2004 FORD CROWN VICTORIA

3 recalls, 175 complaints - 81 TSBs

EXTERIOR LIGHTING:HEADLIGHTS

Defect Description

Ford Motor Company (Ford) is recalling certain model year 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles manufactured October 3, 2001, to August 2, 2005. The affected vehicles have a lighting control module (LCM) that may fail, resulting in a loss of headlights.

Consequence

A loss of headlights can reduce driver visibility and increase the risk of a crash.

Remedy

Ford will notify owners, and dealers will replace the LCM, free of charge. The recall began April 14, 2017. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S39.

296,004 vehicles affected

Manufacturer: Ford Motor Company

FUEL SYSTEM, GASOLINE

Defect Description

CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE... Read more

Consequence

FAILURE OF THIS CONNECTION COULD LEAD TO FUEL SPILLAGE AND, IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.

Remedy

UFI WILL NOTIFY OWNERS AND REPLACE THE FILTERS FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 4, 2006. OWNERS MAY CONTACT UFI FILTERS USA AT 800-230-5876.

58,640 vehicles affected

Manufacturer: UFI FILTERS USA

ELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASH

Defect Description

ON CERTAIN POLICE INTERCEPTORS (CVPI) AND COMMERCIAL HEAVY DUTY (TAXI) VEHICLES, AT EXTREMELY HIGH OPERATING TEMPERATURES, THE SOUND INSULATING PANEL, LOCATED UNDER THE VEHICLE POSITIONED BETWEEN THE EXHAUST SYSTEM AND THE UNDERBODY, COULD SAG AND POSSIBLY CONTACT THE SURFACE OF THE CATALYTIC CONVE... Read more

Consequence

IF THIS OCCURS, THE INSULATOR MIGHT EXPERIENCE CHARRING OF THE OUTER LAYER, BURNING ODOR, OR SMOKE WHICH MAY ULTIMATELY RESULT IN A FIRE.

Remedy

DEALERS WILL REMOVE THE EXISTING DASH INSULATOR AND INSTALL A REVISED DESIGN INSULATOR PAD FREE OF CHARGE. THE RECALL BEGAN ON JUNE 3, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673.

132,800 vehicles affected

Manufacturer: FORD MOTOR COMPANY

Complaint Statistics

175 total complaints 4 crashes 6 fires 5 injuries

Top Reported Components

Component	Complaints
EXTERIOR LIGHTING	76
ELECTRICAL SYSTEM	23
STEERING	18
WHEELS	8
EXTERIOR LIGHTING:HEADLIGHTS	6
ENGINE AND ENGINE COOLING:ENGINE	4
STRUCTURE:BODY	3
VEHICLE SPEED CONTROL	3
FUEL SYSTEM, GASOLINE	2
TIRES	2

Incident date: Sep 7, 2022

Taillight failure and corner light failure likely caused by faulty wiring as mentioned in 2015 lcm recall

Incident date: Sep 7, 2022

Taillight failure and corner light failure likely caused by faulty wiring as mentioned in 2015 lcm recall

Incident date: Feb 1, 2022

I was informed by my mechanic that my steering column shaft needs to be replaced on my 2004 primary vehicle. Ford says they do not have a recall and will not cover the service. I have a recall for THE SAME ISSUE for my (not currently driving) 2005 Ford Crown Victoria Interceptor made in the SAME ... Read more

Incident date: Jan 3, 2021

THE GOOD YEAR EAGLE SPORT TIRES TORE APART ON A SHORT TRIP TO THE GROCERY STORE AND CAUSED THE CAR TO BE UNSAFE TO DRIVE. THE TIRES WERE MANUFACTURED ON JUNE 2019 AND PURCHASED OCTOBER 2019 AND BY JANUARY 3RD OF 2021 THEY WERE FLAT AND CHEWED UP WITH ONLY AROUND 13,000 MILES ON THEM EVEN THOUGH THE... Read more

Incident date: Nov 30, 2020

THE NEAD LIGHTS SHUT OFF WHILE DRIVING AT NIGHT AT 65 MILES A HOUR STOPED ON THE SIDE OF THE HIWAY SHUT OFF THE CAR PLAYED WITH THE HEADLIGHT SWITCH THE LIGHTS CAME BACK ON BUT NOW THEY WILL NOT SHUT OFF SO THE BATTERY MUST BE DICONECTED WHEN NOT IN USE WORKING ON FINDING A REPAIR SHOP T FIX IT

Incident date: Oct 3, 2020

2004 FORD CROWN VIC HEADLIGHTS STOPPED WORKING. I ORDERED AND REPLACED THE HEADLIGHT SWITCH AND MY HEADLIGHTS STILL DON'T WORK. I CAN'T DRIVE AT NIGHT ANYMORE. I HAVE CONTACTED FORD DEALERSHIP ABOUT A RECALL AND HAVE NOT RECEIVED A CALL BACK.

Incident date: Sep 8, 2020

TL* THE CONTACT OWNS A 2004 FORD CROWN VICTORIA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 15V861000 (EXTERIOR LIGHTING) HOWEVER, THE PART TO DO THE RECALL REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. N... Read more

Incident date: May 22, 2020

WHAT HAPPENED IS THAT I GOT THE VIN REPORT ONLINE AND ASKED ABOUT RECALLS, FOUND 5 RECALLS, AND WENT TO THE NHTSA AND NOW YOU DO NOT TELL ME IF THE RECALLS WERE MADE OR THE PROBLEMS FIXED. *TR

Incident date: May 22, 2020

WHAT HAPPENED IS THAT I GOT THE VIN REPORT ONLINE AND ASKED ABOUT RECALLS, FOUND 5 RECALLS, AND WENT TO THE NHTSA AND NOW YOU DO NOT TELL ME IF THE RECALLS WERE MADE OR THE PROBLEMS FIXED. *TR

Incident date: May 22, 2020

WHAT HAPPENED IS THAT I GOT THE VIN REPORT ONLINE AND ASKED ABOUT RECALLS, FOUND 5 RECALLS, AND WENT TO THE NHTSA AND NOW YOU DO NOT TELL ME IF THE RECALLS WERE MADE OR THE PROBLEMS FIXED. *TR

Incident date: Mar 1, 2017

TL* THE CONTACT OWNS A 2004 FORD CROWN VICTORIA. WHILE DRIVING VARIOUS SPEEDS, THE STEERING WHEEL SEIZED WHILE TURNING RIGHT OR LEFT. THE CONTACT MENTIONED THAT THE FAILURE OCCURRED PERIODICALLY. THE VEHICLE WAS NOT TAKEN TO A DEALER OR INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING OR REPAIRS. THE MAN... Read more

Incident date: Dec 1, 2017

TL* THE CONTACT OWNS A 2004 FORD CROWN VICTORIA. WHILE DRIVING 30 MPH, THE LIGHTING CONTROL MODULE COMPLETELY FAILED WITHOUT WARNING. THE CONTACT STATED THAT THE VEHICLE WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 15V861000 (EXTERIOR LIGHTING), BUT THE REMEDY WAS NOT AVAILABLE. THE DEALER AND MANUFACTURE... Read more

Incident date: Jan 30, 2018

THE DASHBOARD LIGHTS ARE NOT WORKING. THE FUSE WAS GOOD BUT I REPLACED IT ANYWAY. I ALSO REPLACED THE HEADLIGHT SWITCH.

