Electrical System. Review the 214 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
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NHTSA owner reports · September 18, 2026 snapshot.

55 crash reports199 fire reports37 injury reports

Electrical System complaints

214 reports

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150,000 miles · Aug 29, 2015

Electrical SystemEngineStructureFire

VEHICLE CAUGHT FIRE AROUND 10:25 PM. VEHICLE WAS PARK AND COLD SINCE THE LAST TIME IT WAS USED WAS AROUND 1:00 PM THE SAME DAY. MY WIFE GOT HOME AND WAS PARKING HER CAR A SUDENLY SAW THE FORD EXPEDITION CACHING FIRE AND FLAMES COMING OUT OF THE ENGINGE COMPARTMENT. VEHICLE IS TOTAL THERE ARE NO POSSIBILITY OF REPAIR.

NHTSA ODI #10760116

155,000 miles · Jul 27, 2015

Electrical SystemEngineVisibility/wiper

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WHILE DRIVING THIS EXPEDITION I BEGAN NOTICING STRANGE INTERMITTANT ELECTRICAL BEHAVIOR LIKE THE WINDSHIELD WIPERS NOT WORKING, RADIO TURNING OFF, WINDSHIELD WASH LIGHT BLINKING, AND 4X4 LIGHT BLINKING. SEVERAL TIMES IN THE MIDDLE OF THE NIGHT I'D NOTICE THAT THE HEADLIGHTS WOULD COME ON ON THEIR OWN. ALSO THE AIR RIDE WOULD TURN ON AND OFF WHILE THE CAR WAS OFF, AND THE HEATER FAN WOULD ALSO COME ON. THIS WOULD KILL THE BATTERY. SEVERAL TIMES WHILE DRIVING THE 4X4 WOULD TURN ON IN THE LOW GEAR MAKING IT DIFFICULT TO MANEUVER. ON SEVERAL OCCASIONS THE STARTER WOULD TURN ON WHILE THE CAR WAS ALREADY RUNNING. I REPLACED THE GEM MODULE AND HAD THE WINDSHIELD RESEALED SEVERAL TIMES, BUT AFTER JUST A FEW MONTHS THE PROBLEMS WOULD RECUR. THE FINAL NAIL IN THE COFFIN WAS WHEN THE STARTER KICKED ON WHILE RUNNING AND IT TOOK A MINUTE TO GET THE CAR SAFELY STOPPED. I COULD SMELL SMOKE FROM THE BURNED UP STARTER MOTOR. THE EXPEDITION HAS SAT FOR 1.5 YEARS AS I AM UNABLE TO SELL IT AND AM UNWILLING TO PUT ANY ADDITIONAL MONEY TO FIX THIS LEMON.

NHTSA ODI #10743786

160,000 miles · Feb 19, 2015

Electrical System

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I BEGAN NOTICING ELECTRICAL PROBLEMS WITH THE LIGHTS GOING ON AND OFF, DASH GAUGES GOING ON AND OFF, RADIO GOING ON AND OFF, HEATER GOING ON AND OFF, DOOR ALARM STAYING ON WHEN DRIVER'S DOOR IS OPEN, BUT NO KEY IN IGNITION OR LIGHTS ON, DOOR LOCKS NOT WORKING PROPERLY, 4WD ENGAGING AUTOMATICALLY, CD PLAYER GOING OFF AND ON, WINDSHIELD WIPERS GOING ON AND OFF, AND WATER ON DRIVER'S SIDE FLOOR AFTER RAINS. IT HAS BECOME MORE OF A PROBLEM. I DID NOT KNOW WHAT WAS CAUSING THE PROBLEMS UNTIL I BEGAN REPLACING PARTS AND FOUND ON THE INTERNET THAT THIS HAS BEEN A KNOWN PROBLEM WITH THE EXPEDITION AND FORD BEING AWARE OF THE PROBLEM FOR MANY YEARS. I JUST WROTE THE FORD COMPANY AND THEY TOLD ME THEY KNEW NOTHING ABOUT SUCH PROBLEMS!!! REFERENCE NUMBER IS [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10689432

