2003 Ford F-250 SD
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Ford › F-250 SD › 2003
These records cover every 2003 Ford F-250 SD. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
6 recalls name the 2003 Ford F-250 SD. Newest first.
Ford IS recalling certain model year 2011 ranger trucks built from january 25, 2011, through april 25, 2011 at the twin cities assembly plant, and service parts distributed to dealers for certain 2004 through 2011 model year ranger trucks, 2002 through 2005 model year excursion vehicles, and 2002 through 2007 model year F-250, F-350, F-450, and F-550 trucks…
Risk and remedy
Risk
Non-functioning lights could increase the risk of a crash.
Remedy
Dealers will replace the switches free of charge. the safety recall began on august 15, 2011. owners may contact ford motor company customer relationship center at 1-866-436-7332.
Ford IS recalling model years 1995-2003 windstar, 2000-2003 excursion diesel, 1993-1997 and 1999-2003 F-250 sd through F-550 sd diesel, 1992-2003 E-150 through E-550, 1995-2002 explorer, 1997 and 2002 mercury mountaineer, 1995-1997 and 2001-2003 ranger, and 1994 F53 vehicles equipped with the texas instruments speed control deactivation switch (scds). the…
Risk and remedy
Risk
A vehicle fire could occur with or without the engine running.
Remedy
Ford will notify owners that dealers will install a fused wiring harness in line with the scds. on 1999-2003 windstar vehicles with a leaking scds, dealers will also inspect the ABS control module connector and repair as necessary. repairs will be completed free of charge. the safety recall began on october 27, 2009. owners may contact ford at 1-888-222-2751.
Certain federal-mogul replacement wheel hub assemblies with the brand names: national, carquest p/nos. 515020, 515021, 515025, 515053, 515054, 515059, and 515060, shipped between january 23, 2006, and december 20, 2007, sold for light duty and medium duty trucks. the inboard retention nut used to maintain hub bearing assembly can loosen resulting in an ABS…
Risk and remedy
Risk
Wheel separation can result in a vehicle crash.
Remedy
Federal-mogul will notify customers and will replace the hub assembly free of charge. the recall began on february 7, 2008. owners can contact federal-mogul toll-free at 877-489-6659.
On certain heavy duty trucks equipped with 7.3L diesel engines, the camshaft position sensor located on the engine of the vehicle may function intermittently, possibly resulting in an engine stall.
Risk and remedy
Risk
In the event of an engine stall, a crash could result without warning.
Remedy
Dealers will inspect the sensor and replace it with an improved camshaft position sensor free of charge. the recall began on december 29, 2007. owners may contact ford at 1-866-436-7332.
On certain trucks equipped with speed control, gasoline or natural gas engines, the speed control deactivation switch may overheat.
Risk and remedy
Risk
Overheating could result in smoke, burn, or an underhood fire.
Remedy
Dealers will install a fused wiring harness into the speed control system free of charge. The recall began on march 12, 2007. owners may contact ford at 1-800-392-3673. (Note: also see recalls 05v017, 05v388, and 06v286)
Certain pro-a motors corner lamps, turn signals, and headlights sold as replacement lamps for use on certain passenger vehicles listed above. some combination lamps that are not equipped with amber side reflectors fail to conform to federal motor vehicle safety standard no. 108, lamps, reflective devices, and associated equipment.
Risk and remedy
Risk
Without the amber reflectors, the vehicle will be poorly illuminated, possibly resulting in a vehicle crash without warning.
Remedy
Pro-a motors will notify owners and offer to repurchase the lamps. the recall began on april 3, 2006. owners may contact pro-a motors at 323-838-2988.
Owner complaints
178 complaints6 involved a crash10 involved a fire5 injuries
What owners report most
Latest complaints
- Fuel/propulsion system
TL* the contact owns a 2003 ford F-250 sd. While the vehicle was parked, the contact noticed that the fuel tank was hanging down. The contact looked underneath the vehicle and saw that the fuel tank strap was fractured and the fuel gauge was damaged. The dealer was not contacted. The vehicle was…
TL* the contact owns a 2003 ford F-250 sd. While the vehicle was parked, the contact noticed that the fuel tank was hanging down. The contact looked underneath the vehicle and saw that the fuel tank strap was fractured and the fuel gauge was damaged. The dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure and stated that the vin was not included in a recall. The failure mileage was 49,000.
