2009 FORD CROWN VICTORIA

2 recalls — 59 complaints — 41 TSBs

STEERING:RACK AND PINION:PINION SHAFT

Defect Description

Ford Motor Company (Ford) is recalling certain model year 2005-2011 Ford Crown Victoria, 2005-2011 Mercury Grand Marquis vehicles manufactured March 23, 2004, to August 30, 2011, and 2005-2011 Lincoln Town Car vehicles manufactured March 8, 2004, to August 30, 2011, and on which the upper intermedia... Read more

Consequence

Improper servicing of the upper intermediate shaft could cause the shaft to separate, which can then result in a loss of steering control, and increasing the risk of a crash.

Remedy

Ford will notify the owners of vehicles whose repair records reflect that the upper intermediate steering shaft was repaired during the course of the prior recall 13V-385. Dealers will inspect and replace the upper immediate shaft if necessary free of charge. The recall began November 17, 2014. O... Read more

36,888 vehicles affected

Manufacturer: Ford Motor Company

STEERING

Defect Description

Ford is recalling certain model year 2005-2011 Ford Crown Victoria (including Crown Victoria Police Interceptors), Mercury Grand Marquis, and Lincoln Town Car vehicles. The affected vehicles are currently registered or were originally sold in Connecticut, Delaware, the District of Columbia, Illinois... Read more

Consequence

If the lower bearing separates, the vehicle may experience a loss of steering, increasing the risk of a crash.

Remedy

Ford will notify owners and dealers will replace the lower intermediate shaft, free of charge. The upper intermediate shaft and steering column lower bearing will be inspected to identify any damage that may have occurred as a result of lower intermediate shaft corrosion, and repaired or replaced a... Read more

355,000 vehicles affected

Manufacturer: Ford Motor Company

Complaint Statistics

59 total complaints 8 crashes 3 fires 1 injuries

Top Reported Components

Component	Complaints
STEERING	15
FUEL SYSTEM, GASOLINE	10
POWER TRAIN	5
ELECTRICAL SYSTEM	4
SUSPENSION	4
AIR BAGS	3
POWER TRAIN:AUTOMATIC TRANSMISSION	2
FUEL/PROPULSION SYSTEM	2
SEAT BELTS	1
STEERING:COLUMN	1

Incident date: May 6, 2025

When starting the vehicle, and extremely loud feedback noise is emitted from the front right speaker. This happens intermittently. Sometimes it's every 5th time you start it, and sometimes every 29th start. This started happening after the dealer-provided SOS Safety subscription expired. The noise i... Read more

Incident date: Dec 19, 2023

The system which has intermittent failure on my 2017 Lexus GS350 is the lane keeping assistance safety option. The system seems to work almost perfectly on straight highways. But highways with curves seem to fail at about a 50% rate and human intervention is quickly required. The car is available fo... Read more

Incident date: May 1, 2023

Driving vehicle home from work and it completely lost power and died. ""Drivetrain Malfunction" error popped up on the screen. Vehicle would crank but not start. Towed to repair shop. High Pressure Fuel Pump issue is on the radar for 2014 BMW 328D, BMW has recalled less than 12000 cars. My vehicle i... Read more

Incident date: Nov 1, 2020

TL* THE CONTACT OWNS A 2009 FORD CROWN VICTORIA. THE CONTACT STATED THAT WHILE DRIVING, THE POWER STEERING MALFUNCTIONED AND THE STEERING WHEEL BECAME DIFFICULT TO TURN IN EITHER DIRECTION. THE CAUSE OF THE FAILURE WAS NOT DETERMINED. THE LOCAL DEALER BERLIN CITY FORD LOCATED AT 485 MAIN ST, GORHAM,... Read more

Incident date: Aug 9, 2019

TL* THE CONTACT OWNS A 2009 FORD CROWN VICTORIA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 13V385000 (STEERING). THE CONTACT CALLED THE MANUFACTURER AND WAS INFORMED THAT THE PARTS WERE AVAILABLE; HOWEVER, THEY WOULD NOT HONOR THE RECALL. THE VEHICLE WAS NOT REPAIRED. A DEALER WAS ... Read more