70,000 miles · Dec 14, 2014

Electrical SystemStructureVisibility/wiperFire

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SUMMARY: WATER LEAKED AROUND THE LEFT SIDE OF WINDSHIELD CAUSING ELECTRICAL FAILURES, INCLUDING BUT NOT LIMITED TO THE STARTER, RADIO, WINDSHIELD WIPERS, HEADLAMPS, ETC. THE WATER ENTERING THE VEHICLE WET THE POWER DISTRIBUTION BOX (PDB) AND THE GENERIC ELECTRONIC MODULE (GEM). THESE COMPONENTS CONTROL VARIOUS ELECTRICAL SYSTEMS IN THE VEHICLE. THE VEHICLE CONTINUED TO ATTEMPT TO START ITSELF WITHOUT ANY KEY IN IGNITION UNTIL IT RESULTED IN THE STARTER BURNING UP AS WELL AS DAMAGING ASSOCIATED WIRING AND BATTERY. VEHICLE'S WINDSHIELD HAD TO BE REPLACED AS WAS THE STARTER, ASSOCIATED WIRING AND BATTERY AFTER VEHICLE WAS TOWED TO REPAIR FACILITY. *TR

NHTSA ODI #10664194

Mileage unknown · Nov 23, 2014

Electrical SystemEquipmentVisibility

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5 PEOPLE IN MY VEHICLE DRIVING 55MPH ON I40 AROUND MIDNIGHT WHEN AIR SUSPENSION WENT OUT AND EVERYTHING IN THE DASH WENT CRAZY. THINGS CUTTING OFF AND ON MOVING BACKWARDS AND FORWARDS, WHEN I CUT IT OFF SO TO NOT DRIVE WITH AIR SUSPENSION DOWN IT WOULD NOT RESTART UNLESS YOU STARTED IT IN NEUTRAL BUT THE BATTERY KEPT DYING AND EXPLODED DRIVING TO SHOP,.GOT ANOTHER BATTERY, IT EXPLODED TO. NOTHING ELECTRICAL WORKED. DOOR LOCKS, WINDOWS,SPEEDOMETER, STEREO WOULDN'T COME ON THEN WOULD COME ON BY ITSELF, LIGHTS TO. AIR SUSPENSION WOULD NOT WORK, BEEN IN THE SHOP TWICE. FIRST TIME THEY DIDN'T KNOW WHAT WAS WRONG. THIS TIME THEY KNOW BUT I CAN AFFORD TO FIX IT. THE GEM MODULE AND FUSE BOX IS OVER 600.00 PLUS LABOR! IM DISABLED WITH A FIXED INCOME AND I HAVEN'T DRIVEN ANYWHERE SINCE FEB I CANT GET TO MY DOCTOR, GROCERY STORE, TO GET MEDICINE FOR HEART ATTACK AND OTHER DISABLING ILLNESSES. I CANT AFFORD ANOTHER CAR OR TO FIX MY EXPO. THIS COULD HAVE BEEN DANGEROUS I SURE NEED SOME HELP WITH THIS.ELECTRICAL SYSTEM FAILURE NHTSA PRELIMINARY EVALUATION #PE05033 STATUS:CLOSED DATE OPENED:JUNE 15, 2005 DATE CLOSED: OCTOBER 13, 2005 RECALL: NO RECALL ISSUED COMPONENT(S): ELECTRICAL SYSTEM EQUIPMENT:ELECTRICAL VISIBILITY:WINDSHIELD SUMMARY: ODI HAS RECEIVED 39 REPORTS ALLEGING THAT WATER LEAKS AROUND THE WINDSHIELD CAUSING ELECTRICAL FAILURES, INCLUDING BUT NOT LIMITED TO THE WINDSHIELD WIPERS AND THE HEADLAMPS.FORD REPORTS THAT WATER ENTERING THE VEHICLE CAN WET THE POWER DISTRIBUTION BOX (PDB) AND THE GENERIC ELECTRONIC MODULE (GEM).THESE COMPONENTS CONTROL VARIOUS ELECTRICAL SYSTEMS IN THE VEHICLE.THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS, EA05015, TO ALLOW FURTHER INVESTIGATION OF THE ISSUE AND TO ASSESS THE NATURE OF THE POTENTIAL SAFETY CONSEQUENCE.NHTSA: FOR DETAILED INFORMATION & SUPPORTING DOCUMENTS, SEE THE OFFICIAL NHTSA INVESTIGATION#PE05033. *TR

