NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
615 reports87,628 miles · Jun 16, 2008
Engine And Engine Cooling
I WAS DRIVING TO A BALLGAME WHEN I HEARD A LOUD POP. I PULLED OVER TO DETERMINE THE PROBLEM. I OPENED THE HOOD TO NOTICE THE #3 SPARK PLUG IN MY 2003 FORD EXPEDITION 5.4L V8 WAS FLOPPING AROUND ON TOP OF THE HOOD. I HAD THE VEHICLE TOWED HOME. I TOOK MY VEHICLE TO THE LOCAL FORD DEALERSHIP AND WAS TOLD THAT THE ENTIRE RIGHT …
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I WAS DRIVING TO A BALLGAME WHEN I HEARD A LOUD POP. I PULLED OVER TO DETERMINE THE PROBLEM. I OPENED THE HOOD TO NOTICE THE #3 SPARK PLUG IN MY 2003 FORD EXPEDITION 5.4L V8 WAS FLOPPING AROUND ON TOP OF THE HOOD. I HAD THE VEHICLE TOWED HOME. I TOOK MY VEHICLE TO THE LOCAL FORD DEALERSHIP AND WAS TOLD THAT THE ENTIRE RIGHT SIDE HEAD NEEDED TO BE REPLACED FROM THIS ONE SPARK PLUG BLOWOUT. AFTER DOING RESEARCH ON SEVERAL ONLINE WEBSITES, FORUMS, AND BLOGS, I HAVE DETERMINED THIS IS A MAJOR PROBLEM WITH THE DESIGN OF THE FORD ENGINE. NUMEROUS COMPLAINTS HAVE BEEN MADE FROM FORD OWNERS ABOUT THIS SAME PROBLEM. *TR
NHTSA ODI #10231126
92,000 miles · Jun 11, 2008
Engine And Engine Cooling
I WAS DRIVING MY 2003 FORD EXPEDITION TO WORK THIS MORNING AND HEARD A LOUD "POP" NOISE, THE VEHICLE BEGAN TO VIBRATE AND I SMELLED GAS FUMES. WHEN I LIFTED THE HOOD, I IMMEDIATELY NOTICED THAT THE ENGINE HAD BLOWN A SPARK PLUG. *TR
NHTSA ODI #10230742
50,000 miles · May 13, 2008
Engine And Engine Cooling
NO WARNING. ENGINE STOP. AT LEAST A DOZEN TIMES.NO BODY AT FORD WILL ADMIT THERE IS A PROBLEM. *TR
NHTSA ODI #10227555
81,461 miles · May 8, 2008
Engine And Engine Cooling
WHILE DRIVING 2003 FORD EXPEDITION SPARK PLUG BLEW OUT AND TRUCK REDUCED SPEED. THE INCIDENT CAUSED DAMAGE TO THE ENGINE - WHICH REQUIRED REPLACEMENT APPROX. $6,000.00. I ASKED THE DOWNEY FORD DEALER IF THIS WAS A MANUFACTURING DEFECT? THEY REPLIED: THEY DID NOT KNOW ALTHOUGH THE TRUCK WAS NOT ON RECALL. THIS DEFECT - B…
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WHILE DRIVING 2003 FORD EXPEDITION SPARK PLUG BLEW OUT AND TRUCK REDUCED SPEED. THE INCIDENT CAUSED DAMAGE TO THE ENGINE - WHICH REQUIRED REPLACEMENT APPROX. $6,000.00. I ASKED THE DOWNEY FORD DEALER IF THIS WAS A MANUFACTURING DEFECT? THEY REPLIED: THEY DID NOT KNOW ALTHOUGH THE TRUCK WAS NOT ON RECALL. THIS DEFECT - BLOWN SPARK PLUG MAY CAUSE EXCESSIVE INJURY AND OR DEATH IF THIS WERE TO OCCUR ON THE FREEWAY. *TR
NHTSA ODI #10227063
Mileage unknown · Apr 25, 2008
Tires
2ND SET OF CONTINENTAL CONTITRAC TIRES ON 2003 EXP. FORD TIRES CONTINUE TO GO FLAT ON WEEKLY BASIS. AFTER PUTTING CORRECT LBS OF AIR WITHIN 2 DAYS DOWN TO LESS THEN 10-15LBS 2ND SET HAS BEEN ON FOR LESS THEN 18 MONTHS. NOTE: 17 INCH MODEL IT IS NOT LISTED UNDER TIRE TYPE NOTE MANY OTHER COMPLAINTS REGARDING TIRE PROBLEM ON S…
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2ND SET OF CONTINENTAL CONTITRAC TIRES ON 2003 EXP. FORD TIRES CONTINUE TO GO FLAT ON WEEKLY BASIS. AFTER PUTTING CORRECT LBS OF AIR WITHIN 2 DAYS DOWN TO LESS THEN 10-15LBS 2ND SET HAS BEEN ON FOR LESS THEN 18 MONTHS. NOTE: 17 INCH MODEL IT IS NOT LISTED UNDER TIRE TYPE NOTE MANY OTHER COMPLAINTS REGARDING TIRE PROBLEM ON SAME MODEL. *TR
NHTSA ODI #10225744
