2002 FORD F-250 SD Engine And Engine Cooling Problems

2002 FORD F250 SUPERDUTY. CONSUMER WRITES IN REGARDS TO A STRONG DIESEL FUEL ODOR AND FINDING FUEL ON THE PASSENGER SIDE OF THE ENGINE COMPARTMENT IN THE CAB OF THE VEHICLE. THE DEALER INFORMED THE CONSUMER, THE DIESEL ENGINE WAS DESIGNED WITH COPPER SLEEVES OR CUPS AROUND THE FUEL INJECTORS. THE PURPOSE OF THE CUPS WERE TO SEPARATE THE ENGINE COOLING SYSTEM FROM THE PRESSURIZED FUEL SYSTEM. OVER A PERIOD OF TIME, THE ENGINE COOLANT REACTED WITH THE COPPER CUPS AND CREATED SMALL PIN HOLES OR CRACKS IN THE INJECTOR CUPS. SINCE THE FUEL SYSTEM WAS PRESSURIZED IT INJECTED DIESEL FUEL INTO THE COOLANT CIRCULATING IN THE ENGINE. EVENTUALLY THE DIESEL FUEL CAME OUT OF THE RADIATOR OVERFLOW AND ALL OVER THE PASSENGER SIDE OF THE ENGINE COMPARTMENT. SINCE THERE WAS NO WAY TO TELL, WHICH INJECTOR CUP WAS BAD, ALL OF THEM WOULD HAVE TO BE REPLACED ALONG WITH THE COOLANT HOSES AND THE RADIATOR WOULD NEED TO BE FLUSHED. THE ENGINE WOULD HAVE TO BE TAKEN APART, THE HEADS WOULD HAVE TO BE REMOVED AND THE INJECTOR CUPS REPLACE.*JB UPDATED 02/13/13

TL*THE CONTACT OWNS A 2002 FORD F250 SD. WHILE DRIVING APPROXIMATELY 50 MPH, THE CONTACT HEARD A LOUD NOISE OUTSIDE OF THE VEHICLE AND SUDDENLY THERE WAS A REDUCTION IN THE ENGINE POWER. THE CONTACT MANEUVERED TO THE SIDE OF THE ROAD AND THEN RESUMED CAUTIOUSLY TO THE RESIDENCE. UPON REACHING THE DESTINATION THE VEHICLE WAS INSPECTED. THE CONTACT DETECTED ONE OF THE SPARK PLUGS EXPLODED FROM THE HEAD. THE VEHICLE HAD NOT BEEN REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 142,000.

Mileage: 142,000

SPARK PLUG IN THE #8 CYLINDER WAS BLOWN OUT BREAKING THE COIL PACK AND MESSING THE THREADS UP INSIDE THE HEAD ON THE TRITON 5.4 V8. *KB

Mileage: 183,595

SPARK PLUG IN THE #8 CYLINDER WAS BLOWN OUT BREAKING THE COIL PACK AND MESSING THE THREADS UP INSIDE THE HEAD ON THE TRITON 5.4 V8. *KB

Mileage: 183,595

ON SUNDAY MAY 1ST. I WAS DRIVING MY FORD F250 ON THE FREEWAY AND NOTICED THAT SMOKE WAS COMING OUT OF THE DASHBOARD, AND OUT OF THE AC VENTS. I PULLED OVER TO THE EMERGENCY LANE OF THE FREEWAY AND OPENED THE HOOD, WE SAW NO SMOKE NOR FIRE UNDER THE HOOD BUT JUST TO BE ON THE SAFE SIDE I DISCONNECTED THE BATTERY. THE SMOKE CONTINUED COMING OUT THROUGH THE DASHBOARD I THEN PROCEEDED TO CALL AAA AND THEY CALLED THE POLICE. MY SON THEN CALLED 911, AND BEFORE THE FIRE DEPARTMENT ARRIVED TO THE SCENE THAT TRUCK CAUGHT FIRE AND KEPT BURNING UNTIL THE FIRE DEPT. TURNED IT OFF. THE TRUCK IS NOW A TOTAL LOSS, ASIDE FROM MY TRUCK BURNING UP I HAD ALOT OF WORK TOOLS THAT BURNED IN THE FIRE AS WELL. *TR

THERE WAS NO EVENT LEADING UP TO THIS FAILURE IT JUST HAPPENED THE SPARK PLUG AND COIL BLEW OUT OF THE CYL HEAD OF THE ENGINE CAUSING A LOUD NOISE AND SEVERE LOST OF POWER. THE TRUCK HAD TO BE TOWED TO THE REPAIR SHOP TO REPAIR THE HEAD AND RETHREAD THE SPARK PLUG HOLE. LOOKING ON THE INTERNET FOR THIS SAME PROBLEM AND FOUND HUNDREDS OF COMPLAINTS WITH THE SAME PROBLEM. *TR

Mileage: 106,390

TL*THE CONTACT OWNS A 2002 FORD F250 SUPER DUTY. WHILE THE CONTACT WAS DRIVING APPROXIMATELY 35 MPH, THE VEHICLE BEGAN TO SHAKE WITH A VIBRATION. THE VEHICLE WAS TAKEN TO A LOCAL INDEPENDENT MECHANIC WHO STATED THAT ONE OF THE SPARK PLUGS EJECTED FROM THE ENGINE. THE VEHICLE WAS IN THE PROCESS OF BEING TOWED TO A DIFFERENT MECHANIC TO BE REPAIRED. THE FAILURE MILEAGE WAS 86,000.

Mileage: 86,000

2002 FORD F-250 5.4L TRITON MOTOR. 95,950 MILES ON ENG. SPARK PLUG BLOW OUT. JUST COST ME $775 DOLLARS TO HAVE SPARK PLUG INSERT,NEW SPARK PLUG, AND SPARK PLUG COIL REPLACED. I DID NOT GET THE OLD PARTS BACK. *TR

Mileage: 95,988

2002 F250 SUPER DUTY LARIAT WITH 80,350 MILES AND ORIGINAL FACTORY INSTALLED PLUGS LOST A SPARKPLUG ON PASSENGER SIDE OF MOTOR ON 8/22/2010, 183 MILES FROM DEALER(WHO SOLD ME AN AFTER MARKET "EXTENDED" WARRANTY. I PAID $300.00 PLUS TO HAVE TRUCK TRAILERED BACK TO THE DEALER AND HAVE INCURRED OTHER EXPENSES NOW THAT WE ARE GOING ON OVER A WEEK SINCE THE PROBLEM! I DON'T HAVE ANY FAITH IN THE VEHICLE NOW AND AM NOT GOING TO BE OVERLY SURPRISED AT WHAT THIS SITUATION HAS DONE TO THE TRADE-IN VALUE OF, WHAT WAS, A BEAUTIFUL TRUCK. FORD SAYS "WON'T HELP" AND WARRANTY PEOPLE SAY "WON'T HELP; NOT A LUBRICATED PART". ASKING FOR LETTERS TO THAT EFFECT FROM BOTH COMPANY'S FOR MY "PERSONAL USE"!!! *TR

Mileage: 80,350

LEAKING HEAD GASKETS ON 2002 FORD F250 TRUCK WITH 5.4L ENGINE ALLOWS OIL TO LEAK ONTO STARTER AND EXHAUST MANIFOLD CREATING SAFETY HAZARD. THIS IS A KNOWN PROBLEM WITH THIS TYPE ENGINE. *TR

Mileage: 78,000

FORD F-250 SPARK PLUG CAME OUT OF HEAD, BROKE OFF COIL PACK, CANT GET NEW PLUG BACK IN. THIS SHOULD NOT BE ABLE TO HAPPEN. I GUESS I AM GOING TO TRY HELICOIL,IT HAPPENED ON THE 3RD CYL BACK FROM THE FRONT ON RIGHT SIDE SO ITS KIND OF UNDER THE WINDSHIELD ALL READY, NOT MUCH ROOM FOR DRILL. *TR

Mileage: 60,560

TL*THE CONTACT OWNS A 2002 FORD F-250 SUPER DUTY. WHILE DRIVING AT 50 MPH, THE CONTACT HEARD A HISSING NOISE AND THE VEHICLE SUDDENLY LOST POWER. THE CONTACT PULLED OVER AND NOTICED A SPARK PLUG HAD FALLEN OUT OF THE VEHICLE. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALERSHIP WHERE IT WAS REPAIRED. THE FAILURE MILEAGE WAS 70,142. THE CURRENT MILEAGE WAS APPROXIMATELY 79,000.

Mileage: 70,142

WELL GUESS WHAT, IT'S ME AGAIN WITH F250 4X4 WITH THE TRITON MOTOR. GOT IN IT MADE IT ABOUT 1/10 OF A MILE, IT STARTED SHIMMING AND RUNNING ROUGH AGAIN AND IT DIED. I'M AFRAID TO START IT BECAUSE OF THE SPARK PLUG EJECTING ALREADY ONCE AND I'M AFRAID IT'S GOING TO DO IT AGAIN AND CATCH FIRE. FORD IF THIS KEEPS UP U WILL HAVE A LAWSUIT AND YOU CAN BRING IN YOUR BIG LAWYERS BUT I GUARANTEE YOU WILL NOT WIN. *TR

Mileage: 160,000

SPARKPLUG EJECTED OUT OF MOTOR ON RIGHT SIDE AND ANOTHER SPARKPLUG ON THE LEFT SIDE KEEPS MISSING OUT BECAUSE OF OIL IN IT. I CAN'T KEEP FIGHTING REPAIRS I'M STILL PAYING ON IT. FROM WHAT I'M HEARING THERE IS SEVERAL MOTORS DOING THIS. I WOULD LIKE TO SEE THIS PROBLEM SOLVED PLEASE OR FORD CAN PAY MY TOW BILLS. MY CRUISE CONTROL QUIT WORKING. I HAVE A RUMBLE IN REAR END WHEN TURNING CORNERS. I HAVE HAD IT LOOKED AT, DIFFERENT THINGS FIXED AND NO REPAIR FACILITY CAN FIGURE IT OUT. I WORK 60 MINUTES AWAY AND I CAN'T KEEP GETTING STRANDED IN IT AND I'M VERY TIRED OF IT. *TR

Mileage: 150,000

I HAD TO REPLACE EXHAUST MANIFOLD BOLTS AT 75,000 MILES AND NOW I AM REPLACING THEM AGAIN ALSO. I HAVE READ ALL THESE COMPLAINTS ABOUT THE SPARKPLUGS AND THE BOLTS BURNING INTO AND I HAVE HAD FORDS SINCE I'VE BEEN DRIVING AT AGE 16 WHICH IS OVER 30 YEARS AGO AND I MIGHT BE CHANGING MY BRAND BECAUSE I AM SICK OF THE TROUBLE. FORD YOU NEED TO STEP UP TO THE PLATE, THESE ARE HARD TIMES FOR EVERYONE BUT YOU NEED TO TAKE RESPONSIBILITY OF THESE PROBLEMS. *TR