NHTSA ODI #10660302

86,000 miles · Aug 1, 2014

Electrical SystemVisibility/wiper

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DRIVING NORMALLY DURING HEAVY RAIN WIPERS AND RADIO WENT DEAD AT HIGHWAY SPEED AND WORKED INTERMITTENTLY AFTER THAT. AFTER THE RAIN STOPPED AND CAR DRIED OUT WIPERS AND RADIO WORKED NORMALLY AGAIN. CARPET ON LEFT SIDE UNDER FUSE PANEL AND GEM MODULE, BOTH OF WHICH HAVE ALREADY BEEN REPLACED WAS WET. THIS IS A SAFETY CONCERN AS IT IS EXTREMELY DIFFICULT TO SEE WHEN THE WIPERS STOP WORKING UNEXPECTEDLY. THE CAUSE SEEMS TO BE THE WINDSHIELD WASN'T SEALED PROPERLY AT THE FACTORY, AS MY FATHER BOUGHT THE VEHICLE NEW AND SAID THE WINDSHIELD HAS ALWAYS LEAKED. I PURCHASED THE VEHICLE FROM HIM. *TR

NHTSA ODI #10618215

Mileage unknown · Jun 9, 2014

Electrical SystemStructureVisibility

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THERE IS A DEFECT WITH THE INSTALLATION OF THE WINDSHIELD THAT CAUSES WATER IN ENTER THE CAB. UPON ENTRY, THE WATER GOES INTO THE GEM MOD AND FUSE PANEL OF THE SUV. THIS SHORTS THE SYSTEM - AT ONE POINT YOU MAY ENCOUNTER THE HEATER TURNING ON WITHOUT THE KEY IN THE IGNITION. HERE IS A SPECIAL NOTICE SENT BY FORD IN 2002 REGARDING THIS PROBLEM: *FORD SPECIAL MESSAGE #15773 VARIOUSELECTRICALCONDITIONS RESULTING FROM WATER INTRUSION INTO THE GEM/CJB SOME 1997-2002 EXPEDITION AND 1998-2002 NAVIGATOR VEHICLES MAY EXHIBIT VARIOUS UNUSUAL ELECTRICAL CONDITIONS, INCLUDING BUT NOT LIMITED TO: XXXXX XXXXX REAR BLOWER OR EATC STAYING ON WITH KEY OUT OF THE IGNITION, RADIO STAYING ON AFTER DOORS OPENED AND KEY OUT OF IGNITION, WIPER CIRCUIT FAILURE CODES, AND MULTIPLE SYSTEM WARNING LIGHTS WITH 'SHORT TO POWER' OR 'LOW BATTERY VOLTAGE' DTCS. THESE SYMPTOMS MOST OFTEN OCCUR AFTER A RAIN OR SNOW. THIS MAY BE DUE TO GEM/CJB WATER INTRUSION RESULTING FROM A WINDSHIELD WATER LEAK. TO SERVICE, REMOVE THE GEM AND CJB FROM THEVEHICLE, SEPARATE THEM AND INSPECT FOR WATER CONTAMINATION OR CORROSION. IF FOUND IN EITHER COMPONENT, REPLACE BOTH COMPONENTS AND COMPLETELY RESEAL THE WINDSHIELD. EFFECTIVE DATE: 04/05/2002 FORD MOTOR COMPANY *TR