Incident date: Aug 6, 2019

FORD HAD A RECALL, 13S08, FOR THE STEERING ON THESE CARS. I JUST PURCHASED THIS CAR ON 08?06/2019 AND IMMEDIATELY CHECKED YOUR SITE FOR RECALLS. THERE IS THIS RECALL AND IT WAS NOT COMPLETED. NEW JERSEY OWNED THIS CAR BEFORE ME AND MUST NOT HAVE TAKEN IT IN. I CALLED FORD AND WAS TOLD THEY WILL NOT ... Read more

Incident date: Jun 18, 2019

THE TRANSMISSION WILL NOT MOVE IN DRIVE. SETS AND IDLES. GIVE IT SOME GAS. WILL NOT MOVE. GOING TO COST $1200 TO REBUILD IT

Incident date: Feb 1, 2019

I HAD JUST GOTTEN HOME FROM WORK. I PUT MY CAR IN REVERSE AND WENT TO GO TURN THE STEERING WHEEL TO RIGHT AND THE STEERING WHEEL SEEMED LIKE IT WAS STUCK OR CAUGHT ON SOMETHING SO I TRIED TO TURN IT IT THE OTHER WAY TO SEE IF I COULDN'T GET IT TO LOOSEN UP AND WHEN I HAD TURNED IT TO THE RIGHT AGAIN... Read more

Incident date: Nov 2, 2018

STERRING BEGAN GIVING A CLUNKING FEELING IN WHEEL WHEN DRIVING STRAIGHT I NOTICE 4 DAYS AGO. MORE NOTICEABLE OVER BUMPS... I THOUGHT IT WAS MY TIRES. I WAS DRIVING DOWN ROAD AND ATTEMPT TO MAKE A RIGHT TURN AND VEHICLE KEEP GOING STRAIGHT AND STEERING WHEEL WAS NOT TURNING ALSO CRASH INTO ONCOMING T... Read more

Incident date: Mar 28, 2018

2004 FORD CROWN VIC POLICE INTERCEPTOR. CONSUMER WRITES IN REGARDS TO SEVERAL PROBLEMS EXPERIENCED WITH VEHICLE. *LD THE CONSUMER STATED SHIFTING OUT OF PARK WAS DIFFICULT, THE BRAKES SEEMED SQUISHY, THE RIGHT FRONT PASSENGER WINDOW, THE LIGHTS ON THE DASHBOARD/SPEEDOMETER WERE INOPERABLE, AND TH... Read more

Incident date: Mar 28, 2018

Incident date: Mar 22, 2018

TL* THE CONTACT OWNS A 2009 FORD CROWN VICTORIA. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 35 MPH, THE SHAFT INSIDE THE STEERING WELL SEPARATED CAUSING THE DRIVER TO LOSS CONTROL OF THE VEHICLE AND CRASHING INTO A CURB. THERE WAS NO WARNING LIGHTS ILLUMINATED. THE VEHICLE WAS DAMAGED BUT D... Read more

Crash

Incident date: Sep 8, 2017

LEALKING FUEL FROM THE QUICK DICONNECT ON THE RETURN FULE LINE. THAT IS CAUSING A DRIING BY THE EXHAUST TAIL PIPE AND A GASOLINE SMELL AROUND THE VEHICLE

Incident date: Sep 8, 2017

LEALKING FUEL FROM THE QUICK DICONNECT ON THE RETURN FULE LINE. THAT IS CAUSING A DRIING BY THE EXHAUST TAIL PIPE AND A GASOLINE SMELL AROUND THE VEHICLE

Incident date: Apr 1, 2017

HELLO, MY BLEND DOOR ACTUATOR STOPPED WORKING,THIS IS AN ELECTRICAL COMPONENT THAT WILL SWITCH THE AIR CONDITIONING TO HEAT AND BACK AGAIN THE PROBLEM IS WHEN IT IS COLD OUTSIDE THE WINDSHIELD WONT DEFROST PROPERLY AND I CANT SEE /OR WARM AND HUMID/RAINING THE CAR WILL FOG UP ON THE INSIDE AND I HAV... Read more

