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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

Service Brakes, Air complaints

9 reports
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27,100 miles · Aug 24, 2005
Service Brakes, Air

BRAKING SYSTEM DEGREDATION, ALL FOUR BRAKE PADS AND ROTORS NEED TO BE REPLACED AT 27K MILES. DURING THE FIRST WEEK OF DRIVING THE NEW VEHICLE I NOTICED THAT THE BRAKING SYSTEM PERFORMED WORSE THAN THE 2000 EXPEDITION I HAD JUST TRADED IN. AFTER EXPLAINING THIS TO THE DEALER, THEY DECIDED TO REPLACE ALL FOUR BRAKE PADS AND ROTO…

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BRAKING SYSTEM DEGREDATION, ALL FOUR BRAKE PADS AND ROTORS NEED TO BE REPLACED AT 27K MILES. DURING THE FIRST WEEK OF DRIVING THE NEW VEHICLE I NOTICED THAT THE BRAKING SYSTEM PERFORMED WORSE THAN THE 2000 EXPEDITION I HAD JUST TRADED IN. AFTER EXPLAINING THIS TO THE DEALER, THEY DECIDED TO REPLACE ALL FOUR BRAKE PADS AND ROTORS DURING THE FIRST MONTH OF OWNERSHIP. AFTER A ROUNTINE MAINTANENCE AT 26K MILES, I WAS TOLD THAT THE BRAKE PADS HAD 10% LIFE LEFT AND ALL FOUR ROTORS NEEDED TO BE REPLACED. THE ROTORS WERE BEYOND SPECIFICATIONS FOR TURNING. I RETURNED TO THE DEALER AND THEY EXPLAINED TO ME THAT THE WARRANTY WILL NOT COVER THIS WORK AND THAT I WOULD HAVE TO PAY FOR THE REPLACEMENT. I AM AFRAID THAT I MAY NOT BE ABLE TO AVOID AN ACCIDENT DUE TO POSSIBLE TOTAL BRAKE FAILURE. THE DEALER AND MAKER SAID IT'S A MAINTANENCE ISSUE AND I AM RESPONSIBLE FOR IT'S REPLACEMENT. I HAVE HEARD OF OTHER PEOPLE HAVING THE SAME PROBLEM WITH THE 2003 EXPEDITION AND HAVE FOUND SEVERAL COMPLAINTS ON THE INTERNET WITH THE SAME ISSUE.

NHTSA ODI #10134038

29,900 miles · Jun 24, 2005
Service Brakes, Air

WE HAD EXCESSIVE BRAKE DUST AND THEN AT 29,000 MILES WHEN WE WOULD TURN RIGHT IT BEGAN SQUEEKING. WE TOOK IT TO THE DEALER AND THEY STATED WE NEEDED BRAKE PADS (FIRST TIME CHANGING AND THEY WERE NOT EVEN TO THE METAL CLIP) AND THAT THE ROTORS NEEDED TO BE REPLACED BECAUSE THEY WERE WORE DOWN BELOW THE SAFTEY LEVEL. DEALER MADE…

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WE HAD EXCESSIVE BRAKE DUST AND THEN AT 29,000 MILES WHEN WE WOULD TURN RIGHT IT BEGAN SQUEEKING. WE TOOK IT TO THE DEALER AND THEY STATED WE NEEDED BRAKE PADS (FIRST TIME CHANGING AND THEY WERE NOT EVEN TO THE METAL CLIP) AND THAT THE ROTORS NEEDED TO BE REPLACED BECAUSE THEY WERE WORE DOWN BELOW THE SAFTEY LEVEL. DEALER MADE MANY EXCUSES LIKE TIRE SIZE, RIMS (THEY SALE EXACT RIMS AT DEALER) AND FINALLY STATED THEY DID NOT KNOW. WHEN CONTACTING FORD CUSTOMER CARE REP STATED THAT IT IS TOO SOON TO CHANGE BUT THAT THE REGIONAL MANAGER SAID IT IS MAINTANCE ISSUE AND THAT WE MUST PAY FOR THEM. THEY STATE THAT TECHNICAL BULLETIN (WHICH THEY HAVE ON PADS AND ROTORS) ARE NOT RECALLS SO EVEN IF THEY KNOW THEY HAVE A PROBLEM THE CONSUMER HAS TO PAY THE PRICE UNTIL THEY ARE FORCED TO DO AN OFFICIAL RECALL. THIS IS UNFAIR AND NEEDS TO BE CHANGED!!!!!!

NHTSA ODI #10126432

33,131 miles · Jun 15, 2005
Service Brakes, Air

ON DECEMBER 9, 2004, I DELIVERED MY 2003 FORD EXPEDITION TO THE ASPEN TIRE AND AUTO CENTER IN CASTLE ROCK, CO FOR THE BRAKE REPAIRS UPON COMPLETION OF THE 30,000 MILE SERVICE AT THE MEDVED FORD DEALERSHIP IN CASTLE ROCK, CO. I HAD REPORTED TO FORD THAT THE BRAKES BEGAN SQUEAKING THAT MORNING AND CONTINUED TO SQUEAK FOR SEVERAL …

