2002 Ford F-250 Engine Problems

The contact owns a 2002 Ford F-250. The contact initially discovered patches of fluid on the garage floor. The vehicle was then taken to a dealer where a diagnostic test was performed. The dealer discovered a leak in the engine oil pan due to a faulty silicone gasket. The contact stated that the oil pan was replaced by the same dealer a year prior to the recent failure. The contact was provided an estimate for the repair. The manufacturer was also notified of the failure and informed the contact that there was no recall on the VIN related to the failure. The contact was referred to the NHTSA Hotline to report the failure. The vehicle was not repaired. The failure mileage was 138,683.

TL* THE CONTACT OWNS A 2002 FORD F-250. THE CONTACT STATED THAT WHILE THE VEHICLE WAS STATIONARY AT A TRAFFIC LIGHT, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS RESTARTED AND DRIVEN TO HIS DESTINATION. THE CONTACT STATED THAT THE FAILURE WAS EXPERIENCED ON THREE SEPARATE OCCASIONS. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. A DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS INFORMED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 300,000.

2002 F-250 7.3L DIESEL. DRIVING DOWN THE HIGHWAY PULLING A HORSE TRAILER ENGINE JUST COMPLETELY STALLED WITHOUT WARNING. I LOST ALL STEERING AND BRAKES. I PUT IT IN NEUTRAL AND RESTARTED WHILE COASTING. DROVE ANOTHER FEW MILES AND IT STALLED AGAIN. WOULD NOT START AGAIN AFTER THAT. THIS HAPPENED ON A REMOTE HIGHWAY AT NIGHT. HAD A WRECKER TOW US TO A DIESEL SHOP WHO REPORTED TRUCK STARTED FINE NEXT DAY. WENT AND PICKED IT UP AND IT STUTTERED A FEW TIMES ON THE WAY HOME BUT DID NOT STALL. A FEW MONTHS LATER, ENGINE STALLED AT A RED LIGHT IN HEAVY TRAFFIC BUT STARTED BACK UP. TOOK IT TO MY MECHANIC WHO READ A CAM POSITION SENSOR CIRCUIT FAULT ON THE COMPUTER. REPLACED CAM POSITION SENSOR. A FEW MONTHS LATER, STALLED AGAIN AT AN INTERSECTION. I COASTED TO THE SIDE OF THE ROAD AND HAD IT TOWED TO MY MECHANIC. UPON ARRIVING AND UNLOADING FROM WRECKER. TRUCK STARTED UP. STARTED TO DRIVE IT HOME AND STALLED AGAIN HALFWAY THERE ON A BUSY RURAL ROAD WITH NO SHOULDER. CALLED WRECKER AGAIN AND TOWED TO DIFFERENT DIESEL SHOP. REPLACED CPS AGAIN AND TRUCK STARTED FINE. TOOK IT HOME AND RAN IT AT IDLE UNTIL ENGINE TEMP WAS NORMAL. ENGINE STALLED AGAIN AND WOULD NOT START. WAITED ABOUT 2 HOURS AND IT STARTED UP JUST FINE AND RAN AT IDLE FOR ONE HOUR WITHOUT STALLING. CURRENT CPS WAS FROM FORD DEALER (THE GREY ONE) BUT APPARENTLY THE SAME PROBLEM AS THE ONE INVOLVED IN NHTSA ID: EA06012 RECALL FROM 2006 IS STILL A PROBLEM. IT COULD STALL WITHOUT WARNING IN THE MIDDLE OF AN INTERSECTION AND CAUSE A SERIOUS CRASH. THIS IS A SERIOUS SAFETY ISSUE!!

TL* THE CONTACT OWNED A 2002 FORD F-250. WHILE THE VEHICLE WAS PARKED FOR A COUPLE OF HOURS IN COLD TEMPERATURES AND CONNECTED TO THE BLOCK HEATER, THE VEHICLE CAUGHT FIRE. THE FIRE WAS EXTINGUISHED BY THE FIRE DEPARTMENT. THE VEHICLE WAS DESTROYED. THE DEALER AND MANUFACTURER WERE NOT MADE AWARE OF THE FAILURE. THE CAUSE OF THE FAILURE WAS NOT DETERMINED. THE FAILURE MILEAGE WAS 177,700.

