Air Bags. Review the 330 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Power Train. Review the 193 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Fuel/propulsion System. Review the 105 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

16 crash reports22 fire reports13 injury reports

Electronic Stability Control (esc) complaints

11 reports

Clear category filter

90,000 miles · Jul 31, 2020

Electrical SystemElectronic Stability Control (esc)Suspension

MAKES NOSIES WHEN GOING OVER BUMPS AND ABS AND SUSPENSION LIGHTS COME ON WHEN THIS HAPPEN.

NHTSA ODI #11342611

123,129 miles · Aug 14, 2019

Electronic Stability Control (esc)Power TrainUnknown Or Other

Read full complaint

VEHICLE WAS IN MOTION FOR AWHILE, CAR WAS RUNNING OKAY UNTIL I CAME TO A STOPLIGHT AND THEN ALL OF A SUDDEN MY CAR GOES LIMP. MY VEHICLE MAKES LOUD/HARD CLANK NOISE. LOSS OF POWER, WRENCH LIGHT CAME ON. PULLED OVER, LOUD/HARD CLANK SOUND WITH EVERY GEAR CHANGE P-2. VEHICLE HAD DISPLAYED NO ISSUES PRIOR TO THIS. I AM ABLE TO PULL THE CAR OVER, TURN IT OFF AND TAKE THEY KEY OUT OF THE IGNITION. THEN THE WRENCH LIGHT IS OFF WHEN I RESTART THE CAR. STAYS IN LOW GEAR FOR A LONG TIME WHEN I START TO ACCELERATE, AND UNTIL VEHICLE EVENTUALLY ACCELERATES FASTER, OTHER CARS ALMOST RUNNING INTO THE BACK OF MY CAR SINCE MY CAR IS NOT ACCELERATING AT A NORMAL PACE. I AM GREATLY CONCERNED ABOUT WHAT APPEARS TO BE A HUGE SAFETY ISSUE WITH THIS CAR. THERE ARE MULTIPLE COMPLAINTS ABOUT THE SAME ISSUE TO BE FOUND ALL OVER THE INTERNET. FORD NEEDS TO ISSUE A RECALL AND FIX THIS ASAP BEFORE SOMEONE GETS SERIOUSLY HURT OR IS KILLED FROM THE EXTREME LOSS OF POWER THE VEHICLE IS SUFFERING FROM WHEN THIS OCCURS!

NHTSA ODI #11244064

70,000 miles · Aug 13, 2019

Electronic Stability Control (esc)Power TrainVehicle Speed Control

THE WRENCH LIGHT AND AIRBAG LIGHTS WERE ON. MY SPEEDOMETER WASN'T WORKING. TRANSMISSION WAS CLUNKING. THE POWERTRAIN (WRENCH) & SERVICE ENGINE SIGNALS COME ON AFTER EXPERIENCING LOSS OF SPEED SUCH AS AFTER A TRAFFIC LIGHT STOP. WE HAVE TO PUSH DOWN FAR ON THE GAS PEDAL JUST TO MOVE AND THIS IS FOLLOWED BY ROUGH SHIFTING (MAKE…

Read full complaint

NHTSA ODI #11243549

127,000 miles · Jul 4, 2019

Electrical SystemElectronic Stability Control (esc)Vehicle Speed Control

WHEN DRIVING DOWN THE HIGHWAY FOR THE 3RD TIME THE TRACTION CONTROL LIGHT CAME ON AND THE CAR JUST STARTED SLOWING DOWN. WHEN I TURN THE CAR OFF AND BACK ON IT GOES OFF, SO FAR IT HAS NOT COME BACK ON OR HAPPENED HAPPENED AGAIN. WHEN THE HAPPENED THE SECOND TIME I GOT HOME TURNED THE CAR OFF AND THE WIPERS CAME ON. NOT SURE IF …

