Ford F-150 Lightning



Table of contents:
Ford F-150 Lightning 2003 recalls
CampaignManufacturerManufacturing dateType# of units affectedDate Owner notified MfgRecall Initiated byManufacturers of recalled vehicles/productsReport Recieved DateRecord Creation DateRegulation Part NumberFMVSS Number
VEHICLE SPEED CONTROL
07V336000FORD MOTOR COMPANYfrom 11/05/2002 to 05/18/2004V (Vehicle)360000008/13/2007ODIFORD MOTOR COMPANY08/03/200708/03/2007
Defect SummaryOn certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn.
Consequence SummaryThis could result in an underhood fire.
Corrective SummaryDealers will install a fused wiring harness. owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. as soon as repair parts are available (expected october 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. the recall began on august 13, 2007, and mailing completed by september 19, 2007. owners may contact ford at 1-888-222-2751.
NotesFord recall no. 05s28.customers may also contact the national highway traffic safety administration;s vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov.
Ford F-150 Lightning 2003 investigations
NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
FUEL SYSTEM, OTHER
PE08063FORD MOTOR COMPANY10/31/200802/27/2009CNG REGULATOR LEAK
 The agency has closed this investigation based on its review of complaint reports, discussions with complainants and field and technical data provided by ford.the subject vehicles are 1/2 ton pickup trucks and are natural gas vehicles (ngv) that are fueled by gasoline or compressed natural gas.the agency has received reports alleging improper operation of the natural gas fuel pressure regulator allowing release of excess amounts of natural gas into the engine compartment.ford reports that the regulator contains an over pressure relief valve that will vent natural gas should the pressure exceed a set threshold.the complaint reports and data reviewed by the agency indicate that an improperly operating pressure regulator can result in an overpressure condition and activate the regulator pressure relief valve.the released natural gas is directed through a vent hose that discharges the natural gas in the vicinity of the right front wheel house and away from the engine compartment's extremely hot areas/surfaces.owners are normally aware of this problem by the presence of an illuminated warning light inside the vehicle, odor of natural gas or the sound of venting gas.when the operator turns the engine off, the natural gas supply tank solenoid will close and the regulator will not release natural gas.at vehicle restart, the solenoid valve will remain closed to prevent leakage and the vehicle will only operate in the gasoline mode.a safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.accordingly, this investigation is closed.the closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist.the agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.
FUEL SYSTEM, OTHER - DELIVERY
PE08063FORD MOTOR COMPANY10/31/200802/27/2009CNG REGULATOR LEAK
 The agency has closed this investigation based on its review of complaint reports, discussions with complainants and field and technical data provided by ford.the subject vehicles are 1/2 ton pickup trucks and are natural gas vehicles (ngv) that are fueled by gasoline or compressed natural gas.the agency has received reports alleging improper operation of the natural gas fuel pressure regulator allowing release of excess amounts of natural gas into the engine compartment.ford reports that the regulator contains an over pressure relief valve that will vent natural gas should the pressure exceed a set threshold.the complaint reports and data reviewed by the agency indicate that an improperly operating pressure regulator can result in an overpressure condition and activate the regulator pressure relief valve.the released natural gas is directed through a vent hose that discharges the natural gas in the vicinity of the right front wheel house and away from the engine compartment's extremely hot areas/surfaces.owners are normally aware of this problem by the presence of an illuminated warning light inside the vehicle, odor of natural gas or the sound of venting gas.when the operator turns the engine off, the natural gas supply tank solenoid will close and the regulator will not release natural gas.at vehicle restart, the solenoid valve will remain closed to prevent leakage and the vehicle will only operate in the gasoline mode.a safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.accordingly, this investigation is closed.the closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist.the agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.
FUEL SYSTEM, OTHER - DELIVERY - HOSES, LINES/PIPING, AND FITTINGS
PE08063FORD MOTOR COMPANY10/31/200802/27/2009CNG REGULATOR LEAK
 The agency has closed this investigation based on its review of complaint reports, discussions with complainants and field and technical data provided by ford.the subject vehicles are 1/2 ton pickup trucks and are natural gas vehicles (ngv) that are fueled by gasoline or compressed natural gas.the agency has received reports alleging improper operation of the natural gas fuel pressure regulator allowing release of excess amounts of natural gas into the engine compartment.ford reports that the regulator contains an over pressure relief valve that will vent natural gas should the pressure exceed a set threshold.the complaint reports and data reviewed by the agency indicate that an improperly operating pressure regulator can result in an overpressure condition and activate the regulator pressure relief valve.the released natural gas is directed through a vent hose that discharges the natural gas in the vicinity of the right front wheel house and away from the engine compartment's extremely hot areas/surfaces.owners are normally aware of this problem by the presence of an illuminated warning light inside the vehicle, odor of natural gas or the sound of venting gas.when the operator turns the engine off, the natural gas supply tank solenoid will close and the regulator will not release natural gas.at vehicle restart, the solenoid valve will remain closed to prevent leakage and the vehicle will only operate in the gasoline mode.a safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.accordingly, this investigation is closed.the closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist.the agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.