- Fuel/propulsion system
The rear fuel tank strap failed while traveling on a state highway.
- Wheels
I have american eagle - 20 " eagle alloy wheels. they are approximately 24 months old. This summer a spoke cracked all the way through on one wheel. the dealer would not warranty it and I had to purchase a replacement. this week I noticed another of the wheels cracked all the way through. I…
I have american eagle - 20 " eagle alloy wheels. they are approximately 24 months old. This summer a spoke cracked all the way through on one wheel. the dealer would not warranty it and I had to purchase a replacement. this week I noticed another of the wheels cracked all the way through. I have not hit any major pot holes, curbs or anything else. my truck IS not a work truck or used for mudding or off road, it IS a pavement princess driven back and forth to work. I am worried there IS a manufacturer defect and that the wheels are not safe.
- Electrical system · Unknown or other
I have had several problems with the spark plugs blowing out of motor and breaking coil causing it too leak fuel vapors out possibly causing a fire this has happened several times. Three different certified mechanics have advised this IS caused to defect in the aluminum heads from factory not…
I have had several problems with the spark plugs blowing out of motor and breaking coil causing it too leak fuel vapors out possibly causing a fire this has happened several times. Three different certified mechanics have advised this IS caused to defect in the aluminum heads from factory not having enough threads causing the spark plug to blow out. Possibly causing injury or fire. This issue needs addressed as it IS a safety concern. We had a small engine fire causing slight damage to engine compartment that had to be repaired.
- Vehicle speed control
TL* the contact owns a 2003 ford F-250 super duty. While attempting to use the cruise control, the vehicle speed function would not work. The contact stated that the switch became hot and failed. The vehicle was not diagnosed nor repaired. The manufacturer was not made aware of the failure. The vin was not included in nhtsa campaign number: 09v399000 (vehicle speed control). The failure mileage was 85,000.
- Engine
5.4 liter motor blows spark plugs out of the engine, because some moron at ford designed an engine with 2 or 3 threads per plug port on aluminum heads. ford IS paying a class-action lawsuit for model years 2004 - 2008, but mine IS a 2003. thanks for the screw-job, ford.
- Engine
A spark plug blew out while acelerating from a stop sign, this has happened 3 separate occasions. A smell of unburnt fuel was present while driving to ford dealer for repair.
- Fuel/propulsion system
1 of the tank straps busted off and the tank began sagging and almost touching the ground, thus causing a severe fire hazard.
- Engine and engine cooling · Engine and engine cooling › Engine › Diesel
TL* the contact owns a 2003 ford F-250 sd. While driving approximately 60 mph, the contact noticed smoke from the rear of the vehicle and there was a loud popping noise. The vehicle was completely surrounded by smoke resulting in a fire. The vehicle stalled. The fire was extinguished independently.…
TL* the contact owns a 2003 ford F-250 sd. While driving approximately 60 mph, the contact noticed smoke from the rear of the vehicle and there was a loud popping noise. The vehicle was completely surrounded by smoke resulting in a fire. The vehicle stalled. The fire was extinguished independently. The vehicle was towed to the contacts residence and was not diagnosed or repaired. The vehicle was not included in nhtsa campaign number: 07v553000 (engine and engine cooling). The manufacturer was notified of the failure. The approximate failure mileage was 81,000. updated 7/1/15*cn the consumer stated there was no fire, just excessive pressure in the crankcase causing the engine to blow oil out the glow plug. Updated 03/31/16.*jb
- Fuel system, gasoline › Delivery › Fuel pump
TL* the contact owns a 2003 ford F-250 sd. The contact stated while driving at various speeds, the vehicle stalled without warning. The contact mentioned that the transmission had to be shifted into neutral and then to drive before the vehicle would resume normal function. The vehicle was taken to…
TL* the contact owns a 2003 ford F-250 sd. The contact stated while driving at various speeds, the vehicle stalled without warning. The contact mentioned that the transmission had to be shifted into neutral and then to drive before the vehicle would resume normal function. The vehicle was taken to the dealer for diagnostic testing. The technician diagnosed that the fuel pump relay box needed to be replaced. The manufacturer was made aware of the failure. The vehicle was repaired. The failure mileage was approximately 89,919.
