 13 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Engine And Engine Cooling. Review the 10 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 5 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
1 crash reports1 fire reports3 injury reports
Engine And Engine Cooling complaints
10 reportsI HAVE A FORD E-350 SUPER DUTY VAN THAT HAS HAD DRIVABLE PROBLEMS SINCE IT WAS NEW. AFTER MANY TRIPS TO DEALERSHIPS I WAS TOLD THAT THERE WAS NO FIX AT THIS TIME AND FORD SHOULD COME OUT WITH A FIX IN THE FUTURE. THE ENGINE DIES WHEN HOT AT TIMES CAUSING HARD BRAKING AND LOSS OF STEERING. AT 100699 MILES, JUST 699 MILES OUT OF W…
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I HAVE A FORD E-350 SUPER DUTY VAN THAT HAS HAD DRIVABLE PROBLEMS SINCE IT WAS NEW. AFTER MANY TRIPS TO DEALERSHIPS I WAS TOLD THAT THERE WAS NO FIX AT THIS TIME AND FORD SHOULD COME OUT WITH A FIX IN THE FUTURE. THE ENGINE DIES WHEN HOT AT TIMES CAUSING HARD BRAKING AND LOSS OF STEERING. AT 100699 MILES, JUST 699 MILES OUT OF WARRANTY THE ENGINE QUITE RUNNING WHEN HOT. IF IT SITS FOR 6 OR MORE HOURS IT WILL RESTART AND RUN FOR ONLY 20 MINUTES. FORD TOLD ME IT WAS NO LONGER UNDER WARRANTY AND WOULD PROVIDE NO ASSISTANCE. *TR
DT*: THE CONTACT STATED WHILE DRIVING 25 MPH, THE ENGINE STALLED. THE VEHICLE WAS ABLE TO BE RESTARTED AFTER 20 MINUTES, AND WAS TAKEN TO A SERVICE DEALER WHERE THE PROBLEM WAS UNABLE TO BE DETERMINED. THERE WAS A NHTSA RECALL # 05V270000, WHICH PERTAINS TO THE WIRING. THE VEHICLE WAS NOT INCLUDED IN THE RECALL DUE TO THE VIN…
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DT*: THE CONTACT STATED WHILE DRIVING 25 MPH, THE ENGINE STALLED. THE VEHICLE WAS ABLE TO BE RESTARTED AFTER 20 MINUTES, AND WAS TAKEN TO A SERVICE DEALER WHERE THE PROBLEM WAS UNABLE TO BE DETERMINED. THERE WAS A NHTSA RECALL # 05V270000, WHICH PERTAINS TO THE WIRING. THE VEHICLE WAS NOT INCLUDED IN THE RECALL DUE TO THE VIN.
2004 FORD E-450 AMBULANCE 5/31/06 CREW STATED THE ENGINE WAS SURGING, EGR VALVE REPLACED BY DEALERSHIP. 5/31/06 CREW STATED A/C QUIT BLOWING AND GRINDING NOISE HEARD LARGER FUSE INSTALLED BY DEALERSHIP. DEALERSHIP STATED ALL OTHER A/C TEST CHECKED OUT OK. DEALERSHIP ADDED BOOSTER REPLACED TO DIESEL FUEL ALSO REPLACED FILTER,…
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2004 FORD E-450 AMBULANCE 5/31/06 CREW STATED THE ENGINE WAS SURGING, EGR VALVE REPLACED BY DEALERSHIP. 5/31/06 CREW STATED A/C QUIT BLOWING AND GRINDING NOISE HEARD LARGER FUSE INSTALLED BY DEALERSHIP. DEALERSHIP STATED ALL OTHER A/C TEST CHECKED OUT OK. DEALERSHIP ADDED BOOSTER REPLACED TO DIESEL FUEL ALSO REPLACED FILTER, DRAINED WATER SEPARATOR. 9/1/06 ENGINE OIL LEAKING, CREW ALSO HAD A/C CONCERNS AGAIN DEALERSHIP REPLACED GEO ROTOR OIL PUMP COVER GASKET AND SEAL WEAR SLEEVE AND REASSEMBLE POST ROAD. DEALERSHIP FOUND COMPRESSOR SHAFT BROKE REPLACED A/C COMPRESSOR AND CLUTCH ASSEMBLE ACCUMULATOR AND FRONT ORIFICE TUBE. DEALERSHIP ALSO REPLACED FUEL INJECTOR CONTROL MODULE HARNESS, AND EXHAUST PRESSURE SENSOR SECONDARY TO RECALL. 