Incident date: Sep 1, 2018

TL* THE CONTACT OWNS A 2004 FORD CROWN VICTORIA. WHILE DRIVING AT UNKNOWN SPEEDS, THE STEERING WHEEL BECAME EXTREMELY STIFF. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THAT THE STEERING SHAFT AND STEERING LINKAGE NEEDED TO BE REPLACED. T... Read more

Incident date: Aug 6, 2018

TL* THE CONTACT OWNS A 2004 FORD CROWN VICTORIA. THE CONTACT STATED THAT THE ELECTRICAL SYSTEM INDICATOR ILLUMINATED. THE VEHICLE WAS SERVICED PER NHTSA CAMPAIGN NUMBER: 15V861000 (EXTERIOR LIGHTING) AT COUNTRY FORD (888) 867-3993 (95 GOODMAN RD E, SOUTHAVEN, MS 38671), BUT THE REMEDY FAILED TO REPA... Read more

Incident date: Aug 6, 2018

Incident date: Aug 13, 2018

I WAS DRIVING AND ALL THE SUDDEN I START HEARING THIS REAL LOUD NOISE COMING FROM PASSENGER REAR AND ALL MY BRAKE LIGHTS ABS LIGHTS AND TRACTION LIGHTS CAME ON . WELL I WAS TOLD IT WAS WHEEL SEALS COME TO GIND OUT THERE IS A BIT GROVE OUT OF SHAFT WHERR BEARING RIDES. AND SHAFT IS VERY WEEK

Incident date: Aug 13, 2018

Incident date: May 15, 2018

THE LIGHTING CONTROL MODULE FAILED ONE NIGHT. THE PASSENGER HEADLIGHT WENT DIM AND MY SIGNALS WOULDN'T WORK ON THAT SIDE. EVENTUALLY THE ENTIRE THING FAILED AND THERE WAS NO AUDIBLE CLICKING FROM THE MODULE.

Incident date: Feb 10, 2018

HORN,CRUSE CONTROL,AND OTHER FUNCTIONS ON THE STEERING WHEEL HAVE FAILED WHEN WE WERE DRIVING. UNKNOWN REASON.

Incident date: Feb 10, 2018

HORN,CRUSE CONTROL,AND OTHER FUNCTIONS ON THE STEERING WHEEL HAVE FAILED WHEN WE WERE DRIVING. UNKNOWN REASON.

Incident date: Feb 10, 2018

HORN,CRUSE CONTROL,AND OTHER FUNCTIONS ON THE STEERING WHEEL HAVE FAILED WHEN WE WERE DRIVING. UNKNOWN REASON.

Incident date: Feb 3, 2018

CARS PAINT IS FLAKING OFF GOING DOWN THE ROAD.

Incident date: Feb 3, 2018

PAINT IS FLAKING.

Incident date: Jan 9, 2018

MY CAR WAS RECALLED FOR A FAULTY LIGHTING CONTROL MODULE AND WAS REPAIRED IN JUNE 2014 BECAUSE THE HEADLIGHTS FAILED. TODAY THE LIGHTS EXPERIENCED THE EXACT SAME FAILURE. FORD IS REFUSING TO REPAIR IT UNLESS WE PAY FULL PRICE FOR DIAGNOSTICS, PARTS AND SERVICE. I HAVE FOUND THAT ANOTHER RECALL WAS I... Read more

Incident date: Jul 3, 2017

TL* THE CONTACT OWNS A 2004 FORD CROWN VICTORIA. WHILE DRIVING 45 MPH, THE RUNNING LIGHTS IN THE FRONT AND REAR OF THE VEHICLE BECAME INOPERABLE. THE VEHICLE WAS TAKEN TO A LOCAL DEALER (THOMASVILLE FORD LINCOLN 1515 EAST JACKSON STREET, THOMASVILLE, GA 31792) WHERE IT WAS DIAGNOSED THAT THE LCM HAR... Read more

Incident date: Jul 3, 2017

I HAVE A 2004 CROWN VICTORIA. FORD HAS A RECALL OUT FOR 2003-2005 GRAND MARQUIS AND CROWN VICTORIA'S FOR THEIR LIGHT CONTROL MODULE (LCM) BECAUSE OF SOLDERS BREAKING CAUSING EXTERIOR LIGHTING NOT TO WORK. I TOOK MY CAR TO MY LOCAL FORD DEALERSHIP (APRIL 22, 2017) TO HAVE SUCH RECALL DONE BECAUSE MY... Read more

Fire

Incident date: Jun 7, 2017

FORD SENT ME A WRITTEN SAFETY RECALL NOTICE 15S39 NHTSA 16V-861 INSTRUCTING ME TO APPROACH MY FORD DEALER TO OBTAIN INSTALLATION OF A LCM BYPASS KIT THAT WILL CORRECT A POTENTIAL HEADLIGHT PROBLEM. I RECEIVED EARLIER LETTERS INFORMING ME THAT FORD WAS SEARCHING FOR A FIX. WHEN I CONTACTED THE DEAL... Read more

Incident date: Apr 18, 2017

TL* THE CONTACT OWNS A 2004 FORD CROWN VICTORIA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 15V861000 (EXTERIOR LIGHTING); HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MAN... Read more

Incident date: Jan 23, 2015

LOWER STEERING SHAFT LOOSE RUSTED FRONT END WOBBLES.

Incident date: Dec 19, 2016

TL* THE CONTACT OWNS A 2004 FORD CROWN VICTORIA. THE CONTACT STATED THAT THE HEADLIGHT CONTROL MODULE MALFUNCTIONED. THE DEALER REPAIRED THE SAME FAILURE ONE YEAR AGO. THE VEHICLE WAS NOT REPAIRED, BUT THE FAILURE OCCURRED ON NUMEROUS OCCASIONS. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FA... Read more

Incident date: Nov 1, 2016

2004 FORD CROWN VICTORIA. CONSUMER REQUESTS FOR INVESTIGATION/ACTION ON CONTINUED AXLE, BEARING FAILURES, DEFECTS (POTENTIAL CATASTROPHIC LOSS OF CONTROL AND ALLEGEDLY DEFECTIVE AIRBAGS TO PROTECT VICTIMS) COLLAPSE OF SAFETY RECALL SYSTEM. *SMD THE CONSUMER STATED FORD DID SOME RECALL WORK ON THE... Read more

Incident date: Nov 1, 2016

Incident date: Dec 1, 2015

THE HEADLIGHTS DO NOT COME ON

Incident date: Aug 17, 2016

HEAD LIGHTS NO LONGER ARE OPERATING. WAS DRIVING AT NIGHT AND THEY WENT OUT AND WILL NOT GO ON AGAIN. HAVE TRIED TO HAVE THEM OPERATE AGAIN AND AGAIN AND NO LUCK. WHEN WILL RECALL PARTS BE AVAILABLE AS THIS VEHICLE IS NOT ABLE TO OPERATE AT NIGHT , IN FOG ,OR IN HEAVY RAIN.