- Tires
TL* the contact owns a 2003 ford F-250 equipped with bf goodrich ultra all range tires, line size: p235/85/r16. The contact stated that while driving 70 mph, the rear passenger side tire blew out. The contact mentioned that after inspecting all the tires, he noticed that the tire tread was wearing…
TL* the contact owns a 2003 ford F-250 equipped with bf goodrich ultra all range tires, line size: p235/85/r16. The contact stated that while driving 70 mph, the rear passenger side tire blew out. The contact mentioned that after inspecting all the tires, he noticed that the tire tread was wearing prematurely and had started separating. The vehicle was taken to a tire shop. The manufacturer was made aware of the failure. The tires were not replaced. The tire failure mileage was 85,151. The vehicle current mileage was 86,000. updated 03/17/15*lj updated 08/25/2017*ct
- Vehicle speed control
2003 ford F-250. consumer writes in regards to speed control deactivation switch fire. *smd the consumer stated the vehicle would occasionally stall and re-start, due to vehicle momentum, but it stalled coming to a low rpm idle, or stop. When it stalled, it gave no code warnings or dash light…
2003 ford F-250. consumer writes in regards to speed control deactivation switch fire. *smd the consumer stated the vehicle would occasionally stall and re-start, due to vehicle momentum, but it stalled coming to a low rpm idle, or stop. When it stalled, it gave no code warnings or dash light indicator. He reset the ignition key and re-started the vehicle. The local ford dealer could not find a problem. After the recall was performed, the consumer did not experience any more problems. *jb
- Service brakes
I was traveling on the highway during five o clock traffic at a speed of approximately 40 mph when suddenly the vehicles in front of me began crashing into each other. I pressed my foot on the brake pedal to stop and suddenly the pedal went straight to the floor and I smashed into the back of the…
I was traveling on the highway during five o clock traffic at a speed of approximately 40 mph when suddenly the vehicles in front of me began crashing into each other. I pressed my foot on the brake pedal to stop and suddenly the pedal went straight to the floor and I smashed into the back of the car in front of me. Today the auto shop handling the repairs called me in to look at what happened. The master cylinder broke completely free from the booster. The metal brackets broke in half and separated causing the lose of brakes and the accident. I have photos of the master cylinder blown away from the booster. *tr
- Service brakes
Truck IS lightly used. Today I hooked up the horse trailer to haul horses and when I was headed down the driveway and used the brakes they completely failed. I engaged the tow mode on the transmission and used the e-brake to stop. There was no warning just brake pedal to the floor failure. If this…
Truck IS lightly used. Today I hooked up the horse trailer to haul horses and when I was headed down the driveway and used the brakes they completely failed. I engaged the tow mode on the transmission and used the e-brake to stop. There was no warning just brake pedal to the floor failure. If this failure occurred 2 minutes later I would of been at highway speed. there was a large leak on the main brake line above the rear fuel tank. I inspected the main brake line and every place the brake line IS attached to the frame there IS significant corrosion of the brake line . 2 inches from the attachment the brake line looks brand new. Looks like the engineers used a dissimilar metal and caused a corrosion cell. 10 year old truck and I am spending $800.00 to replace the entire main brake line. This type of failure on a $50,000 truck should not be happening. Dealer says he has never seen this before. This IS a serious safety failure. *Jb
- Tires
Thread separation , this IS the second bfg tire that has separated refer to odi number 10508448. *tr
- Steering · Suspension
TL* the contact owns a 2003 ford F-250 sd. The contact stated that while driving 70 mph, the vehicle shook violently. The vehicle was taken to an independent mechanic who was unable to diagnose the failure. The manufacturer was not made aware of the failure. The vehicle was not repaired. The vin was not available. The failure mileage was 170,000 and the current mileage was 228,000. *tr
- Tires
Tire tread came off the tire at the steel belts. *tr
- Fuel/propulsion system
TL* the contact owns a 2003 ford F250 sd. The contact stated that while driving up an incline approximately 45 mph, there was a sudden reduction in the engine power and then stalled. The vehicle restarted after numerous attempts. A chemical burning odor emitted outside of the vehicle. The failure…
TL* the contact owns a 2003 ford F250 sd. The contact stated that while driving up an incline approximately 45 mph, there was a sudden reduction in the engine power and then stalled. The vehicle restarted after numerous attempts. A chemical burning odor emitted outside of the vehicle. The failure occurred sporadically and whenever the fuel tank level registered quarter of a tank. The vehicle was taken to an independent mechanic who stated the fuel tank lining was severely damaged and the fuel tank needed to be replaced. The vehicle had not been repaired. The manufacturer was not notified of the problem. The approximate failure mileage was 140,000.