10/12/05 CREW COMPLAINS THAT ENGINE SOUND LIKE IT IS "SUCKING AIR" DEALERSHIP STATED NOTHING WRONG, LATER THAT WEEK CREW MEMBERS FOUND AIR LEAK AT TURBO BRACKET CONTACTED DEALERSHIP THEY ADVISED THAT NOTHING WAS WRONG AND THAT WAS THE WAY IT SHOULD SOUND. WE STILL HAVE THIS EXTREME SURGING SOUND IN THE CAB ON ACCELERATION, THE SOUND IS SO LOUD THAT WE CAN NOT HEAR THE COMMUNICATION RADIO. THIS TRUCK IS A 2004 AMBULANCE WITH ONLY 24,964 MILES ON IT AND IS HOUSED INSIDE A CLIMATE CONTROLLED STATION. WE ARE AGAIN MAKING AN APPOINTMENT TO HAVE TURBO CHECK BECAUSE OF AIR LEAK. *NM
OIL LEAKING FROM 2004 F-350 6.0L DIESEL ENGINE. EGR FAILURE CAUSING TRUCK TO SHUT OFF ON ROAD. *JB
2004 FORD WAGON E350 WITH FLOOR LOWERED BY VANTAGE MOBILITY INT. FOR HANDICAP PEOPLE. DURING STOP AND GO DRIVING LIKE TRAFFIC JAMS WHILE PULLING A TRAILER THE FLOOR BETWEEN FRONT SEATS GETS MORE THAN HOT ENOUGH TO BURN YOUR FOOT. SLIDING DOOR OPENER HAS BROKEN 6 TIMES LEAVING THE DOOR FREE TO SLIDE OPEN AND SHUT. I KEEP A BUNGY…
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2004 FORD WAGON E350 WITH FLOOR LOWERED BY VANTAGE MOBILITY INT. FOR HANDICAP PEOPLE. DURING STOP AND GO DRIVING LIKE TRAFFIC JAMS WHILE PULLING A TRAILER THE FLOOR BETWEEN FRONT SEATS GETS MORE THAN HOT ENOUGH TO BURN YOUR FOOT. SLIDING DOOR OPENER HAS BROKEN 6 TIMES LEAVING THE DOOR FREE TO SLIDE OPEN AND SHUT. I KEEP A BUNGY CORD TO TIE IT UP BUT INTERIOR LIGHTS COME ON AND OFF WHEN USING BUNGY CORD. THE ORIGINAL LATCH BY FORD WAS REMOVED TO INSTALL THE DOOR OPENER. SPLIT DRIVE SHAFT INSTALLED TO MAKE ROOM FOR UNDER VEHICLE LIFT BY BRAUN CORP HAS A LOW ROAR TO IT. BICYCLE TYPE CHAIN FOR THE SLIDING DOOR OPENER AT WHEELCHAIR LIFT DRAGS ACROSS PART OF DOOR JAMB.(NO PULLEY OR SPROCKET). PAID $48,000 FOR THIS NEW 2004 MODEL IN APRIL, 2005 I'M ASKING FOR MY MONEY BACK. PLEASE HELP US. *NM
DT: THE CONTACT OWNS A 2004 FORD E 350 A CONVERSION VAN WHICH WILL NOT START. THE VAN HAS A POWER STROKE DIESEL ENGINE. THE VAN WAS TOWED TWELVE OR MORE TIMES TO MULTIPLE DEALERSHIPS TO LOCATE THE PROBLEM. THE CONTACT STATED THAT NO DEALER COULD FIGURE OUT WHAT THE PROBLEM WAS. A DIAGNOSTICS TEST WAS PERFORMED ON THE VEHICLE A…
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DT: THE CONTACT OWNS A 2004 FORD E 350 A CONVERSION VAN WHICH WILL NOT START. THE VAN HAS A POWER STROKE DIESEL ENGINE. THE VAN WAS TOWED TWELVE OR MORE TIMES TO MULTIPLE DEALERSHIPS TO LOCATE THE PROBLEM. THE CONTACT STATED THAT NO DEALER COULD FIGURE OUT WHAT THE PROBLEM WAS. A DIAGNOSTICS TEST WAS PERFORMED ON THE VEHICLE ABOUT FIFTEEN TIMES. THE CONTACT HAS TALKED TO FORD NUMEROUS TIMES. HE INVESTED $96,000 IN THE VEHICLE AND WOULD LIKE TO BE ABLE TO DRIVE IT. THIS I HAPPENED AT ALL TIMES OF THE DAY. THE CONTACT WAS LIVING OUT OF THE VEHICLE AND WAS HAVING THOUSANDS OF DOLLARS IN TOWING EXPENSES. ALSO, THERE WERE RENTAL CAR AND MEDICAL EXPENSES AS A RESULT OF THE FAILURE.*AK