Incident date: Jul 2, 2016

RECALL # 15S39, PERTAINING TO HEADLIGHT MODULE AND SOLDERING PROBLEMS CAUSING THE HEADLIGHTS TO GO OUT. MY HEADLIGHTS HAVE GONE OUT. IT HAS BEEN CHECKED FOR FUSE PROBLEMS AND BULBS BURNT OUT. NOT THE PROBLEM. CONTACTED THE MANUFACTURER AND 2 DEALERSHIPS. ALL SAID THE PART IS NOT AVAILABLE AND T... Read more

Incident date: Mar 9, 2016

FORD RECALL FOR CRACKS IN POLICE INTERCEPTOR WHEELS THAT WAS CANCELLED AND REMOVED FROM OASIS DATABASE IF WHEELS ARE NOT ON A LAW ENFORCEMENT VEHICLE ANY LONGER. WHEEL IS MARKED WITH THE NUMBERS OF THE DEFECTIVE ONES AND HAS A VISIBLE CRACK AND CREAKS AND WON'T HOLD A BALANCE AND WOBBLES WHILE DRI... Read more

Incident date: Apr 2, 2016

TL* THE CONTACT OWNS A 2004 CROWN VICTORIA. THE CONTACT STATED THAT THE VEHICLE HAD THREE MANUFACTURER RECALLS THAT NEEDED TO BE COMPLETED BY THE DEALER; HOWEVER, THEY WERE NOT COMPLETED WITHIN A REASONABLE TIME FRAME. THE DEALER WAS NOTIFIED SEVERAL TIMES THAT THE WHEEL WELLS HAD A PREMATURE LEAK O... Read more

Incident date: Feb 19, 2016

UNINTENDED ACCELERATION: I WAS IN HEAVY CITY TRAFFIC. WITHOUT WARNING, MY ENGINE STARTED TO RACE FULL SPEED. (IN A CROWN VICTORIA, THAT'S VERY FAST). THE ONLY WAY TO SLOW IT WAS TO PUSH THE BRAKE AS HARD AS I COULD. FINALLY GOT IT PULLED OVER AND STOPPED. EVEN IN NEUTRAL, THE ENGINE RACED FULL ... Read more

Incident date: Jan 5, 2015

TL* THE CONTACT OWNS A 2004 FORD CROWN VICTORIA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 15V861000 (EXTERIOR LIGHTING); HOWEVER, THE PARTS TO DO THE RECALL REPAIR WERE UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR... Read more

Incident date: Jan 14, 2016

VEHICLE BECAME INCREASINGLY HARD TO STEER AT ALL SPEEDS OVER A PERIOD OF SEVERAL MONTHS. THE STEERING WHEEL WOULD BIND AND BECOME STIFF AT MULTIPLE POSITIONS DURING TURNS, BUT COULD STILL BE STEERED WITH ADDITIONAL EFFORT. DURING LOW SPEED TURNING IT WOULD TAKE AN UNREASONABLE AMOUNT OF EFFORT TO ST... Read more

Incident date: Feb 28, 2015

TL* THE CONTACT OWNS A 2004 FORD CROWN VICTORIA. THE CONTACT STATED THAT WHILE DRIVING 25 MPH, THE STEERING WHEEL SEIZED MAKING IT DIFFICULT TO MAKE A LEFT TURN. IN ADDITION, THE CONTACT STATED THAT THE STEERING WHEEL WAS RUSTED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE A... Read more

Incident date: Apr 10, 2015

TL* THE CONTACT OWNS A 2004 FORD CROWN VICTORIA. WHILE DRIVING 55 MPH, THE STEERING WHEEL SEIZED WITHOUT WARNING. THE CONTACT STATED THAT THE FAILURE OCCURRED SEVERAL TIMES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 140,000.

Incident date: Aug 3, 2015

TL* THE CONTACT OWNS A 2004 FORD CROWN VICTORIA. WHILE DRIVING APPROXIMATELY 55 MPH AT NIGHT, THE HEADLIGHTS BECAME INOPERABLE WITHOUT WARNING. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 92,000. THE VIN WAS NOT AVAILABLE.

Incident date: Aug 15, 2015

TRUNK LID TORSION BAR FAILED, FORTUNATELY AFTER DRIVER AND PASSENGER HAD JUST REMOVED ITEMS FROM TRUNK. DUE TO THE WEIGHT OF THE TRUNK LID ON THIS VEHICLE, WE WOULD HAVE BEEN SERIOUSLY INJURED IF THE TRUNK LID HAD FALLEN ON US.

Incident date: Aug 4, 2015

TL* THE CONTACT OWNS A 2004 FORD CROWN VICTORIA. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE HEADLIGHTS FAILED WITHOUT WARNING. THE CONTACT STATED THAT THE HIGH BEAMS HAD TO BE TURNED ON IN ORDER FOR THE VEHICLE TO BE DRIVEN AT NIGHT. THE FAILURE RECURRED THREE TIMES. THE VEHICLE WA... Read more

Incident date: Jul 1, 2011

TL* THE CONTACT OWNS A 2004 FORD CROWN VICTORIA. WHILE THE VEHICLE WAS PARKED WITH THE HEADLIGHTS ACTIVATED, THE LOW BEAM HEADLIGHTS FAILED TO FUNCTION INTERMITTENTLY. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE RECURRED ON NUMEROUS OCCASIONS. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE.... Read more

Incident date: Dec 10, 2014

WHILE STEERING, THE STEERING COLUMN SEEMS TO LOCK AND CLICK WHEN MOVING FROM SIDE TO SIDE. COULD ACTUALLY FEEL IT THRU THE STEERING WHEEL. IT GETS HARD TO TURN AND HAVE TO FIGHT IT TO MOVE THE STEERING WHEEL. *TR

Incident date: Apr 10, 2014

I TOOK THE CAR INTO FUTURE FORD TO REPLACE THE RECALLED HEADLIGHT MODULE. (I WAITED 7 MONTHS BEFORE THE MODULE WAS DELIVERED.) WHEN THEY REPLACED THE MODULE THEY SAID THE LIGHTS STILL WOULDN'T WORK. IT TOOK THEM 4 DAYS TO SOLVE THE PROBLEM AND THEY THEN CHARGED ME $1,051.56 INCLUDING A CAR RENTAL... Read more

Showing 50 of 175 complaints.

EPA Fuel Economy, 2004 FORD CROWN VICTORIA

Trim / Engine	City MPG	Highway MPG	Combined MPG	Fuel Type	Annual Fuel Cost
4.6L 8-cyl, Automatic 4-spd (Rear-Wheel Drive)	15.0	23.0	18.0	Regular	$3,400

CO2 Emissions: -1.0 g/mile (Large Cars)

Source: U.S. Environmental Protection Agency (EPA). Actual fuel economy may vary based on driving conditions.

Technical Service Bulletins, 2004 FORD CROWN VICTORIA

81 manufacturer communications from 62 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
110000 ELECTRICAL SYSTEM	16
061000 ENGINE AND ENGINE COOLING:ENGINE	9
160000 STRUCTURE	3
138120 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:WINDSHIELD:ELECTRICAL HEATING ELEMENT	2
063140 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR	2
010000 STEERING	2
162000 STRUCTURE:BODY	2
116100 ELECTRICAL SYSTEM:IGNITION:SWITCH	2

160000 STRUCTURE

This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint wi

350000 EQUIPMENT

Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Fo

160000 STRUCTURE

061200 ENGINE AND ENGINE COOLING:ENGINE:DIESEL

The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate

060000 ENGINE AND ENGINE COOLING

061000 ENGINE AND ENGINE COOLING:ENGINE

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

061110 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:BELTS AND ASSOCIATED PULLEYS

061120 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:TURBO/SUPERCHARGER

061320 ENGINE AND ENGINE COOLING:ENGINE:OTHER FUEL TYPES:TURBO/SUPERCHARGER

062000 ENGINE AND ENGINE COOLING:COOLING SYSTEM

062100 ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

062300 ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS

063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

063100 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL

062200 ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN

063110 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CRANKCASE (PCV)

063130 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:GAS RECIRCULATION VALVE (EGR VALVE)

063140 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR

063200 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE

060000 ENGINE (PWS)

110000 ELECTRICAL SYSTEM

SUMMARY TO BE PROVIDED ON A FUTURE DATE.

