NHTSA owner reports · September 18, 2026 snapshot.
Electrical System complaints
96 reportsClear category filter128,000 miles · Sep 29, 2014
Electrical SystemVehicle Speed Control
WHILE TRAVELING AT A SPEED OF 60 MPH DOWN THE HIGHWAY, I LOST ALL POWER TO MY EDGE. THE SPEEDOMETER WENT TO 0, MILEAGE BLANKED OUT, AND I HAD THE AIR BAG, WRENCH & LOW TIRE PRESSURE LIGHTS CAME ON. WHEN YOU WOULD GO FROM PARK TO REVERSE OR FROM PARK TO DRIVE, THERE WOULD BE A BIG CLUNKING NOISE AND NO ACCELERATION. WHEN THIS …
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WHILE TRAVELING AT A SPEED OF 60 MPH DOWN THE HIGHWAY, I LOST ALL POWER TO MY EDGE. THE SPEEDOMETER WENT TO 0, MILEAGE BLANKED OUT, AND I HAD THE AIR BAG, WRENCH & LOW TIRE PRESSURE LIGHTS CAME ON. WHEN YOU WOULD GO FROM PARK TO REVERSE OR FROM PARK TO DRIVE, THERE WOULD BE A BIG CLUNKING NOISE AND NO ACCELERATION. WHEN THIS FIRST HAPPENED YOU COULD TURN THE CAR OFF AND IT WOULD RESET AFTER A FEW MINUTES. NOW YOU HAVE TO UNHOOKED THE BATTERY CABLES AND REPLACE THEM, BUT THIS ONLY LASTS FOR A WHILE. IT IS NOT A FIX. THIS IS STILL HAPPENING TO THIS DAY. NO ONE WE HAVE CONTACTED CAN TELL US THE PROBLEM. PLEASE HELP IF YOU CAN. *TR
NHTSA ODI #10640026
Mileage unknown · Sep 23, 2014
Electrical SystemEnginePower Train
CAR IS SKIPPING OR JERKING WHEN GOING UP HILLS. HAPPENS MULTIPLE TIMES WHEN CAR IS MOVING UP HILLS. MOST LIKELY TRANSMISSION PROBLEM OR SENSOR PROBLEM. *TR
NHTSA ODI #10638482
32,000 miles · Sep 4, 2014
Electrical System
THE DOOR AJAR SENSOR IS MALFUNCTIONING. THE DOOR IS CLEARLY SHUT, BUT THE DOOR AJAR LIGHT SHOWS ON DASH BOARD ALONG WITH THE INTERIOR LIGHTS STAYING ON. THE MAIN CONCERN IS WHEN THE DOOR AJAR LIGHT / SENSOR IS MALFUNCTIONING, THE DOOR WILL NOT AUTOMATICALLY LOCK. EVEN IF YOU PUSH THE DOOR LOCK BUTTON, THE DOORS WILL NOT LOCK. TH…
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THE DOOR AJAR SENSOR IS MALFUNCTIONING. THE DOOR IS CLEARLY SHUT, BUT THE DOOR AJAR LIGHT SHOWS ON DASH BOARD ALONG WITH THE INTERIOR LIGHTS STAYING ON. THE MAIN CONCERN IS WHEN THE DOOR AJAR LIGHT / SENSOR IS MALFUNCTIONING, THE DOOR WILL NOT AUTOMATICALLY LOCK. EVEN IF YOU PUSH THE DOOR LOCK BUTTON, THE DOORS WILL NOT LOCK. THIS IS A MAJOR SAFETY ISSUE, BECAUSE CHILDREN CAN OPEN THE DOOR OR A STRANGER CAN HOP IN THE CAR. SUPPOSEDLY THIS IS AN ISSUE WITH A LOT OF FORD'S, AND NEEDS TO BE ADDRESSED OR RECALLED. *TR
NHTSA ODI #10630590
Mileage unknown · Aug 7, 2014
Electrical SystemExterior Lighting
