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2003 Ford Expedition

Owner reports · Recalls · Investigations

More warning signs than most Expedition years

Owner complaints for the 2003 Ford Expedition are substantially higher than the model-year median of 155.

About this comparison →

When problems were reported

Mileage at the reported incident

463 reports with mileage · 152 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.

  • Engine And Engine Cooling. Review the 127 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 104 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes, Hydraulic. Review the 61 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

57 crash reports36 fire reports39 injury reports

Equipment complaints

7 reports
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33,000 miles · Feb 20, 2009
EquipmentTires

TL*THE CONTACT OWNS A 2003 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 45 MPH, THE REAR PASSENGER SIDE TIRE SUDDENLY LOST TIRE PRESSURE. SEVERAL WEEKS LATER, THE CONTACT EXPERIENCED AN IDENTICAL FAILURE WITH THE FRONT DRIVER'S SIDE TIRE. A LOCAL TECHNICIAN IDENTIFIED THE VALVE STEM AS BEING THE CAUSE OF THE FAILURE AND THEY …

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TL*THE CONTACT OWNS A 2003 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 45 MPH, THE REAR PASSENGER SIDE TIRE SUDDENLY LOST TIRE PRESSURE. SEVERAL WEEKS LATER, THE CONTACT EXPERIENCED AN IDENTICAL FAILURE WITH THE FRONT DRIVER'S SIDE TIRE. A LOCAL TECHNICIAN IDENTIFIED THE VALVE STEM AS BEING THE CAUSE OF THE FAILURE AND THEY MADE THE REPLACEMENT. AFTERWARDS, THE FAILURE RECURRED. SHE TOOK THE VEHICLE TO ANOTHER DEALER AND THEY STATED THAT THE NEW SET OF VALVE STEMS WERE CORRODED AND DEFECTIVE. SHE CURRENTLY HAS POSSESSION OF THE VALVE STEMS. THE VALVE STEM INFORMATION WAS UNKNOWN. THE FAILURE AND CURRENT MILEAGES WERE 33,000.

NHTSA ODI #10259441

200,000 miles · Jan 27, 2009
EquipmentExterior LightingLatches/locks/linkages

BRAKES NEED TO BE REPLACED CONSTANTLY. PADS WEAR VERY FAST. ROTORS WEAR EASILY AND NEED REPLACEMENT WITH PADS EACH TIME. WHEN BROUGHT TO HAVE ROTORS TURN, WAS TOLD THEY ARE MANUFACTURED WITH VERY LITTLE TOLERANCE AND COULD NOT BE TURNED EVEN THOUGH THERE WAS MINIMAL VISIBLE WEAR. WAS TOLD THEY DID NOT "MIC" WITH ENOUGH RANGE …

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BRAKES NEED TO BE REPLACED CONSTANTLY. PADS WEAR VERY FAST. ROTORS WEAR EASILY AND NEED REPLACEMENT WITH PADS EACH TIME. WHEN BROUGHT TO HAVE ROTORS TURN, WAS TOLD THEY ARE MANUFACTURED WITH VERY LITTLE TOLERANCE AND COULD NOT BE TURNED EVEN THOUGH THERE WAS MINIMAL VISIBLE WEAR. WAS TOLD THEY DID NOT "MIC" WITH ENOUGH RANGE TO TOLERATE THE CUT WHEN TURNING. ROTORS SHOULD NOT NEED REPLACEMENT WITH EACH BRAKE CHANGE. EXCESSIVE BRAKE DUST. BRAKE DUST HAS EATEN AWAY AT FINISH ON RIMS. AFTER LAST BRAKE REPAIR, FRONT END NOW HAS A CLICKING SOUND. BRAKE PEDAL HAS ALWAYS FELT SPONGY. ON TWO OCCASIONS WITH AGGRESSIVE BRAKING CONDITIONS, BRAKES LOCKED UP. TOLD DEALERSHIP WHO SAID THIS IS NORMAL WITH THE FORD BRAKING SYSTEMS. ADDITIONALLY, WE HAVE HAD AN ONGOING PROBLEM WITH THE PASSENGER SIDE FOG LAMP NOT STAYING LIT AND THE METAL REFLECTOR PIECE IN THE FOG LAMPS COMING LOOSE. WE ARE NOW HAVING PROBLEMS WITH TWO (FRONT DRIVERS/REAR PASSENGERS) DOOR ELECTRIC LOCKS NOT UNLOCKING OR LOCKING THE DOORS. *TR