Incident date: Apr 1, 2017

Incident date: Feb 15, 2017

THE VEHICLE STEERING COLUMN INSIDE THE CAR IS MADE OF TWO PIECES OF METAL THAT ATTACHED THE TOP WITH THE BOTTOM BUT IT HAS NO LOCKING TO PREVENT FROM COMING OFF WHEN YOU ARE DRIVING THE VIBRATIONS OF THE ROAD AND SUSPENSION WITH THE TIME CAUSES TO LOOSE AND YOU LOOSE CONTROL OF THE STEERING THIS CAN... Read more

Incident date: Feb 8, 2017

TL* THE CONTACT OWNS A 2009 FORD CROWN VICTORIA. THE CONTACT ATTEMPTED TO MAKE A LEFT TURN, BUT THE VEHICLE CONTINUED TO MOVE STRAIGHT. THE CONTACT STATED THAT THE STEERING ABILITY SEIZED. THE VEHICLE WAS TOWED TO THE CONTACT'S HOUSE AND THEN TO THE DEALER. THE DEALER DIAGNOSED THAT THE STEERING WHE... Read more

Incident date: Oct 31, 2016

TL* THE CONTACT OWNS A 2009 FORD CROWN VICTORIA. WHILE DRIVING VARIOUS SPEEDS, THE HORN WAS DEPRESSED AND FAILED TO FUNCTION. THE AIR BAG WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 71,000.

Incident date: Oct 31, 2016

Incident date: Jan 7, 2016

TL* THE CONTACT OWNS A 2009 FORD CROWN VICTORIA. WHILE DRIVING 20 MPH, THE STEERING WHEEL SEIZED. UPON INSPECTION, THE CONTACT NOTICED THAT THE DRIVER SIDE HEAT SHIELD FRACTURED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 170,... Read more

Incident date: Sep 16, 2015

THE VEHICLE WAS PARKED, LOCKED AND UNATTENDED IN A PARKING LOT. SURVEILLANCE VIDEO SHOWS FLASHES COMING FROM UNDERNEATH THE HOOD FAIRLY CENTRALLY LOCATED WHERE IT HINGES WITH THE VEHICLE. THE FLASHES BEGIN SLOW, THEN RESUME MORE INTENSELY BEFORE THE VEHICLE CATCHES FIRE. THE FIRE CONSUMES ALL RUB... Read more

Fire

Incident date: Jul 19, 2015

TL* THE CONTACT OWNED A 2009 FORD CROWN VICTORIA. WHILE DRIVING AT APPROXIMATELY 20 MPH APPROACHING AN INTERSECTION, ANOTHER VEHICLE RAN THE RED LIGHT AND CRASHED INTO THE FRONT DRIVER SIDE OF THE CONTACT'S VEHICLE. THE AIR BAGS FAILED TO DEPLOY. A POLICE REPORT WAS FILED AND THE CONTACT SUSTAINED U... Read more

Crash 1 injured

Incident date: Nov 25, 2013

MAR 25TH 2013, MY BROTHER WAS COMING BACK TO HOME, SUDDENLY CAR SPIN/SCATTERED HIT TO TREE AND ELECTRIC POLE, MAR 2014, I RECEIVED SAFETY RECALL # 13S08/NHTSA LETTER FROM FORD COMPANY STEERING COLUMN SHAFT PROBLEM. WE CONTACT TO FORD COMPANY ON MARCH 18,2014 REGARDING THE ABOVE ISSUE. THEY ISSUE US... Read more