UPON REPLACING A BURNED OUT TAIL LITE I NOTICED THE SOCKET WHICH HOLDS THE BULB WAS MELTED. THIS HAS HAPPENED ON BOTH SIDES OF TAIL LITES. *TR
NHTSA ODI #10619531
79,000 miles · Jul 30, 2014
Electrical SystemPower TrainVehicle Speed Control
DRIVING DOWN INTERSTATE HIGHWAY, SPEEDOMETER DROPS TO ZERO THEN DASH LIGHTS ALL COME ON. GET OFF HIGHWAY PULL OVER AND CAR DOES NOT MOVE. WAIT ABOUT 20 MINUTES, PUT CAR IN D, HEAR LOUD BANG, CAR LUNGES FORWARD A LITTLE THEN DRIVES NORMALLY. SECOND TIME IT HAPPENED WAS ON HIGHWAY AT @60MPH WHEN SAME THING HAPPENS, GET OFF HIGHWAY…
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DRIVING DOWN INTERSTATE HIGHWAY, SPEEDOMETER DROPS TO ZERO THEN DASH LIGHTS ALL COME ON. GET OFF HIGHWAY PULL OVER AND CAR DOES NOT MOVE. WAIT ABOUT 20 MINUTES, PUT CAR IN D, HEAR LOUD BANG, CAR LUNGES FORWARD A LITTLE THEN DRIVES NORMALLY. SECOND TIME IT HAPPENED WAS ON HIGHWAY AT @60MPH WHEN SAME THING HAPPENS, GET OFF HIGHWAY AND STOP AT 2ND RED LIGHT WHEN THE CAR DOES NOT MOVE AT ALL. LET CAR SIT FOR @10 MIN. THEN IT STARTS GOING @10MPH, AFTER ABOUT 1 MILE RESUMES NORMAL OPERATION. HAVE BROUGHT TO LOCAL FORD DEALER AND HAD 2 SENSORS REPLACED ALONG WITH A TRANSMISSION FLUID EXCHANGE BUT NOW TODAY IT HAPPENED AGAIN WHEN I STOPPED AT BUSY BACK ROAD INTERSECTION THEN TRIED TO RESUME SPEED THE VEH. WOULD NOT MOVE. E-MAILED LOCAL FORD DEALER TO LET THEM KNOW THAT ISSUE WAS HAPPENING ONCE AGAIN AFTER SENSORS WERE REPLACED. PRIOR TO FORD ALSO HAD SEARS LOOK AT VEH. WHERE THEY DETERMINED IT WAS A SENSOR BUT COULD NOT DETERMINE WHICH ONE. NOW THAT THE VEHICLE IS BACK TO ME IT ALSO SEEMS TO HAVE ALOT OF HESITATION ON WANTING TO GO. THIS VEHICLE HAS NEVER SEEMED TO BE THE BEST TRANSMISSION AND I HAVE A BIG CONCERN ABOUT HOW MANY OTHER PEOPLE HAVE SIMILAR ISSUES WITH THIS VEHICLE. I WONDER WHAT WOULD HAPPEN TO SOMEBODY WHO KEEPS DRIVING IT WITHOUT GETTING OFF THE ROAD? I AM CONCERNED FOR THE SAFETY OF MY FAMILY, MYSELF, OTHERS WHO OWN THIS VEHICLE, AND OTHERS ON THE ROADWAY AROUND THESE VEHICLES WHEN THERE IS A PROBLEM. THE POSTS I KEEP SEEING ALL REFLECT THE SAME ISSUE AND ALL TOO OFTEN THEY ARE TOLD THAT THEY CANNOT FIND ANYTHING WRONG WITH THE VEHICLE, WILL IT TAKE A MAJOR ACCIDENT OR DEATH FOR THIS CONCERN TO BE ADDRESSED? A VEHICLE SHOULD NOT KEEP STOPPING OR PRODUCING LOUD BANGS AFTER IT STOPS MOVING AND I THINK THERE APPEARS TO BE ENOUGH EVIDENCE FROM ENOUGH PEOPLE WHO HAVE VOICED THEIR ISSUES WITH THIS PROBLEM TO WARRANT IMMEDIATE ACTION ON THIS MATTER.