NHTSA ODI #10597038

150,000 miles · Jun 2, 2014

Electrical SystemExterior LightingVisibility/wiper

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IT STARTED WITH THE RADIO AND WINDSHIELD WIPERS NOT WORKING PERIODICALLY THIS WENT ON FOR SEVERAL WEEKS AND THEN ON SATURDAY NIGHT 5/31/14 AT APPROX. 11:30 AM "[XXX]" SHOWED UP AND MY CAR WAS TRYING TO START ITS SELF. IT MADE A CLICKING SOUND FOR ABOUT 30 MINS WITH THE LIGHTS GOING OFF AND ON. THE SOUND WAS LIKE A DEAD BATTERY SOUND. THEN IT WOULD TRY TO START ITSELF. THIS WENT ON FOR ABOUT AND HOUR AND THEN IT FINALLY STOPPED. I ASSUMED THAT THE NEXT MORNING MY BATTERY WOULD BE DEAD BUT WHEN I WENT OUT SUNDAY MORNING IT STARTED RIGHT UP AND I WAS ABLE TO RUN MY ERRANDS. THIS MORNING MONDAY 6/2 I WENT OUT TO GO TO WORK AND IT WOULD NOT START BUT THE LIGHTS CAME ON AND IT CONTINUED TO MAKE A CLICKING SOUND EVEN THOUGH I ASSUMED THE BATTERY WAS DEAD. I AM SCARED TO DO ANYTHING, LIKE JUMP THE BATTERY , FOR FEAR IT WILL EXPLODE OR CATCH FIRE. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10595545

179,000 miles · Oct 15, 2013

Electrical SystemEngine

SPARK PLUG BLOW OUT. *TR

NHTSA ODI #10547894

165,000 miles · Aug 27, 2013

Electrical SystemEngineFire

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AFTER AN APPROXIMATE 30 MINUTE DRIVE, VEHICLE WAS PARKED WITH THE IGNITION OFF AND KEY REMOVED FROM VEHICLE. WHILE UNATTENDED, THE VEHICLE CAUGHT FIRE AND BURNED COMPLETELY TO THE GROUND. THE VEHICLE WAS COMPLETELY DESTROYED AND IS A TOTAL LOSS. WITNESSES REPORTED SMELLING A STRONG ELECTRICAL SMELL BEFORE FIRE WAS OBSERVED, AND STATED THAT FLAMES AND SMOKE WERE FIRST OBSERVED COMING FROM UNDER THE HOOD IN THE ENGINE COMPARTMENT. THE VEHICLE WAS NOT PARKED NEAR COMBUSTIBLE MATERIALS SUCH AS DRY GRASS, ETC. THE OUTSIDE TEMPERATURE WAS APPROXIMATELY 70 DEGREES. *TR

NHTSA ODI #10537463

Official recalls

05V388000 · Vehicle Speed Control

Sep 7, 2005

ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES EQUIPPED WITH SPEED CONTROL, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT, SMOKE, OR BURN.

Consequence & remedy

Consequence: A FIRE AT THE SWITCH COULD OCCUR.

Remedy: BY LETTER DATED SEPTEMBER 12, 2005, OWNERS WERE INSTRUCTED TO RETURN THEIR VEHICLES TO THEIR DEALERS TO HAVE THE SPEED CONTROL DEACTIVATION SWITCH DISCONNECTED. OWNERS WHO HAVE HAD THEIR SPEED CONTROL DEACTIVATED ARE BEING NOTIFIED THAT PARTS WILL BE AVAILABLE AND ADVISED TO MAKE AN APPOINTMENT TO RECONNECT THE SPEED CONTROL BEGINNING IN FEBRUARY 2006. OWNERS WHO DID NOT HAVE THEIR SPEED CONTROL DEACTIVATED ARE BEING NOTIFIED TO HAVE THEIR SYSTEM REMEDIED BEGINNING IN FEBRUARY 2006. OWNERS ARE URGED TO AVAIL THEMSELVES OF THE FREE DISCONNECT SERVICE AS SOON AS POSSIBLE BECAUSE OF THE SIGNIFICANT RISK OF FIRE. OWNERS MAY CONTACT FORD AT 1-800-392-3673. (NOTE: ALSO SEE RECALLS 05V017 AND 06V286)

05V017000 · Vehicle Speed Control:cruise Control

Jan 27, 2005

ON CERTAIN SPORT UTILITY VEHICLES AND PICKUP TRUCKS, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT, SMOKE, OR BURN.

