NHTSA Complaint #10423166 — 2002 FORD CROWN VICTORIA

I HAD BEEN DRIVING 250 MILES OR SO AND DROVE DOWN A LONG WINDING INCLINE, AS THE ROAD FLATTENED OUT I HEARD A NOISE FROM THE ENGINE COMPARTMENT. THE NOISE SOUNDED LIKE A HOLE IN THE FIRST PART OF THE EXHAUST SYSTEM. I FOUND A SAFE PLACE TO PULL OVER AND TURNED OFF THE VEHICLE. THERE WAS A SLIGHT ODOR OF NATURAL GAS AS THIS VEHICLE IS FUELED WITH NATURAL GAS. AFTER THE ODOR PASSED, I OPENED THE HOOD TO FIND THAT THE #2 IGNITION COIL MOUNT WAS BROKEN, AND THE COIL AND SPARK PLUG ASSEMBLY WERE LOOSE IN THE SPARK PLUG WELL. MY INITIAL THOUGHT WAS THE SPARK PLUG HAD LOOSENED AND EJECTED. I ATTEMPTED TO RE-INSTALL THE SPARK PLUG BUT THE THREADS IN THE CYLINDER HEAD WERE INEFFECTIVE. THE SPARK PLUG HAD BLOWN OUT OF THE CYLINDER HEAD. I HAVE SUBSEQUENTLY FOUND OUT THAT THIS IS NOT AN UNCOMMON DEFECT FOR THESE FORD ENGINES. THE REPAIR INVOLVED REAMING AND TAPPING THE SPARK PLUG HOLE AND PLACING AN INSERT IN THE HOLE. THE SPARK PLUG COIL HAD TO BE REPLACED TOO. THE REPAIR COST WAS $450 AND THE REPAIR SHOP WARNED THAT THIS MAY HAPPEN AGAIN. THIS IS A DESIGN DEFECT THAT COULD POTENTIALLY BE DANGEROUS UNDER DIFFERENT CIRCUMSTANCES. IF I WAS NOT ABLE TO STOP IN A SAFE PLACE FAIRLY QUICKLY, THERE COULD HAVE BEEN MORE FUEL AIR MIXTURE ACCUMULATION UNDER THE HOOD AND SINCE THE SPARK PLUG WAS STILL OPERATIVE, AN IGNITION SOURCE WAS PRESENT TOO. *TR