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

FORD: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. INFORMATION REGARDING THE LIGHTING CONTROL MODULE EXTENDED WARRANTY COVERAGE, FOR SOME VEHICLES, TO 15 YEARS OR 250,000 MILES, WHICHEVER OCCURS FIRST. MODEL 2003-2005 VICTORIA, GRAND MAR

120000 EXTERIOR LIGHTING

FORD: THE LIGHTING CONTROL MODULE HAS EXTENDED WARRANTY COVERAGE, ON CERTAIN VEHICLES, DUE TO A POSSIBLE CRACK ON SOLDER JOINT THAT CONNECTS RELAY TO CIRCUIT BOARD. MODEL 2003-2005 CROWN VICTORIA, GRAND MARQUIS. *PE

061000 ENGINE AND ENGINE COOLING:ENGINE

SOME 1997-2008 VEHICLES EQUIPPED WITH A 4.6L 2V, 5.4L 2V, OR 6.8L 2V ENGINE--SPARK PLUG THREAD REPAIR PROCEDURE--NOT COVERED UNDER NEW VEHICLE LIMITED WARRANTY. *NJ THIS INCLUDES F-53 MOTORHOME CHASSIS. UPDATED 2/23/10. *PE

106000 POWER TRAIN:AXLE ASSEMBLY

LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNING MANEUVERS. *TT

060000 ENGINE AND ENGINE COOLING

WDS COP KIT DIAGNOSTIC TIP - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING. *TT

151300 SEAT BELTS:FRONT:RETRACTOR

SAFETY BELT RETRACTION SPEED. *TT

071100 FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

GUIDANCE FOR CNG TANK INSPECTION FOR VEHICLES PRODUCED AFTER DECEMBER 2, 1996. *TT UPDATE. *TT

150000 SEAT BELTS

SAFETY BELT WEB STOP BUTTON SERVICE. *EH

063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

IDLE VIBRATION VEHICLES EQUIPPED WITH SINGLE EXHAUST. *EH

110000 ELECTRICAL SYSTEM

DELAYED REVERSE ENGAGEMENT. *EH

353400 EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC.

AM FM AND CELLULAR PHONE RECEPTION INTERFERENCE . *EH

046300 SERVICE BRAKES, AIR:ANTILOCK:WHEEL SPEED SENSOR

NUMEROUS ANTI-LOCK BRAKE SYSTEM (ABS) WHEEL SPEED SENSOR (WSS) DTCS, SUCH AS C1145, C1155, C1165, C1175, C1296, C1297, C1298, C1299 AND C1222. *TT

110000 ELECTRICAL SYSTEM

AM/FM AND CELLULAR PHONE RECEPTION INTERFERENCE - SERVICE TIP. *TT

110000 ELECTRICAL SYSTEM

DIAGNOSTIC TROUBLE CODE B1342 (RESTRAINTS CONTROL MODULE (RCM) FAULT. *TT UPDATE. *TT

162000 STRUCTURE:BODY

ALUMINUM CORROSION - SERVICE TIP. *TT

036000 SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP

NUMEROUS ANTI-LOCK BRAKE SYSTEM (ABS) WHEEL SPEED SENSOR (WSS) DIAGNOSTIC TROUBLE CODES (DTCS). *TT

103100 POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM)

GENERAL (PCM) POWER TRAIN CONTROL MODULE PROGRAMMING PROCEDURES. *TT

138200 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:REAR WINDOW

REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR. *TT

200000 WHEELS

CUSTOMER SATISFACTION PROGRAM 04M05. STEEL WHEEL ADDITIONAL COVERAGE. *TT

110000 ELECTRICAL SYSTEM

MALFUNCTION INDICATOR LAMPAND P0460 DTC IN MEMORY. *EH

110000 ELECTRICAL SYSTEM

MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODE (DTC) P0460 IN CONTINUOUS MEMORY. OASIS. *TT

110000 ELECTRICAL SYSTEM

MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - SYSTEM LEAN DIAGNOSTIC TROUBLE CODES (DTC'S) - SERVICE TIPS. VARIOUS MODELS INCLUDING 2004 F-SERIES. *TT

063140 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR

EMISSION RELATED SERVICE ACTION 04E12. VEHICLES SERVICED WITH AN INCORRECT RIGHT HAND CATALYTIC CONVERTER. INSPECT AND REPLACE RIGHT HAND CATALYTIC CONVERTER. ATTACHMENTS I-III AND CUSTOMER NOTIFICATION LETTER. *TT

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

TRANSMISSION WON'T SHIFT INTO OVERDRIVE-4R70W-POLICE PACKAGE. *AR

061000 ENGINE AND ENGINE COOLING:ENGINE

ENGINE MISFIRE OR RUNNING - COIL ON PLUG (COP) IGNITION SYSTEMS - WDS COP KIT DIAGNOSTIC TIPS. TO INCLUDE VARIOUS 2005 MODELS. * AR THIS ARTICLE 04161 SUPERSEDES TSB 03-14-04.

021000 SUSPENSION:FRONT

SQUEAK OR RUBBING NOISE FROM FRONT SUSPENSION - FRONT SPRING INSULATOR REVISED. *TT

138120 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:WINDSHIELD:ELECTRICAL HEATING ELEMENT

REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR. *TT

110000 ELECTRICAL SYSTEM

DIAGNOSTIC TROUBLE CODE (DTC) P0442. *TT

138120 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:WINDSHIELD:ELECTRICAL HEATING ELEMENT

INOPERATIVE ELECTRIC REAR WINDOW DEFROSTER (HEATED BACKLITE) GRID LINES, INTEGRAL ANTENNA CONCERNS. *TT

110000 ELECTRICAL SYSTEM

MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODE (DTC) P0442 OR P0456. *TT

110000 ELECTRICAL SYSTEM

A NO CRANK/NO START. CONNECTOR C192 OR C146 NOT FULLY CONNECTED. *TT

110000 ELECTRICAL SYSTEM

DIAGNOSTIC TROUBLE CODE (DTC) P1233 WITH POSSILE DRIVEABILITY OR NO START CONDITION. *TT

100000 POWER TRAIN

LOSS OF OVERDRIVE ON POLICE INTERCEPTORS AND LONG WHEEL BASE TAXI CABS. *TT

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

TRANSMISSION FAILURE WHERE THERE IS A LARGE AMOUNT OF METAL OR DEBRIS IN THE PAN. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