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ON DECEMBER 9, 2004, I DELIVERED MY 2003 FORD EXPEDITION TO THE ASPEN TIRE AND AUTO CENTER IN CASTLE ROCK, CO FOR THE BRAKE REPAIRS UPON COMPLETION OF THE 30,000 MILE SERVICE AT THE MEDVED FORD DEALERSHIP IN CASTLE ROCK, CO. I HAD REPORTED TO FORD THAT THE BRAKES BEGAN SQUEAKING THAT MORNING AND CONTINUED TO SQUEAK FOR SEVERAL SECONDS AFTER THE BRAKE PEDAL WAS RELEASED. FORD ADVISED IT NEEDED NEW FRONT BRAKE PADS, BUT I OPTED TO TAKE IT ELSEWHERE FOR THE REPAIRS. I IMMEDIATELY DROPPED THE VEHICLE OFF AT THE ASPEN TIRE AND AUTO CENTER, 4978 FRONT STREET, CASTLE ROCK, CO 80104 AFTER MEDVED COMPLETED THE INITIAL WORK. WHEN THE ASPEN TIRE AND AUTO SERVICE TECHNICIANS EXAMINED THE BRAKE SYSTEM, THEY REPORTED TO ME THAT BOTH ROTORS WERE UNEVENLY WORN AND WARPED. ADDITIONALLY, THE LEFT CALIPER WAS NOT RELEASING PROPERLY. I WAS IN THE VICINITY AND WAS ABLE TO INSPECT THE ENTIRE BRAKE SYSTEM IN THEIR SERVICE CENTER. THE ASPEN TIRE AND AUTO CENTER BROUGHT THE RIGHT ROTOR TO MINIMUM SAFETY SPECIFICATIONS, BUT WAS UNABLE TO SALVAGE THE LEFT ROTOR. THEIR TECHNICIANS CLEANED THE BRAKE SYSTEM, WHICH ALLOWED BOTH CALIPERS TO PERFORM NORMALLY. BOTH ROTORS HAD TO BE REPLACED. AS A FORD OWNER FOR THE PAST EIGHT YEARS, I NEVER EXPERIENCED SUCH A SIGNIFICANT AND UNSAFE DETERIORATION OF A BRAKING SYSTEM. IF THE REPAIRS TO THE ROTORS AND CALIPERS HAD NOT BEEN ADDRESSED, THE VEHICLE WOULD NOT HAVE BEEN ABLE TO DELIVER OPTIMAL BRAKING PERFORMANCE, ENDANGERING THE LIVES OF MY FAMILY, OTHER MOTORIST, AND MYSELF. THIS VEHICLE NEVER PERFORMED ANY DRIVING ACTIVITIES THAT WOULD GREATLY ALTER THE NORMAL WEAR ON THE BRAKING SYSTEM. IT IS USED PRIMARILY AS A TRANSPORT VEHICLE TO AND FROM WORK, ON A RELATIVELY EVEN DRIVING SURFACE. THERE IS NO JUSTIFIABLE REASON WHY THIS VEHICLE EXPERIENCED THESE PROBLEMS WITH ONLY 33,131 MILES. I HAVE SPOKEN TO OTHER FORD EXPEDITION OWNERS WHO HAVE EXPERIENCED IDENTICAL PROBLEMS WITH THE FRONT BRAKES ON THEIR VEHICLES.

NHTSA ODI #10125403

Mileage unknown · May 14, 2005
Service Brakes, Air

I BOUGHT IT WITH ABOUT 21000 MILES AT AROUND 30000 I REPLACED THE PADS AT A FORD DEALER BECAUSE OF THE WEAR AND SEVER BRAKE DUST I ALSO HAD THE ROTORS TURNED, IT NOW HAS 53000 MILES AND I HAVE HAD TO TURN THE ROTORS ABOUT EVERY 10000 MILES BECAUSE THE SHAKING IN THE STEERING WHEEL GETS SO BAD WHEN BRAKING

NHTSA ODI #10120909

Mileage unknown · Oct 22, 2003
Service Brakes, Air

EXCESSIVE BRAKE DUST ON WHEELS. AFTER CLEANING THE WHEELS ARE COMPLETELY BLACK AFTER ONE DAY. *LA

NHTSA ODI #10043359

Mileage unknown · Sep 12, 2003
Service Brakes, Air

EXCESSIVE BRAKE DUST ON FRONT WHEELS. *PH

NHTSA ODI #10038764

Mileage unknown · Aug 9, 2003
Service Brakes, AirSuspension

WHEN TURNING LEFT OR RIGHT LOUD GRINDING NOISE- HAS BEEN SERVICED 4 TIMES AND AFTER THE LAST TIME IT STOPPED, BUT HAS SINCE RETURNED. ALSO, EXCESSIVE AMOUNTS OF BRAKE DUST ON WHEELS, AND THEY ARE MAKING NOISES. ALSO AS IF THEY NEED TO BE CHANGED AND THERES ONLY 4000 MILES ON THE TRUCK. *AK

NHTSA ODI #10031183

Mileage unknown · Jul 16, 2003
Service Brakes, AirWheels

EXCESSIVE BRAKE DUST ON FRONT WHEELS. BLACK AFTER 2 DAYS.*AK

NHTSA ODI #10028426

Mileage unknown · Jun 20, 2003
Service Brakes, AirCrash

WHEN APPLYING BRAKES AT ANY SPEED IN CURVES OR AT AN INCLINE, BRAKE PEDAL WILL BUCKLE AND GO TO THE FLOOR, RESULTING IN NO BRAKING ACTION. THIS HAPPENED 8 TIMES. ON 27 MAY AT TAKE OFF AFTER A COMPLETE STOP, CONSUMER APPLIED BRAKE, NO BRAKING ACTION, VEHICLE HIT ANOTHER. DAMAGE WAS $1272.*AK

NHTSA ODI #10024581

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.