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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

What owners actually said

615 reports
56,672 miles · Oct 19, 2006
Electrical System

DT*: THE CONTACT STATED WHILE DRIVING 45 MPH, THE VEHICLE COMPLETELY STALLED WITHOUT WARNING AND THERE WERE NO LIGHTS ILLUMINATED. EACH TIME THE VEHICLE WAS RESTARTED, IT STALLED AGAIN. AN INDEPENDENT MECHANIC WAS CONTACTED, AND DETERMINED THE BATTERY NEEDED TO BE REPLACED. BECAUSE THE ALTERNATOR WAS NOT CHARGING THE BATTERY,…

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DT*: THE CONTACT STATED WHILE DRIVING 45 MPH, THE VEHICLE COMPLETELY STALLED WITHOUT WARNING AND THERE WERE NO LIGHTS ILLUMINATED. EACH TIME THE VEHICLE WAS RESTARTED, IT STALLED AGAIN. AN INDEPENDENT MECHANIC WAS CONTACTED, AND DETERMINED THE BATTERY NEEDED TO BE REPLACED. BECAUSE THE ALTERNATOR WAS NOT CHARGING THE BATTERY, THE ALTERNATOR HAD TO BE REPLACED. AFTER BOTH REPLACEMENTS, AND CHECKING THE FUSES, THE BATTERY LIGHT ILLUMINATED INDICATING THE PROBLEM WAS REPAIRED. NOT TOO LONG AFTER, THE PROBLEM RECURRED. THE VEHICLE WAS TAKEN TO THE SERVICE DEALER, WHO DETERMINED THAT THE WIRING HARNESS WAS CORRODED. THE PART WAS UNAVAILABLE AT THE DEALER THEREFORE THE VEHICLE WAS TAKEN TO ANOTHER SERVICE DEALER WHO INSTALLED A NEW WIRING HARNESS. THE MANUFACTURER WAS NOT NOTIFIED.

NHTSA ODI #10171346

75,000 miles · Aug 30, 2006
Engine And Engine Cooling

VEHICLE WAS BROUGHT INTO FORD DEALER FOR A "TAPPING NOISE" IN ENGINE AREA.. DEALER RAN A TEST AND FOUND NOTHING WRONG. SEVERAL DAYS LATER ENGINE STARTING MAKING POPPING NOISES AND WAS UNABLE TO DRIVE VEHICLE DUE TO ENGINE NOT OPERATING PROPERLY..SAME DEALER TOWED TO THEIR FACILITY AND SAID SPARK PLUG IN #3 CYLINDER CAME LOOSE AN…

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VEHICLE WAS BROUGHT INTO FORD DEALER FOR A "TAPPING NOISE" IN ENGINE AREA.. DEALER RAN A TEST AND FOUND NOTHING WRONG. SEVERAL DAYS LATER ENGINE STARTING MAKING POPPING NOISES AND WAS UNABLE TO DRIVE VEHICLE DUE TO ENGINE NOT OPERATING PROPERLY..SAME DEALER TOWED TO THEIR FACILITY AND SAID SPARK PLUG IN #3 CYLINDER CAME LOOSE AND WAS EJECTED AND DAMAGED THE HEAD. THEY WANT $3K TO REPAIR THIS...VEHICLE HAS 75K MILES WITH NO MORE WARRANTY. *JB

NHTSA ODI #10167057

33,000 miles · Aug 28, 2006
Structure

DT*: THE CONTACT STATED THERE WAS RUST APPEARING ON THE LIFTGATE UNDER THE HANDLE AND BETWEEN THE WINDOW AND THE DOOR. IT APPEARED TO BE BUBBLING AND RUST FORMED. THE VEHICLE WAS TAKEN TO A INDEPENDENT SERVICE SHOP FOR REGULAR MAINTENANCE WHEN THE RUST WAS OBSERVED. THE DEALER INDICATED THAT THE RUST MAY BE DUE TO WATER CAPTUR…

