IllustrationWITH NO WARNING, OUR VAN WOULD NOT GO INTO ANY GEAR. WE WERE FORTUNATE TO BE JUST PULLING AWAY WHEN TRANSMISSION DISENGAGED AND NOT ON THE HIGHWAY. AFTER INVESTIGATING PROBLEM, SEEMS MECHANIC WILL HAVE TO REPLACE/REBUILD TRANSMISSION. *TR
2004 Mercury Monterey
Owner reports · Recalls · Investigations
Limited comparison data
There is not enough comparable history to draw a useful model-year comparison.
About this comparison →How this year compares
Owner complaints by model year
Compare all Monterey years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
60–25K
3525–50K
8250–75K
6275–100K
71100–150K
16150K+
272 reports with mileage · 11 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.
- Power Train. Review the 203 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Structure. Review the 19 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Seats. Review the 16 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
2 crash reports6 fire reports1 injury reports
What owners actually said
283 reportsMY FAMILY OWNS A 2004 MERCURY MONTEREY. WHILE DRIVING THROUGH MOUNTAINOUS HIGHWAY CONDITIONS, OUR TRANSMISSION FAILED. EVEN THOUGH THE DASH HAS WARNING LIGHTS, THERE WAS NO WARNING WHEN WE LOST ALL MOTIVE POWER AT HIGHWAY SPEEDS. WE WERE FORTUNATE TO MAKE IT TO THE SIDE OF THE ROAD WITHOUT BEING RUN DOWN BY THE NUMEROUS SEMI …
Read full complaint
MY FAMILY OWNS A 2004 MERCURY MONTEREY. WHILE DRIVING THROUGH MOUNTAINOUS HIGHWAY CONDITIONS, OUR TRANSMISSION FAILED. EVEN THOUGH THE DASH HAS WARNING LIGHTS, THERE WAS NO WARNING WHEN WE LOST ALL MOTIVE POWER AT HIGHWAY SPEEDS. WE WERE FORTUNATE TO MAKE IT TO THE SIDE OF THE ROAD WITHOUT BEING RUN DOWN BY THE NUMEROUS SEMI TRUCKS THAT WERE CLOSE ON OUR TAIL PIPE GOING UP A HILL. WE WERE MORE THAN 100 MILES FROM HOME, SO DECIDED TO GET THE REPAIRS DONE IN THE NEAREST LARGE CITY. WE WERE TOLD THE TRANSMISSION WAS USELESS AND WE NEEDED TO REPLACE IT OR HAVE IT REBUILT. OUR VEHICLE HAD 105K MILES WHEN THIS BREAK-DOWN OCCURRED. THE MECHANIC FOUND A SUITABLE REPLACEMENT TRANSMISSION FROM A VEHICLE THAT HAD BEEN IN A REAR-END COLLISION, AND IT ONLY HAD 38K MILES. WE CHOSE TO HAVE THE TRANSMISSION REPLACED WITH THE USED PART THAT ONLY HAD 38K MILES. OF COURSE, THE MECHANIC KEPT ALL THE OLD PARTS, AND I WAS NEVER IN A POSITION TO SEE THE WORK IN PROGRESS. I WAS NOT GIVEN ANY SPECIFIC INFORMATION ABOUT THE OTHER VEHICLE'S MAKE AND MODEL OTHER THAN THE FACT THAT IT WAS NOT A MERCURY MONTEREY. AFTER DOING SOME RESEARCH, I NOW HAVE CONCLUDED THAT IT WAS MOST LIKELY A FORD FREESTAR TRANSMISSION WE RECEIVED AS A REPLACEMENT PART. IT HAS BEEN 2-1/2 YEARS AND 22K MORE MILES SINCE THIS INCIDENT (EQUALING 60K TOTAL MILES ON THE REPLACEMENT TRANSMISSION), AND WE ARE NOW TAKING THIS VEHICLE BACK INTO THE SHOP AGAIN BECAUSE OF MORE TRANSMISSION PROBLEMS. IS THERE ANYTHING ANYONE CAN DO? *TR
TL*THE CONTACT OWNS A 2004 MERCURY MONTEREY. WHILE DRIVING AT 35 MPH, THE TRANS AXLE LIGHT ILLUMINATED WHICH INDICATED THAT THERE WAS A FAILURE WITHIN THE AUTOMATIC TRANSMISSION. THE TORQUE CONVERTER OUTPUT SHAFT LINES WERE STRIPPING WHICH CAUSED A SUDDEN LOSS OF POWER TO THE DRIVETRAIN. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DE…
Read full complaint
TL*THE CONTACT OWNS A 2004 MERCURY MONTEREY. WHILE DRIVING AT 35 MPH, THE TRANS AXLE LIGHT ILLUMINATED WHICH INDICATED THAT THERE WAS A FAILURE WITHIN THE AUTOMATIC TRANSMISSION. THE TORQUE CONVERTER OUTPUT SHAFT LINES WERE STRIPPING WHICH CAUSED A SUDDEN LOSS OF POWER TO THE DRIVETRAIN. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALERSHIP WHERE THE TORQUE CONVERTER AND TORQUE CONVERTER CLUTCH WAS PARTIALLY REPLACED. THE FAILURE OCCURRED AGAIN; THE DEALER THEN STATED THAT THE ENTIRE TRANSMISSION NEEDED TO BE REPLACED. THE FAILURE MILEAGE WAS APPROXIMATELY 63,000. THE CURRENT MILEAGE WAS APPROXIMATELY 100,370.