Mileage: 75,000

I HAVE 2002 FORD F250 WITH A 5.4L TRITON ENGINE. THE EXHAUST MANIFOLD STUDS ARE RUSTING AND BREAKING OFF. I HAVE CONTACTED MY DEALER AND HAVE BEEN TOLD IT IS COMMON PROBLEM. THIS IS AN $850 TO $1000 FIX. I AM AFRAID THAT THE EXHAUST GASES MAY START SOMETHING BURNING IN THE ENGINE COMPARTMENT AND THAT THE LEAKING EXHAUST IS NOT BEING CLEANED BY THE CATALYTIC CONVERTER. IF THIS IS A COMMON PROBLEM, WHY ISN'T THERE A RECALL? THE REPLACEMENT STUDS ARE STAINLESS STEEL AND ARE BIGGER SO FORD MUST KNOW OF THIS PROBLEM. *TR

Mileage: 80,000

SPARK PLUG BLOWOUT WHILE DRIVING ON 5.4 LITER TRITON MOTOR WITH 48,000 MILES FACTORY INSTALLED SPARK PLUGS. FORD MOTOR DEALER CONTACTED. REFUSED TO ACCEPT RESPONSIBILITY. MECHANIC MADE SHOP REPAIR BY PULLING INTAKE AND INSTALLING INSERT TO NUMBER 3 CYLINDER. $1000.00 DOLLAR REPAIR, POTENTIAL FUEL IGNITION FROM MOTOR, ESCAPING FUEL MIX COMBINED WITH COIL SPARK PRESENT DURING FAILURE. *TR

Mileage: 48,000

I HAD A SPARK PLUG BLOW OUT OF MY CYLINDER HEAD OF MY FORD F250 2002 WITH 79,000 MILES ON IT.

Mileage: 79,000

2002 FORD F-250 V-10 I HAVING THE ISSUE OF THE SPARK PLUG BLOWING OUT THIS IS THE SECOND ONE IN ABOUT A YEARS TIME. LUCKILY THE FIRST TIME SPARK PLUG WENT BACK IN THIS TIME IT ISN'T GOING TO HAPPEN THAT WAY. IF ITS A FORD ISSUE THEY NEED TO FIX IT INSTEAD OF US HAVING TO FIX THERE PROBLEMS. *TR

Mileage: 123,000

I HAVE A 2002 FORD F250 WITH A TRITON V* ENGINE. TO THIS DATE, IT HAS BLOWN OUT 5 SPARK PLUGS! SO FAR, THE REPAIRS HAVE RUN OVER $1000 TO FIX THIS, AND WITH THREE MORE TO GO, I CAN FORESEE AT LEAST ANOTHER $750, WHICH I CAN ILL AFFORD. *TR

Mileage: 97,625

FORD F250 V-10 SPIT SPARK PLUG, CAUSED SMALL FIRE UNDER THE HOOD. BROKE THE COP. IF A SPARK PLUG BLOWS OUT AND COULD INJURE A PERSON WORKING ON THE VEHICLE, WHY IS THAT DIFFERENT FROM THIS THAT IS CLASSIFIED AS A SAFETY RECALL? (ENGINE COOLING FAN BLADES THAT BREAK UNEXPECTEDLY CAUSING INJURY TO PERSONS WORKING ON A VEHICLE). *TR

Mileage: 145,000

I OWN A 2002 F250 V10 WITH APPROX 84,000 MILES. I WAS JUST DRIVING ALONG AND THE SPARK PLUG FROM THE # 8 CYLINDER BLEW OUT. I HAD TO RETAP IT AND PUT A HELICOIL IN IT. THE SPARK PLUGS WERE THE ORIGINAL SPARK PLUGS AND HAVE NEVER BEEN REPLACED. I HAVE SEEN NUMEROUS COMPLAINTS OF THE SAME PROBLEM ON KLINE. IT IS DEFINITELY A MANUFACTURING DEFECT. ALSO I NEED TO REPLACE THE EXHAUST MANIFOLD BOLTS ON THE SAME CYLINDER HEADS. THIS IS ANOTHER PROBLEM I HAVE FOUND NUMEROUS COMPLAINTS ABOUT ONLINE. *TR

Mileage: 84,000

I OWN A 2002 F250 V10 WITH APPROX 84,000 MILES. I WAS JUST DRIVING ALONG AND THE SPARK PLUG FROM THE # 8 CYLINDER BLEW OUT. I HAD TO RETAP IT AND PUT A HELICOIL IN IT. THE SPARK PLUGS WERE THE ORIGINAL SPARK PLUGS AND HAVE NEVER BEEN REPLACED. I HAVE SEEN NUMEROUS COMPLAINTS OF THE SAME PROBLEM ON KLINE. IT IS DEFINITELY A MANUFACTURING DEFECT. ALSO I NEED TO REPLACE THE EXHAUST MANIFOLD BOLTS ON THE SAME CYLINDER HEADS. THIS IS ANOTHER PROBLEM I HAVE FOUND NUMEROUS COMPLAINTS ABOUT ONLINE. *TR

Mileage: 84,000

FORD F-250 2002 ENGINE BLEW OUT A SPARK PLUG. *TR

Mileage: 121,000

SPARK PLUG BLEW OUT AFTER STOPPING FOR RED LIGHT. SHUT OFF ENGINE, POPPED THE HOOD AND THERE WAS A SMALL FIRE UNDER THE HOOD. I WAS ABLE TO PUT THE FIRE OUT QUICKLY WITH MY SHIRT. COP WAS DAMAGED, TRIED TO RE-INSTALL PLUG, BUT THE THREADS IN THE HEAD WERE STRIPPED. I WAS ABLE TO JUST SNUG THE PLUG DOWN ENOUGH TO GET ME HOME. ABOUT .5 MI. I WAS STOPPED IN THE MIDDLE OF THE ROAD WITH TRAFFIC GOING AROUND ME BOTH DIRECTIONS. *TR

Mileage: 146,332

TL* THE CONTACT OWNS A 2002 FORD F-250. HE NOTICED FLAMES EMERGING FROM THE ENGINE COMPARTMENT. THE FIRE DEPARTMENT EXTINGUISHED THE FIRE. THE VEHICLE HAS NOT BEEN INSPECTED TO DETERMINE THE CAUSE OF THE FAILURE. THE CURRENT AND FAILURE MILEAGES WERE 168000.

Mileage: 168,000

5:30 MONDAY MORNING I STARTED MY 2002 FORD F250 SUPERDUTY PICKUP, AS SOON AS MY TRUCK STARTED THERE WAS A HUGE EXPLOSION AND A BIG FIRE BALL FLASH FROM UNDER MY HOOD FOLLOWED BY SMOKE AND THE ODOR OF PLASTIC BURNING AND GAS FUMES. I IMMEDIATELY SHUT THE TRUCK OFF AND OPENED THE HOOD, AFTER SOME INVESTIGATION I WAS AMAZED TO SEE THAT A SPARK PLUG HAD COMPLETELY BLOWN OUT OF THE HEAD OF MY ENGINE. I WAS HAPPY TO SEE THAT THE FIRE WAS MINIMAL BUT I WAS COMPLETELY AMAZED THAT A PLUG BLEW OUT OF MY ENGINE. ABOUT SEVEN OR SO DAYS AGO MY ENGINE STARTED TO MAKE A TAPPING NOISE UNDER THE HOOD, I KNEW THAT IT COULD BE A LIFTER BECAUSE OF THE OVER HEAD CAM BUT NOW I GUESS I KNOW WHAT THAT NOISE WAS, JUST THE GASES PUSHING THROUGH THE THREADS OF THE PLUG. NO ONE WAS HURT AND MY TRUCK DIDN'T BURN TO THE GROUND, BUT I DID HAVE TO BORROW MY WIFE'S TRUCK ALL WEEK AND WORK OUT RIDES WHILE MINE WAS IN THE SHOP. I AM A CARPENTER AND NEED MY TRUCK EVERY DAY SO WHEN THIS HAPPENED I KNEW I HAD TO FIND INFORMATION ON THIS PROBLEM. I WAS AMAZED TO FIND THAT THERE WERE MANY PEOPLE I KNOW THAT THIS HAPPENED TO, SO I LOOKED INTO IT MORE AND FOUND THAT THERE ARE MANY PEOPLE TALKING ABOUT IT ON THE COMPUTER WITH THE EXACT SAME EXPERIENCE AS ME SOME WITH MORE DAMAGE AND SOME SAY IT HAPPENED SEVERAL TIMES IN THE SAME ENGINE. THERE ARE MANY REPAIR KIT OPTIONS AVAILABLE FOR THIS PROBLEM IN THE FORD ENGINES, IT SEAMS QUITE OBVIOUS TO ME THAT THIS IS A HUGE PROBLEM THAT FORD MUST BE RESPONSIBLE FOR, I KNOW I'M NOT I TAKE CARE OF MY TRUCK AND HAVE ALWAYS MAINTAINED IT AT HIGH LEVEL. FORD SAYS THAT THE PLUGS ARE BLOWING OUT BECAUSE OF IMPROPER TORQUING WELL I GUESS THEY MUST HAVE DONE THAT WRONG IN THE PLANT WHEN THE TRUCK WAS BUILT BECAUSE THEY WERE NEVER CHANGED OR TOUCHED BY ANYONE ELSE. AFTER LOOKING INTO THIS PROBLEM I CANT UNDERSTAND WHY THERE HAS NOT BEEN A RECALL TO FIX THIS PROBLEM INSTEAD FORD JUST MAKES MONEY OFF CONSUMERS ON IT BY SELLING THEM NEW HEADS FOR THE ENGINES AND THE LABOR $1500. *TR

Mileage: 79,000

I HAVE A 2002 FORD F250 3/4 TON 4-DOOR LONG BOX TRUCK. IT WAS A WYOMING HIGHWAY DEPARTMENT TRUCK. I GOT IT IN JANUARY AND IT WAS RUNNING GREAT WITH 170,000 MILES ON IT, THEN THE # 3 SPARK PLUG WAS SPIT OUT OF THE ENGINE ON STARTUP, AFTER IT SAT FOR A HALF HOUR IN SEPTEMBER. THE COIL PACK ALSO WAS SPIT OUT AND WAS DANGLING OUT ON THE VALVE COVER. *TR