NHTSA ODI #10618541
60,000 miles · Jul 29, 2014
Electrical System
BOTH REAR BRAKE LIGHT SOCKETS HAVE BURNED AND CHARRED. PLASTIC IS MELTED. BULBS BURN OUT REPEATEDLY. FOUND OTHER COMPLAINTS ONLINE AND FOUND THE BEST SOLUTION WAS A CERTAIN BULB THAT HAD MORE GLASS AT THE BASE AND IT WAS RATED FOR A HIGHER VOLTAGE. THAT COMPANY HAS NOW DISCONTINUED THAT BULB AS OF JUNE 2014 SO NOW I AM UNSURE IF…
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BOTH REAR BRAKE LIGHT SOCKETS HAVE BURNED AND CHARRED. PLASTIC IS MELTED. BULBS BURN OUT REPEATEDLY. FOUND OTHER COMPLAINTS ONLINE AND FOUND THE BEST SOLUTION WAS A CERTAIN BULB THAT HAD MORE GLASS AT THE BASE AND IT WAS RATED FOR A HIGHER VOLTAGE. THAT COMPANY HAS NOW DISCONTINUED THAT BULB AS OF JUNE 2014 SO NOW I AM UNSURE IF IT WILL EVENTUALLY CATCH ON FIRE. I NOTICED THE PROBLEM SEVERAL YEARS AGO. THE BULBS BURN OUT A COUPLE OF TIMES A YEAR WITH THE REGULAR STORE BOUGHT BULBS. AGAIN, SOCKET AND END OF BULBS THAT COME IN CONTACT WITH THE SOCKET ARE VERY CHARRED AND MELTED. *JS
NHTSA ODI #10617451
131,000 miles · Jul 26, 2014
Electrical SystemExterior Lighting
TAIL LIGHT PLUGS ON BOTH SIDES WERE BURNED/ MELTED NEEDS REPLACED. *TR
NHTSA ODI #10616540
95,000 miles · Jul 18, 2014
Electrical SystemEnginePower Train
I WAS DRIVING MY 2007 FORD EDGE WITH 3 CHILDREN IN IT WHEN ALL OF A SUDDEN I LOST THE ABILITY TO NOT ONLY ACCELERATE BUT MY SPEED SUDDENLY FELL FROM 45 MILES AN HOUR TO 15 MILES AN HOUR WITHOUT ANY ABILITY TO ACCELERATE. MY CAR WAS IN A CONSTANT STATE OF SHAKING AND SPUTTERING AND INCREASED WHEN APPLYING THE BRAKES. THERE WAS SO…
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I WAS DRIVING MY 2007 FORD EDGE WITH 3 CHILDREN IN IT WHEN ALL OF A SUDDEN I LOST THE ABILITY TO NOT ONLY ACCELERATE BUT MY SPEED SUDDENLY FELL FROM 45 MILES AN HOUR TO 15 MILES AN HOUR WITHOUT ANY ABILITY TO ACCELERATE. MY CAR WAS IN A CONSTANT STATE OF SHAKING AND SPUTTERING AND INCREASED WHEN APPLYING THE BRAKES. THERE WAS SOMETHING SIGNIFICANTLY WRONG AND IT WAS PRETTY SCARY TO EXPERIENCE PARTICULARLY WITH 3 SMALL CHILDREN. I HAD THE CAR TOWED TO MY AUTOMOTIVE SERVICE COMPANY WHERE THE CAR'S SOFTWARE SYSTEM DISPLAYED CODES INDICATING TWO IGNITION CODES FAILED. SUBSEQUENTLY, THE SERVICE PROVIDER REPLACED ALL THE SPARK PLUGS AND TWO COILS. THE CAR WAS NOT FIXED AND IT WAS FURTHER DETERMINED THAT THE PCM BOARD IS SENDING EXTREMELY HIGH CURRENT TO THE IGNITION COILS AND COULD HAVE CAUSED AN ENGINE FIRE. THIS IS VERY DISTRESSING. FORD HAS ISSUED AN INTERNAL TSB ACKNOWLEDGING THIS ISSUE BUT HAS NOT ENACTED A RECALL. THE ESTIMATED COST TO REPLACE THE PCM, SPARK PLUGS AND COILS (6) IS APPROXIMATELY $3,000. ADDITIONALLY IN MY RESEARCH THERE IS A CLASS ACTION LAWSUIT THAT HAS BEEN FILED BY A GROUP OF FORD OWNERS. *TR
NHTSA ODI #10614661
63,436 miles · Jun 25, 2014
Electrical SystemPower TrainVehicle Speed Control