Crash

Incident date: Nov 25, 2013

Crash

Incident date: Nov 25, 2013

Crash

Incident date: Mar 31, 2014

INTAKE MANIFOLD IS SUBJECT TO EXTREMELY HIGH TEMPERATURES. FORD'S CURRENT DESIGN INCLUDES A PLASTIC INTAKE MANIFOLD THAT IS SUSCEPTIBLE TO WARPING AND MAY CAUSE ENGINE FAILURE IF COOLANT LOOSES PRESSURE DUE TO LEAK. *TT

Incident date: Jan 20, 2014

THIS WAS A POLICE INTERCEPTOR VEHICLE TRAVELING AT A SPEED OF BETWEEN 55 AND 60MPH. THE RIGHT FRONT WHEEL BEARING HAD SEIZED UP AND BURNT THE TIRE DOWN UNTIL IT BLEW, CAUSING THE VEHICLE TO SWERVE INTO THE DITCH. LUCKILY THE DRIVER IS OKAY AND THERE WAS NOBODY ON THE SHOULDER OF THE ROAD. *TR

Incident date: Jan 20, 2014

Incident date: Jun 25, 2013

THE COMPLAINANT ALLEGES THE DRIVER OF A MY 2009 CROWN VICTORIA EXPERIENCED A LOOSENESS AND NOISE IN THE STEERING COLUMN. UPON INSPECTION THE LOWER STEERING COLUMN BEARING WAS FOUND TO BE PARTIALLY DISPLACED FROM THE STEERING COLUMN. THE COMPLAINANT NOTES THAT THERE WAS NOT A COMPLETE LOSS OF THE STE... Read more

Incident date: Sep 26, 2012

INSPECTION FOUND DISLOCATED BUSHING. *TR

Incident date: Sep 26, 2012

INSPECTION FOUND DISLOCATED BUSHING. *TR

Incident date: Sep 26, 2012

INSPECTION FOUND DISLOCATED BUSHING. *TR

Incident date: Sep 26, 2012

INSPECTION FOUND DISLOCATED BUSHING. *TR

Incident date: Sep 26, 2012

REFERENCE ODI NUMBERS 10347404, 10474596, 1047458, 10475030, 1047501; THE AFFECTED VEHICLES SHOULD INCLUDE MODEL YEARS 2009 THROUGH 2011. THE AFFECTED VEHICLE IN THIS NOTICE IS A MODEL YEAR 2009. FURTHER RESEARCH FOUND MODEL YEAR 2005 THROUGH 2011 HAVE THE SAME STEERING COLUMN DESIGN AND AFFECTED PA... Read more

Incident date: Sep 12, 2012

CATASTROPHIC FAILURE OF THE STEERING COLUMN; THE STEERING COLUMN RETAINING RING FAILED. BINDING OF LOWER AND MIDDLE UNIVERSAL JOINTS AND BELIEVE IT IS HEAT RELATED. STEERING SHAFT NOT TRAVELING ON A TRUE AXIS AND A RESULT IS THE RETAINING RING IS BEING WORN AND EVENTUALLY WEARS OUT. *TR

Incident date: Apr 2, 2012

CHARLESTON COUNTY SHERIFF'S OFFICE MARKED PATROL CAR. DRIVER LOST CONTROL AT HIGH SPEED. SLID ACROSS THE MEDIAN.SPUN 180 DEGREES WAS STRUCK IN THE REAR BY ONCOMING VEHICLE. CONTINUED TO SKID ACROSS THE ROAD AND STRUCK THE GUARD RAIL WITH THE FRONT OF THE VEHICLE. VEHICLE CAUGHT FIRE AT THE REAR AN... Read more

Crash Fire

Incident date: Apr 2, 2012

Crash Fire

Incident date: Mar 3, 2012

TL* THE CONTACT OWNS A 2009 FORD CROWN VICTORIA. THE CONTACT STATED THAT WHEN THE VEHICLE WOULD NOT RESPOND WHEN SHIFTED INTO REVERSE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THEY ADVISED HIM THAT HE WOULD NEED TO REPLACE THE TRANSMISSION. THE VEHICLE HAD NOT BEEN REPAIRED NOR WAS THE... Read more