Mileage: 170,000

2002 FORD F250 WITH A TRITON V8 5.4L ENGINE HAD THE SPARK PLUG BLOWN OUT OF THE CYLINDER HEAD AND DESTROYED THE IGNITION COIL. APPARENTLY THIS IS AN EXTREMELY COMMON PROBLEM AND FORD IS UNWILLING TO DO ANYTHING. COST OF REPAIR IS $1100.00. COULD POTENTIALLY START A FIRE AS FUEL AIR MIXTURE ESCAPE THE CYLINDER THE COIL WAS SPARKING AGAINST THE ENGINE AND THIS COULD HAVE STARTED A FIRE. THE ORIGINAL FACTORY PLUGS WERE INSTALLED IN THE ENGINE, AND THE ENGINE HAS NEVER BEEN SERVICED BY ANYONE EXCEPT THE FORD DEALERSHIP. *TR

Mileage: 99,000

WHILE DRIVING MY 2002 FORD F250 SUPER DUTY (5.4L V-8) I EXPERIENCED A POPPING SOUND FROM UNDER THE HOOD WHICH INCREASED IN VOLUME VERY QUICKLY. I PULLED OVER (ON A BUSY HIGHWAY) AND HAD TO BE TOWED TO A SHOP WHERE I LEARNED THAT A SPARK PLUG HAD BEEN EJECTED. THE REPAIR, WHICH WAS ABOUT THE MOST MINIMAL THAT COULD BE DONE, COST ME OVER $600.00, WITH NO GUARANTEE THAT THIS WILL NOT HAPPEN AGAIN. MY INTERNET RESEARCH ON THIS INDICATES THAT THERE HAVE BEEN LITERALLY THOUSANDS OF THESE INCIDENTS INVOLVING FORD ENGINES. FORD CLEARLY KNOWS ABOUT THIS, BUT DOES NOT ACKNOWLEDGE IT, DOES NOT ASSIST WITH THE COSTS, AND WILL NOT RECALL THE ENGINES. THIS IS NOT JUST A VERY COSTLY INCONVENIENCE - IT IS A CLEAR-CUT SAFETY ISSUE THAT STRANDS VEHICLES ON BUSY HIGHWAYS AND HAS RESULTED IN NUMEROUS FIRES. *TR

Mileage: 82,000

FORD F-250 5.4 L WHILE DRIVING LOW SPEED, HEARD LOUD POP IN ENGINE COMPARTMENT, SPARK PLUG EJECTED FROM HEAD. DISCOVERED THAT THIS IS A COMMON OCCURRENCE WITH ALUMINUM HEAD ENGINES, ESP FORD 1989 THROUGH 2005 4.6 AND 5.4 LITER ENGINES. PROBLEM IS THE RESULT OF 5 THREAD DEPTH IN HEAD INSTEAD ON NEW SPEC OF 7. PREVENTIVE MEASURES, REMOVE PLUGS, CLEAN CARBON FROM THREADS, REINSTALL PLUG, TORQUE TO REQUIRED FOOT POUNDS. WHY FORD OR DEALER DOESN'T TELL YOU THIS IS CRIMINAL. THAT'S WHY I NOW DRIVE A TOYOTA. *TR

Mileage: 80,000

WHILE DRIVING AT 35 MPH, A SPARK PLUG WAS EJECTED FROM MY 2002 FORD F-250 5.4L V8 PICKUP TRUCK, CAUSING THE ENGINE TO STALL AND RESULTING IN A LOSS OF POWER FOR STEERING AND BRAKING. I'M TOLD BY MY MECHANIC TODAY, WHO IDENTIFIED THE PROBLEM EVEN BEFORE I TOLD HIM WHY I WAS THERE, THAT THIS IS DUE TO A KNOWN DEFECT WITH MANY FORD ENGINES, BUT THAT NO RECALL WAS EVER ISSUED. GIVEN THE DANGER OF FUEL VAPORS ESCAPING FROM THE SPARK PLUG HOLE AND RISK OF FIRE, PERHAPS THE NHTSA SHOULD PRESS FORD ON THE ISSUE IF IT REALLY IS A COMMON PROBLEM. *TR

Mileage: 152,000

TWO SPARK PLUG SO FAR HAVE BEEN EJECTED. *TR

Mileage: 110,000

TL*THE CONTACT OWNS A 2002 FORD F-250 SD. WHILE DRIVING APPROXIMATELY 15 MPH, THE CONTACT HEARD A LOUD POPPING NOISE OUTSIDE OF THE VEHICLE. SUDDENLY, THERE WAS REDUCED ENGINE POWER. THE DRIVER PULLED OVER TO THE SIDE OF THE ROAD AND TURNED OFF THE ENGINE. THE ENGINE WAS RESTARTED AFTER A FEW MINUTES AND THE CONTACT HEARD AN EXTREMELY LOUD NOISE. THE VEHICLE IS IN THE PROCESS OF BEING TOWED TO AN INDEPENDENT MECHANIC. THE CAUSE OF THE FAILURE HAS NOT BEEN DETERMINED. THE VIN WAS UNKNOWN. THE FAILURE AND CURRENT MILEAGES WERE 89,000. UPDATED 09/01/09 *BF

Mileage: 89,000

THE NUMBER THREE SPARK PLUG BLEW OUT AND CAUSED A SMALL FIRE THAT WAS EXTINGUISHED WITH A LARGE SLURPEE. *TR

Mileage: 165,769

VEHICLE STALLS INTERMITTENTLY. OCCURS OFTEN IN INTERSECTIONS WHEN TAKING OFF. CREATES A VERY DANGEROUS SITUATION. THE SAME YEAR, MAKE, MODEL NUMBER AND ENGINE TYPE HAVE BEEN RECALLED, HOWEVER, OUR VIN WAS NOT INCLUDED SO FORD WILL NOT HONOR. *TR

Mileage: 80,000

TL*THE CONTACT OWNS A 2002 FORD F-250 SD. WHILE DRIVING 60 MPH, THE CONTACT HEARD A POPPING SOUND COMING FROM THE ENGINE. SHE EXAMINED THE VEHICLE AND NOTICED THAT A SPARK PLUG EJECTED OUT OF THE ENGINE. THE VEHICLE HAS NOT BEEN DIAGNOSED BY THE DEALER. THE FAILURE RECURRED ON THREE DIFFERENT OCCASIONS. THE CURRENT AND FAILURE MILEAGES WERE 104,000.

Mileage: 104,000

I PURCHASED AN F250 2002 TRITON V8 SUPER DUTY MID YEAR 2007. LESS THAN A YEAR AFTER THE PURCHASE A SPARK PLUG BLEW OUT OF THE MANIFOLD. THIS ALL HAPPENED UNDER NORMAL HIGHWAY DRIVING CONDITIONS. THE DEALER PUT IN AN INSERT, RETHREADED IT AND REPLACED SPARK PLUG. ALMOST A YEAR TO THE DAY IT HAPPENED AGAIN. SO NOW #2 & #4 HAVE BLOWN OUT. ON 5/30/09 A THIRD ONE BLEW OUT. ALL ON THE LEFT SIDE (PASSENGER SIDE) OF THE MANIFOLD. SO NOW #2, #3 AND #4 HAVE BLOWN OUT. I RESEARCHED THE INCIDENT ONLINE AND HAVE FOUND 500 OTHER CASES. I'M CURIOUS HOW MANY ARE REALLY OUT THERE THAT WEREN'T REPORTED. I'VE BEEN FORTUNATE BECAUSE IN SOME CASES THE SPARK PLUG BLEW THROUGH THE HOOD OR DAMAGED THE MANIFOLD. I DO HOWEVER WONDER WHAT DAMAGE IS OCCURRING EACH TIME IT HAPPENS. HOW MANY REPORTS OR HOW MANY VEHICLES DOES IT TAKE BEFORE THERE'S A RECALL? EVEN THOUGH I HAVE EXTENDED WARRANTY I'VE BEEN CHARGED A DEDUCTIBLE EACH TIME AND NOW FACE A THIRD IF MY WARRANTY IS STILL GOOD. I HAVE ONE MORE PLUG ON THAT SIDE THAT HASN'T BLOWN YET AND SINCE THIS ONE WAS ONLY 7 MONTHS SINCE THE LAST ONE I SUSPECT I'LL BE PAYING AGAIN. I SAW ONLINE WHERE IT WAS SUGGESTED AS A PISTON PROBLEM. *TR

Mileage: 75,000

APPROXIMATELY 5 DAYS BEFORE THE FAILURE, I BEGAN TO HEAR AN EXHAUST LEAK. I KEPT DRIVING MY TRUCK ASSUMING IT WAS JUST A SMALL LEAK IN THE EXHAUST SYSTEM. ON APRIL 29, THE SPARK PLUG BLEW OUT OF THE HEAD OF MY V10 TAKING THE LAST FEW THREADS WITH IT. THE DEALER SAYS, BEST CASE SCENARIO I NEED A HELICOIL REPAIR, COSTING AROUND $600, WORSE CASE SCENARIO, THE FAILURE COULD COST ME MY ENGINE. $1000'S OF DOLLARS. *TR

Mileage: 102,000

I WAS DRIVING WHEN A LOUD POP AND WHAT SOUNDED LIKE A LARGE EXHAUST LEAK CAME FROM UNDER THE HOOD. OPENED HOOD AND FOUND COIL PACK AND SPARK PLUG LAYING ON TOP OF THE VALVE COVER. VEHICLE STALLED AND DIDN'T WANT TO START. TOOK TO REPAIR FACILITY WHERE THE RETAPPED SPARK PLUG CYLINDER ADDED HELI COIL NEW SPARK PLUG AND COIL PACK TWO WEEKS LATER THE ENGINE STARTED MAKING A LOUD GURGLING NOISE WHICH HAS YET TO BE DIAGNOSED. *TR

Mileage: 160,000

DRIVING IN MY CAR AND I HEARD A THUMP AND SOME SMOKE APPEARED FROM HOOD. WHEN I RAISED THE HOOD OF THE CAR I NOTICED A SPARK PLUG HANGING IN WHICH THIS IS A FORD F250 2002. TOOK IT TO THE SHOP AND THEY TOLD ME THAT ALL FORD TRUCKS HAS BEEN DOING THIS. NOT FAIR THAT THERE IS NO CLASS ACTION LAWSUIT AGAINST THEM THIS COULD HAVE HAPPENED TO ME WHILE I WAS ON THE EXPRESS WAY AND CAUSED SOME MAJOR PROBLEMS. WHAT CAN I DO BECAUSE IT IS BOUND TO HAPPEN AGAIN. *TR

TL*THE CONTACT OWNS A 2002 FORD F-250 SD. WHILE DRIVING LESS THAN 65 MPH, THE CONTACT SMELLED BURNING OIL. HE THEN NOTICED SMOKE UNDERNEATH THE HOOD AND OIL DRIPPING FROM THE EXHAUST. THE VEHICLE WAS TAKEN TO THE DEALER AND THEY STATED THAT THE HEAD GASKET WAS LEAKING. THEY WOULD NEED TO DISASSEMBLE THE ENGINE AND REPLACE THE HEAD GASKET AT THE ESTIMATED COST OF $2,800-$4,000. THE MANUFACTURER WAS NOTIFIED AND COULD NOT ASSIST BECAUSE THERE WERE NO RECALLS. THE FAILURE MILEAGE WAS 121,000 AND CURRENT MILEAGE WAS 122,000.