FUEL SYSTEM, OTHER - FUEL INJECTION SYSTEM
PE08063FORD MOTOR COMPANY10/31/200802/27/2009CNG REGULATOR LEAK
 The agency has closed this investigation based on its review of complaint reports, discussions with complainants and field and technical data provided by ford.the subject vehicles are 1/2 ton pickup trucks and are natural gas vehicles (ngv) that are fueled by gasoline or compressed natural gas.the agency has received reports alleging improper operation of the natural gas fuel pressure regulator allowing release of excess amounts of natural gas into the engine compartment.ford reports that the regulator contains an over pressure relief valve that will vent natural gas should the pressure exceed a set threshold.the complaint reports and data reviewed by the agency indicate that an improperly operating pressure regulator can result in an overpressure condition and activate the regulator pressure relief valve.the released natural gas is directed through a vent hose that discharges the natural gas in the vicinity of the right front wheel house and away from the engine compartment's extremely hot areas/surfaces.owners are normally aware of this problem by the presence of an illuminated warning light inside the vehicle, odor of natural gas or the sound of venting gas.when the operator turns the engine off, the natural gas supply tank solenoid will close and the regulator will not release natural gas.at vehicle restart, the solenoid valve will remain closed to prevent leakage and the vehicle will only operate in the gasoline mode.a safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.accordingly, this investigation is closed.the closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist.the agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.
Ford F-150 Lightning 2003 Consumer Complaints
Fail datemilesoccurencesPurchase date
ENGINE AND ENGINE COOLING
02/28/201155000
 Nothing caused this failure other than factory defect. i problem i have had is the sparkplug blow out of my vehicles cylinders it has happened on 3 seperate occasions. leaving me stranded. also all 3 times i have had to buy new spark coils and spark plugs, this last time it ruined the treads in the block costing over $800 to repair. i do have the old parts
10/01/2008695831
 On 10/1/08 i was coming out of a parking lot and heard a loud popping sound. loss of power and ran rough . it was almost dark so i could not see what was wrong so i drove it the two miles home, along the side of the road. next morning i took the truck to holder ford in lakeport, california and they said i had blown out the rear plug on the passenger side of the engine. they repaired it for $715.00 and i got it back on monday 10/6/08. again on 10/11/08 saturday the same plug blew out. this time i was in the fast lane of the freeway in san rafael heading for san francisco. the truck lost power and every time i backed off the gas the engine died. i fought with the truck to get it started and keep it running to get it across three lanes of bumper to bumper traffic to an off ramp. when i stopped and raised the hood i saw it was the same plug that was just repaired. i called holder ford and they said service was closed and there was nothing they could do for me until monday. i drove the car to a toyota dealer only to find the ford dealer had gone out of business there so i called a tow truck and rented a car. i was 150 miles from holder ford and my towing would only allow 100 miles. besides this blown spark plug almost causing an accident it cost me $400.00 for the tow and i don't know how much for a rental car. now i find out there are only three threads in the head to hold the plugs in, and the heads are aluminum. the truck is a 2003 ford f150 lightning 5.4 triton v8 with 70,000 miles. *tr
SERVICE BRAKES, HYDRAULIC
09/01/2008155001
 Anti-lock brake failure - failure of electronic hydraulic control unit while braking a few weeks ago i was driving on a highway at about 65-70 mph when a car on the side of the road started to pull onto the highway. i was only about 200 feet away from the car so i slammed on my brakes - it seemed like the car was going to stop pulling out so i let go of the brakes for a second but then the other drive did pull right in front of me and i slammed on the brakes again. the second time the abs light came on, the rear wheels locked up and the car began to fishtail. only because there wasn't any oncoming traffic was a collision avoided. the light never turned off, and the brakes behave erratically. a friend is a mechanic who used a snap-on solus diagnostic tool which shows the abs dhcu sees the car moving at 3-4 mph while parked, the system off, but when you drive the car it applies the abs system while slowing below about 5mph under normal driving (like approaching a stop light) increasing the stopping distance considerably. the module does not respond to reset attempts, and repair is by replacement only. the car is a special production ford f150 lightning, with a dhcu specific to the lightning edition. replacement of the module is about $700 plus labor. the vehicle only has 16,000 miles on it, about 15,500 when the incident occurred. *tr
SERVICE BRAKES, HYDRAULIC - ANTILOCK
09/01/2008155001
 Anti-lock brake failure - failure of electronic hydraulic control unit while braking a few weeks ago i was driving on a highway at about 65-70 mph when a car on the side of the road started to pull onto the highway. i was only about 200 feet away from the car so i slammed on my brakes - it seemed like the car was going to stop pulling out so i let go of the brakes for a second but then the other drive did pull right in front of me and i slammed on the brakes again. the second time the abs light came on, the rear wheels locked up and the car began to fishtail. only because there wasn't any oncoming traffic was a collision avoided. the light never turned off, and the brakes behave erratically. a friend is a mechanic who used a snap-on solus diagnostic tool which shows the abs dhcu sees the car moving at 3-4 mph while parked, the system off, but when you drive the car it applies the abs system while slowing below about 5mph under normal driving (like approaching a stop light) increasing the stopping distance considerably. the module does not respond to reset attempts, and repair is by replacement only. the car is a special production ford f150 lightning, with a dhcu specific to the lightning edition. replacement of the module is about $700 plus labor. the vehicle only has 16,000 miles on it, about 15,500 when the incident occurred. *tr