Incident date: Jul 5, 2011

VEHICLE STOPPED RUNNING. WOULD NOT RESTART. *TR

Incident date: Oct 1, 2010

TL*THE CONTACT OWNS A 2009 FORD CROWN VICTORIA POLICE INTERCEPTOR(NA). WHILE STARTING THE VEHICLE, THE CONTACT TURNED ON THE VENT AND WHITE TOXIC FLAKES ESCAPED FROM IT. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHO STATED THAT THE VEHICLE WAS NO LONGER UNDER WARRANTY. THE MANUFACTURER AGREED TO... Read more

Incident date: Feb 14, 2010

POSSIBLE FAILURE OF THE PRE-TENSIONER SYSTEM IN A 2009 FORD CROWN VICTORIA FROM ROLL-OVER CRASH. *TR

Crash

Incident date: Jun 25, 2010

FUEL PUMP FAILURE, LOSS OF POWER, SHUT DOWN IN ROADWAYS, POTENTIAL FOR CRASH DUE TO SUDDEN INCREASED STEERING EFFORT REQUIRED AND SUDDEN DECELERATION WITHOUT BRAKE LIGHT ACTIVATION. FORD REPLACES IN-WARRANTY, BUT BLAMES THE FUEL QUALITY WHEN OUT OF WARRANTY. *TR

Incident date: Jun 15, 2010

Showing 50 of 59 complaints.

Technical Service Bulletins — 2009 FORD CROWN VICTORIA

41 manufacturer communications from 16 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
100000 POWER TRAIN	3
350000 EQUIPMENT	3
010000 STEERING	2
353000 EQUIPMENT:ELECTRICAL	2
118000 ELECTRICAL SYSTEM:SOFTWARE	2
061000 ENGINE AND ENGINE COOLING:ENGINE	2
060000 ENGINE (PWS)	2
103000 POWER TRAIN:AUTOMATIC TRANSMISSION	2

350000 EQUIPMENT

All accessory stick-on keyless entry keypads come with a wallet card containing the master code. If the accessory keypad was factory installed, this card will be placed in the glove box and should be handed to the vehicles owner during ini

060000 ENGINE (PWS)

This SKU is a Radiator Fan. The customer communication requested return of unsold inventory to inspect the electrical connections. An electrical connection issue may lead to the fan not working potentially throwing a check engine light fo

110000 ELECTRICAL SYSTEM

350000 EQUIPMENT

Replacing the original equipment SYNC/Navigation system with either an aftermarket SYNC/Navigation kit or modifying original SYNC/Navigation parts to provide additional features is not recommended nor supported on any Ford, Mercury or Linco

353000 EQUIPMENT:ELECTRICAL

The Accessory (Wireless) Keyless Entry Keypad can only be used with vehicles that are factory built with Remote Keyless Entry (RKE). The master code for the Accessory (Wireless) Keyless Entry Keypad can be retrieved from FMCDealer - Parts a

350000 EQUIPMENT

353000 EQUIPMENT:ELECTRICAL

062000 ENGINE AND ENGINE COOLING:COOLING SYSTEM

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

062100 ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

062200 ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN

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

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)

061200 ENGINE AND ENGINE COOLING:ENGINE:DIESEL

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

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

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

061000 ENGINE AND ENGINE COOLING:ENGINE

060000 ENGINE AND ENGINE COOLING

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

160000 STRUCTURE

Inpected or repaired under 13R01 - Requests for recall service action under 13S08

010000 STEERING

Inpected or repaired under 13R01 - Requests for recall service action under 13S08

010000 STEERING

For 2005-2012 Crown Victoria, 2005-2011 Grand Marquis and Town Car vehicles, Regional Program 13R01 applies to vehicles not registered in corrosion states and not included in Safety Recall 13S08, where operation in high corrosion areas for

100000 POWER TRAIN

4R75E TRANSMISSION - GRINDING/WHINE/VIBRATION/GEAR SLIPPAGE - SERVICE KIT AVAILABLE ISSUE A service kit has been released to assist with proper repair of the 4R75E transmission in 2008 Mark LT, 2008-2010 F-150, 2008-2010 / 2013-2014 E-Ser