ON NOVEMBER 26TH 2017, MY TRUCK STARTED HAVING A SIGNIFICANT MIS-FIRE IN CYLINDER #4. TRAVELLING AT ABOUT 30 MPH ON CITY STREETS; THIS PARTICULAR INCIDENT WAS NOT A SAFETY ISSUE ALTHOUGH DIFFICULT TO LIMP THE VEHICLE HOME AS IT DID NOT ACCELERATE WELL. UPON REMOVING THE SPARK PLUG; IT WAS DETERMINED THAT THE CYLINDER HEAD THREADS IN THE SPARK PLUG PORT HAVE BEEN DAMAGED. THIS WOULD HAVE RESULTED IN AN EJECTED SPARK PLUG HAD THE VEHICLE BEEN CONTINUED TO BE OPERATED. SINCE THIS IS THE 3RD DIFFERENT CYLINDER THIS HAS OCCURRED ON WITH NUMEROUS REPORTS FROM MULTIPLE OWNERS OF THE SAME ENGINE DESIGN BY FORD; I HAVE DECIDED TO FILE THIS REPORT. THIS IS THE 2ND REPORT I HAVE FILED WITH THE NHTSA. THE FIRST REPORT I FILED WAS BECAUSE THE 2ND TIME THIS OCCURRED; A SPARK PLUG EJECTED FROM THE #3 CYLINDER AT HIGHWAY SPEEDS WITH A SIGNIFICANT REDUCTION IN SPEED IN TRAFFIC ON THE HIGHWAY. THAT OCCURRENCE ALSO CAUSED A SIGNIFICANT VIBRATION AND HAD TO BE PULLED OVER IMMEDIATELY. EVEN THOUGH THERE HAVE BEEN SIGNIFICANT REPORTS TO FORD AND DOCUMENTED OCCURRENCES DATING BACK TO 1997; FORD CONTINUES TO SAY THAT BECAUSE NO "SAFETY ISSUES" HAVE RISEN OR BEEN PROVEN TO BE CAUSED BY THIS ISSUE THAT IT IS NOT THERE PROBLEM. I WILL ALSO BE FILING REPORTS WITH BBB, CONSUMER AFFAIRS AND CONSUMER REPORTS.

TL* THE CONTACT OWNS A 2002 FORD F-250. WHILE DRIVING 40 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS ABLE TO RESTART ON THE SECOND ATTEMPT; HOWEVER, THE FAILURE RECURRED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 07V553000 (ENGINE). THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 117,000.

TL* THE CONTACT OWNS A 2002 FORD F-250. WHILE DRIVING AT ANY SPEED AND AS SOON AS THE ENGINE BECAME HOT, A BURNING OIL ODOR WAS PRESENT INSIDE THE VEHICLE. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE DEALER DIAGNOSED THAT THERE WAS A DEFECTIVE HEAD GASKET THAT NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 86,000.

TRUCK DIES WHILE DRIVING WITHOUT ANY WARNING, CAN-NOT FIND THE PROBLEM AND FORD WILL NOT ACKNOWLEDGE THAT THERE IS AN ISSUE. *TR

MY 2002 FORD F250 SUPER DUTY 5.4 GASOLINE ENGINE HAD A SPARK PLUG BLOW OUT AT AROUND 165,000 MILES. I HAD PULLED OVER TO TAKE A CALL TURNED OFF THE ENGINE, WHEN I STARTED IT BACK UP IT WAS MAKING A LOUD POPPING SOUND, MY MACHANIC SHOP WAS NEXT DOOR TO WHERE I WAS SO I WAS LUCKY THAT I DID NOT HAVE TO DRIVE IT ANYWHERE.

AT 102000 MILES ENGINE EJECTED #8 SPARK PLUG WHILE DRIVING, TAKING THREADS WITH IT. LOCAL MECHANIC REPAIRED USING INSERT. AT 125000 MILES ENGINE EJECTED #3 SPARK PLUG IN SAME MANNER. SAME MECHANIC INSPECTED #8 WHILE REPAIRING #3 AND FOUND INSERT NOT HOLDING, PLUS TWO OTHER PLUGS BACKING OUT.

OIL PAN RUSTED OUT.

The contact owns a 2002 Ford F-150. The contact stated while driving at an undisclosed speed, the engine seized. No warning light was illuminated. The contact attempted to start the vehicle; however, the vehicle failed to start. The contact stated that the vehicle started after several attempts. The contact stated the vehicle sat for a while before starting the vehicle. The vehicle was towed to the dealer; however, the vehicle was not diagnosed. The contact was informed that the repair was not covered under recall. The vehicle was then towed to an independent mechanic; however, the failure was not officially diagnosed. The contact was informed that the failure was possibly caused by an unknown sensor. The vehicle was not diagnosed or repaired by an independent mechanic or the dealer. The contact stated that the failure started in 2013; however, the vehicle had been parked and undriveable since 2017. The manufacturer was not made aware of the failure. The failure mileage was 109,000.

