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2004 Mercury Mountaineer

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2004 Mercury Mountaineer do not stand out strongly from the model-year median of 117.

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When problems were reported

Mileage at the reported incident

181 reports with mileage · 29 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.

  • Structure. Review the 79 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 64 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Vehicle Speed Control. Review the 21 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

11 crash reports2 fire reports15 injury reports

Power Train complaints

64 reports
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100,000 miles · Apr 8, 2010
Power Train

TRANSMISSION REBUILD AT 100,000 MILES, 6 YRS OLD. FEEL LIKE IT IS TOO SOON TO HAVE THIS KIND OF PROBLEM. I UNDERSTAND THIS HAS BEEN A QUITE A COMMON PROBLEM TOO. THE BODY PANEL UNDER THE BACK GLASS IS ALSO CRACKED. *TR

NHTSA ODI #10324558

985 miles · Apr 5, 2010
Power TrainSuspension

2004 MERCURY MOUNTAINEER HAS HUB BEARING DEFECTS, TRANSMISSION DEFECTS, DRIVE TRAIN DEFECTS, REAR AXLE AND DIFFERENTIAL DEFECTS. THERE ARE THOUSANDS OF COMPLAINTS ABOUT THESE COMPONENTS OF MERCURY MOUNTAINEER AND FORD EXPLORER YET NHTSA DOES NOTHING. FORD WILL NOT FIX THESE PROBLEMS AND HAS BEEN DOING BAND AID FIXES UNDER WAR…

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2004 MERCURY MOUNTAINEER HAS HUB BEARING DEFECTS, TRANSMISSION DEFECTS, DRIVE TRAIN DEFECTS, REAR AXLE AND DIFFERENTIAL DEFECTS. THERE ARE THOUSANDS OF COMPLAINTS ABOUT THESE COMPONENTS OF MERCURY MOUNTAINEER AND FORD EXPLORER YET NHTSA DOES NOTHING. FORD WILL NOT FIX THESE PROBLEMS AND HAS BEEN DOING BAND AID FIXES UNDER WARRANTY. THEY DENY THERE IS A PROBLEM YET THERE ARE THOUSANDS OF COMPLAINTS ON THE VARIOUS WEB SITES. IT MAKES ME BELIEVE NHTSA IS IN BED WITH THE AUTO MANUFACTURERS AND REALLY DON'T CARE ABOUT THE PUBLIC. WHEELS FALL OFF CARS CAUSE HUB BEARINGS FAIL YET THERE IS NO RECALL.. FORD PUTS THE WRONG TRANSMISSION FLUID IN CARS, TRANSMISSION FAILS...THERE IS NO RECALL. REAR AXLE SEAL FAILS AND NO RECALLS WHY!!! *TR

NHTSA ODI #10323883

Mileage unknown · Feb 9, 2010
Power Train

2004 MERCURY MOUNTAINEER SOMETIMES JERK REALLY HARD WHEN PUT IN REVERSE GEAR. TWICE, IT JERKED SO HARD, I HAD TO SLAM ON THE BRAKES, CAUSE IT WAS BACKING BACK FAST. REALLY SCARED ME. OTHER TIMES, IT JERKS HARD, BUT STAYS PUT UNTIL I PRESS THE GAS. I NEVER KNOW WHEN THIS WILL HAPPEN, THERE IS NO WARNING. TOOK TRUCK TO MERCUR…

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2004 MERCURY MOUNTAINEER SOMETIMES JERK REALLY HARD WHEN PUT IN REVERSE GEAR. TWICE, IT JERKED SO HARD, I HAD TO SLAM ON THE BRAKES, CAUSE IT WAS BACKING BACK FAST. REALLY SCARED ME. OTHER TIMES, IT JERKS HARD, BUT STAYS PUT UNTIL I PRESS THE GAS. I NEVER KNOW WHEN THIS WILL HAPPEN, THERE IS NO WARNING. TOOK TRUCK TO MERCURY DEALER ONCE, OVER A YEAR AGO. SAID THEY CHECKED, BUT COULDN'T FIND ANYTHING. VEHICLE IS PAID FOR. NO LONGER HAVE WARRANTY. ABOUT 3 WEEKS AGO WHEN THE LAST JERK OCCURRED. *TR