REDUCTION IN POWER AT WIDE OPEN THROTTLE (WOT) AFTER EXTENDED IDLE. *TT

116100 ELECTRICAL SYSTEM:IGNITION:SWITCH

IGNITION SWITCH BINDING. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

ROLLING IDLE AND CHARGING SYSTEM WARNING INDICATOR ON. *TT

126000 EXTERIOR LIGHTING:TURN SIGNAL

INTERMITTENT RAPID FLASHING OF THE TURN SIGNALS. *TT

110000 ELECTRICAL SYSTEM

LOW CHARGING SYSTEM VOLTAGE AFTER EXTENDED IDLE. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

ENGINE KNOCK DURING INITIAL COLD START, THE KNOCK WILL CEASE AFTER THE ENGINE IS FULLY WARMED UP. *TT

010000 STEERING

STEERING GEAR YOKE PLUG LOCK RING TORQUE. ALSO INCLUDING THE 2004 MERCURY MARAUDER. *MR

110000 ELECTRICAL SYSTEM

ROLLING IDLE AND CHARGING SYSTEM WARNING INDICATOR ON. *MJ

020000 SUSPENSION

COSMETIC CRACKING OF LOWER CONTROL ARM BUSHING SLEEVE. *MJ

116100 ELECTRICAL SYSTEM:IGNITION:SWITCH

IGNITION LOCK CYLINDER BINDING ON POLICE INTERCEPTORS BUILT BEFORE 10/31/2003. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

ENGINE VIBRATION AT IDLE ON VEHICLES EQUIPPED WITH SINGLE EXHAUST. *TT

110000 ELECTRICAL SYSTEM

NOISE-CLIMATE CONTROL-REGISTER VENT RATTLE WITH A/C BLOWER ON. *MJ

162000 STRUCTURE:BODY

COSMETIC CRACKING OF THE CENTER FLOOR PAN. *TT

110100 ELECTRICAL SYSTEM:HORN

INTERMITTENT HORN SELF-ACTIVATION. *TT

132000 VISIBILITY:GLASS, SIDE/REAR

SLOW OR BINDING SIDE DOOR GLASS OPERATION. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

ENGINE-ROMEO BUILT 4.6L 2V-TICK NOISE FROM ENGINE-ENGINES BUILT BEFORE 9/17/2003. *MJ

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

LACK OF AIR CONDITIONER (A/C) COOLING AND RESTRICTED/REDUCED AIR FLOW THROUGH THE A/C VENTS TYPICALLY DURING EXTENDED IDLING CONDITIONS. *TT

010000 STEERING

STEERING NIBBLE - SERVICE TIP. *TT

110000 ELECTRICAL SYSTEM

FLICKERING ELECTRONIC INSTRUMENT CLUSTER DISPLAY, ELECTRONIC AUTOMATIC TEMPERATURE CONTROL DISPLAY, RADIO DISPLAY, AND/OR OVERHEAD CONSOLE DISPLAY. *TT

012200 STEERING:COLUMN LOCKING:ANTI-THEFT DEVICE

PASSIVE ANTI-THEFT SYSTEM (PATS) DO NOT COME WITH A STEERING WHEEL LOCK. *TT

110000 ELECTRICAL SYSTEM

REMOTE KEYLESS ENTRY (RKE) - SERVICE TIPS. *TT

030000 SERVICE BRAKES, HYDRAULIC

UNEVEN REAR BRAKE PAD WEAR ON LONG WHEELBASE VEHICLES. *TT

103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER

CATALYTIC CONVERTER BRICK RATTLE OR BUZZING NOISE. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

REDUCTION IN POWER AT WIDE OPEN THROTTLE. *KB

NHTSA Safety Investigations, FORD CROWN VICTORIA

Investigations opened by NHTSA into potential safety defects. These are separate from recalls and may or may not result in a recall.

PE, Closed , Model Year: 2003

Loss of headlights

The Office of Defects Investigation (ODI) opened an investigation concerning the loss of headlights in model year (MY) 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles. The subject vehicles share the same architecture and major components.ODI has received 636 unique reports (for all ... submission dates) related to the alleged defect, with owners describing a loss of both low and/or high beam headlights occurring while driving.ODI identified 4 Vehicle Owner Questionnaire ( VOQ) reports alleging minor crash or loss of control incidents due to headlight failures.Drivers alleged running off of the road due to a lack of headlights and one driver reportedly struck a deer.No injuries were indicated in the VOQ crashes.In response to ODI's Information Request (IR) letter, Ford Motor Company (Ford) responded with 4173 unique reports related to the alleged problem.There were a total of 11 crashes reported within that group as well as one injury that occurred when the vehicle struck an unseen object on the side of the road when the headlights failed. Ford also submitted 49,843 warranty claims related to headlight failures.Most reports indicate that the headlights failed without warning leaving the driver with no forward lighting, however some noted the headlights flickered or dimmed prior to turning off.Consumers also noted they were able to hold the flash to pass lever on the steering column mounted stalk to activate the high beams however this is only effective as long as the lever is physically actuated.On December 21st, 2015 Ford notified ODI that it would conduct a safety recall (15V-861) to remedy headlight failures on (MY) 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles.According to Ford, the headlights of the vehicle are controlled by the Lighting Control Module (LCM) located in the engine compartment of the vehicle.The LCM uses an internal relay, mounted to a circuit board, to control power to the headlights. The headlight relay is soldered to the circuit board at six different terminals. The original equipment LCMs were manufactured in a manner that resulted in the solder joints fatiguing and/or cracking as a result of repeated thermal cycling and/or vibration, a defect condition. The condition could be exacerbated by manufacturing quality issues such as an insufficient amount of solder, effecting the continuity between the circuit board and the relay terminal, and resulting in loss of headlights while driving.Other lighting functions are unaffected by this condition.The LCM manufacturing processes were revised to address the defect condition and Ford has been conducting a warranty extension program to cover defective LCMs since late 2013.Under the recall Ford will replace any remaining defective LCMs in recalled vehicles with remedy LCMs once they become available.See NHTSA recall 15V-861 for further details on the safety recall.The recall action initiated by Ford addresses the safety risks of concern to ODI.Accordingly, the investigation is closed.The ODI reports cited above can be reviewed at SaferCar.gov under the identification (ODI) numbers found in the attached list.Read more

DP, Closed , Model Year: 2003

Loss of headlamp/exterior lighting

In a letter dated October 2, 2014 the Office of Defects Investigation (ODI) was initially petitioned by the North Carolina Consumers Council, Inc. requesting a defect investigation of an alleged defect condition resulting in headlight and/or exterior lighting failure on 2003-2005 Ford Crown Victoria... and Mercury Grand Marquis vehicles.ODI analyzed Vehicle Owner Questionnaire (VOQ) complaints received from consumers and identified a total of 605 reports (for all submission dates) alleging headlight failure.The complaints indicate failures of both low beam headlights typically while driving, a defect condition that was evaluated under a prior ODI investigation (PE08066).Most consumer VOQs indicate that the headlights failed suddenly and without warning leaving the driver with no forward lighting, however some report the headlights flickered or dimmed prior to turning off.In some cases drivers were able to turn the headlights back on after a period of time while others reported the headlights would not come back on at all.Consumers noted they were able to hold the flash to pass lever on the steering column mounted stalk to activate the high beams however this is only effective as long as the lever is actuated.ODI identified 4 VOQ reports alleging minor crash or loss of control incidents due to headlight failures.Drivers indicated running off of the road due to a lack of headlights and one driver reportedly struck a deer.No injuries were indicated in the VOQ crashes.In response to ODI's April 7, 2015 Information Request letter, Ford provided data indicating it has received 3,092 complaints of failed headlights related to the Lighting Control Module (LCM), a device that controls the headlights and other lighting functions.This number includes the complaints Ford reviewed and classified as headlight failure due specifically to the LCM.Within Ford's complaints, there are 11 reports alleging a crash occurred.These drivers reported hitting objects, including other vehicles after the headlights failed causing damage to the affected vehicles.One driver was injured when their car struck an unseen object in the road, jerking the steering wheel from their hands and injuring their shoulder.In total 15 crash allegations were identified, all of which have occurred since ODI's prior evaluation of this issue.This petition has been granted.Preliminary Evaluation PE15-028 has been opened to assess the scope, frequency, and safety-related consequences of the alleged defect.The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SarchNHTSAID under the identification (ODI) numbers found in the attached list.Read more

