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.
2002 Ford F-250 SD engine complaints
Page 3 of 5: complaints 41 to 70 of 105, newest first, as owners wrote them.
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.
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.
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.
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.
Spark plug ejected from #3 cylinder head.
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.
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........
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 federal safety agency is doing something about this well known defect.
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.
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.
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.
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.
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.
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.
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.
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.
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.
Ford f250 v10 blown spark plugs. 3 in under two months.
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.
Repeated failure of camshaft position sensor.
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.
Cam shaft sensor failed while 7.3 powerstroke was a dealer for scheduled maintenance.
Several cam position sensor failures .
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.
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
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.
Re: the federal safety agency 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
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.
Cam position sensor failure on 2002 ford f250 powerstroke diesel. 70 MPH on interstate. Loss of power brakes and power steering.
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