NHTSA ODI #10308077

64,000 miles · Jan 10, 2010
Power Train

2004 MERCURY MOUNTAINEER WITH 64,000 MILES, TRANSMISSION STARTED TO MAKE NOISES, ABOUT A WEEK LATER IT WOULD NOT SHIFT. SHOP SAID SOME GROVE IN SOMETHING IN THE TRANSMISSION. HAD IT FIXED FOR $3,000. LATER FOUND OUT THE TRANSMISSION WAS OUT AT 10,000 MILES BEFORE WE BOUGHT IT. ALSO HAD A 2004 LINCOLN AVIATOR WITH 54,000 ON …

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2004 MERCURY MOUNTAINEER WITH 64,000 MILES, TRANSMISSION STARTED TO MAKE NOISES, ABOUT A WEEK LATER IT WOULD NOT SHIFT. SHOP SAID SOME GROVE IN SOMETHING IN THE TRANSMISSION. HAD IT FIXED FOR $3,000. LATER FOUND OUT THE TRANSMISSION WAS OUT AT 10,000 MILES BEFORE WE BOUGHT IT. ALSO HAD A 2004 LINCOLN AVIATOR WITH 54,000 ON IT AND HAD TO FIX THE TRANSMISSION, SHOP SAID THERE WAS SOME GROVE ON SOME PART IN THE TRANSMISSION. VERY EXPENSIVE PROBLEMS WITH LOW MILES. *TR

NHTSA ODI #10298872

100,000 miles · Dec 23, 2009
Power Train

HERE IS THE E-MAIL I SENT TO FORD REGARDING WHAT IS GOING ON. : MY NAME IS LEANNE FREEMAN I OWN A 2004 MERCURY MOUNTAINEER,I HAVE BEEN HAVING TRANSMISSION TROUBLE WITH THE CAR SINCE I BOUGHT IT. I AM CONCERNED THAT I AM NOT THE ONLY PERSON HAVING THIS TROUBLE I LOOKED ON THE INTERNET AND WAS ABLE TO FIND 25,000 PAGES OF PEOPL…

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HERE IS THE E-MAIL I SENT TO FORD REGARDING WHAT IS GOING ON. : MY NAME IS LEANNE FREEMAN I OWN A 2004 MERCURY MOUNTAINEER,I HAVE BEEN HAVING TRANSMISSION TROUBLE WITH THE CAR SINCE I BOUGHT IT. I AM CONCERNED THAT I AM NOT THE ONLY PERSON HAVING THIS TROUBLE I LOOKED ON THE INTERNET AND WAS ABLE TO FIND 25,000 PAGES OF PEOPLE HAVING THE SAME TROUBLE MANY OF WHICH HAVE MADE CONTACT WITH FORD. I AM CONCERNED THAT FORD KNOWS THERE IS A PROBLEM AND HAS DONE NOTHING TO FIX IT. WHY HAVE THEY NOT DONE SOME KIND OF RECALL I COULD SEE IF THIS PROBLEM HAD ONLY HAPPENED TO A HAND FULL OF PEOPLE BUT THERE IS OVER 25,000 PAGES WITH EACH PAGE HAVING OVER 50 POST PER PAGE OF OWNERS HAVING THIS SAME PROBLEM ???? I HAVE SAVED ALL THE INFO FROM ALL THE PEOPLE HAVING THIS PROBLEM IF YOU WOULD LIKE ME TO FORWARD IT TO YOU I WILL BE HAPPY TO THANK YOU FOR YOUR TIME LEANNE FREEMAN HTTP://WWW.CARCOMPLAINTS.COM/MERCURY/MOUNTAINEER/2002/TRANSMISSION/OD_LIGHT_CAME_ON.SHTML HTTP://WIKI.ANSWERS.COM/Q/WHY_WOULD_THE_TRANSMISSION_ON_A_MERCURY_MOUNTAINEER_KEEP_SHIFTING_HARD HTTP://WWW.FORD-PROBLEMS.COM/EXPLORER-TRANSMISSION-PROBLEMS.HTM HTTP://TOWNHALL-TALK.EDMUNDS.COM/DIRECT/VIEW/.F1C1B35 HTTP://WWW.GOOGLE.COM/SEARCH?HL=EN&EI=JSUKS6K0ENS0TGEIG4JJBW&SA=X&OI=SPELL&RESNUM=1&CT=RESULT&CD=1&VED=0CDYQBSGA&Q=TRANSMISSION+PROBLEMS+ON+MERCURY+MOUNTAINEER&SPELL=1 HTTP://WWW.CARSURVEY.ORG/REVIEWS/MERCURY/MOUNTAINEER/R65436/COMMENTS/PAGE-2/ HTTP://WWW.CARCOMPLAINTS.COM/MERCURY/MOUNTAINEER/2002/TRANSMISSION/TRANSMISSION_FAILURE.SHTML HTTP://WWW.CARSURVEY.ORG/REVIEWS/MERCURY/MOUNTAINEER/R65436/COMMENTS/ HTTP://TOWNHALL-TALK.EDMUNDS.COM/DIRECT/VIEW/.F0FF573. *TR

