NHTSA owner reports · September 18, 2026 snapshot.
Electrical System complaints
96 reportsClear category filter53,804 miles · Jan 6, 2014
Electrical SystemVehicle Speed Control
AFTER PULLING OUT ONTO A HIGHWAY, MY CAR WOULD NOT ACCELERATE. THE ENGINE DIDN'T STOP BUT PRESSING GAS DID NOT HELP. WAS FORCED TO COAST TO SIDE, CAR SHUDDERED, THEN STALLED. AFTER WAITING A FEW, CAR STARTED. WAS ABLE TO DRIVE IT A MILE TO A NEARBY REPAIR SHOP. WE WERE CALLED AND ADVISED IT WAS A TRANSMISSION ISSUE AND DUE TO …
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AFTER PULLING OUT ONTO A HIGHWAY, MY CAR WOULD NOT ACCELERATE. THE ENGINE DIDN'T STOP BUT PRESSING GAS DID NOT HELP. WAS FORCED TO COAST TO SIDE, CAR SHUDDERED, THEN STALLED. AFTER WAITING A FEW, CAR STARTED. WAS ABLE TO DRIVE IT A MILE TO A NEARBY REPAIR SHOP. WE WERE CALLED AND ADVISED IT WAS A TRANSMISSION ISSUE AND DUE TO MILES ON THE CAR, IT SHOULD BE TOWED TO THE NEAREST DEALERSHIP (UNDER WARRANTY). FORD SERVICE COULD NOT REPRODUCE THE ISSUE. WE WERE TOLD NOTHING WAS WRONG & TO PICK IT UP. PRIOR TO PICKING UP, WE FOUND A TSB THAT DESCRIBED WHAT WE HAD BUT WERE TOLD THERE WAS NOTHING WRONG. MAY 2013, CAR DID SAME BUT THIS TIME, THE WRENCH LIGHT CAME ON. TOWED (TO ANOTHER FORD SERVICE DEALER),& ISSUE WAS FOUND. REPAIR MADE. NOT SURPRISINGLY, ISSUE WAS SAME TSB WE PULLED IN 2011. 7 MONTHS LATER, CAR SHUDDERED, & STALLED AGAIN. ONLY DIFFERENCE WITH THIS OCCURRENCE IS NOW THE ENGINE DIED. TOWED BACK TO DEALER. WAS INFORMED IT WAS THE PCM OR MAIN COMPUTER WHICH CAUSED THE IGNITION COILS TO BURN UP. SO, IN SHORT, OWNING THIS CAR FOR 2 YEARS, HAVING TOWED 3 TIMES FOR THE SAME ISSUE, ALL IN 3 EXTREMELY UNSAFE CONDITIONS, HAS LEFT ME WITH NO CHOICE BUT TO FILE A COMPLAINT. THIS COMPUTER SOFTWARE ISSUE IS A MAJOR SAFETY CONCERN AND BASED ON OTHER COMMENTS FOUND ONLINE, FORD IS NOT WILLING TO TAKE NECESSARY PRECAUTIONS TO PREVENT WHAT COULD BE A SADDENING FATAL SITUATION. THIS CAR IS NOT SAFE TO DRIVE AND THE SERVICE DEPARTMENT AT FORD IS NOT COOPERATIVE IN RESOLVING THE PROBLEM. IT IS A KNOWN ISSUE YET NO RECALL HAS BEEN MADE. SO HEARTBREAKING TO SEE SO MANY THAT HAVE HAD THIS SAME PROBLEM AS ME AND KNOW THAT NOTHING IS BEING DONE. I AM PAYING FOR THIS REPAIR BUT WILL TURN AROUND AND SELL THE CAR. WON'T BE MY DEATH! NEVER WILL I PURCHASE A FORD VEHICLE. THE SAFETY OF MY FAMILY IS MY UTMOST CONCERN AND SHOULD ALSO BE FORD'S BUT APPARENTLY IS NOT. THANK YOU. *TR
NHTSA ODI #10558645
70,500 miles · Dec 15, 2013
Electrical SystemExterior Lighting
TAILLIGHT SOCKETS AND BULBS SCORCHED AND BURNT TOGETHER. SIGNS OF HIGH HEAT. *TR
NHTSA ODI #10556145
50,000 miles · Nov 12, 2013
Electrical SystemExterior Lighting
THE DRIVER'S SIDE TAIL LIGHT HAS BURNED OUT AND MELTED THE BULB AND THE SOCKET. THIS HAS OCCURRED 4 TIMES IN THE 4 MONTHS WE HAVE OWNED THE CAR. *TR