Mileage: 121,000

TL*THE CONTACT OWNS A 2002 FORD F250 SUPER DUTY. WHILE DRIVING LESS THAN 70 MPH, THE CONTACT HEARD A THUMPING NOISE UNDER THE HOOD. HE NOTICED THAT THE SPARK PLUG WIRES WERE LOOSE AND THE NUMBER 3 CYLINDER SPARK PLUG WAS DETACHED. THIS WAS THE SECOND TIME THE FAILURE OCCURRED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO STATED THAT FORD WAS EXPERIENCING ISSUES WITH ALUMINUM HEADS CAUSING THE SPARK PLUGS TO FAIL. THE VIN WAS UNKNOWN. THE FAILURE AND CURRENT MILEAGES WERE LESS THAN 95,000.

Mileage: 95,000

SPARK PLUG EJECTED FROM #3 CYLINDER HEAD. *TR

Mileage: 66,234

TL*THE CONTACT OWNS A 2002 FORD F-250 SUPER DUTY. THE CONTACT STATED THAT THE BOLTS ON THE EXHAUST MANIFOLD SNAPPED OFF ON THREE DIFFERENT OCCASIONS. THE FAILURE WAS BROUGHT TO HIS ATTENTION BY HIS MECHANIC DURING ROUTINE MAINTENANCE. THE DEALER AND MANUFACTURER HAVE NOT BEEN NOTIFIED BECAUSE THE VEHICLE WAS NO LONGER UNDER WARRANTY. THE VEHICLE HAS NOT YET BEEN REPAIRED. THE CURRENT MILEAGE WAS APPROXIMATELY 79,000 AND FAILURE MILEAGE WAS APPROXIMATELY 30,000. UPDATED 10/20/08. *LJ UPDATED 10/20/08. *JB

Mileage: 30,000

ON AUGUST 30, 2008 MY 2002 F-250 BLEW THE NUMBER 2 SPARK PLUG OUT OF THE CYLINDER HEAD. DUE TO THE HOLIDAY WEEKEND I HAVE TO WAIT TILL TUESDAY TO GET AN ESTIMATE ON HOW MUCH IT WILL COST TO REPAIR IT. I HAVE SEARCHED THIS PROBLEM AND FOUND THIS TO BE COMMON AMONG FORD PRODUCTS. FORD NEEDS TO SET THIS AS A RECALL ITEM. FORD BACK YOUR PRODUCT UP YOU CHARGE ENOUGH FOR THEM........ *TR

Mileage: 138,140

DRIVING MY 2002 FORD F-250 W/A 5.4L TRITON ENGINE WITH 80K MILES, #3 CYLINDER SPIT OUT ITS SPARK PLUG AND STRIPS THREADS . VEHICLE STALLED, BROUGHT TO FORD DEALER AND INCURRED $3,800.00 ENGINE REPAIR. THIS IS ABSOLUTE BS!, FORD IS WELL AWARE OF THOUSANDS OF THESE DEFECTIVE CYLINDER HEADS, AS THEY PROFIT FROM THIS VERY EXPENSIVE REPAIR ($3,800.00). MY COMPLAINT IS THAT THERE OUGHT TO BE A RECALL AS THERE ARE THOUSANDS OF VICTIMS OF THIS DEFECTIVE FORD PRODUCT. IT'S A SAFETY ISSUE, I STALLED ON A MAJOR HIGHWAY AND THE SPARKPLUG IS RIGHT UNDER MY FUEL RAIL. PLEASE DON'T TELL ME THIS IS ANOTHER INEFFECTIVE/COSTLY GOVERNMENT AGENCY, SURELY THE NHTSA IS DOING SOMETHING ABOUT THIS WELL KNOWN DEFECT. *TR

Mileage: 80,841

DRIVING MY 2002 FORD F-250 W/A 5.4L TRITON ENGINE WITH 80K MILES, #3 CYLINDER SPIT OUT ITS SPARK PLUG AND STRIPS THREADS . VEHICLE STALLED, BROUGHT TO FORD DEALER AND INCURRED $3,800.00 ENGINE REPAIR. THIS IS ABSOLUTE BS!, FORD IS WELL AWARE OF THOUSANDS OF THESE DEFECTIVE CYLINDER HEADS, AS THEY PROFIT FROM THIS VERY EXPENSIVE REPAIR ($3,800.00). MY COMPLAINT IS THAT THERE OUGHT TO BE A RECALL AS THERE ARE THOUSANDS OF VICTIMS OF THIS DEFECTIVE FORD PRODUCT. IT'S A SAFETY ISSUE, I STALLED ON A MAJOR HIGHWAY AND THE SPARKPLUG IS RIGHT UNDER MY FUEL RAIL. PLEASE DON'T TELL ME THIS IS ANOTHER INEFFECTIVE/COSTLY GOVERNMENT AGENCY, SURELY THE NHTSA IS DOING SOMETHING ABOUT THIS WELL KNOWN DEFECT. *TR

Mileage: 80,841

2002 FORD F250 CREW CAB 4X4 SHORT BOX, 5.4L V-8 GASOLINE ENGINE JUST UNDER 92000 MILES. ON 7/21/2008 MERGING ON THE EXPRESSWAY UNDER HEAVY ACCELERATION, A LOUD BANG WITH SPRING POPPING SOUND WAS HEARD FROM THE ENGINE FOLLOWED BY THE DISTINCT ODOR OF EXHAUST AND UNBURNED GASOLINE. VERIFIED THROTTLE CONTROL AND CONTINUED TO DRIVE WITH LOUD NOISE COMING FROM ENGINE. DROVE 4 MILES TO WORK TO SAFELY INSPECT THE PROBLEM. NOTED THAT THE EXHAUST Y-PIPE WAS SEPARATED FROM THE DRIVERS SIDE EXHAUST MANIFOLD. ASSUMING THAT IT WAS JUST A FAILED MANIFOLD BOLT, DROVE ~20 MILES TO THE DEALERSHIP TO HAVE IT LOOKED AT. RECEIVED THE CALL THAT THE NUMBER 6 SPARK PLUG WAS EJECTED FROM THE HEAD. UPON THE DEALERSHIPS INSPECTION, FOUND THAT THE THREADS WERE STRIPPED OUT OF THE HEAD. THE SPARK PLUG THEN ARRESTED IN THE IGNITION COIL WHICH WAS SEPARATED FROM THE HEAD DUE TO FAILURE OF ITS MOUNTING FLANGE. THE IGNITION WIRE HELD THE COIL AND PLUG ON THE ENGINE. THERE WAS ZERO GAP NOTED ON THE SPARK PLUG ELECTRODE WITH ANTI-SEIZE COMPOUND ON ONLY ABOUT .5" OF THE SPARK PLUG THREAD. THUS SUGGESTED THAT ONLY .5" OF THREAD ENGAGEMENT WAS PRESENT FROM THE FACTORY ORIGINAL PLUGS (I.E. THE SPARK PLUGS WERE NOT REPLACED SINCE THE RECOMMENDED REPLACEMENT INTERVAL IS 10 YEARS 100000 MILES). ADVISED THAT AT A MINIMUM A HEAD NEEDED TO BE REPLACED, BUT THAT AN ENGINE MAY BE A BETTER ECONOMICAL CHOICE SO THAT BOTH HEADS ARE REPLACED AND THIS DESIGN ISSUE COULD BE OVERCOME (THE NEWLY REMANUFACTURED ENGINE IS SUPPOSED TO HAVE LARGER THREAD ENGAGEMENT AT APPROXIMATELY .75"). ENGINE REPLACED TO INSURE THAT THIS FAILURE WOULD NOT OCCUR ON ONE OF THE OTHER CYLINDERS IN THE HEAD THAT WOULD NOT BE REPLACED. *TR

Mileage: 91,573

AFTER STOPPING AT A STOP SIGN I STEPPED ON THE GAS PEDAL AND HEARD A LOUD BANG. AS I WAS ONLY 100 YARDS FROM HOME , I WENT HOME AND CALLED MY MECHANIC. HE SAID I BLEW OUT A SPARK PLUG AND DAMAGED THE COIL FOR THAT PLUG. I HAD TO PUT IN A HELICOIL AND REPLACE THE COIL. AFTER READING MANY REPORTS OF THIS I FELT THE NEED TO FILE THIS COMPLAINT. I FEEL FORD SHOULD DO SOMETHING ABOUT THIS PROBLEM. I AM GOING TO REPLACE MY TRUCK , MOST LIKELY WITH A DIFFERENT BRAND. *TR

Mileage: 64,856

HIGH PRESSURE OIL PUMP O-RING FAILURE. (1) O-RING FAILED AT 08/30/04 WITH 30,000 MILES. DEALER REPAIRED WITH UPDATED O-RING KIT AS SPECIFIED BY FORD BULLETIN. COVERED UNDER WARRANTY (2)O-RING FAILED AGAIN AT 08/16/07 WITH 70,826 MILES. FORD DEALER REPAIRED WITH UPDATED 0-RING KIT AS SPECIFIED BY FORD BULLETIN. THIS TIME I HAD TO PAY $100.00 DEDUCTIBLE. (3)O-RING FAILED AGAIN ON 06/11/08 WITH 83,000 MILES. REPAIRED AGAIN IN 10 MONTH SINCE LAST REPAIR. I HAD TO PAY THE FULL PRICE OF REPAIR OF 561.82. SAME PART HAS FAILED THREE TIMES ON MY 2002 F250 CREWCAB 4 DOOR 7.3 DIESEL. WHEN O-RING FAILS THE OIL IS LEAKING WHILE ENGINE IS RUNNING. THIS IS NOT A SLOW LEAK BUT A STEADY STREAM AS THE LINE IS UNDER HIGH PRESSURE. I HAD TO SHUT DOWN THE ENGINE WHILE DRIVING BECAUSE OF LOW OIL PRESSURE AND YOU HAVE NO CONTROL OF BRAKES OR THE POWER STEERING ON VEHICLE. *TR

Mileage: 83,000

MY FORD F-250 PICKUP BLEW A SPARK PLUG OUT OF THE HEAD. THE DEALER CHARGED ME 5,200.00 TO REPLACE THE HEAD. AT THE TIME OF THIS, THE TRUCK HAD ONLY 47,000 MILES ON IT. IT'S A 2002 FORD F-250 SUPER DUTY, 5.4 LTR ENGINE. *TR

