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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.

About this comparison →

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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Mileage unknown · Apr 18, 2006
Power Train

2004 MERCURY MOUNTAINEER PURCHASED NEW SEPT. 2004. TRANSFER CASE WAS LEAKING WHILE UNDER WARRANTY - ALL REAR SEALS REPLACED. STARTED LEAKING AGAIN AND VEHICLE WAS TAKEN IN FOR ROUTINE SERVICE @ 39,000 MILES. TOLD LARGE CHUNKS OF METAL IN TRANSMISSION PAN - TRANSMISSION NEEDS REPLACED. VEHICLE NO LONGER UNDER WARRANTY AFTER 3…

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2004 MERCURY MOUNTAINEER PURCHASED NEW SEPT. 2004. TRANSFER CASE WAS LEAKING WHILE UNDER WARRANTY - ALL REAR SEALS REPLACED. STARTED LEAKING AGAIN AND VEHICLE WAS TAKEN IN FOR ROUTINE SERVICE @ 39,000 MILES. TOLD LARGE CHUNKS OF METAL IN TRANSMISSION PAN - TRANSMISSION NEEDS REPLACED. VEHICLE NO LONGER UNDER WARRANTY AFTER 30,000 MILES; FORD AND DEALER AGREED TO "SHARE" SOME OF THE COST, $500 TO OWNER. BELIEVE LEAK IS RELATED TO TRANSMISSION PROBLEM THAT WAS NOT CHECKED DURING ORIGINAL COMPLAINT WHEN SEALS WERE REPLACED. *JB

NHTSA ODI #10155563

48,164 miles · Mar 18, 2006
Power Train

REAR AXLE FAILURE AT 11,000 (SIDE BEARINGS) AND 48,000 MILES(BEARINGS AND REAR AXLE). DUE TO DESIGN MISTAKES, AND PROBABLY COST REDUCTION PROGRAMS, MUD CAN TRAP OPEN A BREATHER VALVE FOR THE REAR AXLE. THEN WATER GOES THROUGH THE VALVE AND INTO THE AXLE, AND DESTROYS THE SIDE BEARINGS,AND CLUTCH FLANGE,AND PINION. THE REPLACEME…

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REAR AXLE FAILURE AT 11,000 (SIDE BEARINGS) AND 48,000 MILES(BEARINGS AND REAR AXLE). DUE TO DESIGN MISTAKES, AND PROBABLY COST REDUCTION PROGRAMS, MUD CAN TRAP OPEN A BREATHER VALVE FOR THE REAR AXLE. THEN WATER GOES THROUGH THE VALVE AND INTO THE AXLE, AND DESTROYS THE SIDE BEARINGS,AND CLUTCH FLANGE,AND PINION. THE REPLACEMENT COST OF THESE ITEMS IS NEARLY$1,300. *JB

NHTSA ODI #10153083

10,000 miles · Dec 29, 2005
Power Train

I HAVE HAD REPEATED PROBLEMS WITH THE TRANSMISSION I.E. A NOTICEABLE CLUNK WHEN THE TRANSMISSION SHIFTS FROM OVERDRIVE TO LOW UPON APPROACHING A STOP SIGN. ADDITIONALLY, WHEN BACKING AND SHIFTING TO FORWARD THE TRANSMISSION HESITATES AND SLIPS BEFORE GOING INTO FORWARD DRIVE. THIS CAUSES SOME ANXIETY WHEN YOU HAVE TO BACK FROM…