Read full complaint

NHTSA ODI #11229450

165,000 miles · Sep 25, 2018

Electrical SystemElectronic Stability Control (esc)Injury

Read full complaint

I BOUGHT A 2007 FORD EDGE IN JULY OF 2018. LESS THEN 2 MONTHS LATER MY PCM HAS GONE BAD BURNING UP ALL 6 COIL PACKS IN MY EDGE. I HAVE CONTACTED FORD AND THERE IS A TECHNICAL SERVICE BULLENTIN ON THE PCM AND COIL PACKS, BUT WAS TOLD NOT ENOUGH PEOPLE HAVE REPORTED THE ISSUE TO PUT OUT A RECALL. I CAN NOT AFFORD OVER $2000.00 TO HAVE THIS FIXED. FORD IS AWARE THAT IT IS A DEFECTIVE PART AND I DONT UNDERSTAND WHY THERE IS NOT A RECALL ON IT. I WAS IN THE MIDDLE OF 6 LANES OF TRAFFIC DURING RUSH HOUR AND THE SUV JUST LOST POWER. I COULD HAVE BEEN KILLED. I HAD NO WARNING OR ANYTHING THE SUV JUST SLOWLY STARTED LOSING POWER AND CHECK ENGINE LIGHT DIDNT EVEN CUT ON UNTIL AFTER I TURNED EDGE OFF AND RESTARTED. THIS IS AN ISSUE IN NEED OF A RECALL ASAP! I HAVE DONE ALOT OF RESEARCH AND HAVE FOUND THAT THE FAULTY PCM BURNS UP THE COIL PACKS AND EVERYONE WHO IS JUST REPLACING COILS IS GOING TO HAVE THE SAME ISSUE AGAIN SINCE IT IS THE FAULTY PCM BURNING THE COILS AND UNTIL THE PCM ($835) IS REPLACED THEY WILL CONTINUE TO KEEP REPLACING THE COILS ($80 X 6 =$480.00) NONE OF THESE PRICES INCLUDE LABOR! ALSO DOESNT INCLUDE THE COST TO REPROGRAM THE NEW PCM TO MY KEYS SINCE IF YOU DONT FLASH THE NEW PCM THE EDGE WONT START DUE TO THE KEYS OUR PROGRAMMED SPECIFICALLY TO THE PCM INSTALLED TO THE EDGE. IF YOU HAVE ALREADY PAID TO HAVE THESE ISSUE FIXED PLEASE STILL CALL FORD WHEN AND IF THEY ISSUE A RECALL (WHICH THEY NEED TO!) YOU CAN SUBMIT YOUR RECEIPT AND BE REIMBURSED FOR COST TO HAVE IT FIXED! THE PCM PUSHES TO MUCH ELECTRICITY TO THE SPARK PLUGS IN TURN BURNING THE COILS AND COULD POSSIBLY CAUSE THE SUV TO CATCH FIRE!!!!! I HAVE NOT BEEN ABLE TO DRIVE MY EDGE IN 3 WEEKS AND STILL OWE MONEY ON IT!