NHTSA ODI #10296777

29,225 miles · Sep 28, 2009
Power Train

PROBLEMS WITH TRANSMISSION IN MY 2004 MERCURY MOUNTAINEER. WHEN IN PARK AND SHIFTING IN REVERSE IT DELAYS AND THEN A LOUD HARD CLUNK. IT ALSO CLUNKS FROM GOING INTO SECOND GEAR. MY CAR IS OUT OF THE STANDARD 36,000 MILES/ 3 YEAR WARRANTY. I AM VERY DISAPPOINT IN FORD. THE CAR HASN'T EVEN HIT 30,000 MILES YET. *TR

NHTSA ODI #10285591

35,296 miles · Aug 1, 2009
Power Train

REAR AXLE FAILURE AT 35,000 MILES. REPLACED BOTH REAR AXLE SHAFTS, BEARINGS, SEALS, CV BOOTS, AND COMPLETE DIFFERENTIAL WITH USED PARTS PER THE EXTENDED WARRANTY COVERAGE. *TR

NHTSA ODI #10279037

28,000 miles · May 20, 2009
Power Train

DURING THE LATER PART OF JUNE 2008, I PURCHASED A 2004 MERCURY MOUNTAINEER FROM CARMAX AT THE CHICAGO RIDGE LOCATION IN ILLINOIS WHICH HAD 28,579 MILES. ACCORDING TO THE CARFAX REPORT AND SALES PERSON, THIS VEHICLE HAD SUCCESSFULLY PASSED THE 100 POINT INSPECTION, AND UNDER NORMAL DRIVING CONDITION THIS CAR HAD NO MAJOR MECHANI…

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DURING THE LATER PART OF JUNE 2008, I PURCHASED A 2004 MERCURY MOUNTAINEER FROM CARMAX AT THE CHICAGO RIDGE LOCATION IN ILLINOIS WHICH HAD 28,579 MILES. ACCORDING TO THE CARFAX REPORT AND SALES PERSON, THIS VEHICLE HAD SUCCESSFULLY PASSED THE 100 POINT INSPECTION, AND UNDER NORMAL DRIVING CONDITION THIS CAR HAD NO MAJOR MECHANICAL OR ELECTRICAL DEFECTS. WITHIN THE FIRST 30 DAYS I NOTICED A SLIGHT DELAY BETWEEN SHIFTING GEARS BEGAN TO MANIFEST, SO NATURALLY, I TOOK THE CAR IMMEDIATELY BACK TO CARMAX. SINCE THE PROBLEM EXCEEDED THEIR ABILITY TO FIX IT, I WAS INSTRUCTED BY CARMAX TO TAKE THE CAR BACK TO ITS ORIGINAL MANUFACTURER, WHICH IS YOUR ORGANIZATION, FORD. ON JULY 1ST 2008 A FORD MECHANIC AT THE 95TH WESTERN LOCATION REPORTED THAT THEY REPROGRAMMED THE TRUCK, REPLACED VIBRATION DAMPER, AND WORKED ON THE PULLEY-CRANKSHAFT. THE DELAY CEASED FOR A SHORT PERIOD OF TIME. WITHIN THE NEXT FEW MONTHS, THE PROBLEM REAPPEARED IN AN EVEN GREATER CAPACITY THAN BEFORE AS NOW THE GEARS BETWEEN THE FORWARD AND REVERSE PROCEEDED TO PRODUCE A KICK BACK MOTION. I DECIDED TO GET A SECOND WRITTEN MECHANICAL OPINION FROM MEINEKE TRANSMISSION AND MUFFLER ON 107TH WESTERN, ONLY TO BE TOLD THAT THE TRANSMISSION WAS BAD. SINCE THE 100 POINT INSPECTION ON THE CARFAX DID NOT INDICATE SUCH, AS I WOULD LIKE TO BELIEVE THAT CARMAX WOULD NOT HAVE SOLD ME THE CAR IN THAT CONDITION, I DECIDED TO GET YET ANOTHER WRITTEN OPINION. ONCE AGAIN, BY ANOTHER INDEPENDENT MECHANIC AT LUCHA'S AUTO REPAIR IN SOUTH CHICAGO, I WAS TOLD THAT NOT ONLY WAS THE TRANSMISSION BAD BUT THAT IT HAD TO HAVE BEEN THAT WAY UPON MY ORIGINAL PURCHASE AS THE YEAR OF THE CAR (2004) IS NOT COMMENSURATE WITH THE DEGREE OF DAMAGE TO THE TRANSMISSION AS THE CAR IS LESS THAN SIX YEARS OLD. LET ME ALSO STATE THAT THE CAR IS ALSO UNDER 50,000 MILES. *TR