NHTSA ODI #10256448

Mileage unknown · Oct 7, 2005
Electrical SystemEquipmentService Brakes, Hydraulic

CONSUMER IS HAVING PROBLEMS WITH AIR CONDITION MAKING NOISE, POWER WINDOWS ONLY LOWER, RADIO VOLUME GETS LOUDER WHEN ACCELERATING SEAT CONTROL BUTTONS ARE INOPERABLE. *TS WATER LEAKED FROM THE SUNROOF, EVEN THOUGH IT WAS CLOSED. THE VEHICLE WAS TAKEN TO THE DEALER ON 3 SEPARATE OCCASIONS DUE TO BRAKE AND ROTOR NOISE. THE CONSUM…

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CONSUMER IS HAVING PROBLEMS WITH AIR CONDITION MAKING NOISE, POWER WINDOWS ONLY LOWER, RADIO VOLUME GETS LOUDER WHEN ACCELERATING SEAT CONTROL BUTTONS ARE INOPERABLE. *TS WATER LEAKED FROM THE SUNROOF, EVEN THOUGH IT WAS CLOSED. THE VEHICLE WAS TAKEN TO THE DEALER ON 3 SEPARATE OCCASIONS DUE TO BRAKE AND ROTOR NOISE. THE CONSUMER EXPERIENCED LACK OF POWER WHEN ATTEMPTING TO ACCELERATE. THE CONSUMER WAS UNABLE TO HEAR THE RADIO SEPARATELY WHEN THE DVD WAS PLAYING. *JB

NHTSA ODI #10139949

Mileage unknown · Mar 30, 2005
Air BagsEquipment

I OWN A 2000 FORD EXPEDITION AND IN 2003 AND NOW I HAVE HAD THE AIRBAG LIGHT ON BECAUSE THE AIRBAG HARNESS IS DEFECTIVE ON THE PASSENGERS SIDE. THE COST IS $390.00 TO REPAIR AND $70.00 TO DO A DIAGNOSTIC TEST EACH TIME.*AK

NHTSA ODI #10116115

Mileage unknown · Jul 7, 2004
EquipmentStructure

PURCHASED NEW 2003 EXPEDITON EDDIE BAUER IN 10/03. DOORS RATTLE AS THOUGH THEY ARE NOT CLOSED. HAVE TAKEN VEHICLE BACK TO DEALERSHIP SEVERAL TIMES (THEY'VE HAD VEHICLE FOR CLOSE TO SIX WEEKS TOTAL). PROBLEM STILL EXITS. SOO MUCH BRAKE DUST ON FRONT WHEELS THAT THEY ARE PITTING. DEALERSHIP SAYS FORD WON'T COVER THE WHEELS BECUAS…

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PURCHASED NEW 2003 EXPEDITON EDDIE BAUER IN 10/03. DOORS RATTLE AS THOUGH THEY ARE NOT CLOSED. HAVE TAKEN VEHICLE BACK TO DEALERSHIP SEVERAL TIMES (THEY'VE HAD VEHICLE FOR CLOSE TO SIX WEEKS TOTAL). PROBLEM STILL EXITS. SOO MUCH BRAKE DUST ON FRONT WHEELS THAT THEY ARE PITTING. DEALERSHIP SAYS FORD WON'T COVER THE WHEELS BECUASE OF DUST. *AK