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DT*: THE CONTACT STATED THERE WAS RUST APPEARING ON THE LIFTGATE UNDER THE HANDLE AND BETWEEN THE WINDOW AND THE DOOR. IT APPEARED TO BE BUBBLING AND RUST FORMED. THE VEHICLE WAS TAKEN TO A INDEPENDENT SERVICE SHOP FOR REGULAR MAINTENANCE WHEN THE RUST WAS OBSERVED. THE DEALER INDICATED THAT THE RUST MAY BE DUE TO WATER CAPTURED BETWEEN THE WINDOW AND THE STRUCTURE OF THE DOOR. *AK

NHTSA ODI #10166719

76,491 miles · Aug 16, 2006
Vehicle Speed Control

GAS PEDAL STUCK WHILE UNDER ACCELERATION. WHILE ACCELERATING FROM A STOP LIGHT THE GAS PEDAL STUCK WIDE OPEN. MANAGED TO GET TO PARKING LOT WHILE HOLDING BRAKES TO THE FLOOR. AFTER SEVERAL KICKS THE PEDAL CAME UNSTUCK. TOOK TRUCK TO FORD DEALER WHERE THE SERVICE DEPARTMENT FOUND THAT THE THROTTLE BODY STICKING DUE TO A SHIFTING …

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GAS PEDAL STUCK WHILE UNDER ACCELERATION. WHILE ACCELERATING FROM A STOP LIGHT THE GAS PEDAL STUCK WIDE OPEN. MANAGED TO GET TO PARKING LOT WHILE HOLDING BRAKES TO THE FLOOR. AFTER SEVERAL KICKS THE PEDAL CAME UNSTUCK. TOOK TRUCK TO FORD DEALER WHERE THE SERVICE DEPARTMENT FOUND THAT THE THROTTLE BODY STICKING DUE TO A SHIFTING IN THE LINKAGE AND CARBON BUILD UP INSIDE OF THROTTLE BODY. DEALER REPLACED PART #'S 3L1Z9E926 & F65Z9E936 AND PERFORMED FLUSH OF UPPER PLENUM WITH BG INDUCTION SERVICE. *NM

NHTSA ODI #10165694

45,000 miles · Aug 7, 2006
Visibility

PURCHASED A 2003 FORD EXPEDITION ABOUT 2 MONTHS AGO, SINCE THEN DRIVERS SIDE WINDOW REGULATOR WAS REPLACED. WEEK AND HALF AGO, PASSENGERS FWD INOPERATIVE, YESTERDAY, DRIVERS SIDE INOPERATIVE. WHEN FIRST ONE WAS FIXED. TECHNICIAN SAID IT WAS A BIG PROBLEM. THE REGULATOR CABLES BIND UP. HE SAID BAD DESIGN. STILL WAITING FOR MY APP…

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PURCHASED A 2003 FORD EXPEDITION ABOUT 2 MONTHS AGO, SINCE THEN DRIVERS SIDE WINDOW REGULATOR WAS REPLACED. WEEK AND HALF AGO, PASSENGERS FWD INOPERATIVE, YESTERDAY, DRIVERS SIDE INOPERATIVE. WHEN FIRST ONE WAS FIXED. TECHNICIAN SAID IT WAS A BIG PROBLEM. THE REGULATOR CABLES BIND UP. HE SAID BAD DESIGN. STILL WAITING FOR MY APPOINTMENT TO REPAIR THE OTHER 2 WINDOWS. WHEN THESE WINDOWS FAIL. THEY ARE EITHER STUCK UP, OR DOWN. RESULTING IN A SAFETY ISSUE IN FLOODS OR WATER, OR HEAT ISSUES IF THE WINDOWS CANNOT BE ROLLED DOWN. NOT TO MENTION, EMERGENCY ESCAPE ISSUES. LOOKING ON THE INTERNET, I HAVE FOUND MANY WEBSITES WITH ARCHIVED FORUMS WITH MANY PEOPLE COMPLAINING OF THE SAME SITUATION. *NM

