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Coil-On-Plug, C.O.P.s, ignition coils ALERT

UPDATE: July 1, 2008 - 2004 and 2005 owners have started receiving the letter from Ford explaining the extended warranty on the coil-on-plugs. 

UPDATE:  June 16, 2008 - It now appears that Ford has extended the following warranty to owners of 2004 and 2005 Thunderbirds.  Check with your dealer to find out what is covered by having them run an OASIS report on your VIN# if you have an 04 or an 05. The status of 2002 owners is still the same - no extra coverage. 

The following letter (from July 2007) has come out from Ford to Ford dealerships for 2003 Thunderbird and Lincoln LS owners.  At this time, it does not cover the 2002 or the 2004 or the 2005 Thunderbird BUT SHOULD in my humble opinion!  My 2002 has had all 3 (three) of the problems mentioned in the letter while under extended warranty.

 There is an effort on www.thunderbirdnest.com to have that remedied and it requires help from all 2002 to 2005 Thunderbird owners that have had c.o.p. issues.  Please read Earl aka 007161947 messages on the forum.  The issue and a poll is being discussed in the technical garage forum so you must join thunderbirdnest to participate in the poll and the discussion.  You may also discuss it here and I'll post more info here as it becomes available.

Here is the Ford letter to dealers.  (owners of 2003s are getting a customer version of the letter):

-------------------------------------------------------------- 

Frank M. Ligon
Director
Service Engineering Operations
Ford Customer Service Division

Ford Motor Company
P.O. Box 1904
Dearborn, Michigan 48121

July 3, 2007

TO: All U.S. Ford and Lincoln Mercury Dealers

SUBJECT: Customer Satisfaction Program 07M07
Certain 2003 Model Year Lincoln LS and Ford Thunderbird Vehicles Equipped With 3.9L Engine - Extended Warranty Coverage on Ignition Coil Assemblies and Engine Valve Cover Gaskets

PROGRAM TERMS

This program extends the warranty coverage of the ignition coils and engine valve cover gaskets to 10 years of service from the warranty start date of the vehicle or 100,000 miles, whichever occurs first. For vehicles that have accumulated more than 100,000 miles, coverage will last until December 31, 2007. Coverage is automatically transferred to subsequent owners.

VEHICLES COVERED BY THIS PROGRAM

Certain 2003 model year Lincoln LS and Ford Thunderbird vehicles equipped with 3.9L engine built at the Wixom Assembly Plant from Job 1 through Job Last. Affected vehicles are identified in OASIS.

REASON FOR PROVIDING EXTENDED WARRANTY COVERAGE

Some of the affected vehicles may experience an engine misfire condition predominantly due to internal breakdown in the coil and lack of adhesion between the epoxy and the coil housing material. These issues may cause the coil to operate at an insufficient voltage level, resulting in ignition coil misfires. In addition, on some of these vehicles, the valve cover gaskets may allow engine oil to enter the spark plug well and cause degradation of the ignition coil boot, resulting in ignition coil misfire. Drivability symptoms associated with an ignition coil misfire include rough running engine, surge or hesitation on acceleration, and/or illumination of the check engine light.

SERVICE ACTION

If any of the above mentioned drivability issues are reported on an affected vehicle, dealers are to identify any engine cylinder that is misfiring and perform an ignition coil stress test on the affected cylinders. If the coil fails the stress test, dealers are to replace the ignition coil and associated spark plug. If any coil boot is contaminated with engine oil, dealers are to contact the Special Service Support Center for prior approval to replace the contaminated ignition coil boot, the associated spark plug and install a new valve cover gasket set. This service will be performed on affected vehicles at no charge to the vehicle owner.

NOTES:


This extended warranty coverage program only applies to ignition coil assemblies and valve cover gaskets. During diagnosis, if other concerns or DTC's are found, they will not be covered under this program and are the responsibility of the vehicle owner, if the vehicle has exceeded the time or mileage limits of all other warranty coverages (NVLM/Emissions/Extended/etc.). Owners who received letters announcing 07M07, and who bring their vehicles into the dealership because of an engine misfire condition, should be advised that this program only covers the cost of repairs related to defective ignition coils or valve cover gaskets that are allowing oil to enter the coil on plug wells.
Other repairs are not covered by this program.
COILS CONTAMINATED WITH WATER: If any coils are contaminated with water, dealers should perform Field Service Action 07N09 after performing this program (07M07).
ATTACHMENTS

Attachment I: Administrative Information
Attachment II: Labor Allowances and Parts Ordering Information
Attachment III: Technical Information

Customer Notification Letter


Also:

Frank M. Ligon
Director
Service Engineering Operations
Ford Customer Service Division

Ford Motor Company
P.O. Box 1904
Dearborn, Michigan 48121

July 3, 2007

TO: All U.S. Ford and Lincoln Mercury Dealers

SUBJECT: Customer Satisfaction Program 07N09
Certain 2003 Model Year Lincoln LS and Ford Thunderbird Vehicles Equipped With 3.9L Engine - Extended Warranty Coverage on Ignition Coil Covers and Wiper Motor Bracket Seal

PROGRAM TERMS

This program extends the warranty coverage of the ignition coil covers and the wiper motor bracket seal to 10 years of service from the warranty start date of the vehicle or 100,000 miles, whichever occurs first. For vehicles that have accumulated more than 100,000 miles, coverage will last until December 31, 2007. Coverage is automatically transferred to subsequent owners.