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I HAVE HAD REPEATED PROBLEMS WITH THE TRANSMISSION I.E. A NOTICEABLE CLUNK WHEN THE TRANSMISSION SHIFTS FROM OVERDRIVE TO LOW UPON APPROACHING A STOP SIGN. ADDITIONALLY, WHEN BACKING AND SHIFTING TO FORWARD THE TRANSMISSION HESITATES AND SLIPS BEFORE GOING INTO FORWARD DRIVE. THIS CAUSES SOME ANXIETY WHEN YOU HAVE TO BACK FROM A COMMERCIAL BUSINESS INTO A BUSY TRAFFIC WAY AND THE TRANSMISSION SLIPS LEAVING YOU NOT KNOWING IF YOUR GOING TO BE ABLE TO AVOID APPROACHING TRAFFIC FROM THE REAR. I HAVE REPORTED THE PROBLEM TO COLORADO RIVER FORD IN ON AT LEAST TWO DIFFERENT OCCASIONS AND HAVE HAD THE TRANSMISSION FLUID REPLACED IN ACCORDANCE WITH MERCURY'S RECALL. HOWEVER, THE PROBLEM CONTINUES. SUBSEQUENTLY,I HAVE CHANGED TO BRADLY FORD FOR REPAIRS. ON ONE OCCASION IMMEDIATELY AFTER A RAIN STORM AND WHILE TRAVERSING A HIGHWAY WASH, I SLOWED THE VEHICLE AND STRADDLED THE CENTER LINE (NO TRAFFIC) TO AVOID ANY STANDING WATER. ADMITTEDLY, THERE WAS MUD RESIDUE ON THE FAR SIDE OF THE WASH. REGARDLESS, AS I EXITED THE WASH AND ACCELERATED THE TRANSMISSION SHIFTED FROM OVERDRIVE TO LOW GEAR CAUSING THE REAR WHEELS TO SPIN AND I WENT INTO A BROAD SIDE SKID TO THE RIGHT AND BACK TO THE LEFT AND TO THE RIGHT AGAIN, ALL OF WHICH WAS AS CLOSE TO A NEAR ACCIDENT AS I WANT TO EXPERIENCE. AS A RETIRED ARIZONA HIGHWAY PATROLMAN I WILL ADMIT THAT MY SPEED WAS TOO FAST FOR THE CONDITIONS (ESTIMATED SPEED 30 TO 40 MPH). HOWEVER, I AM ALSO OF THE OPINION THAT THE SHIFTING PATTERN OF THE VEHICLE ADDED TO THE MOMENTARY LOSS OF CONTROL. REGARDLESS, AT THIS POINT THE VEHICLE REGISTERS 35,500 MILES AND BRADLY FORD IN LAKE HAVASU CITY IS GOING TO ATTEMPT TO RECTIFY THE PROBLEM. THEY WILL BE TEARING DOWN THE TRANSMISSION FOR EXAMINATION. THIS IS AFTER THEY HAVE ALREADY REPLACED A PRESSURE SOLENOID AND THE PROBLEM STILL CONTINUES. I DO NOT BELIEVE THE REPAIR WILL RELIEVE THE PROBLEM AND WILL RESULT IN MY TAKING A FINANCIAL LOSS WHEN I TRADE THE VEHICLE IN. *NM

NHTSA ODI #10146379

Mileage unknown · Dec 27, 2005
Power Train

MY 2004 MERCURY MOUNTAINEER SHIFTS ROUGH, LUNGING FORWARD WITH A HARD SHIFT, AND SOMETIMES DRAGGING. ALSO, WHEN SHIFTING FROM PARK TO REVERSE EXPERIENCE A VERY HARD CLUNK FOLLOWED BY A THRUST BACKWARDS. *NM

NHTSA ODI #10146187

Mileage unknown · Oct 21, 2005
Power Train

VEHICLE JERKS INTO REVERSE. VEHICLE WAS PLACED IN SHOP TO HAVE ADDITIVE PLACED IN TRANSMISSION FLUID TO CORRECT THE PROBLEM. THE PROBLEM HAS NOT ABATED. THE TRANSMISSION IS ALSO VERY LOOSE. AFTER BEING PLACED IN PARK IT LUNGES 3 TO 4 INCHES IN THE DIRECTION OF THE SLOPE IT IS PARKED ON. *JB

NHTSA ODI #10140481

2 miles · Jul 6, 2005
Power TrainUnknown Or OtherInjury

I PURCHASED A 2004 MERCURY MOUNTAINEER V6 IN APRIL, 2004. I IMMEDIATELY STARTED TO NOTICE A HARSH JERK WHEN PUTTING THE CAR IN REVERSE AND SOMETIMES WHILE DRIVING FORWARD. IT SOMETIMES FELT LIKE DRIVING A 5-SPEED VEHICLE. IN LATE SEPTEMBER, 04 WHILE BACKING OUT OF MY DRIVEWAY, ME AND MY 13 YR OLD DAUGHTER EXPERIENCED A VERY …