- Fuel/propulsion system
TL* the contact owns a 2003 ford F-250 sd. The contact stated that while performing an oil change, he noticed that the frame was rusted severely.the contact performed a thorough inspection of the vehicle and also discovered that the fuel tank straps were severely rusted. The front strap was…
TL* the contact owns a 2003 ford F-250 sd. The contact stated that while performing an oil change, he noticed that the frame was rusted severely.the contact performed a thorough inspection of the vehicle and also discovered that the fuel tank straps were severely rusted. The front strap was completely detached from the vehicle and the second strap was partially hanging from the vehicle. The manufacturer was contacted and advised him that the vehicle was not included in nhtsa campaign ID number 11v385000 (fuel system, gasoline:storage:tank assembly:mounting). The vehicle was not repaired. The failure and current mileages were approximately 125,000.
- Power train
TL* the contact owns a 2003 ford F250 sd. The contact stated that while driving 35 mph, the clutch failed. Upon further inspection the contact noticed that the plastic bushing had failed and the rod was detached from the clutch. The contact went to the dealer, purchased a new bushing and repaired…
TL* the contact owns a 2003 ford F250 sd. The contact stated that while driving 35 mph, the clutch failed. Upon further inspection the contact noticed that the plastic bushing had failed and the rod was detached from the clutch. The contact went to the dealer, purchased a new bushing and repaired the vehicle himself. the recent failure was the second clutch failure on the vehicle. The vehicle was repaired. The failure and current mileages were 58,000. updated 10/24/12 *cn updated 11/9/2012 *js
- Tires
On friday, june 8TH 2012, on my 2003 ford F250, the front left (drivers side) tire tread separated from the rest of the tire and caused extensive damage to my vehicle. The tire IS a dick cepek fun country 2 purchased in july 2007. At the time of the accident, the tire had 60,000 miles on it and was…
On friday, june 8TH 2012, on my 2003 ford F250, the front left (drivers side) tire tread separated from the rest of the tire and caused extensive damage to my vehicle. The tire IS a dick cepek fun country 2 purchased in july 2007. At the time of the accident, the tire had 60,000 miles on it and was properly inflated, there was adequate tread on it. My 15 1/2 year old son, who has his permit, was driving at the time in heavy traffic, but was able to control the vehicle enough to avoid an accident and remove the truck from the roadway; we were traveling at 50 mph at the time. The tire size IS 315/75/16. *tr
- Fuel/propulsion system
TL* the contact owns a 2003 ford F-250 super duty. The contact was traveling 80 mph when the smell of fuel emitted from the vehicle. The vehicle was taken to a private mechanic. The mechanic confirmed that the steel fuel line was corroded and needed to be replaced. The manufacturer was not contacted. The vehicle was not repaired. The failure mileage was 62,400 and the current mileage was 70,780.
- Steering
TL* the contact owns a 2003 ford F-250 sd. The contact stated the steering wheel was loose while driving. The failure made it very difficult to control the vehicle, especially when making a left or right turn. The dealer advised the contact that the failure was caused by the pitman arm. The dealer…
TL* the contact owns a 2003 ford F-250 sd. The contact stated the steering wheel was loose while driving. The failure made it very difficult to control the vehicle, especially when making a left or right turn. The dealer advised the contact that the failure was caused by the pitman arm. The dealer also stated there was a technical service bulletin (16515) for the pitman arm and there was no recall. The vin was not available. The failure mileage was 85,000 and the current mileage was 87,000.