Consequence & remedy

Consequence: THIS CONDITION COULD LEAD TO A FIRE. FIRES HAVE OCCURRED WHILE THE VEHICLES WERE PARKED WITH THE IGNITION 'OFF.'

Remedy: AS AN INTERIM REPAIR, OWNERS WILL BE INSTRUCTED TO RETURN THEIR VEHICLES TO THEIR DEALERS TO HAVE THE SPEED CONTROL DEACTIVATION SWITCH DISCONNECTED. AS SOON AS REPLACEMENT PARTS ARE AVAILABLE (EARLY APRIL 2005), OWNERS WILL BE INSTRUCTED TO RETURN TO THE DEALERS FOR INSTALLATION OF A NEW SWITCH FREE OF CHARGE. OWNERS MAY CONTACT FORD AT 1-800-392-3673. (NOTE: ALSO SEE RECALLS 05V388 AND 06V286)

03V094000 · Structure

Mar 7, 2003

CERTAIN PICKUP TRUCK, VAN, AND MINI VAN CONVERSIONS EQUIPPED WITH SOUTHERN COMFORT BUILT RUNNING BOARDS THAT CONTAIN CERTAIN COURTESY LIGHTS MANUFACTURED BY AMERICAN TECHNOLOGY COMPONENTS, INC. THESE UNITS CONTAIN A COURTESY LIGHT OR LIGHTS THAT MIGHT OVERHEAT WHEN THE WIRE HARNESS IS EXPOSED TO EXCESSIVE MOISTURE AND ROAD SALT.

Consequence & remedy

Consequence: THIS OVERHEATING CONDITION CAN CAUSE THE RUNNING BOARD TO MELT OR CAUSE A FIRE.

Remedy: DEALERS WILL REPLACE THE WIRING HARNESS ON THESE RUNNING BOARDS. OWNER NOTIFICATION BEGAN MARCH 7, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT SOUTHERN COMFORT AT 1-800-745-6096.

02V239000 · Equipment:other:labels

Sep 9, 2002

CERTAIN 4X2 SPORT UTILITY VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS." THE REAR TIRE PRESSURE IS INCORRECTLY LISTED ON THE LABEL FOR 4.2 VEHICLES.

Consequence & remedy

Consequence: CUSTOMERS MAY INFLATE THEIR REAR TIRES BASED ON THE INCORRECT TIRE PRESSURE INFORMATION ON THE CERTIFICATION LABEL.

Remedy: A SUPPLEMENTARY LABEL WILL BE SENT TO CUSTOMERS TO PLACE NEAR THE CERTIFICATION LABEL TO IDENTIFY THE APPROPRIATE REAR TIRE PRESSURE. THE CUSTOMER MAY ALSO HAVE THE DEALER INSTALL THE LABEL ON THE VEHICLE, IF THEY SO DESIRE. OWNER NOTIFICATION IS EXPECTED TO BEGIN DURING SEPTEMBER OR OCTOBER 2002. OWNERS WHO DO NOT RECEIVE THE FREE LABEL AND INSTALLATION INSTRUCTIONS WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-866-436-7332.