NHTSA ODI #10080527

Mileage unknown · Jun 7, 2004
Equipment

2003 EDDIE BAUER EXPEDITION - WE HAVE THE DVD PLAYER WHICH WAS ALREADY IN PLACE WHEN WE PURCHASED THE VEHICLE. WHEN THE SCREEN IS DOWN, IT IS ALMOST IMPOSSIBLE TO SEE OUT THE BACK WINDOW. I DON'T SEE HOW THIS CAN BE LEGAL, AS IT BLOCKS THE DRIVERS VIEW FROM APPROACHING EMERGENCY VEHICLES, AS IS WHAT HAPPENED TO ME THE OTHER DA…

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2003 EDDIE BAUER EXPEDITION - WE HAVE THE DVD PLAYER WHICH WAS ALREADY IN PLACE WHEN WE PURCHASED THE VEHICLE. WHEN THE SCREEN IS DOWN, IT IS ALMOST IMPOSSIBLE TO SEE OUT THE BACK WINDOW. I DON'T SEE HOW THIS CAN BE LEGAL, AS IT BLOCKS THE DRIVERS VIEW FROM APPROACHING EMERGENCY VEHICLES, AS IS WHAT HAPPENED TO ME THE OTHER DAY WHILE DRIVING WITH MY CHILDREN.*AK

NHTSA ODI #10074937

Mileage unknown · Apr 22, 2004
EquipmentSeat BeltsVisibility

PURCHASED 2003 EXPEDITION XLT IN 9/03 AND HAD THE FOLLOWING PROBLEMS WITHIN ONE WEEK OF PURCHASE: A/C NOISE & DECREASED VOLUME WHEN MAX A/C IS ON; RATTLING NOISE FROM SIDE PANELS (WHICH ALSO SHOWED FADING WITHIN 3 MONTHS AND WERE REPLACED); WASHER FLUID LIGHT SHOWED LOW WHEN FULL; FOAM LOOSE AROUND DEFROSTER. BY 12/03, STEREO S…

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PURCHASED 2003 EXPEDITION XLT IN 9/03 AND HAD THE FOLLOWING PROBLEMS WITHIN ONE WEEK OF PURCHASE: A/C NOISE & DECREASED VOLUME WHEN MAX A/C IS ON; RATTLING NOISE FROM SIDE PANELS (WHICH ALSO SHOWED FADING WITHIN 3 MONTHS AND WERE REPLACED); WASHER FLUID LIGHT SHOWED LOW WHEN FULL; FOAM LOOSE AROUND DEFROSTER. BY 12/03, STEREO SYSTEM REPLACED DUE TO LOUD WHINING NOISE; HAS BEEN REPLACED 3 TIMES (PROBLEM STILL RECURRING); 2/04 SUN ROOF LEAKING PROFUSELY INTO 2ND ROW SEAT AREA (SAME PROBLEM OCCURRED A MONTH LATER THOUGH REPAIRED). WHEN DEALER'S SUBCONTRACTOR REPAIRED MOONROOF THE SECOND TIME, THE TECHNICAN NEGLECTED TO SCREW REAR SEATBELT BOLT TIGHTLY BACK TO SIDE PANEL. SEATBELT BOLT BROKE AWAY FROM SIDE PANEL WHILE CHILD WAS SITTING IN SEAT! DEALER REPAIRED AND CHECKED ALL SEAT BELT ATTACHMENTS AT MY REQUEST BUT DID NOT OFFER TO DETERMINE SOURCE OF PROBLEM UNTIL I INSISTED. SERVICE MGR INITIALLY REPORTED HE THOUGHT IT WAS A FACTORY DEFECT, UNTIL THEY RESEARCHED THE PROBLEM IN DETAIL. I STRONGLY RECOMMEND THAT FORD HAVE A POLICY THAT ANY SAFETY DEVICES REMOVED OR TAMPERED WITH DURING ANY REPAIR SHOULD BE DOUBLE CHECKED FOR PROPER OPERATION PRIOR TO RETURNING VEHICLE TO OWNER. *AK

NHTSA ODI #10067688

Official recalls

1

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.

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

1

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.