NHTSA ODI #10269518

59,000 miles · Mar 9, 2009
Power TrainCrashInjury

TL*THE CONTACT OWNS A 2004 MERCURY MOUNTAINEER. WHILE THE VEHICLE WAS TURNED OFF, THE CONTACT'S TWO YEAR OLD SON GRABBED THE KEY AND PLACED IT IN THE IGNITION. HE ATTEMPTED TO START THE VEHICLE, BUT THE ENGINE NEVER IGNITED. THE CHILD THEN PROCEEDED TO PLACE THE SHIFTER IN EITHER NEUTRAL OR DRIVE AND THE VEHICLE BEGAN TO ROLL…

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TL*THE CONTACT OWNS A 2004 MERCURY MOUNTAINEER. WHILE THE VEHICLE WAS TURNED OFF, THE CONTACT'S TWO YEAR OLD SON GRABBED THE KEY AND PLACED IT IN THE IGNITION. HE ATTEMPTED TO START THE VEHICLE, BUT THE ENGINE NEVER IGNITED. THE CHILD THEN PROCEEDED TO PLACE THE SHIFTER IN EITHER NEUTRAL OR DRIVE AND THE VEHICLE BEGAN TO ROLL APPROXIMATELY 350 FEET DOWN A HILL. THE VEHICLE CRASHED INTO A BRUSH-HOG AND A HONDA VEHICLE BEFORE FINALLY COMING TO A STOP WHEN IT CRASHED INTO A BUILDING. THE CHILD SUSTAINED A CONTUSION AND LACERATIONS TO HIS HEAD, CHEST, AND LEGS. THE VEHICLE WAS TOWED AND IS CURRENTLY AT A SALVAGE YARD. THE POLICE STATED THAT EVEN THOUGH THE VEHICLE WAS NOT STARTED, THE GEARS WERE ABLE TO BE SHIFTED, WHICH SHOULD NOT HAVE OCCURRED. A POLICE REPORT WAS FILED. THE CONTACT BELIEVES THAT THE FAILURE WAS DUE TO A MANUFACTURER DEFECT AND THEY SHOULD BE HELD ACCOUNTABLE. THE SPEED WAS UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 59,000.