01V258000 · Visibility:windshield Wiper/washer:motor

Aug 8, 2001

VEHICLE DESCRIPTION: PASSENGER CARS, SPORT UTILITY VEHICLES, AND LIGHT AND MEDIUM DUTY PICKUP TRUCKS. A SWITCH LOCATED IN THE PLASTIC COVER OF THE WIPER MOTOR GEAR CASE COULD MALFUNCTION AND OVERHEAT, POTENTIALLY RESULTING IN LOSS OF INTERMITTENT WIPER FUNCTION, LOSS OF WIPER PARK FUNCTION, COMPLETE LOSS OF WIPER FUNCTION, OR IGNITION OF THE PLASTIC COVER MATERIAL. SWITCH MALFUNCTION IS MOST LIKELY TO OCCUR WHEN THE INTERMITTENT SETTING OF THE WIPERS IS BEING USED, OR WHEN SNOW OR ICE OBSTRUCTS THE BLADES FROM RETURNING TO THE "PARKED" POSITION AT THE BOTTOM OF THE WINDSHIELD. THESE VEHICLES WERE BUILT AT THE FOLLOWING ASSEMBLY PLANTS: ATLANTA PLANT FROM 2/11/00 THROUGH 7/31/00; CHICAGO PLANT FROM 2/14/00 THROUGH 8/4/00; KANSAS CITY PLANT FROM 2/26/00 TO 9/4/00; KENTUCKY TRUCK PLANT FROM 2/18/00 TO 8/31/00; MICHIGAN TRUCK PLANT FROM 2/23/00 THROUGH 8/3/00; NORFOLK PLANT FROM 2/21/00 THROUGH 7/27/00; WAYNE STAMPING AND ASSEMBLY PLANT FROM 2/25/00 THROUGH 8/15/00; AND WIXOM PLANT FROM 2/15/00 THROUGH 8/8/00.

Consequence & remedy

Consequence: LOSS OF VISIBILITY WHILE DRIVING INCREASES THE RISK OF A CRASH.

Remedy: DEALERS WILL INSPECT THE DATE CODE ON THE WIPER MOTOR. MOTORS BUILT WITH THE SUSPECT TIME FRAME WILL HAVE THE WIPER MOTOR GEAR CASE COVER REPLACED. OWNER NOTIFICATION BEGAN AUGUST 20, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-866-436-7332.

00V396000 · Equipment:other:owners/service/other Manual

Nov 28, 2000

VEHICLE DESCRIPTION: CERTAIN SPORT UTILITY VEHICLES, PICKUP TRUCKS, AND PASSENGER VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FMVSS 225, "CHILD RESTRAINT ANCHORAGE SYSTEMS." THE AFFECTED EXPEDITION/NAVIGATOR OWNER GUIDES DO NOT IDENTIFY THE LOCATIONS OF SEATING POSITIONS EQUIPPED WITH TETHER ANCHORAGES, AND DO NOT PROVIDE INSTRUCTIONS FOR SECURING CHILD SEATS TO THESE TETHER ANCHORAGES. THE F150 SC OWNER GUIDES DO NOT PROVIDE THE PROCEDURE FOR SECURING CHILD SEATS TO THE TETHER ANCHORAGES. THE TAURUS/SABLE OWNER GUIDES DO NOT IDENTIFY THE CENTER REAR SEATING POSITION AS HAVING LATCH COMPATIBLE LOWER ANCHORAGES.

Consequence & remedy

Consequence: IN THE EVENT OF A CRASH, THE CHILD SEAT MAY NOT BE PROPERLY ATTACHED INCREASING THE RISK OF INJURY TO THE CHILD.

Remedy: OWNERS WILL BE PROVIDED WITH OWNER GUIDE INSERTS REVISED TO PROVIDE THE REQUIRED INFORMATION, AND INSTRUCTIONS FOR AFFIXING THESE INSERTS TO THEIR OWNER GUIDES. CUSTOMERS WILL ALSO BE ADVISED THAT IF THEY PREFER, THEIR DEALER WILL AFFIX THE INSERTS TO THEIR OWNER GUIDES.

00V073000 · Trailer Hitches

Mar 7, 2000

VEHICLE DESCRIPTION: MULTI-PURPOSE VEHICLES. THE TRAILER HITCH ASSEMBLY TO THE FRAME ATTACHING BOLTS COULD LOSE THE CLAMP LOAD.

Consequence & remedy

Consequence: THE TRAILER HITCH COULD THEN SEPARATE FROM THE VEHICLE.

Remedy: DEALERS WILL REPLACE THE TRAILER HITCH MOUNTING BOLTS AND NUT PLATES.

