NHTSA Complaint #10177855 — 1997 FORD F-150

COMPLAINT: FORD MOTOR COMPANY, POOR DESIGN OF LOWER INTAKE PLENUM/MANIFOLD GASKET IN THE ESSEX 4.2L V-6. 1: EVENTS LEADING UP TO THIS FAILURE ORIGINALLY THERE WERE NO OBVIOUS SIGNS OF IMPENDING FAILURE. THE INDICATIONS OF FAILURE ARE LOSS OF ENGINE COOLANT WITH NO VISIBLE EXTERNAL LEAK, AND COOLANT IN THE COMBUSTION CHAMBER. 2: FAILURE AND IT'S CONSEQUENCES THIS DEFECT ALLOWS COOLANT LEAKAGE INTO THE COMBUSTION CHAMBER, CAUSING A HYDRAULIC LOCKING CONDITION WHICH WILL BREAK/BEND ONE OR MORE CONNECTING RODS. THIS RENDERS THE ENGINE UNUSABLE, AND IT MUST BE PULLED, REPAIRED IF POSSIBLE (SOME ARE NOT), AND RE-INSTALLED. 3: FAILURE CORRECTION. IN MOST CASES THE ENGINE CAN BE REPAIRED BY REPLACING A CONNECTING ROD, PISTON, AND CRANKSHAFT, AND ALL THE OTHER ASSOCIATED PARTS THAT ARE INVOLVED WITH THIS LEVEL OF DISASSEMBLY. IN SOME CASES THE CONNECTING ROD WILL BREAK AND DAMAGE THE BLOCK BEYOND REPAIR. THIS HAPPENED IN MY CASE. THE REPLACEMENT ENGINE WAS OVER $2000, NOT TO MENTION THE LABOR INVOLVED IN IT'S REPLACEMENT. FORD MOTOR COMPANY IS AWARE OF THIS DESIGN FLAW, AND HAS ISSUED A TECHNICAL SERVICE BULLETIN REGARDING IT. HOWEVER, TO THIS DAY THEY WILL STILL NOT OFFER ANY AID, IN ANY FORM, FOR DAMAGES INCURRED DUE TO THIS DESIGN FLAW. *NM