VEHICLES COVERED BY THIS PROGRAM

Certain 2003 model year Lincoln LS and Ford Thunderbird vehicles equipped with 3.9L engine built at the Wixom Assembly Plant from Job 1 through Job Last. Affected vehicles are identified in OASIS.

REASON FOR PROVIDING EXTENDED WARRANTY COVERAGE

On some of the affected vehicles, the water management system may allow rain water to be directed toward the ignition coils which, may result in internal contamination of the coils, and possibly lead to premature failure of the ignition coil assemblies.

SERVICE ACTION

If evidence of water contamination is found on the ignition coils or in the spark plug wells, dealers are authorized to perform the service procedure described in Attachment III. This service will be performed on affected vehicles at no charge to the vehicle owner.

NOTE: If engine oil is found in the coil on plug wells, dealers should call the Special Service Support Center at xxxxxxxxxxx.

ATTACHMENTS

Attachment I: Administrative Information
Attachment II: Labor Allowances and Parts Ordering Information
Attachment III: Technical Information

Customer Notification Letter

 

 


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Comments

None that I am aware of, bobby.

Is their and after market of metal valve covers for the 2002 ford thunderbird? If so where they be ordered?

Nick,
I don't know about the V6. I assume you're talking about the Lincoln LS. Suggest that you visit the cadillac vs lincoln forum and inquire there.

Is there any way that the issue with the COPs and valve cover gaskets is not only on the v8, but the v6 as well for 2003 model year? I bought the car with 40k miles on it in december of 06. Since then I have replaced 4 of the 6 COPs and found oil on the boot on one of them. The car now has 96k miles. I haven't done the valve cover gaskets yet, as the car seems to be running ok as of now, but my DTC light is on constantly. If I reset it, it comes back on within 30-40 miles. I need to do the gaskets next, but don't have the money right now. If it's found that this issue pertains to the v6 as well as v8 I'd like to know so I can have it all replaced now before things get worse or the car starts running horribly again. Thanks!

Dee Dee,
sorry for the late response.

You do not say if any of those dealers have already checked the coils?
At this point, take it to a Lincoln dealer. It may cost more if they find it's not the coil on plugs but they have much more experience with the engine in these cars than the vast majority of Ford dealers. and if it is a coil on plug issue, it's covered by the extended coil warranty for the 03s.

my t-bird is an 03 and i have been having all three problems since 06. i purchased the vehicle in April 04. To this day I'm still experiencing the same problems. took it ti Beasley Ford in York, pa now their telling me its the Fuel Injectors. 6 are bad 2 are good. stress/flow test the car and now it's shaking real bad. wasnt doing that before i drop the car off. towed the car to another Ford Dealor and this one is telling they have do another test and it "he thinks" its the cataliac converter. called customer service, can't no customer service. $400 later the car isn't fixed. no one even mentioned the extended warranty. Is there a way I can talk to Frank Ligon? and what should i do now. i want this problem resolved.

I've added the customer letter from Ford (a little bit garbled though) to my site "problems" page.
You'll find it here:
http://www.portholeauthority.com/thenewtbird/care/problems.html

To answer your question, Gerald, no V8 emblems were put on the 02s at the factory - It was not part of the design for the 02. If you bought yours new then the dealer added it on. If you bought used, then the previous owners added it on. It was a popular add-on for owners to do to their 02s. There are several styles of V-8 emblems that have been used such as the oem emblem from the 03s & the V-8 emblem from the Ford Exlorer. Others have gone back even further and used a 55 fender emblem. Even one has used an emblem from a 60s Thunderbird.

Gerald,

Yes, it's possible your 2002 was made late in the year but the 2003 was a different engine and its not possible yours has a 2003 engine.

Now that I know you have a 2002 give me the last five digits of your VIN and I'll tell you exactly when your car was built.

I'm retired from Ford, although I don't speak for them, allow me to make a guess.

My guess is that there was a problem unique to the 2003s, a bad batch of supplier parts or the new 2003 variable valve timing engine design, that caused a much greater failure rate than the other years. This increased failure rate triggered the extended coverage. That is not to say there wasn't a problem other years, just that it wasn't as severe. Apparently after the 2003s the problem was corrected (at least partially) and the improved reliability dropped failures below the threshold that would trigger extended coverage for those years.

And yes, much greater cost is the reason Ford doesn't cover all years. And also the reason they don't cover every single thing that goes wrong with every car they ever made.

Harry

I have a 2002 T-Bird and I have V8 on the fender. Your web site states that it is on 2003s. I s it possible that mine was made late in the year?

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