2003 Ford F-350 SD
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Ford › F-350 SD › 2003
These records cover every 2003 Ford F-350 SD. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
5 recalls name the 2003 Ford F-350 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)
Owner complaints
132 complaints6 involved a crash2 involved a fire4 injuries
What owners report most
Latest complaints
- Fuel/propulsion system
Fuel tank delamination leading to stalling and eventual replacement of the tank at my cost
- Engine · Power train · Unknown or other
While preparing for a camping trip this pass summer, I went to check the oil level. when I went to remove the oil dipstick, the dipstick tube broke, due to corrosion. this IS the first time in my 25 years of owning a vehicle for that to happen. it would be alright, but in order to replace the…
While preparing for a camping trip this pass summer, I went to check the oil level. when I went to remove the oil dipstick, the dipstick tube broke, due to corrosion. this IS the first time in my 25 years of owning a vehicle for that to happen. it would be alright, but in order to replace the tube, it IS required to remove the exhaust manifold to properly replace it. in turn it cost more money to replace a product that should not break. I was fueling my truck and wanted to check all my fluids.
- Wheels
I purchased lt265/75/16 bf goodrich rugged terrain t/a tires for my truck exactly 5 years and just over 21K miles later I had 2 separate tire failures less than a few hundred miles apart. First tire a belt slipped. Had a giant bulge in the tread. I put my spare on and inspected the other tires. All…
I purchased lt265/75/16 bf goodrich rugged terrain t/a tires for my truck exactly 5 years and just over 21K miles later I had 2 separate tire failures less than a few hundred miles apart. First tire a belt slipped. Had a giant bulge in the tread. I put my spare on and inspected the other tires. All ok. No cracks no dry rot. I have pics. Tire pressure set equally at 78 psi. I was away camping and pulling a 9000 lb trailer. Local tire store didn't have a replacement so I headed home figured I would replace it with another matching tire at home. About 100 miles later we had a second tire fail. This one blew out at highway speed, causing a lot of damage to the truck and left me stranded with no spare. After doing so research and reading bfg recalls for tires similar to this one but different sizes, I am left to wonder if all of these sizes should have been included in the recall. The recall tires failed in the same manner as mine that was not included only because of the size and I was never notified. I had my wife and 3 kids in the truck and it was a dangerous situation. The tire blew out on the pa turnpike. 65 mph while towing a heavy trailer. Sunny. 85* day. The bulged tire happened a low speed. 25 mph on back roads. All of these tires should have been included in the recall it IS dangerous to have them on the road.
- Tires
Tire failure. destroyed my outer fender on 2003 F350 dually damaged included, outer fender, inner fender, damage to the bed of the truck, and damage to the support brackets. bought this truck used about a month ago. not sure when the tires were purchased. mileage on tires IS an assumption
- Tires
Truck starts to have a vibration and at higher speed gets worse by the time you think it may be a bad tire you may get pulled over before it blows out or it blows doing extensive vehicle damage before you get stopped. between 04/15/09 to 08/16/12 I purchased 6 uniroyal laredo 265/75r16 tires…
Truck starts to have a vibration and at higher speed gets worse by the time you think it may be a bad tire you may get pulled over before it blows out or it blows doing extensive vehicle damage before you get stopped. between 04/15/09 to 08/16/12 I purchased 6 uniroyal laredo 265/75r16 tires for 2003 F-350 ford truck. on 9/15/2910 a tire separated and had a huge knot and adjusted with a new tire. On 8/16/2012 another tire separated and had a knot it was replaced and adjusted with a new tire. since 2012 every one of the 6 tires has separated and had a knot. 2 blew completely before I could get stopped doing extensive vehicle damage. the left front blew out in may of this year taking me directly into incoming traffic and almost hitting a couple headon on a motorcycle and then ending up in the incoming vechicles road ditch at 65 mph. The tire store reccomended to not use the uniroyal laredos because this has become a common qa issue with this tire. the technician showed me where the tires start to come apart. I left 2 uniroyal laredos on the rear wheels and the tire techinician looked at the tires and he said they still looked operable in less than 2 weeks left rear started vibrating and it had a knot on it. So now all uniroyal laredos have been replaced with bfg tires. 6 out of 6 tires all went bad and the tire stores know these uniroyal tires are defective and yet uniroyal has done nothing to fix the problem or recalled the tire. this IS a extremely dangerous safety issue when a tire blows on the front you have no control over the truck your just a bomb heading to incoming traffic.
