NHTSA owner reports · September 18, 2026 snapshot.
Fuel/propulsion System complaints
105 reportsClear category filterMileage unknown · Oct 14, 2014
Fuel/propulsion System
FUEL TANK LEAKING. NOTICED A STRONG FUEL ODOR WHEN I FILLED THE TANK. DID SOME RESEARCH AND THERE ARE OVER A HUNDRED COMPLAINTS ABOUT THIS. LEAK IS COMING FROM THE TOP SEAL OR SEAM. THERE MUST BE A PROBLEM BECAUSE FORD HAS A BACK ORDER ON THE TANK WHEN I TRIED TO GET IT FIXED THEY DID NOT KNOW WHEN THEY COULD GET ONE IN.I DO THI…
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FUEL TANK LEAKING. NOTICED A STRONG FUEL ODOR WHEN I FILLED THE TANK. DID SOME RESEARCH AND THERE ARE OVER A HUNDRED COMPLAINTS ABOUT THIS. LEAK IS COMING FROM THE TOP SEAL OR SEAM. THERE MUST BE A PROBLEM BECAUSE FORD HAS A BACK ORDER ON THE TANK WHEN I TRIED TO GET IT FIXED THEY DID NOT KNOW WHEN THEY COULD GET ONE IN.I DO THINK A RECALL IS IN ORDER. *TR
NHTSA ODI #10644703
Mileage unknown · Oct 14, 2014
Fuel/propulsion System
I PUT A SET TIRES ON MY VEHICLE LAST WEEK AND WAS TOLD MY GAS TANK WAS LEAKING. I TOOK IT TO A FORD DEALERSHIP TO GET ESTIMATE ON REPAIR. THEY ALSO STATED THE TANK WAS LEAKING. THE ENTIRE TANK WOULD NEED TO BE REPLACED TO THE TUNE OF $2,200.00 ROUGHLY. THE IRONIC THING HERE THE FUEL TANK IS ON A NATIONAL BACKORDER AND HAV…
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I PUT A SET TIRES ON MY VEHICLE LAST WEEK AND WAS TOLD MY GAS TANK WAS LEAKING. I TOOK IT TO A FORD DEALERSHIP TO GET ESTIMATE ON REPAIR. THEY ALSO STATED THE TANK WAS LEAKING. THE ENTIRE TANK WOULD NEED TO BE REPLACED TO THE TUNE OF $2,200.00 ROUGHLY. THE IRONIC THING HERE THE FUEL TANK IS ON A NATIONAL BACKORDER AND HAVE NO IDEA WHEN THIS PROBLEM CAN BE FIXED!!!! THERE SHOULD BE A RECALL, SOMEBODY NEEDS TO WAKE UP HERE!!!! ARE WE GOING TO WAIT FOR AN ACCIDENT HERE WHERE SOMEONE IS KILLED BEFORE FORD FIXES THIS PROBLEM!!!! *TR
NHTSA ODI #10644699
100,000 miles · Oct 14, 2014
Fuel/propulsion System
I BEGAN TO SMELL A STRONG GAS SMELL, THEN I SAW DROPS OF GAS ON MY DRIVEWAY. I TOOK THE VEHICLE TO MY DEALERSHIP. THEY INFORMED ME THE FUEL TANK WAS RUSTED WITH A HOLE, THUS THE LEAK. THE REPAIR WAS VERY COSTLY, I ASKED THEM TO PURSUE A USED FUEL TANK. AFTER RESEARCHING EXTENSIVELY, THE DEALER AND I FOUND THAT ALL OF THE USED FU…
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I BEGAN TO SMELL A STRONG GAS SMELL, THEN I SAW DROPS OF GAS ON MY DRIVEWAY. I TOOK THE VEHICLE TO MY DEALERSHIP. THEY INFORMED ME THE FUEL TANK WAS RUSTED WITH A HOLE, THUS THE LEAK. THE REPAIR WAS VERY COSTLY, I ASKED THEM TO PURSUE A USED FUEL TANK. AFTER RESEARCHING EXTENSIVELY, THE DEALER AND I FOUND THAT ALL OF THE USED FUEL TANKS ALSO HAVE HOLES AND ARE RUSTED. THE DEALER WENT FORWARD WITH REQUESTING A NEW FUEL TANK, ONLY TO FIND THAT FORD HAS THEM ON BACKORDER WITH AN ETA OF NEVER. THE DEALERSHIP REP CALLED FORD TO FIND THEY ARE NO LONGER MAKING THE FUEL TANK, THERE IS NO SUPPLIER FOR THE FUEL TANK. I AM LEFT WITH A CAR THAT CANNOT BE REPAIRED PROPERLY. THE FORD RELATIONSHIP CENTER HAS BEEN NO HELP. THIS IS A SERIOUS SAFETY ISSUE. FORD HAS TURNED A BLIND EYE. CONSUMERS NEED TO KNOW ABOUT THIS POTENTIALLY DEADLY DEFECT. *TR