Mileage: 47,000

RECENTLY FOUR GOSHEN VANS AND / OR BUSES HAVE CAUGHT FIRE AND COMPLETELY BURNED UP. IN THREE CASES THE BUSES / VANS WERE PARKED AND EITHER JUST SHUT OFF OR PARKED AND IDLING WHEN SMOKE WAS DISCOVERED AND THEN THE FIRE STARTED. IN EACH CASE THE VEHICLE BURNED UP IN MINUTES (7 MINUTES IN ONE CASE). SOME OF THESE VEHICLES ARE USED TO TRANSPORT DISABLED CLIENTS SO THESE ARE VERY SERIOUS INCIDENTS WHICH COULD LEAD TO DEATH OR INJURY. *TR

Mileage: 100,000

I HAVE A 2002 FORD SD WITH THE 6.8 V10 WITH 42,000 MILES ON IT. WHEN I TOOK IN FOR A NOISE FROM THE EXHAUST I WAS TOLD THAT I HAD 4 MANIFOLD BOLTS RUSTED OFF AND MORE WHERE READY TO BREAK. I HAD THE REPAIR WORK COMPLETED AT A COST OF $3200 WHICH I HAD TO COVER. I WAS TOLD THAT THIS IS A COMMON PROBLEM BUT FORD IS NOT STANDING BEHIND THIS PROBLEM. WHILE THEY WERE WORKING ON THE TRUCK THEY FOUND THE POWER STEERING PUMP COMING OFF AND LOOKING IN TO THAT IT WAS FOUND THAT A BOLT WAS BROKEN OFF IN THE FRAME. THE REPAIR SHOP TOLD ME THAT THEY HAVE DONE MANY OF THEM JUST LIKE MINE. I HAVE OWNED 10 NEW FORD PRODUCTS IN THE PAST 12 YEARS AND THIS WILL PROBABLY BE THE LAST. *TR

TWO MANIFOLD BOLTS SNAPPED OFF EACH SIDE OF MY 02 6.8 LITER ENGINE. THE REST ARE HORRIBLY RUSTED. THE TRUCK HAS ONLY 37000 MI ON IT. THERE HAS BEEN A TSB CONCERNING THIS, BUT IT IS A HUGE AND COMMON PROBLEM. THERE NEEDS TO BE A RECALL FOR THE PEOPLE OUT OF WARRANTY,AS IT DOES CONCERN EMISSIONS AND THE LEAKING OF EXHAUST GASES FROM BEFORE THE CAT. *TR

Mileage: 30,000

I HEARD A SOUND COMING FROM MY EXHAUST AND AFTER LOOKING OVER THE EXHAUST I NOTICE THAT I HAD SOME EXHAUST MANIFOLD STUDS AND NUTS THAT HOLD THE EXHAUST MANIFOLDS TO THE ENGINE HEADS HAD EITHER BROKEN OR SNAPPED OFF CAUSING THE EXHAUST LEAK I HEARD. AFTER SEEING THAT I HAD AN ISSUE WITH THE EXHAUST STUDS I TOOK MY 2002 FORD F-250 SUPER DUTY WITH 6.8 LITER ENGINE TO THE DEALERSHIP WERE I HAVE MY SERVICE WORK DONE AND HAD 1 OF THE SERVICE TECHNICIANS LOOK AT THE ISSUE. I WAS TOLD AT THE DEALERSHIP THAT FORD MOTOR COMPANY KNEW OF THE PROBLEM WITH THE STUDS AND NUTS THAT WAS USED WHEN MY TRUCK WAS MANUFACTURED AND KNEW OF THAT PROBLEM SINCE 1997 THROUGH 2005. YET FORD MOTOR COMPANY WILL NOT DO ANYTHING TO RESOLVE THIS ISSUE. FROM 1997-2005 FORD MOTOR COMPANY USED STEEL STUDS AND NUTS FOR ATTACHING THE EXHAUST MANIFOLDS TO THE ENINES ON THERE 5.4 LITER AND 6.8 LITER ENGINES. THAT'S A PERIOD OF 9 YEARS OF USING PARTS THAT WERE FAULTY FOR USE IN MANUFACTURE. THE FAILURE OF THESE EXHAUST STUDS AND BOLTS CAN AND WILL CAUSE THE EXHAUST MANIFOLDS TO WARP THUS THE CONSUMER HAVING TO REPLACE THE EXHAUST MANIFOLDS AS WELL. ALSO WITH THE FAILURE OF THE FAULTY EXHAUST STUDS AND NUTS COULD CAUSE ENGINE PROBLEMS LIKE WARPED VALVES, OR HEAD DAMAGE, WHICH COULD CAUSE ENGINE TO BLOW OR LOCK-UP. I HAVE NOTIFIED FORD MOTOR COMPANY ON 3 OCCASIONS AND HAVE MET WITH THE SAME RESPONSE THAT THEY WILL DO NOTHING TO AMEND THE ISSUE AT HAND. THEY HAVE A TECHNICAL SERVICE BULLETIN THAT THEY HAVE AVAILABLE WHICH REQUIRES THAT THE USE OF STAINLESS STEEL STUDS AND NUTS IN SERVICE FOR THE 5.4 LITER AND 6.8 LITER ENGINE. AS WELL AS REPLACING THE EXHAUST MANIFOLD ON THE AFFECTED BANK(S), EXHAUST MANIFOLD GASKETS. FORD MOTOR COMPANY FAILED TO NOTIFY THE CONSUMER WHILE THE VEHICLE WAS UNDER WARRANTY SO REPAIRS COULD BE MADE. *TR

Mileage: 90,210

I JUST BOUGHT A FORD F250 IT HAS A 5.4L. AND THE SPARK PLUGS EJECT FROM THE ENGINE WHY I WAS DRIVING. NO WARNING WHAT SO EVER THE TRUCK SEEMED TO BE RUNNING FINE. SPARK PLUG EJECTION IS DANGEROUS BECAUSE FUEL VAPOR STARTS COMING OUT THE SPARK PLUG HOLE, WHICH IS CLEARLY A SERIOUS SAFETY ISSUE. THE FUEL VAPOR CAN BE IGNITED BY THE LOOSE SPARK PLUG . SO I TOOK IT IN AND THE MECHANIC SAID HE HAS SEEN THIS HAPPEN IN FORD TRUCKS TO MANY TIMES. HE TRIED TO FIX IT WITH A HELICOIL KIT . THAT WORKED FOR ABOUT 2 WEEKS THEN IT BLEW OUT AGAIN. THEN I HAD THE HEADS REPLACED. TO MAKE A LONG STORY SHORT TO THIS DAY I AM STILL HAVING A PROBLEM . SINCE THE HEADS WERE REPLACED ITS BEEN IN THE SHOP AT LEAST 6 TIMES BECAUSE OF THIS. AND SPENT MORE THEN $3,000 I JUST THINK THIS IS NOT ONLY A SAFETY PROBLEM BUT IT SHOULD NOT BE MY PROBLEM. *TR

FORD F250 V10 BLOWN SPARK PLUGS. 3 IN UNDER TWO MONTHS. *TR

Mileage: 115,000

I AM ON MY FIFTH SPARKPLUG BLOWOUT,THE FIRST ONE BLEW OUT WITH 42000 MILES AND FORD WOULD NOT COVER IT, IT COST ME $482.00, & NOW I'M UP TO $2,410.00.MY MECHANIC SAID WHEN THE BACK PLUGS BLOW IT WILL COST MORE......HE ALSO SAID THAT THE HELI COIL WOULD LAST ABOUT 1-2 YRS. *TR

Mileage: 42,000

REPEATED FAILURE OF CAMSHAFT POSITION SENSOR. *TR

Mileage: 52,000

MY 2002 FORD F-250 SUPERDUTY (7.3 DIESEL) TRUCK BROKE DOWN WHILE COMING BACK FROM THE MOUNTAINS. CHECK ENGINE LIGHT....HARSH BANGING IN THE DRIVE TRAIN (ALMOST LIKE HITTING A HUGE POT HOLE AT HIGHWAY SPEEDS) AND THEN THE TRUCK DIED. MY TRUCK AND TRAILER HAD TO BE TOWED TO EAGLE COLORADO (THE NEAREST DEALERSHIP). SURE ENOUGH, AS I SUSPECTED AND HAVE SEEN FROM ABOUT TEN OTHER OWNERS OF THESE TRUCKS, IT WAS THE CAMSHAFT POSITION SENSOR. THE REPAIR WAS $237.56. I ONLY WRITE TODAY, BECAUSE MSN REPORTS THAT FORD IS FINALLY RECALLING THESE VEHICLES DUE TO THE CPS. HOW NICE OF THEM TO DO IT AFTER MOST OF US HAVE ALREADY BROKEN DOWN ON THE SIDE OF THE ROAD WITH THIS EXACT PROBLEM...I KNOW I AM ONLY ONE GUY AND I ONLY KNOW 12 OTHER PEOPLE WITH THIS ENGINE, BUT I THINK IT IS FUNNY THAT EVERYONE I KNOW WITH OVER 60K MILES HAS HAD THIS HAPPEN. MY TRUCK ONLY HAS 58K ON THE ODOMETER. SEVERAL OF US CARRY A SPARE CPS AND THE TOOLS TO REPLACE IT WITH US IN THE TRUCK AT ALL TIMES. IN CASE ANYONE WANTS TO KNOW, THEY SEEM TO FAIL MORE REGULARLY AFTER THEY HAVE BEEN REPLACED. *TR

Mileage: 57,452

CAM SHAFT SENSOR FAILED WHILE 7.3 POWERSTROKE WAS A DEALER FOR SCHEDULED MAINTENANCE. *TR

Mileage: 97,440

SEVERAL CAM POSITION SENSOR FAILURES . *TR

Mileage: 64,000

I OWN A 2002 FORD F-250 W/ 5.4 TRITON V8. ON THIS PAST SUNDAY, WHILE DRIVING AT 30 MPH, A LARGE BANG WAS HEARD FORM MY ENGINE. THE ENGINE BEGAN TO LOSE POWER AND SLOW. AFTER BEING TOWED TO MY LOCAL FORD DEALER TO BE CHECKED OUT, IT WAS DISCOVERED THAT A SPARK PLUG HAD BLOWN OUT OF THE CYLINDER HEAD ON THE RIGHT SIDE OF THE ENGINE. THE SERVICE MANAGER AT THE FORD GARAGE STATED IT RUINED THE CYLINDER HEAD AND NEEDS REPLACEMENT. THIS SERVICE WILL REQUIRE A LARGE AMOUNT OF WORK AND NEW PARTS TO COMPLETE. THE COST WILL BE $3400.00. *JB