PE, Closed , Model Year: 2004

Steering Column Shaft Obstruction

On July 7, 2014 the Office of Defects Investigation (ODI) opened a preliminary evaluation based on five complaints (VOQs) alleging incidents ofinterference between dislodged exhaust manifold heat shields and the lower steering shaft/knuckle, including one alleging the interference resulted in a cras... Read more

EA, Closed , Model Year: 2005

Loss of Steering Control

In its recall notice dated August 26, 2013, Ford Motor Company (Ford) notified NHTSA of a safety defect condition that may result in loss of steering in approximately 355,000 model year (MY) 2005 through 2011 Ford Crown Victoria and Mercury Grand Marquis vehicles built at the St. Thomas Assembly Pla... nt, MY 2005 through 2007 Lincoln Town Car vehicles built at the Wixom Assembly Plant, and certain MY 2008 through 2011 Lincoln Town Car vehicles built at the St. Thomas Assembly Plant and that are currently registered or were originally sold in Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, or Wisconsin (NHTSA Recall 13V-385, Ford Recall 13S08).Ford's recall addresses a corrosion related defect in the lower intermediate shaft that may result in separation of the steering column lower bearing and loss of steering control.Ford's recall will remedy the defect condition by instructing dealers to replace the lower intermediate shaft and to inspect and repair the upper intermediate shaft and steering column lower bearing as necessary.A retaining clip will be installed if the lower bearing has separated.Ford's investigation of steering column separations in the subject vehicles identified a defect condition in the lower intermediate shaft that could result in separation of the column lower bearing.According to Ford's August 26th defect report, severe corrosion of the lower intermediate shaft may cause the lower intermediate shaft swing link joint(s) to stiffen or seize.Ford determined that forces acting on the upper intermediate shaft because of seized swing links may eventually cause the upper intermediate shaft to collapse, which may result in separation of the column lower bearing and loss of steering control.Analysis of ODI complaints and Ford complaints and warranty identified 22 incidents of steering separation (12 complaints and 10 non-duplicative warranty claims) that may be related to the lower intermediate shaft defect condition.All 22 incidents involved vehicles in the recall region, where 419,210 or roughly half (52%), of the subject vehicles were sold.Ford's investigation also determined that column lower bearing separation may occur in vehicles that experienced upper intermediate shaft collapse in prior frontal impact collisions if the shaft was not properly diagnosed and repaired.Ford identified 13 steering separation incidents outside the recall region (6 complaints and 7 non-duplicative warranty claims) where 386,003 of the subject vehicles were sold.Ford did not find evidence of the lower intermediate shaft corrosion issue in these vehicles.Six of the vehicles had known prior collisions and the histories of the remaining 7 were unknown.To address concerns with possible steering separations in vehicles outside the region for safety recall 13V-385, Ford is conducting a Regional Program (13R01) to inspect and repair the steering assemblies of those vehicles as necessary.The lower intermediate shaft will be replaced only if it fails the inspection, the upper intermediate shaft will be repaired if it fails a Ford-specified measurement test.In the event the steering column lower bearings are found out of position, they will be re-seated and secured with a retaining clip.Based on Ford's field actions, this investigation is closed.The VOQs cited above can be viewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10505992, 10479893, 10477192, 10475950, 10474596Read more

PE, Closed , Model Year: 2005

Loss of Steering Control

In the subject vehicles, the mechanical connection between the steering wheel and rack and pinion steering assembly consist of the steering column and an upper and lower intermediate shaft.A disconnection of any of these components from the steering system can create a loss of steering control.Alleg... ations of a loss of steering control incidents reviewed during the Preliminary Evaluation PE12-025 appear to be related to a separation of the upper and lower shafts within the steering the column. In response to the Office of Defects Investigation's (ODI) Information Request (IR) during PE12-025, Ford provided 2 complaints and 9 warranty claims related to the alleged defect in the subject vehicles (see Figure 1 for an exemplar picture).ODI has received 5 complaints related to the alleged defect, including 1 related to an incident reported in one of the Ford complaints.The incident rate involving subject vehicles is 7.7 per 100,000 vehicles (15 total incidents).Five of the 15 incident vehicles were associated with a prior history report of a frontal impact incident.ODI also analyzed field data for MY 2005 through MY 2008 non-CVPI Crown Victoria and Grand Marquis models and MY 2009 through MY 2011 CVPI models, which use a similar steering column and intermediate shaft design. This analysis identified 4 reports from Ford and 2 complaints to ODI, including 1 duplicative of a complaint provided by Ford, resulting in 5 total incidents and an incident rate of 1.1 per 100,000 vehicles for a vehicle population of approximately 436,000 vehicles. In the peer vehicle analysis, 4 of 5 incident vehicles had a prior history report of a frontal impact incident.ODI also identified 42 reports (39 reports associated with subject vehicles and 3 reports associated peer vehicles) of the lower steering column shaft bearing displacement that did not result in complete separations of the upper to lower steering column shafts (see Figure 2). Vehicles with this condition were identified during inspections of police fleets or during vehicle repairs for complaints of looseness, binding or noise in the steering system while turning.This Preliminary Evaluation has been upgraded to an Engineering Analysis (EA13-004) has been opened to further assess the scope, frequency, consequence, and contributing factors to the steering column shaft separations.The VOQs associated with the opening of this investigation and a loss of steering control are: 10347404, 10474596, 10475950, 10477192, and 10479893.Read more

PE, Closed , Model Year: 2003

LOSS OF HEADLIGHT FUNCTION

THE AGENCY HAS CLOSED THIS INVESTIGATION BASED ON ITS REVIEW OF COMPLAINT REPORTS, FIELD AND TECHNICAL DATA PROVIDED BY FORD AND COMPLAINANT INTERVIEWS. FORD FOUND THAT SOME LIGHTING CONTROL MODULES (LCM) IN THE SUBJECT VEHICLES CONTAINED DEFECTIVE SOLDER JOINTS ON THE PRINTED CIRCUIT BOARD.THIS CON... Read more