TL*THE CONTACT OWNS A 2004 MERCURY MONTEREY. THE CONTACT STATED THAT WHILE DRIVING AT 65 MPH, THE LOWER PRESSURE WARNING LIGHT FOR THE TIRES FLASHED ON THE INSTRUMENT PANEL. THE CONTACT PULLED OVER TO CHECK THE FRONT DRIVER SIDE TIRE AND ATTEMPTED TO ADD AIR BUT THE AIR WAS RELEASED AS IT WAS ADDED. WHEN THE CONTACT TRIED TO CHA…
Read full complaint
TL*THE CONTACT OWNS A 2004 MERCURY MONTEREY. THE CONTACT STATED THAT WHILE DRIVING AT 65 MPH, THE LOWER PRESSURE WARNING LIGHT FOR THE TIRES FLASHED ON THE INSTRUMENT PANEL. THE CONTACT PULLED OVER TO CHECK THE FRONT DRIVER SIDE TIRE AND ATTEMPTED TO ADD AIR BUT THE AIR WAS RELEASED AS IT WAS ADDED. WHEN THE CONTACT TRIED TO CHANGE THE TIRE WITH THE MANUFACTURER JACK, THE JACK BEGAN TO BEND AND SHIFT TO THE LEFT WHICH CAUSED THE VEHICLE TO FALL OFF THE JACK. HOWEVER, THERE WAS NO DAMAGE TO THE VEHICLE. THE CONTACT CALLED THE MANUFACTURER AND WAS TOLD THAT THEY COULD NOT ASSIST HER AS THE VEHICLE WAS NO LONGER UNDER WARRANTY. THE CONTACT BELIEVED THAT THE JACK WAS FAULTY AND NOT DESIGNED TO HOLD THE WEIGHT OF THE VEHICLE. THE FAILURE MILEAGE WAS APPROXIMATELY 117,000. UPDATED 11/03/10. *LJ UPDATED 11/19/10.*LJ UPDATED 12/01/10*JB UPDATED 05/26/11 *BF UPDATED 12/30/11 *CN
TL*THE CONTACT OWNS A 2004 MERCURY MONTEREY. THE CONTACT NOTICED THAT THE FRONT END OF THE VEHICLE WAS MAKING NOISE. THE VEHICLE WAS TAKEN TO A REPAIR SHOP WHERE THE CONTACT WAS INFORMED THAT THE FRONT WHEEL HUB ASSEMBLY WAS DEFECTIVE. THE VEHICLE WAS THEN TAKEN TO AN AUTHORIZED DEALERSHIP WHERE THE CONTACT WAS TOLD THAT THE VEH…
Read full complaint
TL*THE CONTACT OWNS A 2004 MERCURY MONTEREY. THE CONTACT NOTICED THAT THE FRONT END OF THE VEHICLE WAS MAKING NOISE. THE VEHICLE WAS TAKEN TO A REPAIR SHOP WHERE THE CONTACT WAS INFORMED THAT THE FRONT WHEEL HUB ASSEMBLY WAS DEFECTIVE. THE VEHICLE WAS THEN TAKEN TO AN AUTHORIZED DEALERSHIP WHERE THE CONTACT WAS TOLD THAT THE VEHICLE WAS NOT INCLUDED IN RECALL 04V446000 (WHEELS: CAP/COVER/HUB). THE DEALER REPLACED THE LEFT FRONT HUB BEARING UNDER THE WARRANTY. THE CONTACT CALLED THE MANUFACTURER AND FILED A COMPLAINT; THE MANUFACTURER STATED THAT THEY WOULD NOT ASSIST WITH THE ADDITIONAL REPAIRS AS THE VEHCIEL WAS NO LONGER UNDER WARRANTY. THE FAILURE MILEAGE WAS APPROXIMATELY 63,000. THE CURRENT MILEAGE WAS 63,057.
WE HAVE A 2004 MERCURY MONTEREY WITH A LITTLE OVER 50K MILES AND MY HUSBAND WAS TRAVELING OUT OF STATE AND AFTER A FEW HOURS OF DRIVING ON THE HIGHWAY THE TRANSMISSION STOPPED WORKING. HE IS NOW STRANDED IN ANOTHER STATE 5 HOURS FROM HOME AND 6 HOURS FROM HIS DESTINATION WITH 3 CHILDREN. SOMETHING HAS TO BE DONE ABOUT THIS. *TR
WHILE DRIVING MY DAUGHTER TO SCHOOL THIS MORNING, I FELT LIKE THE ACCELERATOR SEEMED TO SLIP, I HAD TO STOP FOR A BUS STOP AS THIS HAPPENED. WHEN THE BUS MOVED AND I COULD GO I PUSHED THE GAS AND THE ENGINE REVVED BUT THE CAR WOULDN'T MOVE. THERE WERE NUMEROUS CARS BEHIND ME ON A NARROW TWO LANE ROAD. FORTUNATELY A GENTLEMAN …
Read full complaint
WHILE DRIVING MY DAUGHTER TO SCHOOL THIS MORNING, I FELT LIKE THE ACCELERATOR SEEMED TO SLIP, I HAD TO STOP FOR A BUS STOP AS THIS HAPPENED. WHEN THE BUS MOVED AND I COULD GO I PUSHED THE GAS AND THE ENGINE REVVED BUT THE CAR WOULDN'T MOVE. THERE WERE NUMEROUS CARS BEHIND ME ON A NARROW TWO LANE ROAD. FORTUNATELY A GENTLEMAN OFFERED TO PUSH ME OFF THE ROAD, I THOUGHT I WAS GOING TO HAVE TO HAVE A TWELVE YEAR OLD BOY GET BEHIND THE WHEEL SO I COULD PUSH THE VAN OFF THE ROAD. I HAD TO HAVE THE VAN TOWED HOME, AND AM CURRENTLY TRYING TO FIGURE OUT WHAT TO DO. I JUST HAD TO HAVE THE COMPRESSOR AND FAN REPLACED ON THIS VEHICLE. THIS IS JUST ONE MORE PROBLEM IN A LONG LINE OF PROBLEMS I HAVE HAD WITH THIS VAN. THIS IS THE WORST CAR I HAVE EVER OWNED. BASED ON THE COMPLAINTS I'VE NOW FOUND ON THIS VAN SAME YEAR AND MODEL I BELIEVE MY NEXT STEP IS TO CONTACT MY SENATOR, THIS RANKS RIGHT UP THERE WITH THE TOYOTA RECALLS. I'M FRANKLY VERY SURPRISED THERE HAVE BEEN NO RECALLS YET FOR THIS LEMON. I THOUGHT I WAS JUST UNLUCKY BUT I SEE I'M FAR FROM THE ONLY ONE SUFFERING FROM THESE PROBLEMS. BY THE WAY THIS VAN HAS APPROXIMATELY 94K MILES. NOT WHAT I WOULD CALL HIGH MILEAGE. *TR
GOING UP A HILL (56 MPH ZONE) ON A CLEAR SUNNY DAY, LIGHT TRAFFIC. ON THE WAY DOWN OUR 2004 MERCURY MONTEREY VAN WAS PLACED INTO CRUISE CONTROL. AFTER A MINUTE RPM SHOT UP AND LOST MOMENTUM, COASTED TO RIGHT SHOULDER, ALL OF THE TRANSMISSION FLUID SPILLED OVER THE ROAD AND INTO OTHER VEHICLES. FIRST OCCURRENCE, NO WARNING, …
Read full complaint
GOING UP A HILL (56 MPH ZONE) ON A CLEAR SUNNY DAY, LIGHT TRAFFIC. ON THE WAY DOWN OUR 2004 MERCURY MONTEREY VAN WAS PLACED INTO CRUISE CONTROL. AFTER A MINUTE RPM SHOT UP AND LOST MOMENTUM, COASTED TO RIGHT SHOULDER, ALL OF THE TRANSMISSION FLUID SPILLED OVER THE ROAD AND INTO OTHER VEHICLES. FIRST OCCURRENCE, NO WARNING, NO ACCIDENT DUE TO LIGHT TRAFFIC. STRANDED ABOUT 40 MILES AWAY FROM HOME VEHICLE TOWED TO A DEALERSHIP. TRANSMISSION REPLACED. *TR
NO PRIOR WARNING, WORKING FINE THEN NOT WORKING AT ALL... WILL NOT GO INTO GEAR (ENGINE WILL REV, YOU CAN SHIFT TO REVERSE, OR DRIVE BUT NOTHING). TRANSMISSION FAILURE ON MY MERCURY MONTEREY 2004. I HAVE NOT CORRECTED THE PROBLEM AS OF YET DEALERSHIP SAYS NEW TRANSMISSION COST IS $3500. *TR
TL* THE CONTACT OWNS A 2004 MERCURY MONTEREY. THE CONTACT APPLIED THE BRAKES AT SPEEDS OF 30 MPH. SHE THEN ATTEMPTED TO REGAIN SPEED BUT THE VEHICLE WOULD NOT ACCELERATE. THE VEHICLE WAS TOWED TO HER RESIDENCE AND THEN TO AN INDEPENDENT MECHANIC. THE MECHANIC STATED THAT THE TRANSMISSION HAD FAILED AND WOULD NEED TO BE REPLACED…
Read full complaint
TL* THE CONTACT OWNS A 2004 MERCURY MONTEREY. THE CONTACT APPLIED THE BRAKES AT SPEEDS OF 30 MPH. SHE THEN ATTEMPTED TO REGAIN SPEED BUT THE VEHICLE WOULD NOT ACCELERATE. THE VEHICLE WAS TOWED TO HER RESIDENCE AND THEN TO AN INDEPENDENT MECHANIC. THE MECHANIC STATED THAT THE TRANSMISSION HAD FAILED AND WOULD NEED TO BE REPLACED. THE FAILURE AND CURRENT MILEAGES WERE APPROXIMATELY 51,000.