- Engine
I called ford motor company on my 2003 ford F350 sd. Sc. 4X4 5.4 eng. With the problem with both exhaust manifolds rotting away & the studs & nuts rotting , they told me we won't fix the problem for free . I would like for your help to make ford motor company fix this problems for free because I…
I called ford motor company on my 2003 ford F350 sd. Sc. 4X4 5.4 eng. With the problem with both exhaust manifolds rotting away & the studs & nuts rotting , they told me we won't fix the problem for free . I would like for your help to make ford motor company fix this problems for free because I talked to many ford dealers they are replacing this same problems on all 5.4 eng. On ford trucks and have to charge for these problems . Please investagate this problems before all these trucks will catch on fire and people will be injury or fatality will happen . Please help me and many people can get these problems fix for free from ford motor company thanks. *js
- Engine
On 05/31/2013 after driving aprox 50 miles at highway speeds the truck was parked and a small fire started due to leaking oil on the hot exhaust system from a rusted oil pan. The fire was extinguished before it consumed the entire vehicle. I have contacted ford motor co. Customer care and was told…
On 05/31/2013 after driving aprox 50 miles at highway speeds the truck was parked and a small fire started due to leaking oil on the hot exhaust system from a rusted oil pan. The fire was extinguished before it consumed the entire vehicle. I have contacted ford motor co. Customer care and was told that the truck was out of warranty and that the cost to repair 1500.00 to 2000.00 would be my responsibility. I am disabled and on social security with a very fixed income and cannot afford the cost of this repair. From looking at all the other posts and living in michigan with winter salt, ford has recalled many of their vehicles due to rust and corrosion of various components that could cause a accident or death. Please investigate this major problem with ford trucks and other vehicles with the 7.3 liter diesel engine. I have contacted my dealer and they said this IS a very common problem. Thank you in advance. The truck IS currently parked and undriveable. *tr
- Wheels
Bought truck in 2009 . ABS light IS on wanted to find out if there was a recall on hubs and if so would like to find out if truck was serviced , and if not how would I proceed to do recall . thank you *tr
- Engine · Fuel/propulsion system
Vehicle was accelerating onto on-ramp to interstate 90 west bound at pines road in spokane valley wa. Vehicle was driven by my wife. At approximately 30 mph their was a loud bang and noise that sounded like an exhaust leak. Vehicle was driven to the shoulder and shut off. My wife called me and I…
Vehicle was accelerating onto on-ramp to interstate 90 west bound at pines road in spokane valley wa. Vehicle was driven by my wife. At approximately 30 mph their was a loud bang and noise that sounded like an exhaust leak. Vehicle was driven to the shoulder and shut off. My wife called me and I came to investigate what had happened. I turned the engine over and determined it was not an exhaust leak but that a spark plug had been blown out of the right side of the engine. It was the number 4 spark plug from the front on my V-10 gas engine. I located the bent spark plug at the approximate location of where the incident occurred. Other than being bent the threads on the plug were intact and did not appear to have been cross threaded. I had the plugs replaced at just over 100,000 miles as per the owners manual. I checked with the auto repair shop I used, (aafes auto hobby shop on fairchild afb), and informed them of what had occurred. They informed me that ford had a technical service bulletin on this very subject. This appears to be a manufacturing defect in that replacing spark plugs should not lead to an explosive event strong enough to dent my hood from the inside. I am now expecting to have 9 more little time bombs just waiting to go off under the hood of my truck. I am just thankful that my wife hadn't yet gotten up to the speed limit of 60mph. *tr
- Wheels
My wife and I were taking our son back to college. There was a noise coming from the front right tire that sounded like the warning for your brake pads, except when I applied the brakes it didn't stop. Sounded like my brake rotor was grinding. The next day I took my vehicle to my mechanic to have…
My wife and I were taking our son back to college. There was a noise coming from the front right tire that sounded like the warning for your brake pads, except when I applied the brakes it didn't stop. Sounded like my brake rotor was grinding. The next day I took my vehicle to my mechanic to have my brakes and rotors checked. They were fine, but I was surprised when my mechanic told me it wasn't my brakes but instead it was my aluminum alloy rim (factory rims) had cracked all the way through one of the spokes on the rim and had started cracking about an 1 1/2" through another! I told my mechanic that I had never had this happen before in my life. My mechanic replied that he had seen this same thing on 5 or 6 of the super duty's. So, I browsed the internet to see if anyone else had experienced the same problem. Come to find out that there are hundreds of people that have had the exact problem not only with the aluminum alloy rims but the steel rims as well and not specific to any year. From florida to california all over the u.s. Informed ford customer relations of my findings and there response was to hold on to my receipt in case there IS a customer satisfaction program (csp) or a recall ever put in place. *tr
- Exterior lighting
TL* the contact owns a 2003 ford F-350 sd. While parked, the contact inspected the vehicle and noticed that both rear brake lights were inoperable. The contact referenced nhtsa campaign ID number: 11v352000 (exterior lighting:brake lights) and contacted the manufacturer. The manufacturer informed…
TL* the contact owns a 2003 ford F-350 sd. While parked, the contact inspected the vehicle and noticed that both rear brake lights were inoperable. The contact referenced nhtsa campaign ID number: 11v352000 (exterior lighting:brake lights) and contacted the manufacturer. The manufacturer informed the contact that the vin was not included in the recall campaign. The vehicle was not repaired. The approximate failure mileage was 165,000.