NHTSA ODI #10261351

71,000 miles · Mar 7, 2009
Power Train

MY VEHICLES TRANSMISSION HAD SLIPPED ONCE AND TOOK IT IN AS SOON AS IT HAPPENED TO A MERCURY DEALER FOR SERVICE AND THEY CHANGED FLUID AND FILTER NOW IT DON'T HAVE REVERSE OR FORWARD GEARS UNLESS I SHIFT IT MANUALLY THE DEALER SAID IF THEY CHANGE FLUID IT WILL GET WORSE AND IT DID SO THEY ARE AWARE OF THE PROBLEM WHY WASN'T A RE…

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MY VEHICLES TRANSMISSION HAD SLIPPED ONCE AND TOOK IT IN AS SOON AS IT HAPPENED TO A MERCURY DEALER FOR SERVICE AND THEY CHANGED FLUID AND FILTER NOW IT DON'T HAVE REVERSE OR FORWARD GEARS UNLESS I SHIFT IT MANUALLY THE DEALER SAID IF THEY CHANGE FLUID IT WILL GET WORSE AND IT DID SO THEY ARE AWARE OF THE PROBLEM WHY WASN'T A RECALL GIVEN FOR THIS VEHICLES TRANSMISSION PLUS THERE IS NO DIP STICK ON THE TRANSMISSION TO CHECK THE FLUID NOW I HAVE A VEHICLE THAT NEEDS A TRANSMISSION THAT HAS TO BE REPLACED AT A COST OF 3500 DOLLARS AND IS OUT OF WARRANTY I AM VERY DISAPPOINTED THAT A CAR COMPANY CAN GET AWAY WITH THIS. *TR

NHTSA ODI #10261035

Official recalls

0

No recalls in this snapshot.

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

3

EA09013 · Vehicle Rollaway Allegations

Opened Aug 18, 2009 · Closed Feb 12, 2013

Status: closed (inferred from source dates) · Power Train:automatic Transmission:gear Position Indication (prndl); Power Train:automatic Transmission:lever And Linkage:column Shift; Steering; Steering:column; Steering:column LOCKING:ANTI-THEFT Device

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.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.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.

Additional source detail variants (5)

Power Train:automatic Transmission:gear Position Indication (prndl)

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.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.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.

Power Train:automatic Transmission:lever And Linkage:column Shift

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.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.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.

Steering:column

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.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.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.

Steering:column LOCKING:ANTI-THEFT Device

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.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.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.

Steering

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.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.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.

RQ08003 · Rear Liftgate Glass Hatch Failure

Opened Jun 23, 2008 · Closed Oct 24, 2008

Status: closed (inferred from source dates) · Structure:body:hatchback/liftgate; Structure:body:hatchback/liftgate:hinge And Attachments; Structure:body:hatchback/liftgate:support Device/strut; Visibility:glass, Side/rear

THIS INVESTIGATION WAS OPENED ON JUNE 23, 2008, BASED ON 34 COMPLAINTS INVOLVING EIGHT INJURIES IN WHICH THE REAR LIFTGATE GLASS HATCH ON MODEL YEAR 2004 FORD EXPLORERS OR MERCURY MOUNTAINEERS BROKE OFF AND FELL, USUALLY WHILE INDIVIDUALS WERE OPERATING THE GLASS HATCH OR LOADING OR UNLOADING ITEMS FROM THE REAR OF THE VEHICLE.FORD CONDUCTED RECALL 04V-442 IN 2004 TO ADDRESS SIMILAR PROBLEMS ON MODEL YEAR 2002 AND CERTAIN MODEL YEAR 2003 FORD EXPLORERS AND MERCURY MOUNTAINEERS.THE INFORMATION FORD PROVIDED IN RESPONSE TO ODI'S INFORMATION REQUEST LETTER INDICATED THAT FAILURES WITH 2004 VEHICLES WERE PRIMARILY LIFTGATE GLASS HATCH HINGE FAILURES RELATED TO CORROSION AT THE HINGE PIN, WHEREAS THE FAILURES THAT PROMPTED THE RECALL WITH THE EARLIER MODELS WERE PRIMARILY RELATED TO PROBLEMS WITH THE GLASS HATCH'S STRUTS OR FRACTURE OF A PRIOR HINGE DESIGN AT THE BOSS/BOLT CONNECTION AT THE GLASS.ODI'S REVIEW OF FORD'S WARRANTY, COMPLAINT, AND INJURY DATA FOR THE 2004 VEHICLES INDICATES THAT THESE RATES ARE SIGNIFICANTLY LOWER THAN THOSE FOR THE RECALLED POPULATION.A POTENTIAL DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME.ODI WILL CONTINUE TO MONITOR COMPLAINTS AND TAKE APPROPRIATE ACTION AS NECESSARY.THIS INVESTIGATION IS CLOSED.