PE, Closed , Model Year: 2007

TIRE VALVE CRACKING

ON OCTOBER 14, 2008, ODI OPENED PE08-060 TO INVESTIGATE ALLEGATIONS OF CRACKED AND LEAKING SNAP-IN TIRE VALVES IN MODEL YEAR (MY) 2007 VEHICLES MANUFACTURED BY FORD MOTOR COMPANY.THE VALVES WERE SUPPLIED TO FORD BY TOPSEAL AUTO-PARTS, A SUBSIDIARY OF THE SHANGHAI BAOLONG AUTOMOTIVE CORPORATION IN CH... INA.VALVES MADE BY TOPSEAL FOR AFTERMARKET SALE WERE THE SUBJECT OF TWO RECENT SAFETY RECALLS BY TECH INTERNATIONAL (08T-018) AND DILL AIR CONTROLS (08T-028), THE LATTER OF WHICH WAS INVESTIGATED BY ODI IN PE08-036 AND EA08-022.THE DEFECT CONDITIONS ADDRESSED BY THE AFTERMARKET TIRE VALVE RECALLS BOTH INVOLVED INADEQUATE RESISTANCE TO OZONE CRACKING DUE TO ISSUES WITH THE SUPPLY OF ANTI-OZONANT CHEMICALS TO TOPSEAL FOR A PERIOD FROM JULY TO MID-NOVEMBER 2006.THE AFTERMARKET VALVES WERE COMPOUNDED WITH A BLEND OF EPDM AND NATURAL RUBBER, USING A RELATIVELY LOW PERCENTAGE OF EPDM (EPDM PROVIDES INHERENT RESISTANCE TO OZONE CRACKING).HENCE, THE NEED FOR ANTI-OZONANT CHEMICALS AND THE PROBLEMS WITH CRACKING WHEN THOSE CHEMICALS WERE MISSING OR OUT OF SPECIFICATION IN SOME LOTS OF VALVES.BOTH RECALL CAMPAIGNS INVOLVED INSPECTION PROGRAMS TO IDENTIFY AND REPLACE VALVES WITH VISIBLE SURFACE CRACKING.ALTHOUGH THE TOPSEAL VALVES SUPPLIED TO FORD ALSO APPEAR TO HAVE BEEN AFFECTED BY THE ANTI-OZONANT SUPPLY ISSUES IN MID TO LATE-2006, FORD INDICATED THAT ITS VALVES WERE MADE AT A DIFFERENT TOPSEAL PRODUCTION LINE AND WERE COMPOUNDED WITH A HIGHER PERCENTAGE OF EPDM RUBBER TO MEET MORE STRINGENT SPECIFICATIONS FROM FORD.ODI'S ANALYSIS OF COMPLAINT AND WARRANTY DATA PROVIDED BY FORD SHOWED THAT PROBLEMS WITH CRACKED TIRE VALVES WERE SIGNIFICANTLY HIGHER FOR MY 2007 VEHICLES PRODUCED FROM DECEMBER 2006 THROUGH MARCH 2007.FORD RESPONDED BY IMPLEMENTING CHANGES IN ITS MATERIAL SPECIFICATIONS FOR SNAP-IN RUBBER TIRE VALVES AND ALSO INCREASING THE QUALITY AND ACCEPTANCE STANDARDS FOR VALVES IMPORTED FOR USE IN ITS VEHICLES.WHILE THE COMPLAINT AND WARRANTY CLAIM RATES ARE ELEVATED FOR SUBJECT VEHICLES PRODUCED FROM DECEMBER 2006 THROUGH MARCH 2007, THE RATES OF LEAKING VALVES ARE WELL BELOW ONE PERCENT OF PRODUCTION FOR EACH OF THE PEAK MONTHS FOR ALL OF THE AFFECTED MODELS.A SUBSTANTIAL MAJORITY OF THE SUBJECT VEHICLES ARE EQUIPPED WITH TIRE PRESSURE MONITORING SYSTEMS (TPMS) WHICH WARN THE DRIVER WHEN ANY TIRE PRESSURES DROPS BELOW 25 PERCENT OF RECOMMENDED INFLATION PRESSURE. AS OUTLINED IN A LETTER TO ODI DATED APRIL 6, 2009, FORD HAS AGREED TO SEND LETTERS TO OWNERS OF CERTAIN MY 2007 AND 2008 FORD, LINCOLN AND MERCURY VEHICLES TO PROVIDE INFORMATION ABOUT THE CRACKING CONCERN. LETTERS WILL BE SENT TO OWNERS OF VEHICLES BUILT FROM NOVEMBER 2006 THROUGH MAY 2007.OWNERS CAN OPT FOR A FREE DEALER INSPECTION.VALVES EXHIBITING SURFACE CRACKS OR AIR LEAKAGE RELATED TO OZONE ATTACK WILL BE REPLACED BY FORD UNDER ITS NORMAL WARRANTY TERMS.FORD EXPECTS TO SEND THE LETTER BY APPROXIMATELY MID-MAY 2009. BASED ON THE USE OF TPMS IN THE MAJORITY OF SUBJECT VEHICLES AND THE RELATIVELY LOW RATES OF REPAIRS ASSOCIATED WITH LEAKING VALVES AND RESULTANT TIRE DAMAGE, ODI BELIEVES THAT THE ACTIONS FORD HAS AGREED TO TAKE WILL PROVIDE EFFECTIVE AND EXPEDITIOUS RESOLUTION FOR VEHICLES THAT WERE BUILT DURING THE PERIOD WHEN VALVES WITH INADEQUATE RESISTANCE TO OZONE CRACKING WERE MOST LIKELY TO HAVE BEEN USED IN VEHICLE PRODUCTION.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.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 TORead more

DP, Closed , Model Year: 1997

SPARK PLUG EJECTION FROM CYLINDER HEAD

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 T... HE 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.Read more

EA, Closed , Model Year: 2001

FRONT SEAT BELT BUCKLE ASSEMBLY

DURING THE INITIAL RECALL CAMPAIGN IN 2001, THE SUBJECT VEHICLES WERE INSPECTED BY FORD DEALERSHIPS USING A TEST TOOL THAT WOULD DETECT A DEFECTIVE FRONT SEAT OUTBOARD SEAT BELT BUCKLE ASSEMBLY.APPROXIMATELY ONE MILLION VEHICLES PASSED THE INSPECTION TEST FOR ONE OR BOTH FRONT BUCKLES.SUBSEQUENT TO ... Read more

RQ, Closed , Model Year: 2001

FRONT SEAT BELT BUCKLE ASSEMBLY

UNDER RECALL CAMPAIGN (01V227), FORD RECALLED APPROXIMATELY 1.3 MILLION VEHICLES TO INSPECT AND IF NECESSARY REPLACE THE FRONT DRIVER AND/OR PASSENGER SEAT BELT BUCKLE.APPROXIMATELY 1.1 MILLION OWNERS RESPONDED BY TAKING THEIR VEHICLES TO A DEALER FOR INSPECTION OF THE BUCKLE USING A SPECIALIZED BUC... Read more