NHTSA ODI #10551952
89,000 miles · Nov 5, 2013
Electrical SystemEngine
SECOND TIME A YEAR OR SO LATER ELECTRICAL COOLING RADIATOR FAN GOES OUT. REPLACING AGAIN. *TR
NHTSA ODI #10550989
71,111 miles · Nov 5, 2013
Electrical SystemEngine
ELECTRIC RADIATOR COOLING FAN QUIT. CAR OVERHEATED. HAD TO BE REPLACED. *TR
NHTSA ODI #10550987
123,000 miles · Oct 21, 2013
Electrical SystemFire
TL* THE CONTACT OWNS A 2007 FORD EDGE. THE CONTACT STATED THAT WHENEVER HE WAS INSIDE OF THE VEHICLE, HE WOULD SMELL SOMETHING BURNING. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION WHERE THEY STATED THAT THE IGNITION COIL NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE.…
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TL* THE CONTACT OWNS A 2007 FORD EDGE. THE CONTACT STATED THAT WHENEVER HE WAS INSIDE OF THE VEHICLE, HE WOULD SMELL SOMETHING BURNING. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION WHERE THEY STATED THAT THE IGNITION COIL NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 123,000. THE VIN WAS UNAVAILABLE.
NHTSA ODI #10548674
88,000 miles · Sep 3, 2013
Electrical SystemEnginePower Train
WE STARTED UP OUR CAR ON A SUNDAY MORNING, PUT IT IN REVERSE, BACKED OUT OF OUR SPOT, AND THEN PUT THE VEHICLE IN DRIVE. RIGHT AWAY, WE NOTICED THE CAR SHAKING, NOT MUCH POWER, AND IT WAS SPUTTERING ALONG. THE CHECK ENGINE LIGHT WAS FLASHING AS WELL, INDICATING ENGINE MISFIRE. THE CAR WAS TOWED TO A FORD DEALERSHIP. THE FORD DEA…
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WE STARTED UP OUR CAR ON A SUNDAY MORNING, PUT IT IN REVERSE, BACKED OUT OF OUR SPOT, AND THEN PUT THE VEHICLE IN DRIVE. RIGHT AWAY, WE NOTICED THE CAR SHAKING, NOT MUCH POWER, AND IT WAS SPUTTERING ALONG. THE CHECK ENGINE LIGHT WAS FLASHING AS WELL, INDICATING ENGINE MISFIRE. THE CAR WAS TOWED TO A FORD DEALERSHIP. THE FORD DEALERSHIP RAN A DIAGNOSTIC AND DETERMINED THAT THE PCU HAD OVERHEATED AND THE CYLINDER COILS MELTED. THEY ALSO SAID THE PCU IS NO LONGER OPERABLE AND NEEDED TO BE REPLACED, ALONG WITH THE COILS AND PLUGS. GENERALLY, ENGINE MISFIRE INDICATES A TUNE-UP IS NEEDED; HOWEVER, IN THIS CASE, THE CAR NEEDS A BRAND-NEW COMPUTER. THE DEALERSHIP QUOTED US AT 2,700 TOTAL FOR THE REPAIR. FURTHERMORE, THIS IS A KNOWN ISSUE WITH THE CAR, AS DETERMINED BY FORD, AS IT ISSUED TECHNICAL SERVICE BULLETIN 13-4-7, CITING THIS MODEL AND SEVERAL OTHERS AS PRONE TO THIS MALFUNCTION. FORD SHOULD RECALL THIS MODEL AND HAVE THE ISSUE FIXED. NO RECALLS EVEN THOUGH THIS POSES A FIRE HAZARD? SHOCKING. *JB
NHTSA ODI #10538639
85,000 miles · Jul 26, 2013
Electrical SystemPower TrainUnknown Or Other
FIRST OCCURRENCE. TURNED VEHICLE ON, SHIFTED IN DRIVE TO LEAVE PARKING LOT. DID NOT SHIFT CORRECTLY, AND FELT AS IF IT WAS IN NEUTRAL. TURNED VEHICLE OFF, AND BACK ON. IT SHIFTED FINE. TOOK VEHICLE BACK TO DEALERSHIP, AS WE HAD ONLY OWNED IT S MONTH AND BOUGHT IN APRIL 2012. THEY COULD NOT FIND ANYTHING WRONG. OVER TIME, THIS H…