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

EA05015 · Windshield Leak Causes Electric Failures

Opened Oct 13, 2005 · Closed Dec 6, 2006

Status: closed (inferred from source dates) · Electrical System; Exterior Lighting; Visibility:windshield Wiper/washer

CONSUMERS ALLEGED THAT WHEN IT RAINED OR SNOWED, WATER LEAKED INTO THE VEHICLE AROUND THE WINDSHIELD.MOISTURE FLOWING THROUGH THE SEAL THAT SURROUNDS THE FRONT WINDSHIELD FOLLOWS A PATH THROUGH THE SEAL INTO THE GENERIC ELECTRONIC MODULE (GEM) AND FUSE BOX, AND MAY CAUSE THE ELECTRICAL COMPONENTS IN THE VEHICLE TO MALFUNCTION.OVERALL, THE NUMBER OF REPORTS ALLEGING WIPER FAILURES AND LIGHTING FAILURES IS RELATIVELY SMALL.IN REVIEWING A LARGE SAMPLE OF THE 1503 COMPLAINTS FOR WINDSHIELD LEAKS, ODI'S ANALYSIS REVEALS THAT 0.04% OF THE TOTAL VEHICLE POPULATION REPORTED IMPROPER WINDSHIELD WIPER OPERATION AND 0.01% OF THE TOTAL VEHICLE POPULATIONREPORTED LIGHTING FAILURES.THE WARRANTY CLAIMS REVEAL THAT APPROXIMATELY 0.10% OF THE POPULATION HAS BEEN SERVICED FOR WIPER MALFUNCTIONS AND 0.08% FOR LIGHTING MALFUNCTIONS AS A RESULT OF WINDSHIELD LEAKING. ODI'S ANALYSIS OF THE FIELD PERFORMANCE STATISTICS AND AVAILABLE TECHNICAL INFORMATION HAS NOT ESTABLISHED THAT A DEFECT TREND EXISTS IN THE MALFUNCTION, FAILURE OR INTERMITTENT OPERATION OF THE FRONT WINDSHIELD WIPERS OR HEADLIGHTS.SEE THE ATTACHED SUMMARY REPORT.

Additional source detail variants (3)

Electrical System

Exterior Lighting

Visibility:windshield Wiper/washer

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

Engine And Engine Cooling:engine:gasoline

Engine And Engine Cooling

PE05033 · Electrical System Failure

Opened Jun 15, 2005 · Closed Oct 13, 2005

Status: closed (inferred from source dates) · Electrical System; Equipment:electrical; Visibility:windshield

ODI HAS RECEIVED 39 REPORTS ALLEGING THAT WATER LEAKS AROUND THE WINDSHIELD CAUSING ELECTRICAL FAILURES, INCLUDING BUT NOT LIMITED TO THE WINDSHIELD WIPERS AND THE HEADLAMPS.FORD REPORTS THAT WATER ENTERING THE VEHICLE CAN WET THE POWER DISTRIBUTION BOX (PDB) AND THE GENERIC ELECTRONIC MODULE (GEM).THESE COMPONENTS CONTROL VARIOUS ELECTRICAL SYSTEMS IN THE VEHICLE.THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS, EA05015, TO ALLOW FURTHER INVESTIGATION OF THE ISSUE AND TO ASSESS THE NATURE OF THE POTENTIAL SAFETY CONSEQUENCE.

Additional source detail variants (3)

Electrical System

Equipment:electrical

Visibility:windshield

PE04078 · Speed Control Deactivation Switch Fire

Opened Nov 19, 2004 · Closed Mar 22, 2005

Status: closed (inferred from source dates) · Vehicle Speed Control:cruise Control