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

THE #3 SPARK PLUG BLEW OUT OF THE ENGINE HEAD. THIS IS THE SECOND TIME THIS HAS HAPPENED ON THE SAME SIDE OF THE ENGINE. BY BLOWING OUT, IT IS A FIRE HAZARD ,AS THE ENGINE STILL PUMPS GAS THROUGH THIS PISTON. THIS IS AN EXPENSIVE PROBLEM TO FIX AND FORD NEEDS TO TAKE RESPONSIBILITY FOR ITS BAD HEAD PROBLEM. *TR

ON 03/16/2012 AT 10:30PM WHILE ON MY WAY HOME FROM WORK, I CAME TO A STOP AT A STOP SIGN. TRUCK WAS RUNNING FINE. AS I PULLED AWAY FROM THE STOP SIGN AND ACCELERATING I HEARD A LOUD POP AND WHAT SOUNDED LIKE AN EXHAUST LEAK. I IMMEDIATELY PULLED OVER AND LOOKED UNDER THE HOOD. I FOUND THAT THE COIL ON THE #3 SPARK PLUG WAS OUT AND THE EXHAUST SOUND WAS COMING FROM THE HOLE WHERE THE SPARK PLUG SHOULD HAVE BEEN. ONLY LIVING 2 MILES FROM WORK, I DROVE THE TRUCK HOME AND PARKED IT TIL MORNING. IN THE MORNING I WENT OUT AND TRIED TO PUT THE PLUG BACK IN AND REALIZED THERE WERE NO THREADS TO THREAD THE PLUG INTO. THIS IS VERY DISCONCERTING REALIZING THAT THERE WILL BE SOME MAJOR WORK NEEDING TO BE DONE ON THE TRUCK BEFORE I CAN DRIVE IT AGAIN. NOT TO MENTION COST. UPON SOME INTERNET RESEARCH, I HAVE FOUND THAT THIS HAS BEEN A MAJOR PROBLEM WITH THESE FORD TRUCKS AND THAT FORD IS REFUSING TO DO A RECALL ON THIS MATTER. I JUST PURCHASED THIS TRUCK ON 03/12/2012 AND CANNOT DRIVE IT ANY MORE. I WILL NOT DRIVE IT ANY MORE DUE TO THE SAFETY ASPECT OF THE FUEL VAPORS COMING OUT OF THE HOLE AND POSSIBLY CATCHING FIRE FROM THE SPARK PLUG WIRE STILL ARCING. LEAST OF ALL THAT IT WILL CAUSE MORE DAMAGE TO THE ENGINE BEFORE IT CAN BE REPAIRED. THANK YOU FOR YOUR TIME IN THIS MATTER AND I AM HOPING THAT SOMETHING CAN BE DONE IN THE NEAR FUTURE THAT WILL MAKE FORD DO A RECALL ON THESE TRUCKS AND GET THE PROBLEM FIXED ONCE AND FOR ALL. *TR

TL* THE CONTACT OWNS A 2002 FORD F-250 SD. THE CONTACT STATED THAT WHILE DRIVING 55 MPH, A LOUD ABNORMAL SOUND EMITTED FROM THE ENGINE COMPARTMENT. AFTER INSPECTING THE VEHICLE, THE CONTACT NOTICED THAT THE SPARK PLUG HAD EXPLODED OUT OF THE CYLINDER HEAD. THE FAILURE RECURRED SEVERAL TIMES. THE VEHICLE WAS TAKEN TO THE DEALER WHO ADVISED THAT THE ENGINE NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 84,000.

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.

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

HELP! SPARK PLUGS #3 AND #5 HAVE BLOWN IN MY FORD 2002 F250 SINCE THE BEGINNING OF 2011. THESE FAILURES HAVE HAPPENED ON TWO SEPARATE OCCASIONS CAUSING ME TO LOOSE POWER ON MAJOR HIGHWAYS AND NARROWLY AVOIDING AN ACCIDENT WHILE TRYING TO NAVIGATE MY WAY THROUGH TRAFFIC TO GET TO A SAFE PLACE. I UNDERSTAND THAT THIS FAILURE HAPPENS FREQUENTLY TO A LARGE NUMBER OF FORD VEHICLE OWNERS. I ALSO UNDERSTAND THAT NHTSA HAS DENIED ANY FURTHER ACTION AGAINST FORD. I FIND THIS DENIAL QUESTIONABLE WITH THE VAST NUMBER OF COMPLAINTS ABOUT THIS SAME PROBLEM OCCURRING OVER AND OVER. MY SAFETY AND THE SAFETY OF OTHERS WAS JEOPARDIZED ON BOTH OCCASIONS THAT MY PLUGS BLEW OUT OF THEIR SOCKETS. SOMETHING NEEDS TO BE DONE! *TR

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