NHTSA Complaint #753886 — 1996 FORD TAURUS

THE CAR BEGAN MAKING A TICKING SOUND FROM THE VALVE TRAIN AREA. THIS NOISE BECAME MUCH LOUDER OVER A PERIOD OF WEEKS. I TOOK IT TO THE DEALER WHO DIAGNOSED IT AS A LOOSE SPROCKET ON THE REAR BANK INTAKE CAMSHAFT. AS A MEMBER OF THE V8SHO ORGANIZATION (WWW.V8SHO.COM), I AM AWARE OF THIS PROBLEM AND IT'S MANY OCCURRENCES. THERE ARE NOW OVER 30 REPORTS OF THIS EXACT PROBLEM (WITH OCCURRENCES ON ANY ONE OF THE 4 CAMS), AND 14 REPORTED FAILURES IN THE MONTH OF OCTOBER, 2001 ALONE! THIS IS A DESIGN FLAW AS THE SPROCKET IS MERELY "PRESSED" ONTO THE CAMSHAFT WITH NO OTHER MEANS OF ATTACHMENT. OVER TIME, THE CONNECTION WORKS LOOSE CAUSING THE OFFENDING CAMSHAFT TO SPIN FREELY, THUS ALLOWING THE VALVES TO COME IN CONTACT WITH THE PISTONS, CAUSING COMPLETE ENGINE FAILURE. FORTUNATELY, I WAS ABLE TO CATCH THIS ON MY ENGINE PRIOR TO COMPLETE FAILURE. MYSELF AND NUMEROUS OTHERS HAVE CONTACTED FORD DIRECTLY WITH LITTLE SUCCESS ON THEIR OWNING UP TO THE PROBLEM. THE DEALER'S FIX IS USUALLY TO REPLACE THE CAMSHAFT(S) AT A COST OF $1080 EA., FOR PARTS ALONE! THAT IS A TEMPORARY SOLUTION AS THE OWNER IS STILL LEFT WITH A DESIGN FLAW, REGARDLESS OF THE FACT THAT IT'S A NEW CAMSHAFT. MY BILL WILL BE IN THE NEIGHBORHOOD OF $2000+ AND THAT'S WITHOUT THE SPROCKET ACTUALLY COMING LOOSE! FORD NEEDS TO BE HELD ACCOUNTABLE FOR THIS GROSSLY NEGLIGENT DESIGN FLAW!*AK