NHTSA ODI #10644645
92,555 miles · Oct 14, 2014
Fuel/propulsion System
I HAVE AN 2007 FORD EDGE, FILLED THE TANK, THE NEXT DAY SMELLED A FUEL ODOR, 1 WEEK LATER SEEN THAT THERE IS A GAS LEAK. TOOK THE CAR TO A MECHANIC, STATED THE SEAMS ON THE PASSENGER SIDE OF THE TANK ARE RUSTED. HAVE NOT CONTACTED MAUNFACTURE & NOT REPAIRED. THERE ARE ALOT OF GAS TANK COMPLAINTS, NOT TOO SURE WHY THIS YEAR HAS …
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I HAVE AN 2007 FORD EDGE, FILLED THE TANK, THE NEXT DAY SMELLED A FUEL ODOR, 1 WEEK LATER SEEN THAT THERE IS A GAS LEAK. TOOK THE CAR TO A MECHANIC, STATED THE SEAMS ON THE PASSENGER SIDE OF THE TANK ARE RUSTED. HAVE NOT CONTACTED MAUNFACTURE & NOT REPAIRED. THERE ARE ALOT OF GAS TANK COMPLAINTS, NOT TOO SURE WHY THIS YEAR HAS NOT BEEN RECALLED. THIS IS A FIRE RISK. A 7 YEAR OLD CAR SHOULD NOT HAVE A FUEL TANK ISSUE. *TR
NHTSA ODI #10644429
100,000 miles · Oct 13, 2014
Fuel/propulsion SystemPower TrainUnknown Or Other
WILL BE DRIVING ALONG AT ANY SPEED AND CAR WILL NOT ACCELERATE, IT DOES NOT STALL BUT WRENCH LIGHT COMES ON AND YOU CAN'T DO ANYTHING UNTIL YOU SHUT OFF THE CAR AND RESTART IT. THIS HAS HAPPENED NUMEROUS TIMES AND HASN'T CAUSED AN ACCIDENT YET, BUT MOST CERTAINLY WILL EVENTUALLY. THIS PROBLEM IS WELL KNOWN, BUT IS PHRASED AS S…
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WILL BE DRIVING ALONG AT ANY SPEED AND CAR WILL NOT ACCELERATE, IT DOES NOT STALL BUT WRENCH LIGHT COMES ON AND YOU CAN'T DO ANYTHING UNTIL YOU SHUT OFF THE CAR AND RESTART IT. THIS HAS HAPPENED NUMEROUS TIMES AND HASN'T CAUSED AN ACCIDENT YET, BUT MOST CERTAINLY WILL EVENTUALLY. THIS PROBLEM IS WELL KNOWN, BUT IS PHRASED AS STALLING WHEN IT TRULY DOESN'T STALL, ACCELERATOR JUST DOESN'T WORK AND CAR SLOWS DOWN QUICKLY IN TRAFFIC. *TR
NHTSA ODI #10644331
116,000 miles · Oct 10, 2014
Fuel/propulsion System
TL* THE CONTACT OWNS A 2007 FORD EDGE. WHILE DRIVING APPROXIMATELY 45 MPH, THE CONTACT SMELLED FUEL. THE CONTACT ALSO STATED THAT THE FUEL TANK WAS FRACTURED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL TANK NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE…
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TL* THE CONTACT OWNS A 2007 FORD EDGE. WHILE DRIVING APPROXIMATELY 45 MPH, THE CONTACT SMELLED FUEL. THE CONTACT ALSO STATED THAT THE FUEL TANK WAS FRACTURED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL TANK NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 116,000.