100000 POWER TRAIN

4R75E Transmission - Grinding/Whine/Vibration/Gear Slippage - Serrvice Kit available

013200 STEERING:GEAR BOX:SHAFT PITMAN

FORD: THE LOWER INTERMEDIATE STEERING SHAFT, HAS CORROSION OF SWING LINK JOINTS, COMBINED WITH COLLAPSED UPPER INTERMEDIATE STEERING SHAFT, RESULTING IN STEERING COLUMN SEPARATION AND LOSS OF STEERING CONTROL. MODEL 2005-2011 CROWN VICTOR

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

FORD/LINCOLN/MERCURY: FAILURE OF PLANETARY GEAR ASSEMBLY IS DUE TO TRANSMISSION, ON CERTAIN VEHICLES, EXHIBITING GRINDING, GEAR SLIPPAGE, WHINE TYPE NOISE, VIBRATION, WHILE DRIVING OR LOSS OF REVERSE. *PE

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

FORD/LINCOLN/MERCURY: THE INDICATOR MAY ILLUMINATE OVERDRIVE OFF AND/OR SLIPPING IN 3RD OR NO 4TH GEAR, DUE TO DIRECT CLUTCH FAILURE AND DIAGNOSTIC TROUBLE CODE (DTC) P0733 AND/OR P0734. MODEL 2008-2013 MARK LT, F-150, CROWN VICTORIA, GRA

012000 STEERING:COLUMN

FORD: SWING LINK JOINTS ON LOWER INTERMEDIATE STEERING SHAFT, HAS CORROSION, AND COMBINED WITH COLLAPSED UPPER INTERMEDIATE STEERING SHAFT, ON SOME VEHICLES, CAUSES STEERING COLUMN TO SEPARATE, LEADING TO STEERING CONTROL LOSS. MODEL 2005

118000 ELECTRICAL SYSTEM:SOFTWARE

COMM-TRANS LUND: SOME 2009-2011 MODELS MAY HAVE THE AIR BAG INICATOR FLASHING WITH A STORED TROUBLE CODE. THIS IS A SOFTWARE PROBLEM. *RM

140000 AIR BAGS

COMM-TRANS LUND: SOME 2009-2011 MODELS MAY HAVE THE AIR BAG INICATOR FLASHING WITH A STORED TROUBLE CODE. THIS IS A SOFTWARE PROBLEM. *RM

118000 ELECTRICAL SYSTEM:SOFTWARE

FORD: IF THERE IS AN INTERMITTENT LACK OF POWER, SURGE, OR HESITATION WHILE DRIVING THE BRAKES WILL OVERRIDE ACCELERATION. *RM

100000 POWER TRAIN

FORD: IF THERE IS AN INTERMITTENT LACK OF POWER, SURGE, OR HESITATION WHILE DRIVING THE BRAKES WILL OVERRIDE ACCELERATION. *RM

061000 ENGINE AND ENGINE COOLING:ENGINE

FORD: IF THERE IS AN INTERMITTENT LACK OF POWER, SURGE, OR HESITATION WHILE DRIVING THE BRAKES WILL OVERRIDE ACCELERATION. *RM

046000 SERVICE BRAKES, AIR:ANTILOCK

FORD: IF THERE IS AN INTERMITTENT LACK OF POWER, SURGE, OR HESITATION WHILE DRIVING THE BRAKES WILL OVERRIDE ACCELERATION. *RM

022520 SUSPENSION:REAR:AXLE:NON-POWERED AXLE ASSEMBLY

FORD: RIGHT SIDE REAR AXLE OIL LEAKS. OIL LEAKS FROM THE RIGHT REAR AXLE WHEEL BEARING OIL SEAL MAY BE CAUSED BY A COMBINATION OF A DAMAGED SEAL AND/OR POOR SEAL SURFACE FINISH OF THE AXLE SHAFT. *PE

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