Official recalls
413V081000 · Seats
Mar 7, 2013
Ford is recalling certain model year 2004-2007 Freestar and Mercury Monterey vehicles manufactured from March 24, 2003, through November 7, 2006, equipped with a third row seat and originally sold in, or currently registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin and the District of Columbia. The third row stowable seat can experience corrosion and structural degradation at the seat anchor mechanism mounted to the rear wheel wells. As a result of the corrosion, the third row seat may not fully latch into its seating position.
Consequence & remedy
Consequence: In the event that the vehicle is crashed into from the rear, an unlatched seat may increase the risk of personal injury.
Remedy: Ford will notify owners, and dealers will install new third row seat latch striker mounting brackets, free of charge. The recall began on March 28, 2013. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332.
12V006000 · Power Train:automatic Transmission; Power Train:automatic Transmission:torque Converter
Jan 9, 2012
FORD IS RECALLING CERTAIN MODEL YEAR 2004 AND 2005 FORD FREESTAR AND MERCURY MONTEREY VEHICLES. THE TORQUE CONVERTER OUTPUT SHAFT MAY FAIL.
Consequence & remedy
Consequence: THIS CONDITION RESULTS IN A SUDDEN LOSS OF MOTIVE POWER WITH NO WARNING, INCREASING THE RISK OF A CRASH.
Remedy: FORD WILL NOTIFY OWNERS, AND DEALERS WILL REPLACE THE TORQUE CONVERTER FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 9, 2012. OWNERS MAY CONTACT THE FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.
Additional source detail variants (2)
Power Train:automatic Transmission:torque Converter
FORD IS RECALLING CERTAIN MODEL YEAR 2004 AND 2005 FORD FREESTAR AND MERCURY MONTEREY VEHICLES. THE TORQUE CONVERTER OUTPUT SHAFT MAY FAIL.
Consequence: THIS CONDITION RESULTS IN A SUDDEN LOSS OF MOTIVE POWER WITH NO WARNING, INCREASING THE RISK OF A CRASH.
Remedy: FORD WILL NOTIFY OWNERS, AND DEALERS WILL REPLACE THE TORQUE CONVERTER FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 9, 2012. OWNERS MAY CONTACT THE FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.
Power Train:automatic Transmission
FORD IS RECALLING CERTAIN MODEL YEAR 2004 AND 2005 FORD FREESTAR AND MERCURY MONTEREY VEHICLES. THE TORQUE CONVERTER OUTPUT SHAFT MAY FAIL.
Consequence: THIS CONDITION RESULTS IN A SUDDEN LOSS OF MOTIVE POWER WITH NO WARNING, INCREASING THE RISK OF A CRASH.
Remedy: FORD WILL NOTIFY OWNERS, AND DEALERS WILL REPLACE THE TORQUE CONVERTER FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 9, 2012. OWNERS MAY CONTACT THE FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.
04V446000 · Wheels:hub
Sep 13, 2004
CERTAIN MINIVANS MAY HAVE BEEN PRODUCED WITH FRONT WHEEL HUB ASSEMBLIES THAT WERE NOT HEAT TREATED CORRECTLY. THIS CONDITION MAY LEAD TO THE DEVELOPMENT OF SMALL CRACKS IN THE HUB.
Consequence & remedy
Consequence: IF THE CRACKS WERE TO PROGRESS, THIS COULD EVENTUALLY RESULT IN WHEEL SEPARATION. WHEEL SEPARATION MAY LEAD TO LOSS OF VEHICLE CONTROL, AND POTENTIALLY RESULT IN A VEHICLE CRASH.
Remedy: DEALERS WILL REPLACE THE FRONT HUB, ROTORS, AND WHEEL BEARINGS. THE RECALL BEGAN SEPTEMBER 20, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.
03V457000 · Steering:hydraulic Power Assist:hose, Piping, And Connections
Nov 6, 2003
ON CERTAIN MINIVANS, THE POWER STEERING LOW-PRESSURE LINE MAY NOT BE FULLY SEATED AT THE RACK AND PINION STEERING GEAR.
Consequence & remedy
Consequence: IF THIS LINE BECOMES DISCONNECTED, IT MAY CREATE THE POTENTIAL FOR FLUID TO COME INTO CONTACT WITH THE EXHAUST SYSTEM, WHICH COULD RESULT IN SMOKE OR FIRE.
Remedy: DEALERS WILL INSPECT THE POWER STEERING LOW-PRESSURE LINE TO ENSURE THAT IT IS SEATED PROPERLY AT THE RACK AND PINION STEERING GEAR. OWNER NOTIFICATION BEGAN NOVEMBER 10, 2003. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.
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
7EQ12010 · Stabilus Rear Liftgate Struts Failing
Opened Sep 28, 2012 · Closed Dec 31, 2012
Status: closed (inferred from source dates) · Structure:body:hatchback/liftgate:support Device/strut
Please see the attached closing resume summary.It has been attached to this document as a PDF.
