1997 Ford F150 with 4.2L engine. Started car in the morning. Made a grinding sound and stopped it. Restarted the motor and it rattling loudly and stopped it again. The number one piston bent the connecting rod.

- Memphis, TN, USA

Manifold studs rusted away causing exhaust pipe to separate from manifolds. As a result of this failure, emissions portion of nys inspection was failed. Repair is required to pass inspection, and is estimated by new country Ford to be approximately $2200. I believe this to be an excessive expense as a result of the manufacturers poor design and quality of parts.

- Scotia, NY, USA

My 1997 Ford F150 with 4.2L V-6 manifold gasket failed which caused coolant to leak into cylinders. Without any warning, at cold start the coolant in the cylinders caused pistons/rod to break and engine suddenly began loud knocking and pouring white smoke out of exhaust. This truck has been meticulously maintained and has never been driven hard. Local repair shop says the local machine shop they use for rebuilds has seen at least 24 of these engines since January 1st, 2003! estimates to rebuild or replace this engine range from $2,000 to $4,000. We have not yet decided what to do - scared to get new engine from Ford because same problem may still be present.

- Warrenville, SC, USA

Consumer states the exhaust is located at the right side, causing the tires to overheat and blow up. In July Firestone wilderness ht size 23570R16 dot W2081pt were replaced by Goodyear, and problem still recurring. Dealer stated nothing was wrong with the exhaust pipe. Consumer indicated that Firestone diagnosis was that tire blew up due to overheating.

- Deland, FL, USA

The truck was built with the exhaust exiting in front of the right rear tire, which caused excessive heat to the tire and a burning smell. The hub caps and wheels were discolored, and the rear axle seal leaked, all these problems were caused by the defective exhaust system which was due to the extreme heat. The rear oil seal leaked oil.

- Unionville, MI, USA

Goodyear tire had low pressure, causing them to blowout. In addition, consumer replaced wheels:cap/cover/hub, and exhaust system.

- Unionville, MI, USA

With no previous indications that anything was wrong, upon starting engine heard loud clacking sound, shut off and towed to mechanic. Who said it was an internal problem that could only be fixed by Ford dealership or a machine shop. It was a holiday so we took it to a machine shop who verified his previous encounter with the same model engine before that a rod was bent which cracked the piston, caused from a "defect in Ford's intake head gasket", which leaked water into the engine. He also stated one more crank or run a little longer the piston would have shattered and gone through the crank shaft which could have endangered anyone in it's range (hwy, etc.). the engine is now being repaired and when Ford was contacted they denied any problem with the gasket and any responsibility. The machine shop has a "service notification" that the gasket has been replaced with one that will not leak. This is a very costly defect that could have been prevented if Ford had sent notice to owner's. I feel Ford should own up to their defective part and pay for costs owner's like myself have encountered. I have a notice of recall for a different gasket leaking coolant which was replaced by the Ford dealership, #99B29.

- Pearl River, LA, USA

Exhaust on rear rim which has caused the rim to start pitting and may cause failure.

- Arkansas City, KS, USA

Doors have stress cracks at the lower right sides dealer repaired once, but cracked before I picked it up, exhaust fumes entering car and discoloring R-rr wheel.

- Westmont, IL, USA

Initial failure- engine cranks, but wouldn't start. Local dealershjip replaced PCM twice, replaced spark plugs, throttle position sensor, trans shift solenoid, timing cover gasket, radiator.. when vehicle return to customer, it still was not running prope

- Braintree, MA, USA

Ford exhaust design is routed in front of right rear tire. The exhaust gases cause the lug nuts, studs, and brake drum to corrode causing poor brake response and possibly wheel failure.

- Catawissa, MO, USA

While driving vehicle, fire came up from between the cab and bed of truck. Fire investigators came to the conclusion that there is a design flaw in this model truck which allows debris to accumulate under the shield which then ignited, and then ignited the silicone sealer on the shield which allowed the fire to ignite the back seat.

- Little Rock, AR, USA

Grass and weeds get caught in cross over brace under exhaust system, as they pack in they dry out, causing fire. (qcaw)

- Garland, TX, USA

Weeds pack up in and around cross member of cross over exhaust system, which leads to a drying out of weeds, resulting in fires. (qcaw)

- Garland, TX, USA

Location of exhaust system in front of passenger's side causes the ABS brakes to freeze up in winter. Have not taken to dealer as of yet.

- Willow Lake, SD, USA

Consumer took vehicle to dealership to replace right rear wheel/right hub cap/bumper and exhaust system. All parts replacment was due to exhaust system being in the way, which caused corrosion to all above parts. Consumer confronted the servicemen about condition reoccurring. His reply was that after the warranty expired, it became consumer's problems. Dealer notified

- Presque Isle, WI, USA