PULLING OUT INTO TRAFFIC AND EXPERIENCED VERY HARSH SHIFTING. THE TRANSMISSION SHUTTERED AND SHOOK, ALMOST REFUSING TO GO THROUGH THE INTERSECTION. *TR
NHTSA ODI #10605824
19,000 miles · May 9, 2014
Electrical SystemExterior Lighting
TAIL LIGHT BLINKERS ARE MELTING INTO THE SOCKETS. I HAVE TO REPLACE THE BULBS ONCE A YEAR BECAUSE THEY BLOW, I WAS ALSO TOLD BY A MECHANIC THAT THE REASON MY SPEAKER BLEW ON THE RIGHT SIDE OF THE CAR WAS DO TO EXTRA ELECTRICAL POWER. *TR
NHTSA ODI #10587409
Official recalls
5Mar 10, 2021
Ford Motor Company (Ford) is recalling certain 2007-2011 Ranger, 2006-2012 Fusion, Lincoln Zephyr, Lincoln MKZ, 2006-2011 Mercury Milan, 2007-2010 Ford Edge, and Lincoln MKX vehicles. The driver's side air bag inflator may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.
Consequence & remedy
Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.
Remedy: Ford will notify owners, and dealers will replace the driver-side airbag inflator or module with an alternate one, free of charge. Owner notification letters were mailed on April 9, 2021 for the passenger side, and November 14, 2022 for the driver side. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S12.
Feb 16, 2021
Ford Motor Company (Ford) is recalling certain 2005-2014 Mustang, 2004-2011 Ranger, 2009-2011 Mercury Milan, 2006 Ford GT, 2008-2012 Fusion, 2007-2010 Edge and Lincoln MKX, and 2009-2010 Lincoln MKZ vehicles. These vehicles may be equipped with a driver or passenger frontal air bag inflator used as a replacement service part, that may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.
Consequence & remedy
Consequence: In the event of a crash necessitating deployment of the frontal air bag, an inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Ford will notify owners, and dealers will inspect the driver and passenger air bag module, and replace either the module or the inflator, if necessary, free of charge. The recall began March 17, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S05.
Additional source detail variants (3)
Air Bags:frontal:passenger Side:inflator Module
Ford Motor Company (Ford) is recalling certain 2005-2014 Mustang, 2004-2011 Ranger, 2009-2011 Mercury Milan, 2006 Ford GT, 2008-2012 Fusion, 2007-2010 Edge and Lincoln MKX, and 2009-2010 Lincoln MKZ vehicles. These vehicles may be equipped with a driver or passenger frontal air bag inflator used as a replacement service part, that may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.
Consequence: In the event of a crash necessitating deployment of the frontal air bag, an inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Ford will notify owners, and dealers will inspect the driver and passenger air bag module, and replace either the module or the inflator, if necessary, free of charge. The recall began March 17, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S05.