EA12003 · Corrosion Of Third-Row Seat Attachment
Opened Apr 23, 2012 · Closed May 2, 2013
Status: closed (inferred from source dates) · Seats; Seats:mid/rear Assembly; Structure; Structure:body
Ford is conducting a safety recall to repair the third-row seat's latch mechanisms in approximately 196,667 model year (MY) 2004 through 2007 Ford Freestar and Mercury Monterey vehicles (see NHTSA recall 13V-081 for more details).The recall covers vehicles originally sold, or currently registered, in the salt belt states or high corrosion areas of the United States: Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin.Approximately 100,000 remaining MY 2004-2007 Freestar and Monterey vehicles--those vehicles that were not originally sold, or are not currently registered, in salt belt states--are not included in the recall action. Although these vehicles are the same as the ones described above, they experience significantly lower failure rates because of reduced road salt exposure.ODI is currently aware of only one complaint on vehicle outside of the recall scope.ODI will monitor complaints and take further action if warranted by the circumstances.For owners of vehicles that are outside of the recall scope but exhibit the defect condition, owners (and affected Ford dealers) can contact Ford to request the recall repair.This Engineering Analysis is closed.See attached report and associated recall file for additional information.The ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10399896, 10410491, 10420028, 10424850, 10433928, 10436592, 10438529, 10440616, 10441489, 10441641, 10442809, 10446564, 10450295, 10450559, 10450587, 10452933, 10453826, 10454977, 10455545, 10456985, 10457423, 10457910, 10458738, 10459042, 10460511, 10461074, 10462910, 10463126, 10463262, 10463366, 10463600, 10464243, 10467003, 10467680, 10468429, 10469188, 10469200, 10470216, 10470510, 10471280, 10471520, 10471813, 10471978, 10472514, 10473087, 10473159, 10477025, 10477387, 10477954, 10478449, 10479247, 10479758, 10480611, 10480665, 10481054, 10481412, 10482213, 10482236, 10482613, 10482620, 10487872, 10489445, 10490515, 10490641, 10490663, 10490744, 10491495, 10492220, 10493470, 10493572, 10496348, 10497631, 10497976, 10498310, 10498433, 10499681, 10499861, 10500495.
Additional source detail variants (4)
Seats
Ford is conducting a safety recall to repair the third-row seat's latch mechanisms in approximately 196,667 model year (MY) 2004 through 2007 Ford Freestar and Mercury Monterey vehicles (see NHTSA recall 13V-081 for more details).The recall covers vehicles originally sold, or currently registered, in the salt belt states or high corrosion areas of the United States: Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin.Approximately 100,000 remaining MY 2004-2007 Freestar and Monterey vehicles--those vehicles that were not originally sold, or are not currently registered, in salt belt states--are not included in the recall action. Although these vehicles are the same as the ones described above, they experience significantly lower failure rates because of reduced road salt exposure.ODI is currently aware of only one complaint on vehicle outside of the recall scope.ODI will monitor complaints and take further action if warranted by the circumstances.For owners of vehicles that are outside of the recall scope but exhibit the defect condition, owners (and affected Ford dealers) can contact Ford to request the recall repair.This Engineering Analysis is closed.See attached report and associated recall file for additional information.The ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10399896, 10410491, 10420028, 10424850, 10433928, 10436592, 10438529, 10440616, 10441489, 10441641, 10442809, 10446564, 10450295, 10450559, 10450587, 10452933, 10453826, 10454977, 10455545, 10456985, 10457423, 10457910, 10458738, 10459042, 10460511, 10461074, 10462910, 10463126, 10463262, 10463366, 10463600, 10464243, 10467003, 10467680, 10468429, 10469188, 10469200, 10470216, 10470510, 10471280, 10471520, 10471813, 10471978, 10472514, 10473087, 10473159, 10477025, 10477387, 10477954, 10478449, 10479247, 10479758, 10480611, 10480665, 10481054, 10481412, 10482213, 10482236, 10482613, 10482620, 10487872, 10489445, 10490515, 10490641, 10490663, 10490744, 10491495, 10492220, 10493470, 10493572, 10496348, 10497631, 10497976, 10498310, 10498433, 10499681, 10499861, 10500495.
Seats:mid/rear Assembly
Ford is conducting a safety recall to repair the third-row seat's latch mechanisms in approximately 196,667 model year (MY) 2004 through 2007 Ford Freestar and Mercury Monterey vehicles (see NHTSA recall 13V-081 for more details).The recall covers vehicles originally sold, or currently registered, in the salt belt states or high corrosion areas of the United States: Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin.Approximately 100,000 remaining MY 2004-2007 Freestar and Monterey vehicles--those vehicles that were not originally sold, or are not currently registered, in salt belt states--are not included in the recall action. Although these vehicles are the same as the ones described above, they experience significantly lower failure rates because of reduced road salt exposure.ODI is currently aware of only one complaint on vehicle outside of the recall scope.ODI will monitor complaints and take further action if warranted by the circumstances.For owners of vehicles that are outside of the recall scope but exhibit the defect condition, owners (and affected Ford dealers) can contact Ford to request the recall repair.This Engineering Analysis is closed.See attached report and associated recall file for additional information.The ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10399896, 10410491, 10420028, 10424850, 10433928, 10436592, 10438529, 10440616, 10441489, 10441641, 10442809, 10446564, 10450295, 10450559, 10450587, 10452933, 10453826, 10454977, 10455545, 10456985, 10457423, 10457910, 10458738, 10459042, 10460511, 10461074, 10462910, 10463126, 10463262, 10463366, 10463600, 10464243, 10467003, 10467680, 10468429, 10469188, 10469200, 10470216, 10470510, 10471280, 10471520, 10471813, 10471978, 10472514, 10473087, 10473159, 10477025, 10477387, 10477954, 10478449, 10479247, 10479758, 10480611, 10480665, 10481054, 10481412, 10482213, 10482236, 10482613, 10482620, 10487872, 10489445, 10490515, 10490641, 10490663, 10490744, 10491495, 10492220, 10493470, 10493572, 10496348, 10497631, 10497976, 10498310, 10498433, 10499681, 10499861, 10500495.
Structure:body
Ford is conducting a safety recall to repair the third-row seat's latch mechanisms in approximately 196,667 model year (MY) 2004 through 2007 Ford Freestar and Mercury Monterey vehicles (see NHTSA recall 13V-081 for more details).The recall covers vehicles originally sold, or currently registered, in the salt belt states or high corrosion areas of the United States: Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin.Approximately 100,000 remaining MY 2004-2007 Freestar and Monterey vehicles--those vehicles that were not originally sold, or are not currently registered, in salt belt states--are not included in the recall action. Although these vehicles are the same as the ones described above, they experience significantly lower failure rates because of reduced road salt exposure.ODI is currently aware of only one complaint on vehicle outside of the recall scope.ODI will monitor complaints and take further action if warranted by the circumstances.For owners of vehicles that are outside of the recall scope but exhibit the defect condition, owners (and affected Ford dealers) can contact Ford to request the recall repair.This Engineering Analysis is closed.See attached report and associated recall file for additional information.The ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10399896, 10410491, 10420028, 10424850, 10433928, 10436592, 10438529, 10440616, 10441489, 10441641, 10442809, 10446564, 10450295, 10450559, 10450587, 10452933, 10453826, 10454977, 10455545, 10456985, 10457423, 10457910, 10458738, 10459042, 10460511, 10461074, 10462910, 10463126, 10463262, 10463366, 10463600, 10464243, 10467003, 10467680, 10468429, 10469188, 10469200, 10470216, 10470510, 10471280, 10471520, 10471813, 10471978, 10472514, 10473087, 10473159, 10477025, 10477387, 10477954, 10478449, 10479247, 10479758, 10480611, 10480665, 10481054, 10481412, 10482213, 10482236, 10482613, 10482620, 10487872, 10489445, 10490515, 10490641, 10490663, 10490744, 10491495, 10492220, 10493470, 10493572, 10496348, 10497631, 10497976, 10498310, 10498433, 10499681, 10499861, 10500495.