- Power train › Automatic transmission · Structure › Body
Vehicle has 7.3 liter diesel engine and the ford 4r100 automatic transmission and 4 wheel drive. transmission failed at about 88,000 miles despite proper servicing since new. it would intermittently stop shifting in normal use and began to slip badly. only second gear was still working when I…
Vehicle has 7.3 liter diesel engine and the ford 4r100 automatic transmission and 4 wheel drive. transmission failed at about 88,000 miles despite proper servicing since new. it would intermittently stop shifting in normal use and began to slip badly. only second gear was still working when I got it to the dealer the next day. the transmission was replaced at my expense ($3500+). the replacement transmission failed in a similar way at about 135,000 miles despite being serviced as required by the dealer. they are unable to obtain a valve body for this troublesome assembly and it has been at the dealer for nearly two weeks. this model of transmission IS defective and dangerous especially if you are towing and lose engine braking due to the transmission failing. ford no longer uses this transmission as it has a high failure rate. the body has rusted through at one of the cab corners and over both rear wheel wells. ford repaired the rust through once under warranty but the rust throughs continue and have a negative effect on the integrity of the vehicle structure and protection of it's occupants in the event of a crash. a rusted body would not protect occupants as well as an an unrusted one. *kb
- Tires
TL* the contact owns a 2003 ford F250 sd with big o big foot ht tires, size lt265/75r16, dot number: upw8t264005. The contact was driving 65 mph when the vehicle started shaking abnormally. the dealer advised that three of the tires exhibited tread separation and needed to be replaced. The tires…
TL* the contact owns a 2003 ford F250 sd with big o big foot ht tires, size lt265/75r16, dot number: upw8t264005. The contact was driving 65 mph when the vehicle started shaking abnormally. the dealer advised that three of the tires exhibited tread separation and needed to be replaced. The tires were replaced. The manufacturer was not notified of the failure. The failure mileage of the tire was 948. The vehicle failure mileage was 50,988. updated 10/04/11*bf
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Engine stalling
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…
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) re-exposing those consumers to the risks associated with a stalling event.in their voq reports, half of the odi complainants described difficulty controlling the vehicle due to lose of power assist systems, especially those who were towing at the time of the incident. The one alleged injury incident occurred in an intersection when a subject vehicle stalled while turning across oncoming lanes of traffic.although unsubstantiated, the complainant alleged an injury to a child occupant during odi's interview.the other crash allegations mostly involved low speed, loss of control incidents often caused by lack of power assist; no injuries are reported in these incidents, and property damage, if any, was minimal.consumers also reported other incidents with significant safety risks, such as disablement in a lane or on a shoulder of a high-speed roadway or interstate, or extended disablement in remote areas during severe weather conditions. The population above IS ford's estimate of the 1.4 million subject vehicles produced that are currently registered.the ford complaint and warranty counts noted above are current as of ford's last submission dated june 21, 2007; they do not include F-450, F-550, or econoline counts as these products were not formally within scope of the investigation when failure information was requested.warranty data analysis indicates that about half the claims involved a stall while driving event ( ford's assessment) and that poor cps durability was a longstanding concern.ford reported that the new cps design should meet or exceed their 10 year, 150K mile life expectancy design requirement.
- 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 the complainant, or…
On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton V-8 and V-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi IS not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi IS aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi?s analysis showed, it IS possible for a spark plug to detach from the engine cylinder threads in the subject vehicles.however, odi?s analysis of 474 complaints describing such incidents found only a very few alleged any safety-related consequences.none of these showed any evidence of a serious safety consequence.given the large population and relatively long exposure time of the subject vehicles, the complaint analysis indicates that the risk to motor vehicle safety from the alleged defect IS very low.in view of the foregoing, it IS unlikely that nhtsa would issue an order for the notification and remedy of the alleged defect at the conclusion of the investigation requested in the petition.therefore, in view of the need to allocate and prioritize nhtsa?s limited resources to best accomplish the agency?s safety mission, the petition IS denied.
- Engine stalling
In a june 7, 2005 letter, ford notified odi that it would be conducting a safety recall of approximately 180,000 ford f-super duty, excursion and e-series vehicles equipped with 6.0L diesel engines to correct two wiring related conditions that could result in engine stall (nhtsa recall no. 05V-270, ford no. 05S34).the…
In a june 7, 2005 letter, ford notified odi that it would be conducting a safety recall of approximately 180,000 ford f-super duty, excursion and e-series vehicles equipped with 6.0L diesel engines to correct two wiring related conditions that could result in engine stall (nhtsa recall no. 05V-270, ford no. 05S34).the affected vehicles were built between september 29, 2003 and may 31, 2004.according to ford, vehicles with the conditions may stall without warning and may or may not restart.ford will instruct owners of vehicles included in the recall to take their vehicles to a dealer to have the fuel injector control module wire harness upgraded or replaced and or have a new injection control pressure sensor connector installed.during a may 2005 presentation to odi, ford identified a number of potential failure mechanisms that could affect engine performance in various segments of the subject vehicle population, including the wiring conditions addressed by 05v-270.the wiring conditions, which both affect engine fueling, were the most likely conditions to result in engine stall.the recalled vehicles comprise approximately 43% of the subject vehicle population and account for 75 of the 113 odi reports that have a valid vin (66%).the voq complaint rate for the recall population IS 45/100k while the rate for vehicles outside the recall population IS 17/100k and their trend (by date of receipt) IS declining.based on the analysis, odi believes ford?s actions are sufficient to address the current safety risks and the investigation IS thus closed.the closing of this investigation does not constitute a finding by nhtsa that a safety related defect does not exist.further action will be taken if warranted by future circumstances.