Mileage: 101,000

I OWN A 2002 F-250 SD TRUCK WHICH HAS THE 5.4 TRITON ENGINE IN IT. ON SEPTEMBER 28,2007, I WAS DRIVING DOWN THE ROAD AND THE # 3 SPARK PLUG EJECTED OUT OF THE CYLINDER HEAD IN WHICH STRIPPED ALL THE THREADS IN THE CYLINDER HEAD AND THE SPARK PLUG. I HAVE THE SPARK PLUG. I AM HAVING THE PROBLEM REPAIRED BY AN INDEPENDENT AUTO SHOP. I HAVE DONE SOME RESEARCH ON THIS SITUATION AND FOUND THIS HAS HAPPENED ALOT FROM 1998 TO 2003. THE PLUGS ARE TAPERED AND THE PLUGS HAVE 12 THREADS , BUT ONLY 4 THREADS ARE THE CYLINDER HEAD WHICH MEANS THAT THE SPARK PLUG IS ONLY HELD BY 4 THREADS. I BELIEVE FORD MOTOR COMPANY HAS AN ENGINEERING FLAW AND SHOULD BE HELD RESPONSIBLE FOR THE COST OF THE REPAIRS. *TR UPDATED 02-13-08 *BF UPDATED 02/13/08 *TR

Mileage: 120,000

CAM POSITION SENSOR FAILED ON 2002 FORD F250 W. 7.3L DIESEL. WHEN THIS SENSOR FAILS YOU LOOSE ALL POWER ASSIST AND THE STEERING BECOMES VERY HARD AND BREAKS ARE AT BEST NO EXISTENT. I WAS ABLE TO GET THE TRUCK TO THE SIDE OF THE HIGHWAY AND NOT BECOME A HAZARD. REPLACE SENSOR WITH SPARE I HAD WITH ME DUE TO MULTIPLE FAILURES OVER THE YEARS MADE ME AWARE TO KEEP AN EXTRA WITH ME AT ALL TIMES. *TR

Mileage: 133,450

RE: NHTSA ACTION #: PE06011 I AM CURRENTLY EXPERIENCING THESE PROBLEMS RELATED TO CPS FAILURES AND WOULD LIKE TO ADD MY SUPPORT FOR A RECALL REQUEST. * UPDATED 12/12/07 *BF UPDATED 12/12/07 *TR

Mileage: 103,000

MY 2002 FORD F-250 SUPERCAB DIESEL 7.3 STARTED WITH A MISS AS I DROVE DOWN THE HIGHWAY AND HAS GOTTEN PROGRESSIVELY WORSE. NOW IT DIES OUT AT LOW SPEEDS IN TOWN DRIVING LEAVING ME WITH NO BRAKES OR STEERING. I HAVE BEEN TOLD THIS IS A COMMON PROBLEM WITH THIS TRUCK CAUSED BY THE CAMSHAFT POSITIONING SENSOR BUT FORD ASSUMES NO RESPONSIBILITY. THIS IS A VERY DANGEROUS PROBLEM ESPECIALLY WHEN THE VEHICLE IS PULLING A LOAD. *TR

Mileage: 160,000

CAM POSITION SENSOR FAILURE ON 2002 FORD F250 POWERSTROKE DIESEL. 70 MPH ON INTERSTATE. LOSS OF POWER BRAKES AND POWER STEERING.*AK

Mileage: 67,000

2002 FORD F-250 5.4L SPARK PLUG LOOSENED AND BLEW OUT OF CYLINDER HEAD. 3RD PLUG FROM THE FRONT ON PASSENGER SIDE. STRONG SMELL OF GASOLINE. BROKE THE COIL OVER PLUG, COULD HAVE BROKEN THE FUEL RAIL AND RESULTED IN FIRE. REPAIR COST NOT YET AVAILABLE - WILL ATTEMPT TO FIX MYSELF AS OUT OF WARRANTY. CRUISE CONTROL ALSO NOT WORKING BUT THIS TRUCK NOT INCLUDED IN PAST RECALL - CONCERNED ABOUT FIRE HAZARD IN CRUISE CONTROL ALSO.

Mileage: 120,000

VEHICLE HAS QUIT RUNNING ON SEVERAL OCCASIONS, ENGINE JUST DIES, HAS BEEN HAPPENING FOR ABOUT 6 MONTHS PERIODICALLY. ON JUNE 2 2007 ENGINE QUIT 3 TIMES IN A HALF HOUR TIME PERIOD,REPLACED CAMSHAFT SENSOR AT MY EXPENSE WARRANTY EXPIRED ON JAN 1 2007. I HAVE READ OF SEVERAL COMPLAINTS ABOUT THESE SENSORS ON THE INTERNET AND WOULD LIKE TO SHARE MINE ALSO. *TR

Mileage: 85,450

I HAD 2 OCCURRENCES OF THIS PROBLEM. BOTH TIMES CAMSHAFT POSITION SENSOR FAILED , CAUSING LOSS OF CONTROL.(ENGINE DIED IN TRAFFIC. 2002 FORD F-250 7.3L DIESEL. EXTREME SAFETY HAZARD , ESPECIALLY SINCE THESE TRUCKS WERE FOR HEAVY TOWING WHICH I DID FROM TIME TO TIME. SEEMED TO BE WIDESPREAD PROBLEM NEEDING TO BE ADDRESSED.*AK

Mileage: 52,000

I HAVE A FORD F-250 7.3 LITER DIESEL TRUCK THAT HAS STRANDED ME, MY WIFE AND FAMILY TOO MANY TIMES DUE TO FORD P/N F7TZ-12K073-A SENSOR-CAMSHAFT FAILURE. I HAD TO PURCHASE FIVE OF THE SENSORS AT $100 PLUS, AND HAD ONLY 59,000 MILES ON MY TRUCK. I JUST ORDERED TWO P/N F7TZ-12K073-B SENSOR-CAMSHAFT BECAUSE THE CURRENT SENSOR FAILED. *AK

Mileage: 20,000

#3 SPARK PLUG BLEW OUT OF THE HEAD. FIRST HAPPENED IN 2004 FORD SERVICE ACTED LIKE HE NEVER SAW IT BEFORE AND DIDN'T KNOW A SOLUTION . I HAD A HELI COIL INSTALLED, IT HAPPENED 3 MORE TIMES BEFORE THE LAST TIME, I HAD ALL PLUGS HELI COILED .WELL WHEN #3 BLEW OUT AGAIN ON 4-14-07 AND COULD NOT BE REPAIRED AGAIN. I WAS TOLD THE ENTIRE ENGINE SHOULD REPLACED AS PREVIOUS PROBLEMS HAD CAUSED EXCESSIVE CYLINDER WEAR. IT WAS BEING DONE TODAY. TOTAL OUT OF POCKET $ 7,000 PLUS 16 LOST DAYS OF WORK RENTAL FEES.*AK

VEHICLE IS A 2002 FORD F-250 W/ 7.3L DIESEL ENGINE. THE CAM POSITION SENSOR (CPS) FAILED. WHEN IT FAILS, THE ENGINE STALLS. THIS MEANS THAT A NEARLY 7400 POUND VEHICLE SUDDENLY HAS NO POWER, INCLUDING LOSS OF POWER STEERING & BRAKES. THE REPORTED INCIDENT DATE IS THE DATE OF THE FIRST FAILURE (HAPPENED AT A STOP LIGHT). THE SECOND FAILURE HAPPENED ABOUT 1 YEAR LATER (WHILE DRIVING). WHEN PURCHASING A REPLACEMENT CPS, THE PARTS GUY SAID THEY SELL A LOT OF THESE (AS IN THEY FAIL OFTEN). *JB

Mileage: 60,000

I HAVE A 2002 FORD F250 POWER STROKE DIESEL TRUCK. THE DIESEL ENGINE JUST SHUTDOWN AS I WAS DRIVING ON A MAJOR ROAD IN MEMPHIS TN. I LOST POWER STEERING AND BRAKES BUT WAS ABLE TO AVOID AN ACCIDENT BECAUSE I MUSCLED THE STEERING WHEEL AND THE BRAKES TO GET MY TRUCK OFF THE ROAD INTO A PARKING LOT. FORTUNATELY I WAS IN THE OUTSIDE LANE AND NOT TRAVELING AT 65 MPH OR THE ACCIDENT COULD HAVE BEEN VERY SERIOUS. I AM TOLD THAT THE PROBLEM IS THE CPS ALTHOUGH I JUST FOUND THAT OUT TODAY. THE TRUCK HAS BEEN STALLING INTERMITTENTLY AT STOP LIGHTS AND SPUTTERING ON THE INTERSTATE SO I HAD A HARD TIME DIAGNOSING THE PROBLEM. *TR

Mileage: 74,467

TRUCK STARTED CUTTING OFF RANDOMLY. TRUCK FINALLY QUIT RUNNING ON MAJOR STREET WAS ABLE TO GET IT OFF THE ROAD COASTING. CPS WAS REPLACED AND PROBLEM WAS CORRECTED. OLD PART MAY STILL BE AVAILABLE. *TR

Mileage: 63,400

CAM POSITION SENSOR FAILURE. *JB

Mileage: 45,000

I HAVE MY TRUCK AT THE DEALERSHIP TODAY AND AFTER DIAGNOSTIC THEY FIND OUT THAT MY PROBLEM IS CAUSED BY THE CAM SENSOR. MY PROBLEM START ABOUT TWO WEEKS A GO WHEN MY TRUCK JUST WITH NO ALERTS/LIGHTS JUST SHUT OFF ON THE MIDDLE OF THE ROAD BUT ON TUESDAY 24TH OF 2007 I WAS DRIVING ON AN SMALL ROAD I'M PULLING A 6X12 CARGO TRAILER WHEN MY TRUCK DID IT AGAIN BUT THIS TIME BECAUSE MY TRAILER ON THE BACK WAS VERY DIFFICULT TO DRIVE WITH NO POWER STEERING AND NO BRAKES. I DID A SEARCH JUST NOW AND FOUND OUT THAT IS A PROBLEM THAT FORD IS AWARE OFF AND THEY JUST DON'T WANT TO ADMIT PLEASE ADVICE ME TO WHAT I NEED TO DO. DEALER ESTIMATE TO FIX THE PROBLEM IS ABOUT $500.00 LABOR AND PARTS. *JB

I WAS DRIVING DOWN THE HIGHWAY AT APPROX 65 MPH WHEN ALL OF A SUDDEN I HEARD A POP AND LOST ENGINE POWER. I PULLED OVER AND LOOKED UNDER THE HOOD OF THE TRUCK AND OBSERVED A SPARKPLUG LYING IN THE ENGINE COMPARTMENT AND THE WIREHARNESS FOR IT WAS TORN LOOSE. IT WAS CLEAR THAT A SPARKPLUG HAD ROTATED LOOSE CAUSING IT TO COME OUT OF ENGINE WHICH CAUSED SUDDEN ENGINE FAILURE AT HIGHWAY SPEEDS. THE SPARKPLUG WHICH ROTATED LOOSE, TORE OUT THE LAST 3 THREADS OF THE SPARKPLUG HOLE IN THE CYLINDER HEAD AND DESTROYED THE SPARKPLUG WIRE HARNESS. THE TRUCK WAS BROUGHT TO THE DEALERSHIP ON A FLAT BED TRUCK. THE CYLINDER HEAD HAD TO BE REMOVED AND A HELICOIL PUT IN TO REPLACED THE TORN OUT THREAD FOR THE FAILED SPARKPLUG HOLE. ALL SPARKPLUGS HAD TO BE REPLACED WITH NEW ONES. A NEW SPARKPLUG WIREHARNESS WAS INSTALLED. I OBSERVED THAT THE CERAMIC PORTION OF THE SPARKPLUG ROTATED INDEPENDANTLY OF THE TREADED PART OF THE SPARKPLUG BODY WHICH WOULD ALLOW ROTATION OF THE SPARKPLUG BODY INDEPENDANT OF THE CERAMIC PORTION. I DO NOT HAVE THE SPARKPLUG THAT ROTATED LOOSE.