Structure
Ford is conducting a safety recall to repair the third-row seat's latch mechanisms in approximately 196,667 model year (MY) 2004 through 2007 Ford Freestar and Mercury Monterey vehicles (see NHTSA recall 13V-081 for more details).The recall covers vehicles originally sold, or currently registered, in the salt belt states or high corrosion areas of the United States: Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin.Approximately 100,000 remaining MY 2004-2007 Freestar and Monterey vehicles--those vehicles that were not originally sold, or are not currently registered, in salt belt states--are not included in the recall action. Although these vehicles are the same as the ones described above, they experience significantly lower failure rates because of reduced road salt exposure.ODI is currently aware of only one complaint on vehicle outside of the recall scope.ODI will monitor complaints and take further action if warranted by the circumstances.For owners of vehicles that are outside of the recall scope but exhibit the defect condition, owners (and affected Ford dealers) can contact Ford to request the recall repair.This Engineering Analysis is closed.See attached report and associated recall file for additional information.The ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10399896, 10410491, 10420028, 10424850, 10433928, 10436592, 10438529, 10440616, 10441489, 10441641, 10442809, 10446564, 10450295, 10450559, 10450587, 10452933, 10453826, 10454977, 10455545, 10456985, 10457423, 10457910, 10458738, 10459042, 10460511, 10461074, 10462910, 10463126, 10463262, 10463366, 10463600, 10464243, 10467003, 10467680, 10468429, 10469188, 10469200, 10470216, 10470510, 10471280, 10471520, 10471813, 10471978, 10472514, 10473087, 10473159, 10477025, 10477387, 10477954, 10478449, 10479247, 10479758, 10480611, 10480665, 10481054, 10481412, 10482213, 10482236, 10482613, 10482620, 10487872, 10489445, 10490515, 10490641, 10490663, 10490744, 10491495, 10492220, 10493470, 10493572, 10496348, 10497631, 10497976, 10498310, 10498433, 10499681, 10499861, 10500495.
PE11039 · Corrosion Of Third-Row Seat Attachment
Opened Dec 21, 2011 · Closed Apr 27, 2012
Status: closed (inferred from source dates) · Latches/locks/linkages; Seats; Seats:mid/rear Assembly; Structure; Structure:body
ODI has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells.Additionally, ODI identified 4 similar reports from Ford's response to the investigation.Ford submitted a total of 10 reports to ODI (6 of 10 Ford reports are duplicates of ODI reports).The complaints indicated difficulty or inability to latch the rear seat as some of the complaints reported the entire anchor plate completely detached from the vehicle (rear wheel well).The first report of this condition was received in March 2011 and subsequent reporting frequency indicates a potentially increasing trend over time.ODI seeks to evaluate the potential occupant safety risks resulting from structurally degraded seat anchorages.In addition to the subject vehicles, ODI also will collect and review information on MY 2005-2007 Freestar/Monterey vehicles that appear to have a seat design identical to the subject vehicles.To date, ODI is not aware of any similar complaints on the MY 2005-2007 vehicles.ODI also will collect and review information on Freestar/Monterey vehicles used outside of the salt belt states.This Preliminary Evaluation has been upgraded to an Engineering Analysis (EA12-003) to further assess whether a safety defect exists in the subject vehicles.The ODI reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10454977, 10453826, 10452933, 10450587, 10450559, 10450295, 10446564, 10442809, 10441641, 10441489, 10440616, 10438529, 10436592, 10433928, 10424850, 10420028, 10410491 and 10399896.
Additional source detail variants (5)
Latches/locks/linkages
ODI has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells.Additionally, ODI identified 4 similar reports from Ford's response to the investigation.Ford submitted a total of 10 reports to ODI (6 of 10 Ford reports are duplicates of ODI reports).The complaints indicated difficulty or inability to latch the rear seat as some of the complaints reported the entire anchor plate completely detached from the vehicle (rear wheel well).The first report of this condition was received in March 2011 and subsequent reporting frequency indicates a potentially increasing trend over time.ODI seeks to evaluate the potential occupant safety risks resulting from structurally degraded seat anchorages.In addition to the subject vehicles, ODI also will collect and review information on MY 2005-2007 Freestar/Monterey vehicles that appear to have a seat design identical to the subject vehicles.To date, ODI is not aware of any similar complaints on the MY 2005-2007 vehicles.ODI also will collect and review information on Freestar/Monterey vehicles used outside of the salt belt states.This Preliminary Evaluation has been upgraded to an Engineering Analysis (EA12-003) to further assess whether a safety defect exists in the subject vehicles.The ODI reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10454977, 10453826, 10452933, 10450587, 10450559, 10450295, 10446564, 10442809, 10441641, 10441489, 10440616, 10438529, 10436592, 10433928, 10424850, 10420028, 10410491 and 10399896.
Seats
ODI has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells.Additionally, ODI identified 4 similar reports from Ford's response to the investigation.Ford submitted a total of 10 reports to ODI (6 of 10 Ford reports are duplicates of ODI reports).The complaints indicated difficulty or inability to latch the rear seat as some of the complaints reported the entire anchor plate completely detached from the vehicle (rear wheel well).The first report of this condition was received in March 2011 and subsequent reporting frequency indicates a potentially increasing trend over time.ODI seeks to evaluate the potential occupant safety risks resulting from structurally degraded seat anchorages.In addition to the subject vehicles, ODI also will collect and review information on MY 2005-2007 Freestar/Monterey vehicles that appear to have a seat design identical to the subject vehicles.To date, ODI is not aware of any similar complaints on the MY 2005-2007 vehicles.ODI also will collect and review information on Freestar/Monterey vehicles used outside of the salt belt states.This Preliminary Evaluation has been upgraded to an Engineering Analysis (EA12-003) to further assess whether a safety defect exists in the subject vehicles.The ODI reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10454977, 10453826, 10452933, 10450587, 10450559, 10450295, 10446564, 10442809, 10441641, 10441489, 10440616, 10438529, 10436592, 10433928, 10424850, 10420028, 10410491 and 10399896.
Seats:mid/rear Assembly
ODI has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells.Additionally, ODI identified 4 similar reports from Ford's response to the investigation.Ford submitted a total of 10 reports to ODI (6 of 10 Ford reports are duplicates of ODI reports).The complaints indicated difficulty or inability to latch the rear seat as some of the complaints reported the entire anchor plate completely detached from the vehicle (rear wheel well).The first report of this condition was received in March 2011 and subsequent reporting frequency indicates a potentially increasing trend over time.ODI seeks to evaluate the potential occupant safety risks resulting from structurally degraded seat anchorages.In addition to the subject vehicles, ODI also will collect and review information on MY 2005-2007 Freestar/Monterey vehicles that appear to have a seat design identical to the subject vehicles.To date, ODI is not aware of any similar complaints on the MY 2005-2007 vehicles.ODI also will collect and review information on Freestar/Monterey vehicles used outside of the salt belt states.This Preliminary Evaluation has been upgraded to an Engineering Analysis (EA12-003) to further assess whether a safety defect exists in the subject vehicles.The ODI reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10454977, 10453826, 10452933, 10450587, 10450559, 10450295, 10446564, 10442809, 10441641, 10441489, 10440616, 10438529, 10436592, 10433928, 10424850, 10420028, 10410491 and 10399896.