NHTSA ODI #10164801

42,000 miles · Jul 27, 2006
StructureInjury

DT*: THE CONSUMER EXITED THE DRIVER'S SEAT, LEFT THE FRONT DOOR OPEN AND OPENED THE BACK DOOR TO PLACE SOME ITEMS IN THE BACK. UNAWARE HER 5 YEAR OLD DAUGHTER HAD CLIMBED OVER THE FRONT SEAT AND SAT IN THE DRIVER'S SEAT FACING THE OPEN DOOR, THE CONSUMER OPENED THE BACK DOOR FARTHER TO EXIT AND THEN SHUT THE DOOR. WHEN SHE SH…

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DT*: THE CONSUMER EXITED THE DRIVER'S SEAT, LEFT THE FRONT DOOR OPEN AND OPENED THE BACK DOOR TO PLACE SOME ITEMS IN THE BACK. UNAWARE HER 5 YEAR OLD DAUGHTER HAD CLIMBED OVER THE FRONT SEAT AND SAT IN THE DRIVER'S SEAT FACING THE OPEN DOOR, THE CONSUMER OPENED THE BACK DOOR FARTHER TO EXIT AND THEN SHUT THE DOOR. WHEN SHE SHUT THE DOOR THE CHILD'S HAND WAS CAUGHT IN THE DOOR, HER LEFT HAND RING FINGER WAS CRUSHED, ALMOST SEVERED BY THE HINGE THAT HOOKS THE DOOR TO THE VEHICLE. WHEN THE CONSUMER OPENED THE DOOR IT CRUSHED HER FINGER AND WHEN THE CONSUMER CLOSED THE DOOR IT RELEASED HER FINGER. *NM

NHTSA ODI #10163660

Mileage unknown · Jul 19, 2006
Power Train

CLUTCH PLATE AND PINION GEAR IS FAULTY AND FORD MOTOR COMPANY DOES NOT WANT TAKE FULL RESPONSIBILITY FOR THE PROBLEM. *NM

NHTSA ODI #10162921

23,000 miles · Jul 18, 2006
Structure

MY 2003 EXPEDITION HAD A CRACK IN THE OVERHEAD CONSOLE WHEN I PURCHASED IT USED IN 2004. I DIDN'T SEE IT AT THE TIME OF PURCHASE AND DIDN'T THINK THAT MUCH OF IT WHEN I DID DISCOVER THE CRACK. IN THE PAST YEAR AND A HALF THE CONSOLE HAS SIMPLY CRACKED APART AND THE PLASTIC IS VERY BRITTLE. I'VE GLUED IT A NUMBER OF TIMES BUT IT …

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MY 2003 EXPEDITION HAD A CRACK IN THE OVERHEAD CONSOLE WHEN I PURCHASED IT USED IN 2004. I DIDN'T SEE IT AT THE TIME OF PURCHASE AND DIDN'T THINK THAT MUCH OF IT WHEN I DID DISCOVER THE CRACK. IN THE PAST YEAR AND A HALF THE CONSOLE HAS SIMPLY CRACKED APART AND THE PLASTIC IS VERY BRITTLE. I'VE GLUED IT A NUMBER OF TIMES BUT IT KEEPS CRACKING APART IN DIFFERENT PLACES. I'VE CALLED THE PARTS DEPARTMENT AT MY LOCAL FORD DEALER AND THEY TELL ME THAT I CANNOT PURCHASE THE HOUSING FOR THE OVERHEAD CONSOLE SEPARATELY. THEREFORE, I MUST PURCHASE AN ENTIRE NEW CONSOLE PACKAGE INCLUDING THE LIGHTS, SWITCH, ETC. ACCORDING TO THE DEALER, THIS PART WILL COST ME APPROXIMATELY $450.00 NOT INCLUDING ANY INSTALLATION LABOR. I DON'T NEED THE LIGHTS, SWITCH, MIRROR, ETC., BECAUSE THOSE PARTS ARE ALL FUNCTIONAL AND FINE. ALL I NEED IS THE HOUSING. THE PART CANT BE WORTH MORE THAN $10.00, ESPECIALLY WHEN YOU CONSIDER HOW EASILY IT BROKE INTO PIECES. I DON'T KNOW IF THIS PROBLEM IS PREVALENT IN OTHER EXPEDITIONS, BUT I SHOULD NOT BE FORCED TO PAY OVER $500.00 (PARTS AND LABOR) FOR A SMALL, CHEAP PIECE OF PLASTIC. *NM