NHTSA ODI #10643816
96,000 miles · Oct 8, 2014
Fuel/propulsion System
I DETECTED A FAINT ODOR OF GASOLINE. A WEEK LATER AFTER VEHICLE WAS SITTING IN THE DRIVEWAY OVERNIGHT THERE WAS AN OVERWHELMING ODOR OF GAS AROUND THE VEHICLE. OUR MECHANIC FOUND A LEAKING FUEL TANK, RUSTED AT THE SEAM, DRIPPING ON TO THE EXHAUST. VEHICLE IS NOT DRIVABLE. AS OF THIS TIME THE LOCAL FORD DEALER CANNOT EVEN GIVE AN…
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I DETECTED A FAINT ODOR OF GASOLINE. A WEEK LATER AFTER VEHICLE WAS SITTING IN THE DRIVEWAY OVERNIGHT THERE WAS AN OVERWHELMING ODOR OF GAS AROUND THE VEHICLE. OUR MECHANIC FOUND A LEAKING FUEL TANK, RUSTED AT THE SEAM, DRIPPING ON TO THE EXHAUST. VEHICLE IS NOT DRIVABLE. AS OF THIS TIME THE LOCAL FORD DEALER CANNOT EVEN GIVE AN ESTIMATE WHEN A REPLACEMENT TANK MIGHT BE AVAILABLE AND USED TANKS ARE APPARENTLY DIFFICULT TO FIND. *TR
NHTSA ODI #10643247
101,000 miles · Oct 7, 2014
Fuel/propulsion System
STRONG FUEL SMELL COMING FROM REAR OF VEHICLE. FUEL IS LEAKING SLIGHTLY AT SEAM AND HAS STRONG VAPOR SMELLS. HASN'T BEEN OVERFILLED. I CAN NOT PARK THE VEHICLE IN THE GARAGE ANYMORE DUE TO THE DANGER OF THE VAPORS. THIS NEEDS TO BE ADDRESSED BEFORE SOMEONE GETS HURT OR KILLED. TO MANY PEOPLE HAVE ALREADY COMPLAINED ON THIS ISSUE…
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STRONG FUEL SMELL COMING FROM REAR OF VEHICLE. FUEL IS LEAKING SLIGHTLY AT SEAM AND HAS STRONG VAPOR SMELLS. HASN'T BEEN OVERFILLED. I CAN NOT PARK THE VEHICLE IN THE GARAGE ANYMORE DUE TO THE DANGER OF THE VAPORS. THIS NEEDS TO BE ADDRESSED BEFORE SOMEONE GETS HURT OR KILLED. TO MANY PEOPLE HAVE ALREADY COMPLAINED ON THIS ISSUE, SO WHY HAS A RECALL NOT BEEN ISSUED? *TR
NHTSA ODI #10641965
Mileage unknown · Oct 6, 2014
Fuel/propulsion System
SMELLING GAS FUMES. LOOKED UNDERNEATH AND GAS WAS LEAKING FROM FUEL TANK. *TR
NHTSA ODI #10641847
106,000 miles · Oct 6, 2014
Fuel/propulsion System
LEAKING FUEL TANK. ADVISED BY TECHNICIAN NOT TO PARK INSIDE ENCLOSED GARAGE DUE TO FIRE HAZARD. FORD MOTOR COMPANY IS AWARE OF LEAKING FUEL TANKS ON THESE MODEL VEHICLES AND IS NOT ASSISTING OWNERS IN REPAIRS OR REPLACEMENT. REPLACEMENT COST $2,018 AND TANKS ARE ON BACK ORDER. FORD ALLOWING HAZARDOUS CONDITIONS FOR VEHICLE OWNER…
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LEAKING FUEL TANK. ADVISED BY TECHNICIAN NOT TO PARK INSIDE ENCLOSED GARAGE DUE TO FIRE HAZARD. FORD MOTOR COMPANY IS AWARE OF LEAKING FUEL TANKS ON THESE MODEL VEHICLES AND IS NOT ASSISTING OWNERS IN REPAIRS OR REPLACEMENT. REPLACEMENT COST $2,018 AND TANKS ARE ON BACK ORDER. FORD ALLOWING HAZARDOUS CONDITIONS FOR VEHICLE OWNERS. *TR
NHTSA ODI #10641708
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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