- Tires
TL* the contact owns a 2003 ford F-350 sd equipped with bf goodrich commercial t/a a/s tires, size: 235/85/16. while driving approximately 65 mph, the rear tire exploded and caused rear end damage to the vehicle. The contact was able to maneuver the vehicle to the side of the road where the rear…
TL* the contact owns a 2003 ford F-350 sd equipped with bf goodrich commercial t/a a/s tires, size: 235/85/16. while driving approximately 65 mph, the rear tire exploded and caused rear end damage to the vehicle. The contact was able to maneuver the vehicle to the side of the road where the rear passenger side tire was replaced with a spare. The vehicle was taken to a tire center where a where a new tire was mounted onto the vehicle. The manufacturer was notified of the defect. There was a recall associated with the tire under nhtsa campaign ID number 12t019000 (tires:tread/belt) however, the contact's tire was not included in the recall. The approximate failure mileage was 82,000. The dot number and vin were unavailable.
- Engine and engine cooling › Engine › Diesel
I was hauling a loaded horse trailer and had just merged onto the highway. as I was trying to accelerate, the engine was "catching" and wouldn't let me accelerate past 35 mph and was revving very high and wouldn't shift up into the next gear. it finally stalled and completely shut off in the…
I was hauling a loaded horse trailer and had just merged onto the highway. as I was trying to accelerate, the engine was "catching" and wouldn't let me accelerate past 35 mph and was revving very high and wouldn't shift up into the next gear. it finally stalled and completely shut off in the middle of traffic and I had to coast to the side of the road where white smoke started pouring out from under the hood. my entire rig - truck, trailer and horses, had to be towed home and then the truck towed to the mechanic. he found the engine running poorly, and found low compression on cylinders #3 and #8. he found low oil pressure and when he removed the oil pan from the chassis, he found piston material in the oil pump. he removed the engine and found the pistons in cylinder 3 and 8 melted down. he had to bore out and hone all the cylinders, replace all 4 valves in cylinder #3 head, replace all pistons, replace the main bearing and rod bearing, update the oil cooler and replace 8 pistons and 6 head gaskets. when he put it all back together and test drove it, he found an exhaust leak from the ebp sensor and tube. those had to be replaced. before all this happened, I had noticed that the engine seemed to be "skipping" when I was hauling my horse trailer. it only happened when I was over 55 mph and it only happened when I was hauling. I had taken the truck to the mechanic before the big breakdown (described above) and he couldn't find anything wrong. I think that IS because he was not hauling a trailer and that's the only time the problem occurred. the total bill for all these repairs IS $6400.00 and I have been told that ford will do nothing to help me. *jb
- Tires
Purchased 4 LT continental conitrac 275/70r18 tires/ford oem wheels from barney's tire and wheel in temecula, ca for my 2003 F350 ford truck. These tire and wheels were in new condition. June 2, 2011 I had dinsaur tire located in calimesa ca replace the left front tire due to tire separation.…
Purchased 4 LT continental conitrac 275/70r18 tires/ford oem wheels from barney's tire and wheel in temecula, ca for my 2003 F350 ford truck. These tire and wheels were in new condition. June 2, 2011 I had dinsaur tire located in calimesa ca replace the left front tire due to tire separation. neither I or dinosaur tire were aware of the continental tire recall. march 22, I had the left rear tire separate and again contacted dinosaur tire to schedule a replacement. Again, they were unaware of the recall. thinking two tire separations were odd, I performed a search on the web for problems related to these tires and discovered continental had recalled certain tires. emailed continental the dot numbers of the tires and they confirmed with a email these were tires subject to the recall and I was directed to contact an authorized dealer. contacted dinosaur tire (authorized dealer) and faxed all correspondence to them. they were still unaware of the recall and did not know the process to file a claim. dinosaur tire called continental with me in their company to get an authorization. unfortunately and wrongfully, continental will only prorate the remaining three tires because there was a compliance date of october 15, 2011 and stated all persons who purchased the tires were contacted. had the authorized dealer dinosaur tire been made aware of the recalled tires last june, I could of replaced the 4 tires without any fees and free of charge. however, because continental failed to communicate this to the public and authorized continental dealerships, demonstrates a lack to take full responsibility to the public for tires the public accidentally came in possession of, and sold by unaware tire companies. Continental would not provide any reimbursement for the tire replaced last june, 2011. again - failure to communicate the recall to the public demonstrates a lack of responsibility. *tr
