The defect
ON CERTAIN VANS, THE AIR FILTER ELEMENT MATERIAL PROCESS RESULTED IN AN AIR FILTER PAPER ELEMENT THAT CAN SMOLDER OR BURN. THIS CHANGE IN FILTER PAPER COMPOSITION COMBINED WITH THE CONFIGURATION OF THE AIR INDUCTION SYSTEM, MAY ALLOW HOT CARBON PARTICLES TO CONTACT THE AIR FILTER ELEMENT DURING CERTAIN DRIVING CONDITIONS THAT CREATE HOT PARTICLES.
The risk
THESE HOT PARTICLES MAY IGNITE THE AIR FILTER ELEMENT WITH THE POTENTIAL FOR AIR INDUCTION SYSTEM DAMAGE OR UNDERHOOD FIRE.
The remedy
DEALERS WILL INSPECT AND REPLACE THE AIR FILTER ELEMENT. THE RECALL BEGAN SEPTEMBER 27, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673. ALSO FORD IS EXTENDING THE LIMITED WARRANTY (FOR A ONE TIME REPLACEMENT) OF THE ABS MODULE FOR A TOTAL OF 10 YEARS OR 150,000 MILES FROM THE WARRANTY START DATE, WHICHEVER OCCURS FIRST. IF YOUR VEHICLE HAS ALREADY ACCUMULATED MORE THAN 150,000 MILES, THIS COVERAGE WILL LAST UNTIL SEPTEMBER 30, 2005.
NHTSA's own wording · initiated by MFR
Vehicles covered
| Model | Model years |
|---|---|
| Ford E-150 | 2003, 2004 |
| Ford E-250 | 2003, 2004 |
| Ford E-350 | 2003, 2004 |
| Ford E-450 | 2003, 2004 |
| Ford E-550 | 2003, 2004 |
Components: ENGINE AND ENGINE COOLING
Model years in this recall
NHTSA complaints and the number of recall campaigns for each model year this recall covers.
| Model | Year | Complaints | Recalls |
|---|---|---|---|
| Ford E-150 | 2003 | 21 | 5 |
| Ford E-150 | 2004 | 33 | 4 |
| Ford E-250 | 2003 | 17 | 6 |
| Ford E-250 | 2004 | 8 | 16 |
| Ford E-350 | 2003 | 46 | 6 |
| Ford E-350 | 2004 | 46 | 9 |
| Ford E-450 | 2003 | 18 | 4 |
| Ford E-450 | 2004 | 27 | 3 |
| Ford E-550 | 2003 | 1 | 4 |
| Ford E-550 | 2004 | 1 | 2 |
Other engine and engine cooling recalls in 2004
30 of the 601 recall campaigns reported to NHTSA in 2004 concerned the engine and engine cooling; FORD MOTOR COMPANY filed 963 campaigns in all.
| 04V543000 12 Nov 2004 | ORION BUS INDUSTRIES LTD. |
| 04V544000 11 Nov 2004 | ORION BUS INDUSTRIES LTD. |
| 04V542000 10 Nov 2004 | MITSUBISHI CARIBBEAN |
| 04V515000 28 Oct 2004 | COACHMEN RV COMPANY, LLC |
| 04V529000 27 Oct 2004 | FOUR WINDS INTERNATIONAL |
| 04V516000 20 Oct 2004 | WINNEBAGO INDUSTRIES, INC. |
| 04V540000 20 Oct 2004 | SAAB CARS USA, INC. |
| 04V485000 7 Oct 2004 | GILLIG CORPORATION |
NHTSA recalls (public domain) · all recalls of 2004