- Engine stalling
Twenty five of the odi failure reports are duplicative of ford complaints.twenty odi reports do not contain a vin (and may or may not be duplicative of ford reports).the 14 alleged crashes and 2 alleged injuries were all minor.submitted during preliminary evaluation (pe) 04-070, ford's response to odi's information…
Twenty five of the odi failure reports are duplicative of ford complaints.twenty odi reports do not contain a vin (and may or may not be duplicative of ford reports).the 14 alleged crashes and 2 alleged injuries were all minor.submitted during preliminary evaluation (pe) 04-070, ford's response to odi's information request (ir) letter contained about 5,000 consumer reports (mors) and 8,700 field reports (cqis).ford reviewed the complaints and categorized them.the manufacturer reports shown above represent a count of unique vehicles that ford categorized as allegedly stalling due to a subject engine component ('a' category, see ford's ir response letter for further detail); some of these vehicles received multiple reports.odi has not yet confirmed ford's categorization of these reports, nor has odi confirmed ford's categorization of the remaining reports (which ford states do not pertain to the alleged defect).ford submitted nearly 19,000 warranty claims, many of which involved claims for a technical service bulletin (tsb 04-13-08) and field service action (fsa 03b05) which ford identified as potential remedies for stalling complaints.odi has not confirmed that either of these are a remedy for engine stalling complaints.several other dealer communications related to engine stall were also submitted as well as over 50 product modifications, 15 of which involve revisions to the software for the electronic engine control unit.further investigation IS required and odi IS upgrading pe04-070 to an engineering analysis (ea).during the ea, odi will establish and update manufacturer failure report counts, further investigate the frequency and trend of stalling complaints, and determine the scope and safety implication of stalling events.odi will also investigate ford's remedies, their effectiveness, and whether further action IS required.
- Accelerator pedal sensor (etc)
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…
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 pedal re-application.the failure progresses until the engine remains at idle.the engine does not stall, power assisted steering and braking systems are unaffected. Ford corrected the etc sensor defect and conducted field service action (fsa) 03b03 to replace etc pedals, addressing 50% of vehicles.at agency request to improve completion rate, ford extended fsa 03b03 for 6 months.based on odi's analysis of available data, ford's action has appropriately resolved the etc sensor proplem in the subject vehicles.the closing of the investigation does not constitute a finding by nhtsa that a safety-related defect does not exist, and should not be considered as having any precedential value or effect binding the agency in future defect investigations. See the attached summary report for additional information.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 10243490When performing any transmission fluid changes or topoffs involving MERCON SP, MERCON LV has replaced all versions of MERCON SP and can be used going forward. Mixing MERCON LV and MERCON SP in the same transmission is acceptable. After 30-Jun-2023, MERCON SP ATF will no longer be manufactured and will only be available until inventory depletes.
- 10189008This SKU is a Transmission Line. The customer communication requested return of unsold inventory to inspect the connector. The transmission line connector may have an incorrect thread size, which will prevent it from being installed.
- 10171326This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for testing and containment. We don't have evidence that these test results have contributed to a product failure.
- 10171325This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for testing and containment. We don't have evidence that these test results have contributed to a product failure.
- 10165713Some 2002-2008 F-Super Duty, F-150 and Mark LT vehicles may exhibit concern during or after programing the VSM. The programming may fail or vehicle symptoms such as inoperative door locks, dome lamps, door ajar indicators or auto lamps may occur after successful programing. To ensure the VSM is configured correctly, use the Integrated Diagnostic System (IDS) scan tool and select the blue ball and socket icon in the upper left corner. Select the utility knife in the bottom left corner. Select Update/Special Function and enter 53061 in the blue box then press the tick mark. The screen will go back to the system utilities page. Navigate to the toolbox tab and run the Programmable Module Installation (PMI) on the VSM. The procedure will prompt you to manually enter the as-built into the VSM. Obtain the as-built data from PTS > OASIS > As-Built.