Air Bags:frontal:driver Side:inflator Module
Ford Motor Company (Ford) is recalling certain 2005-2014 Mustang, 2004-2011 Ranger, 2009-2011 Mercury Milan, 2006 Ford GT, 2008-2012 Fusion, 2007-2010 Edge and Lincoln MKX, and 2009-2010 Lincoln MKZ vehicles. These vehicles may be equipped with a driver or passenger frontal air bag inflator used as a replacement service part, that may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.
Consequence: In the event of a crash necessitating deployment of the frontal air bag, an inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Ford will notify owners, and dealers will inspect the driver and passenger air bag module, and replace either the module or the inflator, if necessary, free of charge. The recall began March 17, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S05.
Air Bags:frontal
Ford Motor Company (Ford) is recalling certain 2005-2014 Mustang, 2004-2011 Ranger, 2009-2011 Mercury Milan, 2006 Ford GT, 2008-2012 Fusion, 2007-2010 Edge and Lincoln MKX, and 2009-2010 Lincoln MKZ vehicles. These vehicles may be equipped with a driver or passenger frontal air bag inflator used as a replacement service part, that may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.
Consequence: In the event of a crash necessitating deployment of the frontal air bag, an inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Ford will notify owners, and dealers will inspect the driver and passenger air bag module, and replace either the module or the inflator, if necessary, free of charge. The recall began March 17, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S05.
Jan 10, 2017
Ford Motor Company (Ford) is recalling certain 2012 Ford Fusion and Mustang and Lincoln Zephyr and MKZ vehicles originally sold, or ever registered, in Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands, or "Zone A." Additionally, unless included in "Zone A" above, Ford is recalling certain 2009 Ford Ranger, Edge, Fusion and Mustang, Lincoln MKX, MKZ and Zephyr and Mercury Milan vehicles originally sold, or ever registered, in Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia and West Virginia, or "Zone B." Additionally, unless included in "Zone A" or "Zone B" above, Ford is recalling certain 2007-2008 Ford Ranger, Edge and Lincoln MKX, 2006-2008 Ford Fusion, Mercury Milan, Lincoln Zephyr and MKZ, 2005-2008 Ford Mustang and 2005-2006 Ford GT vehicles originally sold, or ever registered, in the states of Alaska, Colorado, Connecticut, Idaho, Iowa, Maine, Massachusetts, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, Oregon, Rhode Island, South Dakota, Utah, Vermont, Washington, Wisconsin and Wyoming. These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the passenger frontal air bag, these inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.
Consequence & remedy
Consequence: An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.
Remedy: Owners are advised not to drive their vehicles until the repair has been performed. Ford will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. Interim letters informing owners of the recall and that parts are not yet available began mailing March 1, 2017. Owners will receive a second notice when remedy parts become available. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S01.
May 31, 2016
Ford Motor Company (Ford) is recalling certain model year 2007-2011 Ford Ranger vehicles, 2006-2011 Ford Fusion, Mercury Milan and Lincoln Zephyr/MKZ vehicles, 2007-2010 Ford Edge, Lincoln MKX vehicles, 2005-2006 Ford GT vehicles, and 2005-2011 Ford Mustang vehicles originally sold, or ever registered, in Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands, or "Zone A." Additionally, unless included in "Zone A" above, Ford is recalling certain model year 2007-2008 Ford Ranger, Edge and Lincoln MKX vehicles, 2006-2008 Ford Fusion, Mercury Milan and Lincoln Zephyr/MKZ vehicles, 2005-2006 Ford GT vehicles and 2005-2008 Ford Mustang vehicles originally sold, or ever registered, in Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia, or "Zone B." Any vehicle not included in "Zone A", or "Zone B" is not included in the safety recall. These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules, and used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the front air bags, these inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.
Consequence & remedy
Consequence: An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.
Remedy: Owners are advised not to drive their vehicles until the repair has been performed. Ford will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. Ford mailed interim letters informing owners that parts are not yet available on July 15, 2016. Owners will receive a second notice when remedy parts become available. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S01.
