NHTSA Complaint #10166349 — 2005 FORD E-350

THE AGENCY FOR COMMUNITY TRANSIT PROVIDES SERVICES FOR MADISON COUNTY MASS TRANSIT DISTRICT WHO IS RESPONSIBLE FOR PUBLIC TRANSPORTATION SERVICES IN THE MADISON COUNTY, ILLINOIS AND METROPOLITAN ST. LOUIS, MO. AREA. WE HAVE APPROXIMATELY 48 FORD E450 VAN CUTAWAY CHASSIS EQUIPPED WITH TURTLE TOP BUS BODIES, ALL EQUIPPED WITH 6.0L DIESEL ENGINES. BUSES ARE 2004 & 2005 MODEL YEARS. COKING (UN-COMBUSTION) DEPOSITS FORM ON THE EGR VALVE CAUSING DRIVABILITY ISSUES SUCH AS LACK OF POWER, SURGES, AND STALLING. THIS CONDITION IS ESPECIALLY DANGEROUS WHEN THE BUS DEVELOPS THIS CONDITION WHEN CROSSING INTERSECTIONS, RAILROAD TRACKS ETC AND IS TRANSPORTING PASSENGERS BOTH MOBILE AND HANDICAPPED. DRIVERS HAVE VOICED THEIR CONCERN OVER THIS CONDITION AS THEY BELIEVE IT IS UNSAFE FOR THEM AND THEIR PASSENGERS. FORD MOTOR COMPANY HAS REPLACED EGR VALVES (APPROX. 36-40) OR RECOMMENDS A FUEL ADDITIVE TO TRY TO TAKE CARE OF THE PROBLEM BUT IT DOES NOT REPAIR THE PROBLEM AS IT EVENTUALLY RETURNS ONCE THE REPLACEMENT EGR BUILDS UP COKING DEPOSITS. WE HAVE BEEN IN CONTACT WITH FORD BUT HAVE BEEN INFORMED THERE ARE NO CURRENT PLANS TO PERMANENTLY CORRECT THE PROBLEM. WE HAVE BEEN IN TOUCH WITH FORD FIELD SERVICE ENGINEERS AND ENGINEERS IN MICHIGAN BUT TO NO AVAIL. PREVIOUSLY WE HAD SIMILAR FORD VEHICLES WITH 7.3L DIESEL ENGINES OPERATING UNDER IDENTICAL CONDITIONS WITH NO PROBLEMS. THESE PROBLEMS OCCURRED WHEN THE 6.0L DIESEL WAS INTRODUCED INTO THE FLEET AS THE 7.3L PREVIOUSLY USED WAS DISCONTINUED. *JB