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FIRST OCCURRENCE. TURNED VEHICLE ON, SHIFTED IN DRIVE TO LEAVE PARKING LOT. DID NOT SHIFT CORRECTLY, AND FELT AS IF IT WAS IN NEUTRAL. TURNED VEHICLE OFF, AND BACK ON. IT SHIFTED FINE. TOOK VEHICLE BACK TO DEALERSHIP, AS WE HAD ONLY OWNED IT S MONTH AND BOUGHT IN APRIL 2012. THEY COULD NOT FIND ANYTHING WRONG. OVER TIME, THIS HAS HAPPENED 10-15 MORE TIMES. THE COMPUTER ALSO SEEMS TO BE AFFECTED BY THIS AS WELL. TODAY 7/26/2013, I TURNED ON THE VEHICLE, LEFT IT START UP, BEGAN TO GO INTO DRIVE, IT STALLED, AND A POWERTRAIN LIGHT CAME ON. MILEAGE COMPUTER DASH DISAPPEARED. I TURNED THE CAR OFF. TURNED IT BACK ON. WHEN I TRIED TO SHIFT IT, TRANSMISSION WAS VERY VIOLENT. SAT IN THE PARKING LOT FOR TWENTY MINUTES. TURNED THE CAR BACK ON, LET IT RUN FOR 2MINUTES, PUT IT IN DRIVE, AND IT WAS COMPLETELY FINE. WHEN I DRIVE UP HILL, IT SEEMS TO BE USING A LOT MORE POWER THAN NECESSARY, AND MY RPMS GO ALL THE WAY UP TO 5-6K. LOOKING FOR A SHOP TO HAVE THE CAR LOOKED AT, OR AT THE DEALERSHIP. *TR
NHTSA ODI #10531928
84,334 miles · Jun 25, 2013
Electrical SystemEnginePower Train
TL* THE CONTACT OWNS A 2007 FORD EDGE. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 73 MPH THERE WAS A SLIGHT REDUCTION IN THE ENGINE POWER. THE VEHICLE BEGAN TO VIBRATE VIOLENTLY. THERE WERE NO WARNING INDICATORS ILLUMINATED AT THE TIME OF FAILURE. THE VEHICLE WAS MANEUVERED TO THE SIDE OF THE ROAD FOR INSPECTION. THE VEHICLE…
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TL* THE CONTACT OWNS A 2007 FORD EDGE. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 73 MPH THERE WAS A SLIGHT REDUCTION IN THE ENGINE POWER. THE VEHICLE BEGAN TO VIBRATE VIOLENTLY. THERE WERE NO WARNING INDICATORS ILLUMINATED AT THE TIME OF FAILURE. THE VEHICLE WAS MANEUVERED TO THE SIDE OF THE ROAD FOR INSPECTION. THE VEHICLE WAS THEN TAKEN TO AN AUTHORIZED DEALER FOR DIAGNOSIS. THE IGNITION COIL ASSEMBLY, HLA ENGINE CONTROL MODULE AND PCM WERE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 84,334. ...UPDATED 07-24-13 *BF THE CONSUMER STATED AFTER THE REPAIRS WERE DONE, THE VEHICLE CONTINUED TO EXHIBIT ERRATIC IRREGULAR SHIFTING, ALTHOUGH NOT TO THE EXTENT FOR WHICH HE BROUGHT THE VEHICLE IN.
NHTSA ODI #10521648
90,000 miles · Apr 11, 2013
Electrical SystemExterior Lighting
REAR BRAKE/TAIL LIGHT SOCKET ON BOTH THE LEFT AND RIGHT REAR OF VEHICLE HAVE OVERHEATED AND MELTED THE PLASTIC AROUND LAMP. LAMP WAS BURNT OUT. NOT SURE WHAT CAUSED THE HIGH HEAT PROBLEM. NO FUSE WAS BLOWN, NEW BULB WORKED IN SOCKET. THIS PROBLEM HAS HAPPENED TWICE IN THE LAST TWO MONTHS. *TR
NHTSA ODI #10506027
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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