2002 Ford F-350 Sd recalls and problems

IN A DECEMBER 3, 2007 LETTER, FORD ADVISED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL TO REPLACE THE CAM POSITION SENSOR (CPS) IN APPROXIMATELY 1.2 MILLION SUBJECT VEHICLES TO ADDRESS REPORTS OF ENGINE STALLING.A NEW DESIGN CPS WITH IMPROVED PERFORMANCE AND DURABILITY WILL BE INSTALLED AS A REMEDY.OWNER NOTIFICATIONS WILL BEGIN IN DECEMBER 2007. THE SUBJECT VEHICLES ARE DURABLE, FULL-SIZED, MEDIUM DUTY TRUCKS COMMONLY USED FOR COMMERCIAL PURPOSES, RESCUE/EMERGENCY RESPONSE, AND COMMERCIAL OR RECREATIONAL TOWING.CPS FAILURE IS COMPARABLE TO UNEXPECTEDLY TURNING THE KEY OFF SINCE THE SIGNAL IT PRODUCES IS VITAL TO THE ELECTRONIC ENGINE CONTROL SYSTEM.CPS SIGNAL LOSS TERMINATES FUEL INJECTION RESULTING IN AN ENGINE STALL.ONCE STALLED, THE ENGINE MAY RESTART RIGHT AWAY, OR MAY RESTART AFTER A DELAY (TYPICALLY 5 TO 10 MINUTES), OR MAY NOT RESTART AT ALL.IN ADDITION TO EXPOSING THE DRIVER AND OTHER MOTORISTS TO CRASH RISK DUE TO LOSS OF MOTIVE POWER OR VEHICLE DISABLEMENT, ENGINE STALLING ALSO EFFECTS THE POWER ASSISTED STEERING AND BRAKING. THROUGH CONSUMER INTERVIEWS, ODI DETERMINED THAT CPS FAILURES OCCURRED WITHOUT ANY FORM OF WARNING, AT ANY VEHICLE SPEED (50% AT HIGHWAY SPEEDS), AND UNDER ANY DRIVING CONDITION, SUCH AS ACCELERATING.CONSUMERS REPORTED THAT ABOUT A THIRD OF THE VEHICLES FAILED TO RESTART, WITH ANOTHER THIRD REPORTING DELAYED RESTARTING.HALF THE VEHICLES THAT DID RESTART EXPERIENCED ANOTHER STALL ON THE SAME OR A SUBSEQUENT DRIVE CYCLE (BEFORE CPS REPLACEMENT) R…

ON SEPTEMBER 6, 2005, ODI RECEIVED A PETITION REQUESTING THAT THE AGENCY INVESTIGATE ALLEGATIONS OF ENGINE SPARK PLUG EJECTION IN CERTAIN MODEL YEAR 1997 THROUGH 2004 FORD VEHICLES WITH TRITON V-8 AND V-10 ENGINES.ODI RECEIVED A TOTAL OF 474 NON-DUPLICATIVE COMPLAINTS ON THE SUBJECT VEHICLES WHERE THE COMPLAINANT, OR THE DEALER REPAIRING THE VEHICLE, REPORTED THAT A SPARK PLUG DETACHED FROM THE CYLINDER AND/OR EJECTED FROM THE ENGINE.AS OF DECEMBER 8, 2005, ODI IS NOT AWARE OF ANY ALLEGATIONS WHERE THE ALLEGED DEFECT RESULTED IN A LOSS OF VEHICLE CONTROL, A CRASH, AN INJURY, OR A FATALITY IN ANY OF THE 10,319,810 SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF ONLY TWO INCIDENTS WHERE THE VEHICLE STALLED WITHOUT RESTART.INFORMATION CONTAINED IN THE ODI CONSUMER COMPLAINTS AND OBTAINED FROM 72 TELEPHONE INTERVIEWS WITH COMPLAINANTS SHOWED THE FOLLOWING:(1) 99% OF THE COMPLAINTS WERE ON MY 1997 TO 2002 SUBJECT VEHICLES.(2) MOST THE COMPLAINANTS REPORTED HEARING A LOUD POP WHILE DRIVING OR UPON STARTING UP THE VEHICLE FOLLOWED BY A LOUD, REPETITIVE CLICKING OR POPPING SOUND.(3) MANY OF THE COMPLAINANTS REPORTED THAT THE POPPING SOUND WAS ACCOMPANIED BY SOME LOSS OF VEHICLE POWER; HOWEVER, IN 99% OF THE INCIDENTS REPORTED, THE VEHICLE DID NOT STALL.IN THE VERY FEW INCIDENTS WHERE THE VEHICLE DID STALL, MOST VEHICLES COULD BE RESTARTED.(4) ONLY A SMALL PERCENTAGE OF THE COMPLAINANTS CITED THAT THEY SMELLED GAS OR A SLIGHT BURNING SMELL WHEN THE INCIDENT OCCURRED.(5) IN ALL BUT A VER…

