Ford F Series 2002

• Recall 64400 [USA]: This overheating condition can cause the running board to melt or cause a fire.
  Certain pickup truck, van, and mini van conversions equipped with southern comfort built running boards that contain certain courtesy lights manufactured by american technology components, inc. These units contain a courtesy light or lights that might overheat when the wire harness is exposed to excessive moisture and road salt.
  dealers will replace the wiring harness on these running boards. Owner notification began march 7, 2003. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact southern comfort at 1-800-745-6096.
  customers can also contact the national highway traffic safety administration's auto safety hotline at 1-888-dash-2-dot (1-888-327-4236).

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• Recall R/2009/128 [UK]: Speed control deactivation switch may overheat and catch fire
  It has been identified that corrosion within the speed control deactivation switch cavity can create a conductive path between the uninterrupted battery power and ground. This could cause the switch to overheat smoke or burn either with the engine running or when it is switched off.
  recalled vehicles will be inspected for corrosion of the specified area and if required will install a revised speed control deactivation switch. If no corrosion is present dealers will install a universal fused jumper harness.

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• Recall R/2011/124 [UK]: Risk of fire
  It is possible that where these vehicles are operating in high road salt conditions the fuel tank straps could fracture due to corrosion. This could lead to the detachment of the fuel tank resulting in the fuel tank contacting the road surface causing a fuel leak which could cause a risk of a vehicle fire.
  recall all affected vehicles and replace the fuel tank straps with improved salt corrosion protection straps.

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To ensure accuracy and for your safety, it is recommended to do a free VIN recall check here or here [USA] - UK - Canada.

Bulletins are notices put out by manufacturers in conjunction with the NHTSA to notify the public of manufacturing issues or changes.

• Spark plug ejection from cylinder head investigation # DP05005

  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.
  

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We purchased a car from nab autos in fredericksburg, va. After the 7th day of driving it, the motor blew up. Wrong spark plugs were installed by dealer. Also the truck had been raced with nitrous which we were unaware of until we tried to find out what happened to motor. I have documentation from the repair shop. My 18 year old son drives this vehicle which began losing power and shaking before he was able to pull off to the side of the highway.

Driving on the freeway a spark plug came out of the engine causing the vehicle to shake and loose power. The dealer and a shop i took the vehicle to stated that this is a frequent problem with this engine. *tr

While backing into my truck started making a load noise, it was obvious it was in the front end. Trying to turn the steering wheel, it was stuck. Stopped the truck, looked under the front of truck at steering, i noticed that there was a hole in the frame, it was then that i saw the steering link, against the right cv axle. The idler arm had some how ripped off the frame, leaving na hole where the idler arm was, the frame of the truck had weakened, causing the metal to weaken and separate, thank again ford. *tr

Failure of the abs module has led to a near miss accident that was avoided via steering around the obstruction instead of braking. The obdii module is throwing code C1185 as a part of the failure of the abs controller.. *tr

On 06/25/2014 i was driving my 2002 ford f-250 super duty 7.3 litre diesel south on rt. 81 in syracuse ny. At exit 81 and in congested traffic when i lost all engine power. The transmission light came on but when i pressed the accelerator nothing happened. The engine was still running but the truck would not go. I was in the left lane intending to go south on 81 with a barrier on my left and no shoulder to escape traffic. I signaled and drifted over to the right and ended up stopping in an area between the rt 81 lane and an exit ramp. While doing this i had slowed considerably as the truck had no power and cars and trucks behind me had to swerve and brake abruptly to avoid striking me. The area where i finally came to rest was directly between the two lanes without room on either side. I attempted to exit the truck to try to evaluate the situation but traffic was traveling within a foot or two of the truck. I contacted aaa and had to wait in this very hazardous position for about 45 minutes for a tow truck to arrive. I had to be towed almost 200 miles to my home after my mechanic diagnosed the problem he stated that it was one of or possibly two sensors that had failed. These sensors controlled the fuel and air flow to the engine and when they failed it refused to allow the engine to accelerate not allowing me to move the truck. I feel that ford should be made to design a sensor that provides a warning or a means to override the system in order for a driver to make it to a point of safety. This situation mimicked the same situation caused by gm cars having their ignition shut off causing death and serious injuries. I just happened to be very luck as i narrowly missed be struck by fast moving tractor trailers and cars. Hopefully something can be done by ford to correct this dangerous situation. My wife and i feel very lucky to be home safe today. *tr

Gas petal sticks and when pushed on truck accelerates rapidly, this happens when starting out from a stop and during all driving. *js

Was driving down the road at 35 mph and heard a pop then the engine started to run rough. Took to the mechanic said that i had a blown spark plug. *tr

Spark plug failure as accelerating from a stop light, and engine problem resulting from 7 cylinder operation. Got it to a mechanic and he was able to sleeve the spark plug thread and install a new plug. Now the same is starting again. I am taking the vehicle to the mechanic to make permanent repairs for all the spark plug. This may end up with the engine heads being removed in order to make complete repairs, and the cost for that will be thousands of dollars. This is a ford engine design problem that ford has been aware of, yet they continue to deny any responsibility. *tr

Cross frame member which contains the transmission mount was extremely rusted out and cracked. State safety inspection rep indicated it would not pass inspection in the near future. Ford no longer manufactures the frame member. I was lucky after a long search to find a dealer which still had the part available. Part # is: xl3z6a023ca. The vehicle has been operated in warwick ny since new and in northeastern pa since 2007. I believe if the frame member would fail the transmission would drop down. I have photos of the rusted unit. If you care to see them please send an e-mail address and i'll attach them to a e-mail. Something must be done to require manufactures to use better material for pickup truck frames and brake lines. I have also reported problems with brake lines on this truck rusting out. One incident, i reported, occurred after backing up a rv in a campsite after just driving over 150 miles on the interstate highway. Providence protected me as i could have lost the brakes while traveling on the interstate! *js .

Common OBD-II Error Codes

• P0102 [1] Mass or Volume Air Flow "A" Circuit Low Input
• P0103 [1] Mass or Volume Air Flow "A" Circuit High Input
• P0112 [1] Intake Air Temperature Circuit Low Input Bank 1
• P0113 [1] Intake Air Temperature Circuit High Input Bank 1
• P0171 [1] System too Lean (Bank 1)
• P0172 [1] System too Rich (Bank 1)
• P0174 [1] System too Lean (Bank 2)
• P0175 [1] System too Rich (Bank 2)
• P0455 [2] Evaporative Emission Control System Leak Detected (gross leak)
• P1105 [1] MAF Sensor Out Of Self Test Range./
• P1106 [1] KOER Not Able To Complete KOER Aborted
• C1185 [1] ABS Power Relay Output Circuit Failure