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I PURCHASED A 2004 MERCURY MOUNTAINEER V6 IN APRIL, 2004. I IMMEDIATELY STARTED TO NOTICE A HARSH JERK WHEN PUTTING THE CAR IN REVERSE AND SOMETIMES WHILE DRIVING FORWARD. IT SOMETIMES FELT LIKE DRIVING A 5-SPEED VEHICLE. IN LATE SEPTEMBER, 04 WHILE BACKING OUT OF MY DRIVEWAY, ME AND MY 13 YR OLD DAUGHTER EXPERIENCED A VERY HARSH JERK AS IF SOMEONE HAD SLAMMED IN THE BACK OF THE CAR. WE WERE BOTH SHAKEN. I STARTED TO EXPERIENCE NECK PROBLEMS. I MADE MY FIRST DR. APPT. IN EARLY TO MID OCTOBER 2004 AND WAS TOLD THAT MY VERTABRE WAS OUT OF PLACE. WHEN THE RECALL NOTICE CAME IN FEBRUARY 2005 (I BELIEVE) TO ME, I TOOK MY CAR TO BE REPAIRED AND I WAS TOLD THAT IT WOULD TAKE AT LEAST 4 HOURS TO FIX. IT ACTUALLY TOOK THE DEALSHIP 3 DAYS TO FIX IT. THE AUTO TECHNICIAN TOLD ME THAT MY CAR WAS WORSE OFF THAN OTHERS THAT HE'D SEEN BEFORE WITH THE SAME PROBLEM AND ADDITONAL PARTS HAD TO BE ORDERED. MY CAR IS WORKING OKAY NOW THAT IT HAS BEEN FIXED. ON THE OTHER HAND, I HAVE BEEN TO THE DOCTOR SEVERAL TIMES WITH THIS NECK INJURY. I HAVE HAD X-RAYS, MRI AND ULTRA SOUND COMPLETED. THE JERKING OF MY VEHICLE HAS CAUSED INJURY TO THE #2 VERTABRE IN MY NECK. I EXPERIENCE HEAD ACHES, SEVERE NECK PAIN, AND SHOULDER AND BACK PAIN. I HAVE BEEN TO PHYSICAL THERAPY- RECOMMENDED BY MY DOCTOR AND TO THE CHIROPRACTOR. I HAVE A VERY HARD TIME SLEEPING AND WORKING DUE TO THIS PAIN. I CALLED FORD MOTOR COMPANY TO ALARM THEM OF MY INJURY DUE TO THE DEFECTIVE TRANSMISSION IN THE VEHICLE THAT THEY MANUFACTURED. THE INDIVIDUAL THAT I SPOKE WITH WAS VERY RUDE, NON- CARING OF MY INJURY AND SPOKE TO ME IN A NEGATIVE TONE. I WAS TOLD THAT THERE WERE NO MEDICAL PROVISIONS ON THIS PARTICULAR RECALL. TO THIS DAY, I AM STILL IN CONSTANT PAIN. I HAVE SUFFERED LONG ENOUGH AND I FEEL THAT IT IS TIME FOR FORD MOTOR COMPANY TO OWN UP TO THE RRESPONSIBILITY THAT THEIR DEFECTIVE VEHICLE HAS CAUSED AN INJURY.

NHTSA ODI #10127570

Mileage unknown · Feb 28, 2005
Power Train

WHILE SHIFTING INTO REVERSE TRANSMISSION HESITATED THREE TO FOUR MINUTES BEFORE ENGAGING. THEN, VEHICLE SHOOK. DRIVER DROVE VEHICLETO THE DEALER, AND MECHANIC DETERMINED THAT TRANSMISSION NEEDED TO BE REPLACED. *AK

NHTSA ODI #10113179

21,000 miles · Feb 22, 2005
Power Train

2004 MERCURY MOUNTAINEER, V8, AUTOMATIC, AWD. VIN DU86W84ZJ23248, PURCHASED AUGUST 2004. CURRENT MILEAGE IS 22000. MID DECEMBER 2004 I STARTED EXPERIENCING ODD OR ROUGH SHIFTS GOING FROM 2ND TO 3RD. IT STARTED HAPPENING OCCASIONALLY THEN IT BECAME MORE CONSTANT. I ALSO EXPERIENCED HARSH REVERSES, ONE WAS HARD ENOUGH THAT MY…