Additional source detail variants (4)

Structure:body:hatchback/liftgate

THIS INVESTIGATION WAS OPENED ON JUNE 23, 2008, BASED ON 34 COMPLAINTS INVOLVING EIGHT INJURIES IN WHICH THE REAR LIFTGATE GLASS HATCH ON MODEL YEAR 2004 FORD EXPLORERS OR MERCURY MOUNTAINEERS BROKE OFF AND FELL, USUALLY WHILE INDIVIDUALS WERE OPERATING THE GLASS HATCH OR LOADING OR UNLOADING ITEMS FROM THE REAR OF THE VEHICLE.FORD CONDUCTED RECALL 04V-442 IN 2004 TO ADDRESS SIMILAR PROBLEMS ON MODEL YEAR 2002 AND CERTAIN MODEL YEAR 2003 FORD EXPLORERS AND MERCURY MOUNTAINEERS.THE INFORMATION FORD PROVIDED IN RESPONSE TO ODI'S INFORMATION REQUEST LETTER INDICATED THAT FAILURES WITH 2004 VEHICLES WERE PRIMARILY LIFTGATE GLASS HATCH HINGE FAILURES RELATED TO CORROSION AT THE HINGE PIN, WHEREAS THE FAILURES THAT PROMPTED THE RECALL WITH THE EARLIER MODELS WERE PRIMARILY RELATED TO PROBLEMS WITH THE GLASS HATCH'S STRUTS OR FRACTURE OF A PRIOR HINGE DESIGN AT THE BOSS/BOLT CONNECTION AT THE GLASS.ODI'S REVIEW OF FORD'S WARRANTY, COMPLAINT, AND INJURY DATA FOR THE 2004 VEHICLES INDICATES THAT THESE RATES ARE SIGNIFICANTLY LOWER THAN THOSE FOR THE RECALLED POPULATION.A POTENTIAL DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME.ODI WILL CONTINUE TO MONITOR COMPLAINTS AND TAKE APPROPRIATE ACTION AS NECESSARY.THIS INVESTIGATION IS CLOSED.

Structure:body:hatchback/liftgate:hinge And Attachments

THIS INVESTIGATION WAS OPENED ON JUNE 23, 2008, BASED ON 34 COMPLAINTS INVOLVING EIGHT INJURIES IN WHICH THE REAR LIFTGATE GLASS HATCH ON MODEL YEAR 2004 FORD EXPLORERS OR MERCURY MOUNTAINEERS BROKE OFF AND FELL, USUALLY WHILE INDIVIDUALS WERE OPERATING THE GLASS HATCH OR LOADING OR UNLOADING ITEMS FROM THE REAR OF THE VEHICLE.FORD CONDUCTED RECALL 04V-442 IN 2004 TO ADDRESS SIMILAR PROBLEMS ON MODEL YEAR 2002 AND CERTAIN MODEL YEAR 2003 FORD EXPLORERS AND MERCURY MOUNTAINEERS.THE INFORMATION FORD PROVIDED IN RESPONSE TO ODI'S INFORMATION REQUEST LETTER INDICATED THAT FAILURES WITH 2004 VEHICLES WERE PRIMARILY LIFTGATE GLASS HATCH HINGE FAILURES RELATED TO CORROSION AT THE HINGE PIN, WHEREAS THE FAILURES THAT PROMPTED THE RECALL WITH THE EARLIER MODELS WERE PRIMARILY RELATED TO PROBLEMS WITH THE GLASS HATCH'S STRUTS OR FRACTURE OF A PRIOR HINGE DESIGN AT THE BOSS/BOLT CONNECTION AT THE GLASS.ODI'S REVIEW OF FORD'S WARRANTY, COMPLAINT, AND INJURY DATA FOR THE 2004 VEHICLES INDICATES THAT THESE RATES ARE SIGNIFICANTLY LOWER THAN THOSE FOR THE RECALLED POPULATION.A POTENTIAL DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME.ODI WILL CONTINUE TO MONITOR COMPLAINTS AND TAKE APPROPRIATE ACTION AS NECESSARY.THIS INVESTIGATION IS CLOSED.