Oct 29, 2014
Ford Motor Company (Ford) is recalling certain model year 2007-2008 Lincoln MKX, and Ford Edge vehicles, manufactured June 15, 2006, to September 22, 2008, and originally sold, or currently registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin and the District of Columbia. Due to corrosion from salt water exposure such as from road salt use, the affected vehicles may leak fuel from the fuel tank seam weld under the tank mounting reinforcement brackets.
Consequence & remedy
Consequence: A fuel leak in the presence of an ignition source increases the risk of a fire.
Remedy: Interim notices were mailed to owners on December 12, 2014. The recall began on October 6, 2015. Dealers will inspect the vehicles and either clean and treat the fuel tank with a corrosion preventative or replace the tank, free of charge. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 14S22.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
2PE09031 · Front Suspension Lower Ball Joint
Opened Jul 13, 2009 · Closed Nov 19, 2009
Status: closed (inferred from source dates) · Suspension:front:control Arm:lower Ball Joint
ON JULY 13, 2009, THE OFFICE OF DEFECTS INVESTIGATIONS (ODI) OPENED PRELIMINARY EVALUATION PE09-031 TO INVESTIGATE ALLEGATIONS OF FRONT LOWER BALL JOINT SEPARATION IN MODEL YEAR (MY) 2007 AND 2008 FORD EDGE AND LINCOLN MKX VEHICLES.THE INVESTIGATION WAS BASED ON THREE OWNER COMPLAINTS ALLEGING THAT THE FRONT LOWER BALL JOINT SEPARATED AND CAUSED THE FRONT SUSPENSION TO COLLAPSE WHILE DRIVING.ODI ALSO IDENTIFIED INFORMATION RELATED TO THE ALLEGED DEFECT IN EARLY WARNING DATA SUBMITTED BY FORD.PRELIMINARY ANALYSIS INDICATED THAT THE FAILURES WERE RELATED TO THE PINCH BOLT USED TO SECURE THE FRONT LOWER BALL JOINT STUD TO THE STEERING KNUCKLE.ONE COMPLAINT ALLEGED THAT A CRASH OCCURRED WHICH RESULTED IN A MINOR INJURY.HOWEVER, NO ADDITIONAL INFORMATION COULD BE OBTAINED TO SUPPORT THIS CLAIM.INFORMATION PROVIDED BY FORD IN RESPONSE TO ODI'S INFORMATION REQUEST LETTER FOR PE09-031 INDICATE THAT IN EARLY MY 2007 PRODUCTION THERE WERE SOME ISSUES WITH THE FRONT LOWER CONTROL ARM BALL JOINT ASSEMBLY PROCESS.THE PINCH BOLTS USED WERE HAND STARTED AND HAD THE POTENTIAL TO CROSS THREAD AND NOT ACHIEVE PROPER CLAMP LOAD, POTENTIALLY RESULTING IN A LOOSE JOINT.IN NOVEMBER 2007, CHANGES WERE IMPLEMENTED TO CHASE AND CLEAN THE FIRST SIX THREADS OF THE BOLT TO PROVIDE EASIER HAND STARTING OF THE NUT AND ENSURE GOOD THREAD ENGAGEMENT BEFORE TIGHTENING. FORD ALSO IDENTIFIED ONGOING CONCERNS WITH THE POWER TRANSMISSION UNIT (PTU) SEALS AND FRONT SUSPENSION HYDRO-BUSHINGS ON THE SUBJECT VEHICLES, WHICH