Structure:body
ODI has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells.Additionally, ODI identified 4 similar reports from Ford's response to the investigation.Ford submitted a total of 10 reports to ODI (6 of 10 Ford reports are duplicates of ODI reports).The complaints indicated difficulty or inability to latch the rear seat as some of the complaints reported the entire anchor plate completely detached from the vehicle (rear wheel well).The first report of this condition was received in March 2011 and subsequent reporting frequency indicates a potentially increasing trend over time.ODI seeks to evaluate the potential occupant safety risks resulting from structurally degraded seat anchorages.In addition to the subject vehicles, ODI also will collect and review information on MY 2005-2007 Freestar/Monterey vehicles that appear to have a seat design identical to the subject vehicles.To date, ODI is not aware of any similar complaints on the MY 2005-2007 vehicles.ODI also will collect and review information on Freestar/Monterey vehicles used outside of the salt belt states.This Preliminary Evaluation has been upgraded to an Engineering Analysis (EA12-003) to further assess whether a safety defect exists in the subject vehicles.The ODI reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10454977, 10453826, 10452933, 10450587, 10450559, 10450295, 10446564, 10442809, 10441641, 10441489, 10440616, 10438529, 10436592, 10433928, 10424850, 10420028, 10410491 and 10399896.
Structure
ODI has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells.Additionally, ODI identified 4 similar reports from Ford's response to the investigation.Ford submitted a total of 10 reports to ODI (6 of 10 Ford reports are duplicates of ODI reports).The complaints indicated difficulty or inability to latch the rear seat as some of the complaints reported the entire anchor plate completely detached from the vehicle (rear wheel well).The first report of this condition was received in March 2011 and subsequent reporting frequency indicates a potentially increasing trend over time.ODI seeks to evaluate the potential occupant safety risks resulting from structurally degraded seat anchorages.In addition to the subject vehicles, ODI also will collect and review information on MY 2005-2007 Freestar/Monterey vehicles that appear to have a seat design identical to the subject vehicles.To date, ODI is not aware of any similar complaints on the MY 2005-2007 vehicles.ODI also will collect and review information on Freestar/Monterey vehicles used outside of the salt belt states.This Preliminary Evaluation has been upgraded to an Engineering Analysis (EA12-003) to further assess whether a safety defect exists in the subject vehicles.The ODI reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10454977, 10453826, 10452933, 10450587, 10450559, 10450295, 10446564, 10442809, 10441641, 10441489, 10440616, 10438529, 10436592, 10433928, 10424850, 10420028, 10410491 and 10399896.
PE11033 · Service Jack Failure
Opened Sep 13, 2011 · Closed Dec 7, 2012
Status: closed (inferred from source dates) · Equipment:mechanical:accessory Scissor/screw/bottle Jack/lift
The subject vehicles (SV) are all automatic transmission, front wheel drive vehicles with hand actuated mechanical park brakes. The investigation focused on allegations that the service jack failed and caused the vehicles to fall. The subject scissors-type jack appears to fail at the slotted hinge joints where the jack screw is located (bends at mid-point). The failures occur while the jack is in use, and vehicle movement (forward or backward) is typically reported coincident with the failure. Ford reported that most MY 2003 Windstar and all MY 2006-2007 Freestar/Monterey also use the subject jack, an additional 223,246 vehicles.NHTSA has received six consumer complaints (VOQs) involving three injury incidents and a fatality.Ford reported 26 complaints for the SVs involving an additional 4 injuries. In the fatal incident, the van fell on a person working on the engine under the otherwise unsupported vehicle; ODI was unable to determine whether the vehicle was adequately chocked or the park brake was properly set. Reported injuries include a broken arm, head and hand injuries, arm and rib bruises, and muscle strains. NHTSA has received just one new report since opening this investigation. The complaint trend in ODI and Ford data is flat if not declining.Ford provides instructions and warnings in the owner's manual, on a placard placed with the jack, and on the jack itself. These instruct consumers to put the vehicle gear selector in Park, properly set the parking brake, chock the opposite wheel, use the jack only for changing a tire, loosen the lug nuts prior to jacking, and to not get under a vehicle supported by the jack only (NHTSA also recommends that jacks only be used for tire changing).In the VOQs, roughly half the consumers were using the jack for something other than tire changing, half had not chocked a wheel, and half had not properly set the parking brake. ODI notes that since the front wheels are drive wheels (with an open center differential) the Park gear cannot provide vehicle stability (longitudinally) when a front wheel is raised. All NHTSA complaints and most of the complaints to Ford involved failures while a front wheel was raised.In response to ODI's inquiry, Ford conducted testing on a 2004 Freestar. Ford's tests showed that when a front tire was raised the service jack held without failing under various scenarios except when a rocking force was applied and the parking brake was not properly set. Based on its testing and its analysis of field data, Ford concluded that the type of jack failure evidenced in this investigation (bending at mid-point) was likely caused by vehicle movement due to an improperly secured vehicle, or other misuse of the jack. Ford notes that rates in this investigation were similar to those in another investigation (EA91-049) which ODI closed. ODI also analyzed jack data for MY 2003 and newer vehicles to compare to the SV population. To assist with this analysis, ODI requested data from the jack manufacturer (actually its successor company) who provided limited data but did identify other models using the same design jack. ODI was unable to identify a significant difference in the incidence of jack failures (including those involving bending failures) between the SVs, other vehicles which used the same jack, or other vehicles where the jack type was unknown or different.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, investigation PE11-033 is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist and ODI reserves
PE10033 · Engine Stalling
Opened Aug 23, 2010 · Closed Jul 15, 2011
Status: closed (inferred from source dates) · Power Train:automatic Transmission:control Module (tcm/pcm/tecm); Vehicle Speed Control
The subject vehicles suffered from a design issue whereby water could run down onto the cowling under the hood and located in the area of the windshield wipers and then drip onto a computer module, the Powertrain Control Module (PCM), which could be manifested in a variety of symptoms depending on which part of the circuit board became wet or which of the connector pins shorted out.In addition to causing an engine to stall, which may or may not then restart, the water intrusion could also cause the transmission to shift poorly, the vehicle to have erratic power, a malfunction indicator light to come on, or result in an inability to start the vehicle, an inability to shift the vehicle into either forward or reverse. Also the problem could cause a higher than normal idle RPM in Park, or for the radio to malfunction, or the interior lights to stay on.During this investigation ODI was concerned with the effect of the engine stalling or a drastic and sudden loss of power either of which may create a safety risk.In reviewing the actual number of these types of incidents, collectively referred to here as engine stalls, the number was found to be below what would be considered a defect trend.For example, the number of engine stalls identified in Ford's warranty claims for the model year (MY) 2004 subject vehicles, the MY with the most failures, was 200 out of population of 125,865, for a failure rate of 0.16%.The one crash recorded by a complainant to NHTSA, VOQ 10311522, alleged that the engine stalled, due to water intrusion into the PCM, while the road was turning causing her to go off the road and according to the police report the vehicle then hit an embankment and a tree stump. Ford reported in their response that there were three alleged crashes but none of these were validated as being caused by a problem with water intrusion into the PCM causing a stall.Accordingly this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted.