IN ITS LETTER DATED JANUARY 27, 2005 TO ODI, FORD INDICATED THAT IT WOULD CONDUCT A SAFETY RECALL (NHTSA RECALL # 05V-017) TO REMEDY AN OVERHEATING SPEED CONTROL DEACTIVATION SWITCH IN APPROXIMATELY 738,490 SUBJECT VEHICLES.THE VEHICLES AFFECTED BY THE RECALL ARE CERTAIN 2000 MODEL YEAR (MY) FORD F150, FORD EXPEDITION AND LINCOLN NAVIGATOR EQUIPPED WITH SPEED CONTROL AND CERTAIN 2001 MODEL YEAR F150 SUPERCREW VEHICLES BUILT THROUGH AUGUST 7, 2000.SINCE OPENING PE04-078, ODI HAS IDENTIFIED OTHER REPORTS OF KEY OFF ENGINE COMPARTMENT FIRES IN FORD VEHICLES WITH SIMILAR SPEED CONTROL DEACTIVATION SWITCHES THAT WERE NOT THE SUBJECT OF THIS PRELIMINARY EVALUATION OR FORD'S RECALL 05V-017.FORD'S RESPONSE TO THE ODI INFORMATION REQUEST LETTER DATED DECEMBER 3, 2004, PROVIDED AN ADDITIONAL 107 ALLEGATIONS OF KEY OFF ENGINE COMPARTMENT FIRES THAT WERE ALSO IN VEHICLES NOT SUBJECT TO THIS INVESTIGATION OR INCLUDED IN THE FORD RECALL 05V-017.AN ENGINEERING ANALYSIS (EA) IS WARRANTED TO DETERMINE IF A SAFETY DEFECT TREND EXISTS RELATING TO KEY OFF ENGINE COMPARTMENT FIRES IN VEHICLES OUTSIDE THE SCOPE OF THIS PRELIMINARY EVALUATION.ODI WILL EXPAND THE SCOPE OF IT'S INVESTIGATION AT THE EA PHASE TO INCLUDE THE 1995 THROUGH 2002 MODEL YEARS OF THE FORD F150, FORD EXPEDITION AND LINCOLN NAVIGATOR VEHICLES.

SQ00016 · Wheel Stud And Nut

Opened Sep 15, 2000 · Closed Dec 6, 2001

Status: closed (inferred from source dates) · Wheels

IN DECEMBER 1999, FORD ISSUED TECHNICAL SERVICE BULLETIN 99-26-3, ENTITLED INCREASED WHEEL NUT AND STUD SIZE-SERVICE TIP,FOR 2000 MODEL YEAR EXPEDITION, NAVIGATOR, AND CERTAIN F-150 VEHICLES, BUILT ON OR AFTER NOVEMBER 27, 1999.THESE VEHICLES HAVE INCREASED WHEEL STUD AND NUT DIAMETERS FROM 12MM TO 14MM.THE WHEEL NUT TORQUE WAS INCREASED FROM 100 FT-LB. TO 150 FT-LB., RESPECTIVELY.ODI HAS RECEIVED THREE REPORTS OF WHEELS SEPARATING FROM 2000 MODEL YEAR EXPEDITION VEHICLES, INCLUDING TWO CRASHES.TWO ADDITIONAL REPORTS ALLEGE BROKEN STUDS AND/OR LOOSE WHEEL NUTS.LOOSE WHEEL NUTS CAN ALLOW THE WHEEL TO WOBBLE AND CAUSE WHEEL STUD BREAKAGE.THERE ARE NO SIMILAR ODI REPORTS ON 2000 MODEL YEAR LINCOLN NAVIGATOR VEHICLES.THE FAILURES APPEAR TO BE ATTRIBUTED TO IMPROPER WHEEL NUT TORQUE; HOWEVER, THERE IS NO EVIDENCE THAT THERE ARE TORQUE QUALITY DEFICIENCIES AT THE ASSEMBLY PLANTS.DUE TO THE MILEAGES THE INCIDENTS OCCURRED, IT IS MOST LIKELY THAT IMPROPER WHEEL NUT TORQUES WERE APPLIED DURING SERVICING, BECAUSE IN ALL CASES WHEN LOOSE WHEELS WERE RE-TORQUED TO A LEAST 100 FT-LB., THERE WERE NO FAILURE RE-OCCURRENCES.