- Engine and engine cooling › Engine › Diesel
TL* the contact owns a 2003 ford F-350 sd diesel. the contact stated the vehicle experienced a blown head gasket. the dealer replaced the motor but the failure recurred. The manufacturer was notified of the failure but denied any assistance with repairs to the vehicle. the vehicle was not…
TL* the contact owns a 2003 ford F-350 sd diesel. the contact stated the vehicle experienced a blown head gasket. the dealer replaced the motor but the failure recurred. The manufacturer was notified of the failure but denied any assistance with repairs to the vehicle. the vehicle was not repaired. the failure mileage was 25,000 and the current mileage was 150,000. ..Updated 11/28/12 *bf the consumer stated when the heads cracked it pushed water in the fuel and destroyed the fuel pump, injectors, and turbo. updated 11/29/12
- Exterior lighting · Exterior lighting › Turn signal › Switch
During high speed highway driving the turn signal became stuck in right hand turn position. After clicking the signal lever from left, center, and right hand turn positions the right hand turn signal remained on in all positions. I have been driving for 6 days now with the four way hazards on. I…
During high speed highway driving the turn signal became stuck in right hand turn position. After clicking the signal lever from left, center, and right hand turn positions the right hand turn signal remained on in all positions. I have been driving for 6 days now with the four way hazards on. I found online there was a safety recall on the multi function turn switch, but when I took vehicle to the dealer they turned me away and said there was no recall. Then I called ford customer relationship center and they said there was no recall either and also said that even though my truck was within the years and models stated that the vin # was not within the recall. How could that be? IS a ford F-350 sd 2003 different from another ford F-350 sd 2003. I still have the problem described in the recall. Safety hazard indeed. *kb
- Electrical system
TL* the contact owns a 2003 ford F-350 sd. the contact stated that the vehicle would stall sporadically without warning. In addition, the vehicle would hesitate when attempting to start. the dealer diagnosed that the injection control pressure module would need replacing. the manufacturer…
TL* the contact owns a 2003 ford F-350 sd. the contact stated that the vehicle would stall sporadically without warning. In addition, the vehicle would hesitate when attempting to start. the dealer diagnosed that the injection control pressure module would need replacing. the manufacturer advised the contact that the vehicle was not included in nhtsa campaign ID number: 05v270000 (electrical system:wiring) recall. the vehicle was not repaired. the failure mileage was 60,000 and the current mileage was 60,200.
- Fuel system, diesel
I had several breakdowns with my truck and had to have it towed twice. The first place it was towed to could not find the problem then after several more instances I had it towed to the dealership where I purchased the vehicle and they new the problem right away. The fuel tank delaminated and I…
I had several breakdowns with my truck and had to have it towed twice. The first place it was towed to could not find the problem then after several more instances I had it towed to the dealership where I purchased the vehicle and they new the problem right away. The fuel tank delaminated and I waited two months for one because they were in production at a cost of $2000.00 to be repaired. This seems to be a wide spread problem with these trucks and it should be warrantied. *tr
- Power train › Automatic transmission › Gear position indication (prndl)
TL* the contact owns a 2003 ford F-350 sd. the contact would shift the vehicle into park, but instead the vehicle would shift into reverse. the contact stated that the gear shift would read properly, but perform in inaccurately. The manufacturer nor dealer were notified. The vehicle was not repaired. the failure and current mileage was 120,000.