NHTSA ODI #11131588

115,100 miles · Aug 6, 2017

Electronic Stability Control (esc)Unknown Or OtherVehicle Speed Control

Read full complaint

THE FIRST TIME IT HAPPENED A MONTH AGO, IT WAS A SIMILAR ISSUE THAT RESOLVED ITSELF WITHIN ABOUT 10 MINUTES. BUT THE SECOND TIME IT HAPPENED 7 DAYS AGO, IT LASTED LONGER AND UNFORTUNATELY I HAD MY 14 MONTH OLD IN THE CAR. I WAS PULING OUT OF A PARKING SPACE ONE LATE AFTERNOON AND PROCEEDED TO DRIVE FORWARD AND NOTICED THAT IT WAS REVING VERY LOUDLY EVEN THOUGH IT WAS BARELY MOVING. WHENEVER I WOULD COME TO A LIGHT AND STOP OR SLOW DOWN TO TURN AND THEN TRY TO INCREASE MY SPEED I NOTICED THAT IT WOULD BE REVING SO LOUDLY AND BARELY MOVING AT FIRST, BUT THEN AFTER ABOUT 10 SECONDS IT WOULD START TO MOVE A LITTLE FASTER - BUT NOT AS FAST AS IT USUALLY MOVES WHEN I PUT THE SAME AMOUNT OF PRESSURE ON THE GAS PEDAL. I ALSO NOTICED ALONG THE WAY THAT MY SPEDOMETEER WAS NOT MOVING. IT WAS STUCK ON 0MPH THE WHOLE TIME. THEN ABOUT 5 MINUTES INTO THIS HORROR, THE WRENCH LIGHT CAME ON AND ALTHOUGHH I HAD MY SEATBELT ON AND I HAD NO FRONT PASSENGER, THE SETBELT LIGHT CAME ON TOO. I MANAGED TO PULL THE CAR OVER NEAR MY HOME AND MOVED INTO A SPACE IN FRONT OF A NEIGHBOR'S HOUSE. WHEN I WENT TO BACK UP AND CORRECT MY PARKING THE CAR MADE SUCH A LOUD CLUNK SOUND. I THEN TURNED OFF THE CAR AND RIGHT THEN A MESSAGE FLASHED ON THE DASH BOARD ABOUT 'CHECK TIRE PRESSURE' OR SOMETHING LIKE THAT. BUT MY TIRES WERE PERFECTLY AND PROPERLY INFLATED. THE FIRST INCIDENT SHOOK ME A LITTLE BUT IT WAS ONLY ME IN THE CAR AND I THOUGHT THAT MAYBE, (ALTHOUGH UNLIKELY), I MADE A MISTAKE AND WAS USING THE WRONG GEAR TO MANUVER. BUT AFTER THIS SECOND INCIDENT (ESPECIALLY WITH MY BABY IN THE CAR) I HAVE NOT TOUCHED THE CAR SINCE. I BOUGHT IT AS A FAMILY VEHICLE, AND IF IT COULD LEAD TO ME OR MY FAMILY BEING KILLED ON THE ROAD, THERE IS NO POINT. I THANK GOD THAT I AVOID HIGHWAYS BECAUSE I COULD NOT HAVE IMAGINED WHAT WOULD HAVE HAPPENED IF I WAS ON A HIGHWAY WHEN THIS HAPPENED.

NHTSA ODI #11013141

125,000 miles · Mar 22, 2017

Electronic Stability Control (esc)Fuel/propulsion SystemPower Train

Read full complaint

FORD DEALER HAS MY 2007 FORD EDGE DUE TO IT STALLING OUT WHILE DRIVING 60 MPH ON A HIGHWAY CAUSING MY ENGINE TO DIE SO I HAD TO GET TOWED HOME AND OFF OF THE HIGHWAY. THE DEALER ORIGINALLY THOUGHT IT WAS THE ELECTRONIC THROTTLE BODY BUT THEY HAVE NOW DETERMINED THAT WAS NOT THE PROBLEM. INSTEAD IT IS THE PCM WHICH IS COSTING ME OVER $1500, IF THAT EVEN FIXES THIS. PLUS I HAVE BEEN PAYING FOR A RENTAL CAR BECAUSE THE DEALERS DON'T HAVE FREE LOANER VEHICLES. SO THIS WHOLE THING IS GOING TO COST ME ABOUT $2000. NOW I HAVE BEEN RESEARCHING THIS PROBLEM, AND CAN CLEARLY TELL THIS IS NOT NORMAL WEAR AND TEAR INSTEAD IT IS A FAULTY PART THAT SO MANY OTHER OWNERS ARE EXPERIENCING. I CLEARLY SEE FORD HAS BEEN MADE AWARE OF THIS PROBLEM AND THEY SHOULD BE TAKING RESPONSIBILITY FOR THEIR MISTAKE. FORD HAS REFUSED TO ISSUE A RECALL ON THIS PROBLEM EVEN THOUGH IT IS VERY DANGEROUS AND COSTLY FOR THE VEHICLE OWNER. I HAVE NEVER OWNED A FORD BEFORE AND LIKELY WILL NOT AGAIN BECAUSE OF THIS BAD EXPERIENCE.