Additional source detail variants (2)
Power Train:automatic Transmission:control Module (tcm/pcm/tecm)
The subject vehicles suffered from a design issue whereby water could run down onto the cowling under the hood and located in the area of the windshield wipers and then drip onto a computer module, the Powertrain Control Module (PCM), which could be manifested in a variety of symptoms depending on which part of the circuit board became wet or which of the connector pins shorted out.In addition to causing an engine to stall, which may or may not then restart, the water intrusion could also cause the transmission to shift poorly, the vehicle to have erratic power, a malfunction indicator light to come on, or result in an inability to start the vehicle, an inability to shift the vehicle into either forward or reverse. Also the problem could cause a higher than normal idle RPM in Park, or for the radio to malfunction, or the interior lights to stay on.During this investigation ODI was concerned with the effect of the engine stalling or a drastic and sudden loss of power either of which may create a safety risk.In reviewing the actual number of these types of incidents, collectively referred to here as engine stalls, the number was found to be below what would be considered a defect trend.For example, the number of engine stalls identified in Ford's warranty claims for the model year (MY) 2004 subject vehicles, the MY with the most failures, was 200 out of population of 125,865, for a failure rate of 0.16%.The one crash recorded by a complainant to NHTSA, VOQ 10311522, alleged that the engine stalled, due to water intrusion into the PCM, while the road was turning causing her to go off the road and according to the police report the vehicle then hit an embankment and a tree stump. Ford reported in their response that there were three alleged crashes but none of these were validated as being caused by a problem with water intrusion into the PCM causing a stall.Accordingly this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted.
Vehicle Speed Control
The subject vehicles suffered from a design issue whereby water could run down onto the cowling under the hood and located in the area of the windshield wipers and then drip onto a computer module, the Powertrain Control Module (PCM), which could be manifested in a variety of symptoms depending on which part of the circuit board became wet or which of the connector pins shorted out.In addition to causing an engine to stall, which may or may not then restart, the water intrusion could also cause the transmission to shift poorly, the vehicle to have erratic power, a malfunction indicator light to come on, or result in an inability to start the vehicle, an inability to shift the vehicle into either forward or reverse. Also the problem could cause a higher than normal idle RPM in Park, or for the radio to malfunction, or the interior lights to stay on.During this investigation ODI was concerned with the effect of the engine stalling or a drastic and sudden loss of power either of which may create a safety risk.In reviewing the actual number of these types of incidents, collectively referred to here as engine stalls, the number was found to be below what would be considered a defect trend.For example, the number of engine stalls identified in Ford's warranty claims for the model year (MY) 2004 subject vehicles, the MY with the most failures, was 200 out of population of 125,865, for a failure rate of 0.16%.The one crash recorded by a complainant to NHTSA, VOQ 10311522, alleged that the engine stalled, due to water intrusion into the PCM, while the road was turning causing her to go off the road and according to the police report the vehicle then hit an embankment and a tree stump. Ford reported in their response that there were three alleged crashes but none of these were validated as being caused by a problem with water intrusion into the PCM causing a stall.Accordingly this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted.
EA09016 · Transmission Torque Converter Failure
Opened Nov 10, 2009 · Closed Feb 2, 2012
Status: closed (inferred from source dates) · Power Train:automatic Transmission; Power Train:automatic Transmission:torque Converter
On January 4, 2012 Ford Motor Company submitted a Defect Information Report (NHTSA Recall No. 12V-006) to NHTSA regarding a defect in the performance of the transmission torque converter for approximately 205,896 Ford Freestar and Mercury Monterey vehicles.The supplier of the torque converter manufactured converters containing a pump shaft spline that did not consistently meet the specified heat treatment requirements.In normal use, the spline may wear excessively and eventually fails without warning.If a torque converter malfunctions due to a sheared pump drive spline, the vehicle will abruptly lose motive power.This problem affected model year 2004 and 2005 Freestar and Monterey minivans.During the investigation NHTSA identified 532 complaints alleging incidents of vehicle stall while driving due to torque converter failure.These failures were sudden and without any prior warning.Of the 490 complaints that reported the speed at the time of the failure:218 (44%) occurred at or above 55 mph; and 344 (70%) occurred at or above 40 mph.Of the 382 complaints that reported the position of the vehicle relative to traffic after it came to a stop following the loss of motive power: 122 (32%) alleged that the vehicle came to a stop in the flow of traffic and remained in the flow of traffic until pushed or towed out of the way; 225 (59%) reported that the vehicle was maneuvered to the side of the roadway and remained there until towed; and 35 (9%) reported that they were able to maneuver to a location away from the flow of traffic, such as a parking lot.Two crashes were allegedly caused by torque converter failure, including an incident in which a Freestar suddenly lost power in 65 mph traffic in an area where there was no shoulder available.As a result, the Freestar stopped in a travel lane and when trailing traffic maneuvered to avoid the stalled vehicle, a four vehicle collision occurred.In these types of circumstances NHTSA believes the defect presents an unreasonable risk to motor vehicle safety and so advised Ford.In its Defect Information Report, Ford refers to its response to NHTSA's Preliminary Evaluation information request, which stated that a vehicle that loses motive power due to torque converter malfunction remains readily controllable; the vehicle will coast during which it can be safely maneuvered and stopped because the engine continues to run.Because the engine continues to run, steering and braking are unaffected, and the vehicle's electrical system and directional signals remain functional.In view of the foregoing, NHTSA does not agree with this statement.This investigation is closed based on Ford's recall.