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2004 MERCURY MOUNTAINEER, V8, AUTOMATIC, AWD. VIN DU86W84ZJ23248, PURCHASED AUGUST 2004. CURRENT MILEAGE IS 22000. MID DECEMBER 2004 I STARTED EXPERIENCING ODD OR ROUGH SHIFTS GOING FROM 2ND TO 3RD. IT STARTED HAPPENING OCCASIONALLY THEN IT BECAME MORE CONSTANT. I ALSO EXPERIENCED HARSH REVERSES, ONE WAS HARD ENOUGH THAT MY HUSBAND SAID IT COULD GIVE YOU WHIP LASH! WHAT WAS IRONIC ABOUT THE WHOLE THING WAS I WAS GOING TO MAKE AN APPOINTMENT WITH MY LOCAL GARAGE WHEN I GOT A LETTER FROM FORD (JANUARY 2005) INDICATING A PROBLEM WITH THE TRANSMISSION FLUID WHICH MIGHT CAUSE A HARSH REVERSE. SO I TOOK IT TO A FORD GARAGE JANUARY1 5,2005, AND THEY INSTALLED THE ADDITIVES. I DROVE THE TRUCK ABOUT 2 WEEKS AFTER THAT AND DIDN'T FEEL IT FIXED THE PROBLEM. I TOOK IT BACK TO THE GARAGE AND THIS TIME THEY SAID THEY RECONFIGURED THE COMPUTER. AFTER I PICKED IT UP AND DROVE IT FOR A WEEK OR SO, IT WASN'T ANY BETTER. I'M TAKING IT BACK TO THE GARAGE AGAIN BECAUSE IT STILL HAS THE PROBLEM. THIS PROBLEM IS A LOT LIKE YOUR OTHER COMPLAINTS ESPECIALLY #10103034. I THINK THIS IS A PROBLEM THAT FORD SHOULD LOOK INTO BEFORE IT CAUSES AN ACCIDENT ESPECIALLY THOSE OWNERS THAT DRIVE IN WINTER WEATHER. *AK

NHTSA ODI #10111992

9,600 miles · Dec 15, 2004
Power Train

2004 MERCURY MOUNTAINEER, V6, AUTOMATIC, 2WD. VIN 4M2ZU66K8UJ13274. PURCHASED MARCH 2004. CURRENTLY MILEAGE 9821. STARTING APPROXIMATELY 12/1/04, WHEN REVERSE GEAR DOES NOT ENGAGE FOR 2 OR 3 SECONDS, THEN ENGAGES WITH A VERY HARD JOLT THAT SHAKES THE WHOLE VEHICLE. THIS OCCURS WHEN FIRST STARTING THE VECHICLE AND ALSO MID-D…

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2004 MERCURY MOUNTAINEER, V6, AUTOMATIC, 2WD. VIN 4M2ZU66K8UJ13274. PURCHASED MARCH 2004. CURRENTLY MILEAGE 9821. STARTING APPROXIMATELY 12/1/04, WHEN REVERSE GEAR DOES NOT ENGAGE FOR 2 OR 3 SECONDS, THEN ENGAGES WITH A VERY HARD JOLT THAT SHAKES THE WHOLE VEHICLE. THIS OCCURS WHEN FIRST STARTING THE VECHICLE AND ALSO MID-DAY WHEN BACKING INTO A PARKING SPACE. ALSO THE AUTOMATIC TRANSMISSION ROUGH SHIFTS IN FREEWAY SLOW TRAFFIC BETWEEN 20 AND 30 MPH. FORD MOTOR CO. CONSUMER HOTLINE SAID ON 12/15/04 THAT MY VEHICLE VIN NUMBER HAS NO RECALLS. FROM PRESS RELEASES, I KNOW OF FORD'S 11/22/04 ANNOUNCEMENT OF 740,000 EXPLORERS AND MOUNTAINEERS WITH THIS SAME TRANSMISSION PROBLEM.*AK

NHTSA ODI #10103034

Mileage unknown · Dec 13, 2004
Power Train

THE REVERSE GEAR TENDS TO POP AND SWITCH TO ANOTHER GEAR, MAKING THE VEHICLE JUMP. TAKEN TO DEALER, BUT THE CAUSE WAS UNDETERMINED.*AK

NHTSA ODI #10103598

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.