81,071 miles · Mar 17, 2008
Electrical SystemInjury
WHILE TRAVELING AT HIGHWAY SPEEDS, THE ENGINE WOULD QUIT WITH NO PROCEEDING SYMPTOMS OR INDICATIONS. SHIFTING TO NEUTRAL AND TRYING TO RE-START WOULD NOT WORK. SHIFTING TO NEUTRAL, TURNING OFF THE IGNITION AND THEN TURNING THE KEY TO START DID CAUSE A RE-START. THIS PROBLEM CAUSES THE "SERVICE ENGINE SOON" LIGHT ON THE DASH TO L…
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WHILE TRAVELING AT HIGHWAY SPEEDS, THE ENGINE WOULD QUIT WITH NO PROCEEDING SYMPTOMS OR INDICATIONS. SHIFTING TO NEUTRAL AND TRYING TO RE-START WOULD NOT WORK. SHIFTING TO NEUTRAL, TURNING OFF THE IGNITION AND THEN TURNING THE KEY TO START DID CAUSE A RE-START. THIS PROBLEM CAUSES THE "SERVICE ENGINE SOON" LIGHT ON THE DASH TO LIGHT, SO A CODE IS BEING GENERATED. FORD IS AWARE OF THIS PROBLEM, SINCE IT HAS ISSUED A NOTICE (NOT A RECALL) TO IT'S SERVICE DEPARTMENTS. THE REPAIR IS THE REPLACEMENT OF THE ALTERNATOR WIRING HARNESS ASSEMBLY AND REPROGRAMMING OF THE PROCESSOR. FORD HAS NOT ISSUED A RECALL FOR THIS VERY UNSAFE PROBLEM, SO THE CHARGE FOR THE WORK IS $ 342.64. *TR
NHTSA ODI #10221414
Mileage unknown · Mar 10, 2008
Engine And Engine Cooling
DECEMBER 15, 2007, MY 2003 FORD EXPEDITION'S SPARK PLUG WAS BLOWN OUT. LEAVING MY THREE KIDS AND MYSELF STRANDED ON THE HIGHWAY. AFTER PAYING $1,200 TO GET IT FIX, ON MARCH 9, 2008 THE SAME THING HAPPEN. *TR
NHTSA ODI #10220661
153,208 miles · Mar 7, 2008
Service Brakes, HydraulicCrash
MY 2003 FORD EXPEDITION HAD A SUDDEN BRAKE FAILURE WHILE MY SEVENTEEN YEAR OLD DAUGHTER WAS DRIVING. LUCKILY SHE WAS NOT HURT WHEN THIS INCIDENT TOOK PLACE. I FOUND THE BRAKE RESERVOIR TO BE COMPLETELY EMPTY AND REFILLED IT IMMEDIATELY. THEN I DISCOVERED THE REAL PROBLEM. THE REAR FACTORY BRAKE LINES WERE CONSTANTLY RUBBING AGAI…
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MY 2003 FORD EXPEDITION HAD A SUDDEN BRAKE FAILURE WHILE MY SEVENTEEN YEAR OLD DAUGHTER WAS DRIVING. LUCKILY SHE WAS NOT HURT WHEN THIS INCIDENT TOOK PLACE. I FOUND THE BRAKE RESERVOIR TO BE COMPLETELY EMPTY AND REFILLED IT IMMEDIATELY. THEN I DISCOVERED THE REAL PROBLEM. THE REAR FACTORY BRAKE LINES WERE CONSTANTLY RUBBING AGAINST THE REAR SPRINGS OF THE CAR , THUS WEARING A HOLE IN THE BRAKE LINE. THIS RESULTED IN RAPID LOSS OF BRAKE FLUID , WHICH ALSO LED TO SUDDEN BRAKE FAILURE. THIS WOULD OBVIOUSLY BE A MANUFACTURERS DEFECT AND I CANT IMAGINE WHY SOMEONE AT FORD DIDN'T SEE SUCH AN OBVIOUS PROBLEM. *TR
NHTSA ODI #10220394
119,282 miles · Mar 3, 2008
Engine And Engine Cooling
2003 EXPEDITION 5.4L ENGINE. PRODUCTION DATE 10-08-02 . HAVING OIL LEAK FROM RIGHT HEAD GASKET DIAGNOSED BY FORD. I BELIEVE PROBLEM IS RELATED TO TSB 02-22-7. THIS SHOULD BE A RECALL AND REPAIR EXPENSES COVERED BY FORD / MANUFACTURER. *TR
NHTSA ODI #10219865
69,500 miles · Feb 28, 2008
Air BagsCrashInjury
DRIVING DOWN TAR ROAD WHEN MY TRUCK CAUGHT THE EDGE OF PAVEMENT AND SHOOT ACROSS THE GRAVEL SHOULDER THEN CAUGHT SNOWY HILLSIDE. VEHICLE CAME IN CONTACT WITH SEVERAL TREES. THE TRUCK HAD SEVERE IMPACT TOTALING THE UNIT . NO AIR BAGS EVER CAME OUT. *TR
NHTSA ODI #10219614
NHTSA investigations
1DP05005 · 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.
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