Additional source detail variants (2)
Power Train:automatic Transmission
On January 4, 2012 Ford Motor Company submitted a Defect Information Report (NHTSA Recall No. 12V-006) to NHTSA regarding a defect in the performance of the transmission torque converter for approximately 205,896 Ford Freestar and Mercury Monterey vehicles.The supplier of the torque converter manufactured converters containing a pump shaft spline that did not consistently meet the specified heat treatment requirements.In normal use, the spline may wear excessively and eventually fails without warning.If a torque converter malfunctions due to a sheared pump drive spline, the vehicle will abruptly lose motive power.This problem affected model year 2004 and 2005 Freestar and Monterey minivans.During the investigation NHTSA identified 532 complaints alleging incidents of vehicle stall while driving due to torque converter failure.These failures were sudden and without any prior warning.Of the 490 complaints that reported the speed at the time of the failure:218 (44%) occurred at or above 55 mph; and 344 (70%) occurred at or above 40 mph.Of the 382 complaints that reported the position of the vehicle relative to traffic after it came to a stop following the loss of motive power: 122 (32%) alleged that the vehicle came to a stop in the flow of traffic and remained in the flow of traffic until pushed or towed out of the way; 225 (59%) reported that the vehicle was maneuvered to the side of the roadway and remained there until towed; and 35 (9%) reported that they were able to maneuver to a location away from the flow of traffic, such as a parking lot.Two crashes were allegedly caused by torque converter failure, including an incident in which a Freestar suddenly lost power in 65 mph traffic in an area where there was no shoulder available.As a result, the Freestar stopped in a travel lane and when trailing traffic maneuvered to avoid the stalled vehicle, a four vehicle collision occurred.In these types of circumstances NHTSA believes the defect presents an unreasonable risk to motor vehicle safety and so advised Ford.In its Defect Information Report, Ford refers to its response to NHTSA's Preliminary Evaluation information request, which stated that a vehicle that loses motive power due to torque converter malfunction remains readily controllable; the vehicle will coast during which it can be safely maneuvered and stopped because the engine continues to run.Because the engine continues to run, steering and braking are unaffected, and the vehicle's electrical system and directional signals remain functional.In view of the foregoing, NHTSA does not agree with this statement.This investigation is closed based on Ford's recall.
Power Train:automatic Transmission:torque Converter
On January 4, 2012 Ford Motor Company submitted a Defect Information Report (NHTSA Recall No. 12V-006) to NHTSA regarding a defect in the performance of the transmission torque converter for approximately 205,896 Ford Freestar and Mercury Monterey vehicles.The supplier of the torque converter manufactured converters containing a pump shaft spline that did not consistently meet the specified heat treatment requirements.In normal use, the spline may wear excessively and eventually fails without warning.If a torque converter malfunctions due to a sheared pump drive spline, the vehicle will abruptly lose motive power.This problem affected model year 2004 and 2005 Freestar and Monterey minivans.During the investigation NHTSA identified 532 complaints alleging incidents of vehicle stall while driving due to torque converter failure.These failures were sudden and without any prior warning.Of the 490 complaints that reported the speed at the time of the failure:218 (44%) occurred at or above 55 mph; and 344 (70%) occurred at or above 40 mph.Of the 382 complaints that reported the position of the vehicle relative to traffic after it came to a stop following the loss of motive power: 122 (32%) alleged that the vehicle came to a stop in the flow of traffic and remained in the flow of traffic until pushed or towed out of the way; 225 (59%) reported that the vehicle was maneuvered to the side of the roadway and remained there until towed; and 35 (9%) reported that they were able to maneuver to a location away from the flow of traffic, such as a parking lot.Two crashes were allegedly caused by torque converter failure, including an incident in which a Freestar suddenly lost power in 65 mph traffic in an area where there was no shoulder available.As a result, the Freestar stopped in a travel lane and when trailing traffic maneuvered to avoid the stalled vehicle, a four vehicle collision occurred.In these types of circumstances NHTSA believes the defect presents an unreasonable risk to motor vehicle safety and so advised Ford.In its Defect Information Report, Ford refers to its response to NHTSA's Preliminary Evaluation information request, which stated that a vehicle that loses motive power due to torque converter malfunction remains readily controllable; the vehicle will coast during which it can be safely maneuvered and stopped because the engine continues to run.Because the engine continues to run, steering and braking are unaffected, and the vehicle's electrical system and directional signals remain functional.In view of the foregoing, NHTSA does not agree with this statement.This investigation is closed based on Ford's recall.
PE09033 · Torque Converter Output Shaft Failure
Opened Jul 15, 2009 · Closed Nov 17, 2009
Status: closed (inferred from source dates) · Power Train:automatic Transmission; Power Train:automatic Transmission:torque Converter
ODI HAS RECEIVED 227 OWNER COMPLAINTS ALLEGING A SUDDEN AND UNEXPECTED LOSS OF MOTIVE POWER DUE TO AN INTERNAL TRANSMISSION FAILURE IN THE SUBJECT VEHICLES.OF THOSE COMPLAINTS, 124 CAN BE ATTRIBUTED TO THE TORQUE CONVERTER OUTPUT SHAFT SPLINES STRIPPING CAUSING A SUDDEN LOSS OF POWER TO THE DRIVETRAIN.THE REMAINING 103 COMPLAINTS EXPERIENCED A LOSS OF MOTIVE POWER BUT THE SPECIFIC INTERNAL FAILURE CAUSE WITHIN THE TRANSMISSION IS NOT KNOWN.ODI HAS UPGRADED THE INVESTIGATION TO AN ENGINEERING ANALYSIS (EA09-016) TO CONTINUE ITS ASSESSMENT OF THE SCOPE, FREQUENCY AND SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.
Additional source detail variants (2)
Power Train:automatic Transmission
ODI HAS RECEIVED 227 OWNER COMPLAINTS ALLEGING A SUDDEN AND UNEXPECTED LOSS OF MOTIVE POWER DUE TO AN INTERNAL TRANSMISSION FAILURE IN THE SUBJECT VEHICLES.OF THOSE COMPLAINTS, 124 CAN BE ATTRIBUTED TO THE TORQUE CONVERTER OUTPUT SHAFT SPLINES STRIPPING CAUSING A SUDDEN LOSS OF POWER TO THE DRIVETRAIN.THE REMAINING 103 COMPLAINTS EXPERIENCED A LOSS OF MOTIVE POWER BUT THE SPECIFIC INTERNAL FAILURE CAUSE WITHIN THE TRANSMISSION IS NOT KNOWN.ODI HAS UPGRADED THE INVESTIGATION TO AN ENGINEERING ANALYSIS (EA09-016) TO CONTINUE ITS ASSESSMENT OF THE SCOPE, FREQUENCY AND SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.
Power Train:automatic Transmission:torque Converter
ODI HAS RECEIVED 227 OWNER COMPLAINTS ALLEGING A SUDDEN AND UNEXPECTED LOSS OF MOTIVE POWER DUE TO AN INTERNAL TRANSMISSION FAILURE IN THE SUBJECT VEHICLES.OF THOSE COMPLAINTS, 124 CAN BE ATTRIBUTED TO THE TORQUE CONVERTER OUTPUT SHAFT SPLINES STRIPPING CAUSING A SUDDEN LOSS OF POWER TO THE DRIVETRAIN.THE REMAINING 103 COMPLAINTS EXPERIENCED A LOSS OF MOTIVE POWER BUT THE SPECIFIC INTERNAL FAILURE CAUSE WITHIN THE TRANSMISSION IS NOT KNOWN.ODI HAS UPGRADED THE INVESTIGATION TO AN ENGINEERING ANALYSIS (EA09-016) TO CONTINUE ITS ASSESSMENT OF THE SCOPE, FREQUENCY AND SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.