Structure:body:hatchback/liftgate:support Device/strut

THIS INVESTIGATION WAS OPENED ON JUNE 23, 2008, BASED ON 34 COMPLAINTS INVOLVING EIGHT INJURIES IN WHICH THE REAR LIFTGATE GLASS HATCH ON MODEL YEAR 2004 FORD EXPLORERS OR MERCURY MOUNTAINEERS BROKE OFF AND FELL, USUALLY WHILE INDIVIDUALS WERE OPERATING THE GLASS HATCH OR LOADING OR UNLOADING ITEMS FROM THE REAR OF THE VEHICLE.FORD CONDUCTED RECALL 04V-442 IN 2004 TO ADDRESS SIMILAR PROBLEMS ON MODEL YEAR 2002 AND CERTAIN MODEL YEAR 2003 FORD EXPLORERS AND MERCURY MOUNTAINEERS.THE INFORMATION FORD PROVIDED IN RESPONSE TO ODI'S INFORMATION REQUEST LETTER INDICATED THAT FAILURES WITH 2004 VEHICLES WERE PRIMARILY LIFTGATE GLASS HATCH HINGE FAILURES RELATED TO CORROSION AT THE HINGE PIN, WHEREAS THE FAILURES THAT PROMPTED THE RECALL WITH THE EARLIER MODELS WERE PRIMARILY RELATED TO PROBLEMS WITH THE GLASS HATCH'S STRUTS OR FRACTURE OF A PRIOR HINGE DESIGN AT THE BOSS/BOLT CONNECTION AT THE GLASS.ODI'S REVIEW OF FORD'S WARRANTY, COMPLAINT, AND INJURY DATA FOR THE 2004 VEHICLES INDICATES THAT THESE RATES ARE SIGNIFICANTLY LOWER THAN THOSE FOR THE RECALLED POPULATION.A POTENTIAL DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME.ODI WILL CONTINUE TO MONITOR COMPLAINTS AND TAKE APPROPRIATE ACTION AS NECESSARY.THIS INVESTIGATION IS CLOSED.

Visibility:glass, Side/rear

THIS INVESTIGATION WAS OPENED ON JUNE 23, 2008, BASED ON 34 COMPLAINTS INVOLVING EIGHT INJURIES IN WHICH THE REAR LIFTGATE GLASS HATCH ON MODEL YEAR 2004 FORD EXPLORERS OR MERCURY MOUNTAINEERS BROKE OFF AND FELL, USUALLY WHILE INDIVIDUALS WERE OPERATING THE GLASS HATCH OR LOADING OR UNLOADING ITEMS FROM THE REAR OF THE VEHICLE.FORD CONDUCTED RECALL 04V-442 IN 2004 TO ADDRESS SIMILAR PROBLEMS ON MODEL YEAR 2002 AND CERTAIN MODEL YEAR 2003 FORD EXPLORERS AND MERCURY MOUNTAINEERS.THE INFORMATION FORD PROVIDED IN RESPONSE TO ODI'S INFORMATION REQUEST LETTER INDICATED THAT FAILURES WITH 2004 VEHICLES WERE PRIMARILY LIFTGATE GLASS HATCH HINGE FAILURES RELATED TO CORROSION AT THE HINGE PIN, WHEREAS THE FAILURES THAT PROMPTED THE RECALL WITH THE EARLIER MODELS WERE PRIMARILY RELATED TO PROBLEMS WITH THE GLASS HATCH'S STRUTS OR FRACTURE OF A PRIOR HINGE DESIGN AT THE BOSS/BOLT CONNECTION AT THE GLASS.ODI'S REVIEW OF FORD'S WARRANTY, COMPLAINT, AND INJURY DATA FOR THE 2004 VEHICLES INDICATES THAT THESE RATES ARE SIGNIFICANTLY LOWER THAN THOSE FOR THE RECALLED POPULATION.A POTENTIAL DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME.ODI WILL CONTINUE TO MONITOR COMPLAINTS AND TAKE APPROPRIATE ACTION AS NECESSARY.THIS INVESTIGATION IS CLOSED.

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.