NHTSA ODI #10967799

125,000 miles · Mar 22, 2017

Electronic Stability Control (esc)Fuel/propulsion System

BAD ELECTRONIC THROTTLE BODY AND IT'S SENSOR. THIS IS A COMMON AND COSTLY REPAIR WITH FORD VEHICLES BUT THEY HAVE REFUSED A RECALL. IT IS DANGEROUS AS IT CAUSES YOUR VEHICLE TO COMPLETELY SHUT DOWN WHILE DRIVING. IT HAPPENS FREQUENTLY WHEN ACCELERATING OR RANDOMLY WHEN DRIVING AT VARIOUS SPEEDS. THE FIRST TIME IT HAPPENED I WAS …

Read full complaint

NHTSA ODI #10967717

120,000 miles · Dec 22, 2015

Electrical SystemElectronic Stability Control (esc)Power Train

Read full complaint

I WAS TRAVELING AROUND 40 MPH ON A STATE HIGHWAY WHEN SPUTTERING AND VIBRATION ISSUES STARTED WITH 2007 FORD EDGE AND CHECK ENGINE LIGHT CAME ON. STILL DROVE VEHICLE TO MY MECHANIC WHICH STATED COIL BURNED OUT AND SENT SURGE OF POWER TO THE PCM. MECHANIC STATED DESIGN OF PCM WOULDN'T STOP THE FIRING OF COIL AND NOT TO DRIVE VEHICLE ANY FURTHER OR IT WILL BURN TO THE GROUND. MECHANIC STATED ONLY THE FORD DEALERSHIP CAN INSTALL A NEW ONE AND REST THE CAR TO GET IT RUNNING. TOWED VEHICLE TO FORD DEALERSHIP WHO STATED THEY HAVE A TSB ISSUED FOR THIS PROBLEM AND THEY WILL NEED TO REPLACE THE PCM AND ALL 6 COILS BECAUSE THEY HAVE ALL MELTED. FORD DEALERSHIP STATED THIS WAS AN ON GOING PROBLEM DUE TO A FAULTY DESIGN OF THE PCM THAT WHEN A COIL BURNS OUT (COMMON WEAR AND TEAR AND $100 TO $200 FIX) THE PCM DOESN'T STOP FIRING TO THE COILS WHICH COULD CAUSE THE CAR TO CATCH FIRE. ESTIMATE TO FIX THE PCM AND ALL SIX COILS WAS $2,958. REASON FOR COMPLAINT - I UNDERSTAND WEAR AND TEAR ON A VEHICLE, BUT DUE TO A DESIGN ISSUE IN THE FORD/MERCURY/LINCOLN PCM, IT CAUSED EXTENSIVE DAMAGE AND REPAIR TO THE CAR AND POTENTIAL TO BURN TO THE GROUND. $100 FIX WITH PROPER DESIGN AND NOW $2,958 DUE TO PCM ISSUE. I AM REQUESTING THIS ISSUE TO BE REVIEWED FOR REIMBURSEMENT BY THE MANUFACTURER OR RECALL ISSUED. THANKS YOU FOR YOUR TIME.

NHTSA ODI #10811721

120,000 miles · Dec 22, 2015

Electrical SystemElectronic Stability Control (esc)Power Train

TL* THE CONTACT OWNS A 2007 FORD EDGE. WHILE DRIVING AT APPROXIMATELY 40 MPH, THE CONTACT FELT A LOSS OF PRESSURE ON THE ACCELERATOR PEDAL AND THE VEHICLE SHOOK. THE CONTACT HAD THE VEHICLE DIAGNOSED AND WAS INFORMED THAT THE POWER CONTROL FAILED AND THE COIL MELTED. THE MECHANIC STATED THAT THE VEHICLE WAS NOT SAFE TO DRIVE. TH…

Read full complaint

NHTSA ODI #10811703

Official recalls

21V158000 · Air Bags:frontal:driver Side:inflator Module

Mar 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.

21V081000 · Air Bags:frontal; Air Bags:frontal:driver Side:inflator Module; Air Bags:frontal:passenger Side:inflator Module

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

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

Air Bags:frontal

17V024000 · Air Bags:frontal:passenger Side:inflator Module

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.

16V384000 · Air Bags:frontal:passenger Side:inflator Module

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.

14V682000 · Fuel System, Gasoline:storage:tank Assembly

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

PE09031 · 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