- Structure › Frame and members
TL* the contact owns a 2003 ford F250. the contact noticed that the frame underneath the vehicle was covered with rust. he also noticed that the rust was affecting the drivers side door panel. the dealer did not offer any assistance since the vehicle was no longer under warranty. the…
TL* the contact owns a 2003 ford F250. the contact noticed that the frame underneath the vehicle was covered with rust. he also noticed that the rust was affecting the drivers side door panel. the dealer did not offer any assistance since the vehicle was no longer under warranty. the manufacturer also offered no assistance. the current mileages were 65,000 and the failure mileages were 50,000. updated 5/24/11 *cn updated 06/10/11
- Steering · Suspension › Front
My 2003 F350 has all of the death wobble issues, driving at 55 or 70 on the highway the front end will just go into a crazy wobble in which I have to slow down to try and fix. Sometimes when I use the brake pedal it will also go into the same event. I've read all these issues on the net and cannot…
My 2003 F350 has all of the death wobble issues, driving at 55 or 70 on the highway the front end will just go into a crazy wobble in which I have to slow down to try and fix. Sometimes when I use the brake pedal it will also go into the same event. I've read all these issues on the net and cannot understand that if its such a huge problem why IS it not being addressed. Will it take one of these vehicles killing a family member of the people at ford to get this under control or maybe they just don't care as long as they are making money. To the family members of the ford people and everyone else I pray for you. I do not know what to do for my truck to fix it. *tr
- Engine and engine cooling
Spark plug ejection from 2003 ford F-350 super duty engine: triton 5.4L V8 date of failure: 03-10-11 mileage of truck: 139414 this incident happened while traveling on a state hwy51 near postville, ia ejection of spark plug from number 7 cylinder on 5.4L V8 engine. damage to cylinder head…
Spark plug ejection from 2003 ford F-350 super duty engine: triton 5.4L V8 date of failure: 03-10-11 mileage of truck: 139414 this incident happened while traveling on a state hwy51 near postville, ia ejection of spark plug from number 7 cylinder on 5.4L V8 engine. damage to cylinder head of engine and spark plug coil. this IS a well maintained 2003 F-350, spark plugs replaced at a ford dealer 01-19-09: 109156 miles. *tr
- Parking brake
Have a 2003 F-350 super duty ford truck.noise in rear brakes upon investigation found that the emergency brake backing plate that the emergency brake shoes attach to was rusted away and the emergency brake shoes and their hard ware fell apart creating a very dangerous situation since super duty trucks carry and tow heavy loads and could cause serious accident. *tr
- Electrical system
TL* the contact owns a 2003 ford F-350 6.0L diesel sd. The contact was driving approximately 10-20 mph and attempting a right turn when the vehicle stalled without warning. The vehicle was taken to an independent mechanic where the icp sensor was replaced yet the failure recurred two days following…
TL* the contact owns a 2003 ford F-350 6.0L diesel sd. The contact was driving approximately 10-20 mph and attempting a right turn when the vehicle stalled without warning. The vehicle was taken to an independent mechanic where the icp sensor was replaced yet the failure recurred two days following the repairs. The vehicle was taken back to the local mechanic and the contact was referred to the dealer. The dealer was installed a flat record on the vehicle but was not repaired. The contact referenced nhtsa campaign ID number: 05v270000 (electrical system:wiring) which included the 2005 model ford 350 diesel and stated that he was experiencing the exact same failure. The vehicle was not repaired. The vin was unavailable. The failure mileage was 23,000 and the current mileage was 25,000.
- Fuel system, diesel
On the ford F350 7.3 diesel, the clamp beneath the turbo holding the high pressure diesel fuel line in place IS a poor design. the clamp appears to be aluminum with a rubber coating. the rubber coating wears away and the fuel line passes metal on metal through the clamp causing wear. in this…
On the ford F350 7.3 diesel, the clamp beneath the turbo holding the high pressure diesel fuel line in place IS a poor design. the clamp appears to be aluminum with a rubber coating. the rubber coating wears away and the fuel line passes metal on metal through the clamp causing wear. in this particular case the pinhole leak in the high pressure fuel line caused by the wear created a mist of fuel to be blown on the hot turbo causing a flammable cloud of diesel. I immediately shut the vehicles ignition off and stood by with an extinguisher. this IS going to happen again to somebody and needs to be repaired. somebody IS going to be injured or the vehicles engine compartment will catch fire. the fuel line needs to pass through a clamp of better design. *tr
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.
- 10021281Water in the fuel tank behind rear axle - 6.0L, 6.4L and 7.3L diesel engine. Updated 2/29/08.
- 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.
Every Ford F-350 SD model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.