DT: CONTACT STATED ON 7-31-05 WAS TRAVELING NORTH ON I-81 70 MPH AND CARRYING 3000 LBS OF STEEL AND ENGINE SHUT OFF 2 MILES SOUTH OF EXIT #66. ENGINE SOUNDED LIKE A WASHING MACHINE AFTERWARDS. CONTACT WAS ABLE TO RESTART THE VEHICLE BRIEFLY IN ORDER FOR THE WRECKER TO LOAD IT. CONTACT RECEIVED RECALL 05S34 ON 07/29/2005. …
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DT: CONTACT STATED ON 7-31-05 WAS TRAVELING NORTH ON I-81 70 MPH AND CARRYING 3000 LBS OF STEEL AND ENGINE SHUT OFF 2 MILES SOUTH OF EXIT #66. ENGINE SOUNDED LIKE A WASHING MACHINE AFTERWARDS. CONTACT WAS ABLE TO RESTART THE VEHICLE BRIEFLY IN ORDER FOR THE WRECKER TO LOAD IT. CONTACT RECEIVED RECALL 05S34 ON 07/29/2005. DEALER SAID THIS VEHICLE WAS NOT COVERED UNDER THE RECALL. THIS WAS THE FIRST PROBLEM CONTACT HAD WITH THE ENGINE. *AK
FORD E-450 6.0L ENGINE LOSES POWER, STALLS, WILL NOT RESTART. BAYSHORE FORD SERVICE (WILMINGTON DE) RESULTS IN IDENTIFIED PROBLEMS OF DEFECTIVE EXHAUST BACK PRESSURE SENSORS, THROTTLE BODIES AND UNDERHOOD WIRING HARNESS. THIS IS A SAFETY ISSUE AS VEHICLE STALLS IN TRAFFIC WITH PASSENGERS ON BOARD. THESE DEFECTS SHOULD BE ADDED T…
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FORD E-450 6.0L ENGINE LOSES POWER, STALLS, WILL NOT RESTART. BAYSHORE FORD SERVICE (WILMINGTON DE) RESULTS IN IDENTIFIED PROBLEMS OF DEFECTIVE EXHAUST BACK PRESSURE SENSORS, THROTTLE BODIES AND UNDERHOOD WIRING HARNESS. THIS IS A SAFETY ISSUE AS VEHICLE STALLS IN TRAFFIC WITH PASSENGERS ON BOARD. THESE DEFECTS SHOULD BE ADDED TO NHTSA RECALL # ) 05V270000. *NM
I HAVE 3 VEHICLES WITH 5.4 LITER EXHAUST MANIFOLD LEAK, SEVERAL BOLTS ARE CRAKED I HAVE 50,000 MI JUST SHORT OF WARR.MY MECHANIC WON'T TOUCH IT.*AK
Official recalls
909V100000 · Equipment Adaptive/mobility
Mar 27, 2009
VAN CONVERSIONS IS RECALLING 52 MY 2004-2007 FORD E-150, E-250 E-350 AND MY 2006 GM SAVANNA 3500 VANS BUILT ON FORD AND GM CHASSIS AND EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE LIFTS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 403, "PLATFORM LIFT SYSTEM ACCESSIBLE FOR MOTOR VEHICLES," THE ANTI-STOW INTERLOCK MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER. THE PRESSURE SENSING SWITCH THAT DETECTS THE PRESENCE OF WEIGHT ON THE PLATFORM WAS NOT ADJUSTED TO THE NECESSARY SENSITIVITY LEVEL. THE LIFT COULD STOW EVEN THOUGH SOMEONE OR SOMETHING IS STILL ON THE LIFT.
Consequence & remedy
Consequence: A LIFT OCCUPANT CAN BE INJURED SHOULD THE LIFT BEGIN TO STOW UNINTENTIONALLY.
Remedy: VAN CONVERSIONS IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E097). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR VAN CONVERSIONS AT 610-837-0707.
09V102000 · Equipment Adaptive/mobility
Mar 27, 2009
VAN CONVERSIONS IS RECALLING 74 MY 2004-2007 FORD E-150, E-250 E-350 AND MY 2006 GM SAVANNA 3500 VANS BUILT ON FORD AND GM CHASSIS AND 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: VAN CONVERSIONS 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 VAN CONVERSIONS AT 610-837-0707.