EA05-005 IS CLOSED WITH FORD?S ACTIONS IN RECALLS 05V-017, 05V-388, AND 06V-286, RECALLING APPROXIMATELY 6.7 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).THE BRAKE SYSTEMS IN THESE RECALLED VEHICLES GENERATE A VACUUM THAT CAN POTENTIALLY CAUSE THE SCDS TO FAIL AND, IN CERTAIN SWITCH INSTALLATION ORIENTATIONS, CATCH FIRE.FORD IS ALSO INCLUDING THE ENTIRE POPULATION OF 1998 EXPLORERS.FORD HAS INFORMED ODI THAT TESTING TO DETERMINE THE CAUSE OF FAILURES IN THE 1998 EXPLORERS WILL CONTINUE AFTER THIS INVESTIGATION IS CLOSED.ODI BELIEVES THAT THE VEHICLES EXHIBITING THE FACTORS CAUSING SCDS FAILURE DESCRIBED IN THIS REPORT CORRELATE WELL WITH THE OBSERVED FAILURE RATES ON THESE VEHICLES BY MODEL AND MODEL YEAR.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE NON-RECALLED VEHICLES MANUFACTURED WITH SCDS THAT ARE NOT INCLUDED IN FORD?S RECALLS.ODI WILL CONTINUE TO MONITOR THE NON-RECALLED POPULATION FOR INCIDENCE OF ENGINE COMPARTMENT FIRES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE ATTACHED CLOSING REPORT FOR DETAILS.

FAILURE COUNTS FROM ODI?S ANALYSIS ARE STATED ABOVE; SEE THE ADDITIONAL PROBLEM EXPERIENCE DISCUSSION IN THE SUMMARY REPORT.FORD DATA CONTAINED DUPLICATIVE REPORTS FOR 4 ODI COMPLAINTS AND 1 CRASH.THREE CRASHES WERE ALLEGEDLY DUE TO INTERMITTENT OPERATION OF THE ELECTRONIC THROTTLE CONTROL (ETC) PEDAL, ONE CRASH OCCURRED WHEN AN ETC DISABLED VEHICLE WAS STRUCK BY ANOTHER MOTORIST, ONE REPORT CONTAINED NO DETAIL.THE INJURIES WERE MINOR.AN ISSUE INVOLVING FIXED ETC PEDALS WAS INVESTIGATED ALSO, HOWEVER FAILURE REPORTS AND POPULATIONS ARE NOT SHOWN ABOVE; SEE SUMMARY REPORT FOR DETAIL.ALTHOUGH FORD HAS USED ETC BASED THROTTLE CONTROL SYSTEMS FOR MANY YEARS, THE PAP FEATURE WAS NEW FOR MY 2002.THE SUBJECT ETC SENSOR PRODUCES TWO OUTPUT SIGNALS WHICH THE ENGINE MANAGEMENT SYSTEM (EMS) UTILIZES TO:1) DETERMINE FUELING REQUIREMENTS; AND 2) PERFORM SENSOR DIAGNOSTICS.ONE SIGNAL IS LINEARLY PROPORTIONAL TO THROTTLE PEDAL POSITION; THE SECOND IS A DIGITAL SIGNAL.BY DESIGN, THE DETECTION OF A SENSOR FAULT RESULTS IN THE ENGINE RETURNING TO (OR REMAINING AT) THE IDLE STATE.FORD IDENTIFIED A DEFECT IN THE PAP ETC SENSOR WHICH PREMATURELY AFFECTED AN OUTPUT SIGNAL; THE MIGRATION OF INTERNAL SENSOR LUBRICANT CAUSED A LOSS OF PROPORTIONAL SIGNAL.THE FAILURE MECHANISM IS PROGRESSIVE AND AS THE SENSOR DETERIORATES, THE EMS WILL DETECT A FAULT, STORE A FAULT CODE, ILLUMINATE A WARNING LAMP, AND THE ENGINE MAY REMAIN AT/RETURN TO IDLE.IN THE EARLY STAGES, NORMAL OPERATION CAN BE REGAINED BY PEDA…