BOTH REQUIRE DISASSEMBLY OF THE FRONT LOWER BALL JOINT TO REPAIR.IF THE BALL JOINT IS NOT PROPERLY REASSEMBLED FOLLOWING SUCH SERVICE, THE JOINT MAY SEPARATE IN LATER SERVICE.FORD HAS PROVIDED ADDITIONAL INSTRUCTIONS AND NEW PINCH BOLTS TO THE PTU REPAIR KIT TO IMPROVE THE JOINT REASSEMBLY PROCESS. ODI'S ANALYSIS OF FAILURE DATA IDENTIFIED 31 INCIDENTS OF JOINT SEPARATION (WITH 12 SPECIFICALLY STATING THAT THEY OCCURRED WHILE DRIVING).REPAIR RECORDS FOR THESE 31 VEHICLES SHOWS THAT 28 INVOLVE SEPARATION OF THE JOINT ON THE PASSENGER (RIGHT) SIDE, WHICH IS THE SIDE THAT MUST BE DISASSEMBLED FOR PTU SERVICE.TWENTY-THREE OF THESE WERE FOUND TO HAVE BEEN PREVIOUSLY DISASSEMBLED FOR CONTROL ARM BUSHING SERVICE, PTU SERVICE OR OTHER TRANSMISSION REPAIR. THE EIGHT CLAIMS THAT DID NOT INVOLVE PRIOR SERVICE REPAIRS REQUIRING JOINT DISASSEMBLY ALL OCCURRED VERY EARLY IN VEHICLE LIFE, INDICATING THAT IT IS UNLIKELY THAT ANY JOINTS MANUFACTURED WITH LOOSE PINCH BOLTS ARE STILL IN SERVICE.ALL OF THESE JOINTS FAILED WITHIN 6 MONTHS IN SERVICE AND 10,000 MILES (THE MAXIMUM FAILURE MILEAGE IS 8,097 MILES).THERE HAVEN'T BEEN ANY SUCH FAILURES (I.E., NOT INVOLVING PRIOR SERVICE/DISASSEMBLY) SINCE DECEMBER 2008.THE RATE FOR INCIDENTS THAT DID NOT OCCUR FOLLOWING SERVICE AND, THUS, MAY BE RELATED TO THE MANUFACTURING PROCESS ISSUES IDENTIFIED BY FORD IS VERY LOW (2.5 PER 100,000 VEHICLES) AND THESE INCIDENTS OCCURRED VERY EARLY IN THE LIFE OF THE VEHICLES AND ARE NOT SHOWING A CONTINUING FAILURE TREND.ACCORDINGLY, THIS INVESTIGATION HAS BEEN CLOSED. THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.
PE08060 · Tire Valve Cracking
Opened Oct 14, 2008 · Closed Apr 9, 2009
Status: closed (inferred from source dates) · Tires:valve
ON OCTOBER 14, 2008, ODI OPENED PE08-060 TO INVESTIGATE ALLEGATIONS OF CRACKED AND LEAKING SNAP-IN TIRE VALVES IN MODEL YEAR (MY) 2007 VEHICLES MANUFACTURED BY FORD MOTOR COMPANY.THE VALVES WERE SUPPLIED TO FORD BY TOPSEAL AUTO-PARTS, A SUBSIDIARY OF THE SHANGHAI BAOLONG AUTOMOTIVE CORPORATION IN CHINA.VALVES MADE BY TOPSEAL FOR AFTERMARKET SALE WERE THE SUBJECT OF TWO RECENT SAFETY RECALLS BY TECH INTERNATIONAL (08T-018) AND DILL AIR CONTROLS (08T-028), THE LATTER OF WHICH WAS INVESTIGATED BY ODI IN PE08-036 AND EA08-022.THE DEFECT CONDITIONS ADDRESSED BY THE AFTERMARKET TIRE VALVE RECALLS BOTH INVOLVED INADEQUATE RESISTANCE TO OZONE CRACKING DUE TO ISSUES WITH THE SUPPLY OF ANTI-OZONANT CHEMICALS TO TOPSEAL FOR A PERIOD FROM JULY TO MID-NOVEMBER 2006.THE AFTERMARKET VALVES WERE COMPOUNDED WITH A BLEND OF EPDM AND NATURAL RUBBER, USING A RELATIVELY LOW PERCENTAGE OF EPDM (EPDM PROVIDES INHERENT RESISTANCE TO OZONE CRACKING).HENCE, THE NEED FOR ANTI-OZONANT CHEMICALS AND THE PROBLEMS WITH CRACKING WHEN THOSE CHEMICALS WERE MISSING OR OUT OF SPECIFICATION IN SOME LOTS OF VALVES.BOTH RECALL CAMPAIGNS INVOLVED INSPECTION PROGRAMS TO IDENTIFY AND REPLACE VALVES WITH VISIBLE SURFACE CRACKING.ALTHOUGH THE TOPSEAL VALVES SUPPLIED TO FORD ALSO APPEAR TO HAVE BEEN AFFECTED BY THE ANTI-OZONANT SUPPLY ISSUES IN MID TO LATE-2006, FORD INDICATED THAT ITS VALVES WERE MADE AT A DIFFERENT TOPSEAL PRODUCTION LINE AND WERE COMPOUNDED WITH A HIGHER PERCENTAGE OF EPDM RUBBER TO MEET MORE STRINGENT SPECIFICATIONS FROM FORD.ODI'S ANALYSIS OF COMPLAINT AND WARRANTY DATA PROVIDED BY FORD SHOWED THAT PROBLEMS WITH CRACKED TIRE VALVES WERE SIGNIFICANTLY HIGHER FOR MY 2007 VEHICLES PRODUCED FROM DECEMBER 2006 THROUGH MARCH 2007.FORD RESPONDED BY IMPLEMENTING CHANGES IN ITS MATERIAL SPECIFICATIONS FOR SNAP-IN RUBBER TIRE VALVES AND ALSO INCREASING THE QUALITY AND ACCEPTANCE STANDARDS FOR VALVES IMPORTED FOR USE IN ITS VEHICLES.WHILE THE COMPLAINT AND WARRANTY CLAIM RATES ARE ELEVATED FOR SUBJECT VEHICLES PRODUCED FROM DECEMBER 2006 THROUGH MARCH 2007, THE RATES OF LEAKING VALVES ARE WELL BELOW ONE PERCENT OF PRODUCTION FOR EACH OF THE PEAK MONTHS FOR ALL OF THE AFFECTED MODELS.A SUBSTANTIAL MAJORITY OF THE SUBJECT VEHICLES ARE EQUIPPED WITH TIRE PRESSURE MONITORING SYSTEMS (TPMS) WHICH WARN THE DRIVER WHEN ANY TIRE PRESSURES DROPS BELOW 25 PERCENT OF RECOMMENDED INFLATION PRESSURE. AS OUTLINED IN A LETTER TO ODI DATED APRIL 6, 2009, FORD HAS AGREED TO SEND LETTERS TO OWNERS OF CERTAIN MY 2007 AND 2008 FORD, LINCOLN AND MERCURY VEHICLES TO PROVIDE INFORMATION ABOUT THE CRACKING CONCERN. LETTERS WILL BE SENT TO OWNERS OF VEHICLES BUILT FROM NOVEMBER 2006 THROUGH MAY 2007.OWNERS CAN OPT FOR A FREE DEALER INSPECTION.VALVES EXHIBITING SURFACE CRACKS OR AIR LEAKAGE RELATED TO OZONE ATTACK WILL BE REPLACED BY FORD UNDER ITS NORMAL WARRANTY TERMS.FORD EXPECTS TO SEND THE LETTER BY APPROXIMATELY MID-MAY 2009. BASED ON THE USE OF TPMS IN THE MAJORITY OF SUBJECT VEHICLES AND THE RELATIVELY LOW RATES OF REPAIRS ASSOCIATED WITH LEAKING VALVES AND RESULTANT TIRE DAMAGE, ODI BELIEVES THAT THE ACTIONS FORD HAS AGREED TO TAKE WILL PROVIDE EFFECTIVE AND EXPEDITIOUS RESOLUTION FOR VEHICLES THAT WERE BUILT DURING THE PERIOD WHEN VALVES WITH INADEQUATE RESISTANCE TO OZONE CRACKING WERE MOST LIKELY TO HAVE BEEN USED IN VEHICLE PRODUCTION.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.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 CONTINUE TO
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