NHTSA ODI #10162791

65,000 miles · Jul 11, 2006
Latches/locks/linkages

WE OWN A 2003 FORD EXPEDITION. THE CHILD-LOCK ON DRIVER SIDE STAYS IN THE LOCKED POSITION AND THE DOOR HAS TO BE MANUALLY OPENED FROM EXTERIOR. THE SAME DOOR WILL ONLY LOCK MANUALLY AND NOT BY AUTOMATION. CAUSING MY CHILDREN NOT TO WANT TO SIT BY THAT DOOR OUT OF FEAR OF NOT BEING ABLE TO GET OUT IN AN EMERGENCY. *JB

NHTSA ODI #10162150

Mileage unknown · Jun 24, 2006
Service Brakes, Hydraulic

MY BRAKES BEGAN TO SQUEAL AROUND 50K. THIS IS THE FIRST BRAKE SERVICING REQUIRED ON THIS VEHICLE. I WAS TOLD BY A NUMBER OF MECHANICS THAT THE FRONT ROTORS NEEDED TO BE REPLACED BECAUSE THEY WERE WORN DOWN TOO MUCH. I WAS SURPRISED ABOUT THIS AND FOUND THAT THIS IS A VERY WELL KNOWN AND COMMON PROBLEM WITH THE 2003 FORD EXPED…

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MY BRAKES BEGAN TO SQUEAL AROUND 50K. THIS IS THE FIRST BRAKE SERVICING REQUIRED ON THIS VEHICLE. I WAS TOLD BY A NUMBER OF MECHANICS THAT THE FRONT ROTORS NEEDED TO BE REPLACED BECAUSE THEY WERE WORN DOWN TOO MUCH. I WAS SURPRISED ABOUT THIS AND FOUND THAT THIS IS A VERY WELL KNOWN AND COMMON PROBLEM WITH THE 2003 FORD EXPEDITIONS. APPARENTLY, THESE ROTORS ARE NOT "DEFECTIVE" IN MATERIAL OR WORKMANSHIP OTHERWISE THERE WOULD BE A RECALL. THIS IS A PRIME EXAMPLE OF POOR DESIGN AND ENGINEERING. IT IS COMPLETELY RIDICULOUS TO EXPECT ANYONE TO BELIEVE IT IS NORMAL TO REPLACE BRAKE ROTORS ON EACH BRAKE PAD CHANGE. I HAVE BOUGHT AMERICAN MADE VEHICLES MY ENTIRE LIFE. I WAS ALWAYS TOLD THAT THE FOREIGN CARS WERE JUNK AND COST A LOT OF MONEY TO MAINTAIN. OVER THE YEARS I HAVE SPENT MUCH MONEY AND TIME REPAIRING MY AMERICAN MADE CARS. I HAD BOUGHT THE CHEAPEST CAR I COULD FIND BACK IN 2000. A HYUNDAI ELANTRA. I HAVE HAD ZERO PROBLEMS. NOT A SINGLE ONE. THE MILEAGE IS OVER 100K AND I HAVEN'T EVEN NEEDED TO CHANGE THE BRAKE PADS. THIS CAR WAS THE ABSOLUTE CHEAPEST CAR I COULD FIND ON THE MARKET IN 2000. I WILL TAKE THIS AS AN ILLUSTRATION OF HOW POORLY THE FORD LINE OF PRODUCTS ARE EITHER DESIGNED OR BACKED UP BY THE MANUFACTURER. *JB

NHTSA ODI #10160667

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.