NHTSA Defect Investigation #DP05005

SPARK PLUG EJECTION FROM CYLINDER HEAD: Engine And Engine Cooling**

CLOSED

no recall issued

** This defect investigation is filed under 3 related vehicle components.
2003 FORD F150 -- 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. Investigation was initiated on September 22 2005. Closed on January 04 2006. For detailed information & supporting documents, see the official NHTSA page concerning investigation #DP05005 »

NHTSA Defect Investigation #PE08063

CNG REGULATOR LEAK: Fuel System, Other:Delivery:Hoses, Lines/Piping, And Fittings**

CLOSED

no recall issued

** This defect investigation is filed under 8 related vehicle components.
2003 FORD F-150 -- The Agency has closed this investigation based on its review of complaint reports, discussions with complainants and field and technical data provided by Ford. The subject vehicles are 1/2 ton pickup trucks and are natural gas vehicles (ngv) that are fueled by gasoline or compressed natural gas. The Agency has received reports alleging improper operation of the natural gas fuel pressure regulator allowing release of excess amounts of natural gas into the engine compartment. Ford reports that the regulator contains an over pressure relief valve that will vent natural gas should the pressure exceed a set threshold. The complaint reports and data reviewed by the Agency indicate that an improperly operating pressure regulator can result in an overpressure condition and activate the regulator pressure relief valve. The released natural gas is directed through a vent hose that discharges the natural gas in the vicinity of the right front wheel house and away from the engine compartment's extremely hot areas/surfaces. Owners are normally aware of this problem by the presence of an illuminated warning light inside the vehicle, odor of natural gas or the sound of venting gas. When the operator turns the engine off, the natural gas supply tank solenoid will close and the regulator will not release natural gas. At vehicle restart, the solenoid valve will remain closed to prevent leakage and the vehicle will only operate in the gasoline mode. A safety-related defect has not been identified at this time and further use of Agency resources does not appear to be warranted. Accordingly, this investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency will monitor this issue and reserves the right to take further action if warranted by the circumstances. Investigation was initiated on October 31 2008. Closed on February 27 2009. For detailed information & supporting documents, see the official NHTSA page concerning investigation #PE08063 »