RQ, Closed , Model Year: 2003

FRACTURE OF THE STEEL WHEEL RIM

DURING A SEPTEMBER 23, 2004 MEETING AND IN SUBSEQUENT DISCUSSIONS IN NOVEMBER, FORD ADVISED THE OFFICE OF DEFECTS INVESTIGATION (ODI) OF THEIR PLANS TO INTRODUCE AN IMPROVED STEEL WHEEL FOR MANUFACTURING AND SERVICE COMPONENT USE ON THE SUBJECT VEHICLES, INDICATING THIS WOULD OCCUR IN DECEMBER 2004.... THE NEW WHEEL DESIGN INCORPORATES AN ADDITIONAL MANUFACTURING PROCESS (SHOT PEENING) WHICH LOWERS TENSILE STRESS IN THE SURFACE LAYER OF THE RIM MATERIAL ADJACENT TO THE CIRCUMFERENTIAL WELD. THEORETICALLY THIS SHOULD IMPROVE RIM DURABILITY BY REDUCING FATIGUE CRACK INITIATION SITES.INDICATIONS FROM FORD?S ACCELERATED TESTING METHODS SHOW AN IMPROVEMENT IN THE PERFORMANCE OF THE NEW WHEEL.IN ADDITION TO PRIOR SAFETY RECALL 03V279 AND SERVICE ACTION (SA) 03M03, FORD WILL ANNOUNCE A NEW EXTENDED WARRANTY SA FOR VEHICLES BUILT PRIOR TO DECEMBER 2004 THAT SUFFER RIM FRACTURES IN SERVICE.THE NEW WHEEL DESIGN WILL BE USED AS A REMEDY.FORD ADVISES THAT A SA IS SUFFICIENT FOR ADDRESSING FUTURE WHEEL FAILURES (INCLUDING RECALL 03V279 REMEDY WHEEL FAILURES) BECAUSE: 1) FAILURE RATES ARE LOW BASED ON FORD?S ANALYSIS, AND 2) DRIVER WARNINGS (REPETITIVE SLOW AIR LOSS, AND OR STEERING WHEEL VIBRATION) ALLOW EARLY AND SAFE DETECTION OF CRACKED WHEELS.ODI HAS RECEIVED 25 VEHICLE OWNER QUESTIONNAIRE (VOQ) REPORTS (INVOLVING 22 VEHICLES) WHICH ALLEGE A RIM FRACTURE OF ONE OR MORE STEEL WHEELS.ABOUT HALF THE REPORTS INVOLVE VEHICLES BUILT WITH THE REMEDY WHEEL USED FOR RECALL 03V279, AND MOST OF THE REMAINING VEHICLES WERE SUBJECT TO THE RECALL.THE PROCESS OF IDENTIFYING PERTINENT FORD COMPLAINTS IS MADE DIFFICULT BY FORD?S PRIOR RECALL AND WARRANTY PROGRAM ACTIVITIES.THE MANUFACTURER COMPLAINT AND WARRANTY COUNTS, WHICH PRIMARILY INVOLVE FAILURES OF RECALL 03V279 REMEDY WHEELS, ARE BASED ON ANALYSIS CONDUCTED TO DATE AND ARE CONSIDERED TO BE CONSERVATIVE.FURTHER INVESTIGATION IS REQUIRED, THUS ODI IS UPGRADING THIS INVESTIGATION TO AN ENGINEERING ANALYSIS (EA).DURING THE EA, PERTINENT FAILURE REPORTS AND CONSEQUENCES WILL BE IDENTIFIED AND REVIEWED.ODI AND FORD WILL DISCUSS DETAILS FOR CONDUCTING AN AUDIT ANALYSIS OF FAILED WHEELS REPLACED UNDER THE NEW SA.ADDITIONALLY, ODI IS AWAITING FORD?S LAB ANALYSIS OF TWO WHEELS WHICH WERE THE SUBJECT OF VOQ REPORTS, ONE OF WHICH WAS INVOLVED IN THE NOTED CRASH EVENT.A DETERMINATION WILL BE MADE AS TO WHETHER FORD?S SERVICE ACTION IS SUFFICIENT FOR ADDRESSING ONGOING RIM FRACTURES.Read more

PE, Closed , Model Year: 2003

REAR AXLE FRACTURE

THIS PE WAS OPENED AFTER ODI BECAME AWARE OF TWO ALLEGATIONS CONCERNING REAR AXLE FRACTURE AND PARTIAL WHEEL SEPARATION INVOLVING MY 2003 FORD CROWN VICTORIA POLICE INTERCEPTORS (CVPI).INITIALLY, THE PE'S SCOPE INVOLVED ALL MY 2003 GRAND MARQUIS, CROWN VICTORIA, AND LINCOLN TOWN CARS (I.E., PANTHER ... Read more

EA, Closed , Model Year: 1995

REAR BRAKE LINE FAILURE

IN A LETTER DATED FEBRUARY 25, 2005, FORD MOTOR COMPANY (FORD) NOTIFIED ODI THAT IT WOULD BE CONDUCTING A CUSTOMER SATISFACTION PROGRAM (FORD NO. 04B26) TO CORRECT A REAR BRAKE LINE CHAFING CONCERN IN APPROXIMATELY 44,000 MODEL YEAR (MY) 1997 FORD CROWN VICTORIA AND GRAND MARQUIS NON-FLEET VEHICLES ... Read more

RQ, Closed , Model Year: 1995

REAR BRAKE LINE FAILURE

ODI HAS RECEIVED 40 COMPLAINTS ALLEGING REAR BRAKE LINE FAILURE IN THE SUBJECT VEHICLES, INCLUDING 8 THAT HAVE BEEN RECEIVED THIS YEAR.AN ADDITIONAL 192 REPORTS AND 478 WARRANTY CLAIMS HAVE BEEN RECEIVED FROM FORD.A LEAK IN THE REAR BRAKE LINE CAN CAUSE EXTENDED STOPPING DISTANCE.A SEARCH OF ODI'S C... Read more

PE, Closed , Model Year: 2003

FRACTURE OF THE STEEL WHEEL RIM

THE SUBJECT WHEEL (NEW FOR MY 2003) IS USED ON CROWN VICTORIA (CV) AND GRAND MARQUIS.COMPLAINT DATA INDICATES THAT WHEEL FAILURE AFFECTS PRIMARILY THE COMMERCIAL SPECIFICATION CV MODEL (POLICE AND TAXI) WHICH HAS UNIQUE DESIGN CHARACTERISTICS AND IS GENERALLY SUBJECTED TO HIGHER USAGE DEMANDS.DURING... Read more

EA, Closed , Model Year: 1996

CNG TANK EXPLOSION

IN SEPTEMBER 2002, A FUEL CYLINDER IN A NATURAL GAS POWERED VEHICLE (NGV) EXPLODED DURING A FIRE.FORD AND VRTC TEST ENGINEERS JOINTLY EXAMINED THE INCIDENT VEHICLE AND REVIEWED TESTING TO DETERMINE WHETHER THE PERFORMANCE OF THE PRESSURE RELIEF VALVE (PRD) WAS PROPER.THE PURPOSE OF A PRD IS TO PROTE... Read more

RQ, Closed , Model Year: 1995

BALL JOINT SEPARATION

SEE ATTACHED REPORT.

PE, Closed , Model Year: 1996

CNG TANK EXPLODING IN A FIRE

AN EXPLOSION OF A COMPRESSED NATURAL GAS (CNG) TANK SHOULD NOT BE ABLE TO OCCUR, AS THE TANK IS FITTED WITH A PRESSURE RELIEF DEVICE (PRD). THIS PRD SHOULD RELEASE THE CNG IN THE TANK, PRIOR TO THE PRESSURE REACHING THE TANK BURST PRESSURE.THE PRD DID NOT RELEASE IN THE SUBJECT WISCONSIN POLICE CRUI... Read more

EA, Closed , Model Year: 1992

SPEED CONTROL DEACTIVATION SWITCH FIRES

BASED ON THE LOW RATE OF FIRE INCIDENTS (2.5 INCIDENTS PER 100,000 VEHICLES SOLD) WHERE FAILURE OF THE SCDS IS INVOLVED AND THE AGE OF THE VEHICLES ? 7 TO 11 YEARS ? A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING ... Read more

DP, Closed , Model Year: 1992

FUEL-FED FIRES

THE FARS DATA SHOWS THAT THE RISK OF FIRE FROM IMPACT IN ALL DIRECTIONS IN THE SUBJECT VEHICLES IS THE SAME AS ALL OTHER SEDANS.THE SUBJECT VEHICLES ARE NOT OVER REPRESENTED WITH RESPECT TO THE RISK OF FIRE IN REAL-WORLD HIGH-ENERGY CRASHES.A FURTHER DISCUSSION OF ISSUES RELATED TO POST CRASH FIRES ... Read more

SQ, Closed , Model Year: 1992

POST REAR END COLLISION FIRES