2004 Ford EXPLORER NHTSA Investigations
Defect Investigations
The following investigations on the Ford EXPLORER have been announced by the ODI. Interested in how this information is collected? Read more about investigations by the NHTSA.
Recent 2004 EXPLORER Investigations
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SPARK PLUG EJECTION FROM CYLINDER HEAD Defect Investigation for the 2004 EXPLORER
Vehicle Component: Engine And Engine Cooling:Engine*
Summary: 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.
More Details: For detailed information & supporting documents, see the official NHTSA page concerning investigation #DP05005 »
Status of Investigation: This investigation was closed on January 04 2006 and no recall was issued.
* This defect investigation is filed under 3 related vehicle components.
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VEHICLE ROLLAWAY ALLEGATIONS Defect Investigation for the 2004 EXPLORER
Vehicle Component: Steering*
Summary: In response to an information request (ir) letter sent by the Office Of Defects Investigation (ODI), Ford stated consumer reports of higher than expected efforts when shifting into and out of park could be a result of a groove being worn into the swing arm ramp of the steering column. The swing arm is a component bolted to the steering column that assists in shifting through the transmission gears. An engineering evaluation conducted by Ford of returned steering columns found the groove could be created over time if consumers shift more quickly from the drive or reverse to park than the brake shift interlock (bsi) solenoid pin retracts after the brake pedal is applied. In November of 2004 Ford released a redesigned bsi solenoid with a shorter pin retracting time as a serviceable component. Ford has noted the shorter retraction time significantly lessens the likelihood of bsi solenoid pin to swing arm contact even with rapid consumer shifts. Ford also issued a technical service bulletin, tsb 04-22-12, to instruct service technicians on the proper diagnosis and vehicle repair. Reviewing complaints to ODI and data submitted by Ford, ODI has identified 200 alleged incidents of unintended vehicle movement after consumers believe they have shifted the vehicle into park, resulting in 85 alleged crashes and 32 alleged injuries. In addition to the reports of alleged incidents of unintended vehicle movement, ODI has also identified 883 reports of consumers alleging difficulty or the inability to shift the vehicle into park. Preliminary evaluationpe09-020 has been upgraded to an engineering analysis to further assess the scope, frequency and risk to motor vehicle safety of the alleged defect in the subject vehicles.
More Details: For detailed information & supporting documents, see the official NHTSA page concerning investigation #EA09013 »
Status of Investigation: and there is a possible recall.
* This defect investigation is filed under 5 related vehicle components.
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VEHICLE ROLLAWAY ALLEGATIONS Defect Investigation for the 2004 EXPLORER
Vehicle Component: Steering*
Summary: In response to an information request (ir) letter sent by the Office Of Defects Investigation (ODI), Ford stated consumer reports of higher than expected efforts when shifting into and out of park could be a result of a groove being worn into the swing arm ramp of the steering column. The swing arm is a component bolted to the steering column that assists in shifting through the transmission gears. An engineering evaluation conducted by Ford of returned steering columns found the groove could be created over time if consumer shift more quickly from the drive or reverse to park than the brake shift interlock (bsi) solenoid pin retracts after the brake pedal is applied. In November of 2004, Ford released a redesigned bsi solenoid with a shorter pin retracting time as a serviceable component. Ford has noted the shorter retraction time significantly lessens the likelihood of bsi solenoid pin to swing arm contact even with rapid consumer shifts. Ford also issued a technical service bulletin, tsb 04-22-12, to instruct service technicians on the proper diagnosis and vehicle repair. Reviewing complaints to ODI and data submitted by Ford, ODI has identified 200 alleged incidents of unintended vehicle movement after consumers believe they have shifted the vehicle into park, resulting in 85 alleged crashes and 32 alleged injuries. In addition to the reports of alleged incidents of unintended vehicle movement, ODI has also identified 883 reports of consumers alleging difficulty or the inability to shift the vehicle into park. This preliminary evaluation has been upgraded to an engineering analysis (EA09-013) to further assess the scope, frequency and risk to motor vehicle safety of the alleged defect in the subject vehicles.
More Details: For detailed information & supporting documents, see the official NHTSA page concerning investigation #PE09020 »
Status of Investigation: This investigation was closed on August 19 2009 and no recall was issued.
* This defect investigation is filed under 3 related vehicle components.
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REAR LIFTGATE GLASS HATCH FAILURE Defect Investigation for the 2004 EXPLORER
Vehicle Component: Structure:Body:Hatchback/Liftgate:Hinge And Attachments*
Summary: This investigation was opened on June 23, 2008, based on 34 complaints involving eight injuries in which the rear liftgate glass hatch on model year 2004 Ford Explorers or Mercury Mountaineers broke off and fell, usually while individuals were operating the glass hatch or loading or unloading items from the rear of the vehicle. Ford conducted recall 04V-442 in 2004 to address similar problems on model year 2002 and certain model year 2003 Ford Explorers and Mercury Mountaineers. The information Ford provided in response to ODI's information request letter indicated that failures with 2004 vehicles were primarily liftgate glass hatch hinge failures related to corrosion at the hinge pin, whereas the failures that prompted the recall with the earlier models were primarily related to problems with the glass hatch's struts or fracture of a prior hinge design at the boss/bolt connection at the glass. ODI's review of Ford's warranty, complaint, and injury data for the 2004 vehicles indicates that these rates are significantly lower than those for the recalled population. A potential defect trend has not been identified at this time. ODI will continue to monitor complaints and take appropriate action as necessary. This investigation is closed.
More Details: For detailed information & supporting documents, see the official NHTSA page concerning investigation #RQ08003 »
Status of Investigation: This investigation was closed on October 24 2008 and no recall was issued.
* This defect investigation is filed under 4 related vehicle components.