08V518000 · Equipment Adaptive/mobility
Oct 6, 2008
MOBILITYWORKS IS RECALLING 224 MY 2007-2008 FORD E150, MY 2006-2008 E250, MY 2004-2007 E350, MY 2006 E450, MY 2005-2007 CHEVROLET 2500, MY 2007 CHEVROLET 1500, AND MY 2006 DODGE 2500 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: MOBILITYWORKS 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 MOBILITY WORKS AT 1-800-769-8267.
08V519000 · Equipment Adaptive/mobility
Oct 6, 2008
MOBILITYWORKS IS RECALLING 133 MY 2005-2006 FORD E250, MY 2000, 2004-2006 E350, MY 2000, 2005 E450, MY 2005-2006 GMC 2500, GMC 3500, AND MY 2006 DODGE 2500 VANS EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE LIFTS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 403, "PLATFORM LIFT SYSTEMS FOR MOTOR VEHICLES." THE ANTI-STOW INTERLOCK MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER. THE PRESSURE SENSING SWITCH THAT DETECTS THE PRESENCE OF WEIGHT ON THE PLATFORM WAS NOT ADJUSTED TO THE NECESSARY SENSITIVITY LEVEL. THE LIFT COULD STOW EVEN THOUGH SOMEONE OR SOMETHING IS STILL ON THE LIFT.
Consequence & remedy
Consequence: A LIFT OCCUPANT CAN BE INJURED SHOULD THE LIFT BEGIN TO STOW UNINTENTIONALLY.
Remedy: MOBILITYWORKS IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E097). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR MOBILITYWORKS AT 1-800-769-8267.
05V270000 · Electrical System:wiring
Jun 10, 2005
CERTAIN PICKUP TRUCKS, SPORT UTILITY VEHICLES AND VANS EQUIPPED WITH 6.0L DIESEL ENGINES MAY EXPERIENCE STALLING WITHOUT WARNING WHILE DRIVING AND MAY OR MAY NOT RESTART.
Consequence & remedy
Consequence: SHOULD THE ENGINE STALL, A VEHICLE CRASH COULD OCCUR.
Remedy: DEALERS WILL UPGRADE THE FUEL INJECTION CONTROL MODULE (FICM) WIRE HARNESS OR REPLACED, AND/OR HAVE A NEW INJECTION CONTROL PRESSURE (ICP)) SENSOR CONNECTOR INSTALLED FREE OF CHARGE. THE RECALL BEGAN ON JULY 22, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
04V589000 · Equipment Adaptive/mobility
Dec 15, 2004
ON CERTAIN VANS BUILT ON FORD E250/E350 CHASSIS AND EQUIPPED WITH SURE-LOK WHEELCHAIR SECUREMENT SYSTEMS, THE SPROCKET TEETH OF THE RETRACTOR ASSEMBLY IS OUT OF ALIGNMENT.
Consequence & remedy
Consequence: IN THE EVENT OF A VEHICLE CRASH, THE WHEELCHAIR MAY NOT BE ADEQUATELY SECURED POSSIBLY RESULTING IN INJURIES TO A WHEELCHAIR OCCUPANT.
Remedy: DEALERS WILL INSPECT AND REPLACE THE WHEELCHAIR SECUREMENT RETRACTORS AS NECESSARY. SURE-LOK IS CONDUCTING THE OWNER NOTIFICATION AND REMEDY FOR THIS CAMPAIGN. OWNERS SHOULD CONTACT SURE-LOCK AT 1-908-231-1804 OR ACCUBUILT AT 419-222-1501.
04V562000 · Equipment Adaptive/mobility
Nov 26, 2004
ON CERTAIN VANS EQUIPPED WITH SURE-LOK WHEELCHAIR SECUREMENT SYSTEMS, THE SPROCKET TEETH OF THE RETRACTOR ASSEMBLY IS OUT OF ALIGNMENT.
Consequence & remedy
Consequence: IN THE EVENT OF A VEHICLE CRASH, THE WHEELCHAIR MAY NOT BE ADEQUATELY SECURED POSSIBLY RESULTING IN INJURIES TO A WHEELCHAIR OCCUPANT.
Remedy: DEALERS WILL INSPECT AND REPLACE THE WHEELCHAIR SECUREMENT RETRACTORS AS NECESSARY. SURE-LOK WILL HANDLE THE REPAIRS FOR THIS CAMPAIGN. OWNERS SHOULD CONTACT SURE-LOCK AT 1-908-231-1804 OR MOBILITYWORKS AT 1-800-769-8267.
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
3EA10003 · 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.