- 10148818This SKU is a front upper ball joint. The Customer communication requested return of unsold inventory to inspect for ball studs with excessive rotational friction in the ball joint assembly. Excessive friction in the ball joint assembly may cause a perceptible increase in steering effort.
- 10056196Ford: when shifting between park, reverse and/or during 2-3 shift, an intermittent clunk occurs with a torqshift transmission. Model 2003-2014 f-super duty, e series, excursion, F-53 motorhome chassis, low cab forward.
- 10055648Ford: the restraint control module (rcm) when using vcm II, would have an error code 35 and diagnostic trouble code (dtc) b1035, and difficulty attempting programmable module installation (pmi). Model 2001-2004 f-super duty.
- 10055629Ford: on some trucks, there IS a no crank situation and if voltage on transmission range sensor at pin 21, IS less than 5 volts, disconnect the engine cooling fan clutch, electronically, and recheck voltage. Model 2003-2007 f super duty, 2004-2010 e series, 2003-2005 excursion.
- 10028404Ford trucks service campaign: see document search button for owner letter. Vehicles have experienced severe steering wheel and front wheel vibrations and oscillations after traveling over a bump or dip in the road. Models 2006 f-250/350 super duty 4X4. Updated 7/22/09. Csc letter was received.
- 100248651999-2008 7.3l/6.0l/6.4l/4.5l diesel f-super duty - clean the charge air cooler (cac) system after certain turbo or engine failures - service tip.
- 100243256.0L turbocharger carbon deposit diagnostics and service tips. Updated 5/29/08.
- 100238556.0L--mil on--p0401, p0402, p0404, p1335--lack of power or surge with some 2003-2007 f-super duty, 2003-2005 excursion and 2004-2008 e-series vehicles.
- 100236531999-2008 f250-f550 super duty 4X4 with electronic shift transfer case not engaging 4X4.
- 10022675Brake booster system may exhibit a brake pedal kickback and/or grabbing condition when applying the brakes.
- 10022295Dtc's p006a or p132b - lacks power, surge, or flutter after field service action 06e17.
- 100222936.0L diesel engine - oil leak or boost pressure leak at hot side charge air cooler duct.
- 10022243Lack of power due to low fuel pressure - fuel tank liner seperation.
- 10021621Lack of power due to low fuel pressure, fuel tank liner seperation.
- 10021619Air filter water ingestion / snow packing with codes p0103.
- 10021484Adding additional bulbs to turn indicator or hazard flasher circuits.
- 100214646.0L oil seep or boost pressure leak at hot side charge air cooler duct.
- 10021462Cold start driveability - white smoke, lacks power, exhaust odor, surges, runs, rough, or no start.
- 10021236Lack of cooling fan operation.
- 100212326.0L turbocharger carbon deposit diagnostics and service tips - lack of power, white or black smoke, surge, p0238, p0299, p0404, p2262, and/or p2263.
- 10021229Watch for oil flow from the base engine oil pump. Vehicles equipped with a 6.0L diesel engine.
- 10021174Driveability issues and/or dtc p132b, p006a immediately after reprogramming.
- 10021173Oil flow from the base engine oil pump.
- 10020069Misfire, lack of power, buck/jerk, excessive smoke or crank/no start.
- 10019949Water-in-fuel (wif) lamp on.
- 10019945Voluntary emission recall 06e17 supplement #1: control module recalibration. Corrosion may exist at the electrode surface on the exhaust pressure (ep) sensor; fuel delivery timing during cold weather may not be optimal; and/or exhaust gas recirculation (egr) system operation at idle may not be optimal.
- 10019808Exhaust pressure sensor input no longer used if pcm IS reprogrammed - service tip.
- 10019795P0404 service tip.
- 10019385Coolant degas bottle overflow - 6.0L.
- 10019380White smoke, lacks power, exhaust odor, surges, runs rough, or no start - 6.0L.
- 10018939Coolant degas bottle overflow.
- 10018070Torqshift transmission - intermittent clunk when shifting from reverse gear or drive gear to park. Multiple vehicles. Ford oasis. To include 2006 ford F-53.
- 10018067Vacuum pump inoperative or runs continuously - climate control defaults to defrost mode.
- 10018062Coolant degas bottle overflow.
- 10018054Service kit available for wiper motor wiring.
Every Ford F-250 SD model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.