Mileage: 59,456

I OWN A 2002 FORD F250 7.3L POWER STROKE DIESEL. ON 10-20-06 THE CPS FAILED IN A RAINSTORM. MY WIFE (7 MONTHS PREGNANT) WAS DRIVING AND WAS NEARLY INVOLVED IN A CRASH BECAUSE WHEN THE FAILURE OCCURRED ALL ELECTRONICS DIED AS DID THE MOTOR. THIS RENDERED THE POWER STEERING AND POWER BRAKES USELESS. THIS PROBLEM COULD HAVE CAUSED A FATALITY IF NOT TO MY WIFE BUT OTHER DRIVERS AS WELL. THE TRUCK STRANDED MY WIFE ON THE SIDE OF A COUNTRY ROAD FOR 2 HRS. WAITING FOR A TOW SERVICE. THE VEHICLE HAD TO BE TOWED AND THE CPS REPLACED BEFORE THE TRUCK WOULD RESTART. *JB

Mileage: 123,575

NO WARNING , THE SPARK PLUG JUST BLEW OUT OF THE CYLINDER HEAD WITH A LOUD BANG WHILE DRIVING DOWN THE ROAD. FORD MOTOR COMPANY DENIED RESPONSIBILITY AND PLACED THE BLAME ON ONE OF IT'S DEALERS WHO PREVIOUSLY HAD REPLACE AN IGNITION COIL ON A DIFFERENT CYLINDER. NEITHER PARTY WANTED TO ACCEPT RESPONSIBILITY FOR THE REPAIR COST. THIS VEHICLE IS USED FOR BUSINESS PURPOSE AND IT GETS EXPENSIVE WHEN IT IS NOT IN SERVICE. AFTER A WEEK OF PHONE CALLS AND CORRESPONDENCE BETWEEN THE DEALER AND FORD AND GETTING NO WHERE I HAD A LOCAL MECHANIC REPAIR THE VEHICLE A MY COST. *JB

Mileage: 98,000

2002 FORD F-250, EXHAUST LEAK DEVELOPED JUST AFTER 50,000 MILES. RIGHT SIDE MANIFOLD HAD SPLIT. FORD REFUSED TO WARRANTY IT, EVEN THOUGH IT WAS ONLY 4 1/2 YEARS INTO A 5 YR/ 50,000 MILE EMISSIONS WARRANTY. THERE IS A RECALL ON THE MOUNTING STUDS THAT CHANGES THEM TO STAINLESS STEEL. THEY HAVE A PROBLEM WITH THE FACTORY STUDS ROTTING OUT. THEY ALSO HAVE MADE IMPROVEMENTS TO THE HOLES IN THE MANIFOLD. THEY WERE ENLARGED TO RESIST CRACKING. BOTH MANIFOLDS HAD TO BE REPLACED ALONG WITH THE BROKEN STUDS. ALL OLD PARTS ARE IN MY POSSESSION. OTHERWISE THE TRUCK IS IN LIKE NEW CONDITION. *JB

Mileage: 54,000

ENGINE STALLING TRUCK SHUTS DOWN, ALL POWER IS LOST. *JB

Mileage: 42,000

FAILURE OF ENGINE HELI-COIL IN 2002 FORD F-250 TRITON 5.4L GASOLINE ENGINE. FAILURE OCCURRED AT 89,000 MILES. FAILURE OCCURRED UPON STARTUP. VEHICLE TOWED TO DEALER AND HELI-COIL RETHREADED FOR $1,000. SUBSEQUENT RESEARCH ON THE WEB INDICATES THIS PROBLEM IS EXTREMELY COMMON IN THIS ENGINE AND DUE TO MANUFACTURING/DESIGN FLAW. *NM

Mileage: 89,740

2002 FORD F250 DIESEL TRUCK ON INTERSTATE 25 IN DENVER. PROCEEDING AT 70 MPH IN MIDDLE LANE IN HEAVY FAST TRAFFIC AND SUDDENLY EVERYTHING SHUT DOWN. NO POWER, NO ELECTRICAL, NO BRAKES, NO STEERING, VERY DANGEROUS SITUATION IN RUSH HOUR TRAFFIC. HAD IT TOWED. THIS IS THE SECOND TIME THE CAM SENSOR HAS JUST QUIT WITHIN 1.5 YEARS AT $500 COST TO REPLACE EACH TIME. BUT, I COULD HAVE BEEN SERIOUSLY INJURED. I BELIEVE THIS JUSTIFIES A RECALL TO PREVENT SOMEONE FROM BEING SERIOUSLY HURT. CAM SENSOR!!! *JB

Mileage: 90,000

TRUCK (2002 FORD F-250 POWERSTROKE) ENGINE RANDOMLY QUITS DURING BRAKING OR LOW/NO ACCELERATION. THIS CAUSES LOSS OF POWER BRAKES AND STEERING. BRAKING AND LOW ACCELERATION OCCUR IN INTERSECTIONS FREQUENTLY I HAVE DISCOVERED. TRUCK WILL RESTART AND PROBLEM MAY OR MAY NOT RETURN IMMEDIATELY. I TOOK IT TO A DEALERSHIP WHO SAID THEY COULD NOT DUPLICATE THE EVENT AND THE CODES SET BY THE PCM WERE "UNRELATED". I TOOK IT TO THE DEALER A TOTAL OF THREE TIMES FOR THIS PROBLEM. I READ ON THE INTERNET (WWW.DIESELSTOP.COM) THAT THIS SYMPTOM WAS FREQUENTLY CAUSED BY A BAD CPS SENSOR. I WENT TO AN INTERNATIONAL ENGINE (MAKER OF THE FORD POWERSTROKE) DEALER AND BOUGHT A NEW CPS WHICH RESOLVED THE PROBLEM. I HAVE THE OLD PART FOR INSPECTION IF NEEDED. THIS PROBLEM IS DANGEROUS. IF PULLING MY TRAILER, LOSS OF ASSISTED BRAKES AND STEERING COULD QUICKLY BECOME CATASTROPHIC. *NM

Mileage: 75,000

TWO TIMES IT DIED WHILE DRIVING THE THIRD I WAS IDLING TALKING TO A FRIEND AND IT JUST DIED AND WOULD NOT RESTART. *NM

Mileage: 92,000

DT: THE CONTACT STATED WHILE DRIVING 15-20 MPH, THERE WAS A LOUD POPPING SOUND. THE VEHICLE WAS TAKEN TO THE DEALER WHO DETERMINED THE HEAD, SPARK PLUG AND IGNITION COIL ON THE SPARK PLUGS NEEDED TO BE REPLACED. WHILE SEARCHING THE INTERNET FOR INFORMATION RELATED TO THE DEFECT ON THE VEHICLE, A CASE ACTION SUIT IN CALIFORNIA WAS OBSERVED AGAINST THE MANUFACTURER.

Mileage: 69,500

THE CPS (CAMSHAFT POSITION SENSOR) FAILED ON MY 2002 F250 FORD POWERSTROKE WHILE DRIVING. THIS RESULTED IN VERY HARD STEERING AND VERY POOR BRAKING ABILITY. IF I HAD BEEN TOWING MY FIFTH WHEEL THE SITUATION COULD HAVE BEEN VERY SERIOUS. I LATER FOUND THAT THE FAILURE OF THE CPS IS VERY COMMON ON FORD POWERSTROKES FROM 1999 THROUGH 2003. *NM

Mileage: 82,116

I WAS MAKING A LEFT TURN WHEN I HEARD A POP,POP, POP. I BLEW OUT #3 SPARK PLUG IN MY 2002 F250. IT HAS 72,000 MILES ON IT. I CHOSE TO HAVE IT REPAIRED RATHER THAN REPLACING THE HEAD(600$ AS OPPOSED TO 3000$). THE FORD DEALERSHIP IN WAUSAU WI. WOULD NOT REPAIR IT,THEY WOULD ONLY REPLACE THE HEAD, AND WOULD NOT ADMIT THAT THIS WAS A RECURRING PROBLEM. *JB

Mileage: 71,800

#2 SPARK PLUG BLOWN OUT OF HEAD WHILE DRIVING. SPARK PLUG THREADS IN HEAD STRIPPED OUT CAUSING PLUG TO BLOW OUT AND DAMAGE COIL. TRUCK WAS TAKEN TO DEALER FOR DIAGNOSIS, DEALER HAD TO INSTALL A HELICOIL IN HEAD AT LOCATION #2. *NM

Mileage: 54,630

I HAVE A FORD 2002 F-250 SUPER DUTY THAT THE SPARK PLUG BLEW OUT F THE CYLINDER HEAD. THIS CAUSED A VERY SIGNIFICANT POWER LOSS CAUSING THE TRUCK TO SLOW VERY QUICKLY MUCH LIKE APPLYING THE BRAKES BUT NOT USING THEM. THIS CAUSED A VERY NEAR ACCIDENT ON A HIGHWAY TRAVELING AT 50 MPH AND THE SLOWING WITHOUT BRAKE LIGHTS NEARLY CAUSED AN ACCIDENT. AFTER APPROXIMATELY 1 MIN OF RESEARCHING THE PROBLEM ABOUT THE ACCIDENT I REALIZED THAT THIS PROBLEM IS HUGE !!!! TO SAY THE LEAST. THERE HAVE BEEN COUNTLESS REPORTS OF SPARK PLUGS BLOWING AND EITHER PEOPLE BEING STRANDED TO NEAR COLLISIONS. ALSO I AM A FIREFIGHTERS PARAMEDIC AND MY NOSE IS NO HYDROCARBON METER BUT THE LEVELS OF GASOLINE VAPORS THAT ACCUMULATE IN A VERY SHORT TIME. MY QUESTION TO THAT IS HOW MUCH VAPOR COLLECTS IN THE CAB COMPARTMENT AND CAN IT CAUSE A COMPARTMENT FIRE BEFORE THE DRIVER CAN SAFELY GET THE VEHICLE TO A SAFE AREA TO EXIT THE VEHICLE? I BRING THIS TO YOUR ATTENTION BECAUSE OF MY RESEARCH I DO NOT BELIEVE ANY LETTERS OR CALLING FORD MOTOR AS JUST A VEHICLE OWNER CAN MAKE FORD MOTOR COMPANY MORE AWARE OF THIS PROBLEM. THANK YOU! *JB

Mileage: 42,000

DT*: THE CONTACT STATED WHILE DRIVING AT ANY SPEED, THE VEHICLE STALLED WITHOUT PRIOR WARNING. THE ENGINE HAD TO REMAIN IN THE OFF POSITION FOR 15 MINUTES BEFORE IT WOULD RESTART. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION.

Mileage: 29,000

CAMSHAFT POSITION SENSOR (CPS) HAS FAILED 3 TIMES SINCE I'VE HAD THE VEHICLE. MY TRUCK HAS ONLY 77,000 MILES ON IT. WHEN THIS SENSOR FAILS THE TRUCK DIES INSTANTLY AND WILL NOT RESTART. I WAS LUCKY ALL 3 TIMES TO NOT BE PULLING A TRAILER IN HEAVY TRAFFIC. *JB

Mileage: 77,200

I HAVE A 2002 FORD F-250 POWER STROKE DIESEL. I WAS ON MY WAY TO WORK AND ALL OF A SUDDEN THE ENGINE JUST SHUT OFF AS IF I HAD TURNED THE KEY OFF. IT PICKED RIGHT BACK UP ALMOST IMMEDIATELY AND CONTINUED TO RUN FOR ABOUT A MILE. THEN IT SHUT OFF AGAIN AND DID NOT PICK BACK UP. THIS WAS ON A 4 LANE HIGHWAY AT 55-60 MPH WITH NO POWER STEERING AND NO POWER BRAKES ON A 7000# TRUCK. I MANAGED TO COAST INTO A TURN LANE AND GOT IT TO RE-FIRE AND MOVED IT INTO A PARKING LOT. CHECKED ALL OF MY ELECTRICAL CONNECTIONS UNDER THE HOOD AND RESTARTED THE TRUCK. IT IDLED FINE FOR A WHILE SO I THOUGHT MAYBE A CONNECTOR WAS LOOSE AND I HAD FIXED THE PROBLEM. I DECIDED TO CONTINUE ON MY WAY TO WORK. I PULLED BACK OUT ONTO THE HIGHWAY AND NO PROBLEMS. I HAD TO MAKE A U-TURN ON THE 4 LANE HIGHWAY AND RIGHT IN THE MIDDLE OF IT, THE TRUCK DECIDES TO DIE AGAIN. LUCKILY, I WAS ABLE TO GET IT INTO NEUTRAL AND RE-FIRED BEFORE I GOT HIT IN THE SIDE BY ONCOMING TRAFFIC. HAD HEARD OF THE CPS FAILURES BEING A PROBLEM ON THE 7.3 POWER STROKE ENGINES SO I HAD IT TOWED HOME AND REPLACED THE CAM POSITION SENSOR. NO PROBLEMS SINCE. I STARTED LOOKING ON WEB SITES TO FIND OUT HOW MANY PEOPLE HAD BEEN HAVING THIS SAME TYPE FAILURE AND IT SEEMS TO BE A VERY COMMON PROBLEM. SEVERAL WEB SITES ARE RECOMMENDING THAT THE POWER STROKE OWNERS THAT HAVE HAD THIS PROBLEM NOTIFY YOU ALL SO MAYBE WE CAN GET THE PROBLEM SOLVED. *JB

Mileage: 83,000

TRUCK SAT ALL NIGHT, STARTED TRUCK WAITED APPROX 10 MIN , DROVE APPROX 2 MILES, TRUCK STALLED/DIED IN THE MIDDLE OF INTERSECTION, BRAKES DID NOT HAVE POWER ASSIST. COASTED DOWN HILL APPROX .5 MILES BEFORE I COULD STOP THE TRUCK. TRUCK COOLED AND RESTARTED THEN DIED APPROX 2 MIN LATER. TRUCK WAS TOWED TO LOCAL FORD. CPS REPLACED AS BAD. *JB

Mileage: 45,000

TRUCK STOPS RUNNING WITH NO WARNING DURING NORMAL OPERATION. *NM

Mileage: 80,000

WHEN DRIVING AT 25 MPH THE # 3 SPARK PLUG BLEW OUT OF THE CYLINDER HEAD. *AK

CAM POSITION SENSOR FAILURE. LOSS OF POWER. NO STEERING. NO BRAKES. REPLACED SENSOR. *NM

2002 FORD F-250 SUPER CAB SPARK PLUG BLEW OUT OF CYLINDER HEAD. JUST DRIVING DOWN THE STREET AND ALL AT ONCE THERE WAS A LOUD BANG LIKE A BIG HOLE BLEW OUT OF THE MUFFLER. SHUT THE ENGINE OFF, PULLED OVER AND TRIED TO DETERMINE CAUSE. DROVE TRUCK ANOTHER COUPLE OF MILES TO REPAIR SHOP. THE REPAIR BILL WAS OVER $2,000. THE REPAIR SHOP STATES THEY HAVE HAD AT LEAST 6 OF THESE SITUATIONS IN THE LAST 2 MONTHS. WE BELIEVE THIS IS A DEFECT IN THIS TRUCK - THE TRUCK HAS 61,700 MILES ON IT AND IT IS TOO EARLY TO EXPERIENCE THIS KIND OF DIFFICULTY. *JB

Mileage: 61,717

I OWN A FORD F250,2002, DIESEL. ON THREE DIFFERENT OCCASIONS, WHILE DRIVING DOWN THE ROAD THE ENGINE HAS SIMPLY QUIT. ON TWO OF THOSE INSTANCES, I WAS VERY LUCKY NOT TO HAVE HAD A TERRIBLE ACCIDENT. THE FIRST TIME, IT WAS UNDER WARRANTY AND THEY FIXED IT NO PROBLEM, THE LAST TWO TIMES, IT HAS BEEN RATHER EXPENSIVE TO HAVE IT FIXED. FORD DOES PAY FOR THE PART AND IT IS THE SAME PART EACH TIME, A CAM SENSOR, BUT I HAVE TO PAY FOR THE TOWING AND THE DEDUCTIBLE. THIS IS EXTREMELY DANGEROUS, AND IT IS THE SAME PART THAT IS FAILING. ACCORDING TO THE TOW TRUCK DRIVERS WHO HAVE PICKED UP THE VEHICLE, THEY SAY IT IS A COMMON PROBLEM. IT HAS ALSO HAPPENED TO MY BROTHER-IN-LAW AND HE HAS A 1999 MODEL, BUT ONLY ONCE. I ONLY HAVE 57,000 MILES ON THE TRUCK, AND AS I SAID, IT IS EXTREMELY DANGEROUS, AS WHEN IT GOES, THERE IS NO WARNING, IT SIMPLY DIES. THE FIRST TIME I WAS DOING 70 MPH AND WAS JUST ABOUT WIPED OUT BY A SEMI BEHIND ME. *JB

Mileage: 56,496

I HAVE A 2002 FORD F-250 SUPER DUTY PICKUP TRUCK WITH A V-10 ENGINE. IT HAS APPROX. 63,000 MILES AND IS SUBSEQUENTLY 'OUT OF WARRANTY' (3/36,000). ON JULY 9, 2004 I HEARD A BRIEF TAPPING NOISE AND A POP THEN A LOUD NOISE LIKE AN EXHAUST MANIFOLD LEAK. IMMEDIATELY UPON HEARING THIS NOISE I SHUT OFF THE ENGINE AND CALLED A TOW TRUCK, AS I AM NOT A MECHANIC AND DID NOT WANT TO CREATE FURTHER DAMAGE. WHEN THE MECHANIC ARRIVED TO TOW MY TRUCK HE OBSERVED THAT A SPARK PLUG HAD BEEN BLOWN OUT OF THE CYLINDER. I INFORMED HIM TO TOW IT TO HIS LOT UNTIL I COULD DECIDE WHAT TO DO. THE NEXT DY I HAD THE TOW TRUCK COMPANY BRING MY TRUCK TO THE FORD DEALERSHIP I PURCHASED IT FROM. TODAY AFTER THE DEALERSHIP'S MECHANIC INSPECTED MY TRUCK THEY INFORMED ME THAT THE CYLINDER HEAD WAS BROKEN AND I WOULD BE LIABLE FOR THE $3,700.00 REPAIR. WHAT I FIND DISTUBING IS MY SCHEDULED SPARK PLUG REPLACEMENT SERVICE INTERVAL: FORD RECOMMENDS 100,000 MILES BEFORE REPLACEMENT. HOW WOULD I EVER KNOW THAT THE SPEARK PLUG WAS NOT INSTALLED PROPERLY AT THE FACTORY PRIOR TO THE SCHEDULED SERVICE? ADDITIONALLY, HAD IT NOT BLOWN OUT ON ITS OWN, WHO KNOWS WHAT OTHER DAMAGES WOULD HAVE GONE UNCHECKED. I HAVE RESEARCHED THIS PARTICULAR DEFECT ON THE WEB AND HAVE FOUND NOT LESS THAN 100 PEOPLE THUS FAR WITH THE EXACT SAME COMPLAINT. ADDITIONALLY , I HAVE FOUND NUMEROUS PEOPLE THAT THIS HAS HAPPENED TO MORE THAN ONCE ON THE SAME ENGINE. I STOPPED RESEARCHING BECAUSE I FEEL THIS IS SUFFUCIENT SUPPORTING DOCUMENTATION OF MY COMPLAINT. IF NECESSARY, I WILL BE HAPPY TO FURNISH THIS DOCUMENTATION FOR YOU. I HAVE FOUND THIS PROBLEM TO BE INHERENT IN ALL V10 FORD ENGINES SINCE 1999. I HAVE ALSO FOUND THAT FORD IS AWARE OF THIS PROBLEM AND HAS ISSUED A TECHNICAL SERVICE BULLETIN TO ALL OF THEIR DEALERSHIPS DESCRIBING THIS PARTICULAR REPAIR PROCEDURE. *AK

Mileage: 63,000

DIESEL EMISSIONS ENTERING INTO PASSENGER COMPARTMENT OF 2001 FORD F250 SUPER DUTY V8-7.30. IS THERE ANYONE OUT THERE THAT HAS EXPERIENCED DIFFICULT BREATHING CONDITIONS AND OR IN GENERAL, SICK, AFTER PROLONGED EXPOSURE THE ULTRA FINE PARTICULATE MATTER CONTAINED IN THE EMISSIONS OF DIESEL ENGINE. *AK