NHTSA owner reports · September 18, 2026 snapshot.
Fuel/propulsion System complaints
105 reportsClear category filter107,450 miles · Oct 1, 2014
Fuel/propulsion System
I AM THE OWNER OF A 2007 FORD EDGE SE. WE RECENTLY SMELLED GAS COMING FROM THE DRIVER'S SIDE OF THE VEHICLE. THE CAR WAS TAKEN TO A FORD DEALERSHIP TO HAVE THE PROBLEM DIAGNOSED. THE FORD DEALERSHIP EXPLAINED THAT THERE WAS A HOLE IN THE GAS TANK DUE TO CORROSION AND WOULD NEED A NEW GAS TANK AND FUEL PUMP THAT WOULD COST APP…
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I AM THE OWNER OF A 2007 FORD EDGE SE. WE RECENTLY SMELLED GAS COMING FROM THE DRIVER'S SIDE OF THE VEHICLE. THE CAR WAS TAKEN TO A FORD DEALERSHIP TO HAVE THE PROBLEM DIAGNOSED. THE FORD DEALERSHIP EXPLAINED THAT THERE WAS A HOLE IN THE GAS TANK DUE TO CORROSION AND WOULD NEED A NEW GAS TANK AND FUEL PUMP THAT WOULD COST APPROXIMATELY $1,800 TO $2,500 TO FIX. THE DEALERSHIP REFUSED TO COMPLETE THE WORK WITHOUT PAYMENT SINCE NO RECALL HAS BEEN GIVEN FOR THE 2007 EDGE. WE WERE LEFT WITH THE OPTIONS OF PAYING FOR A NEW GAS TANK AND FUEL PUMP OR CALLING FORD TO COMPLAIN. ANOTHER MECHANIC EXPLAINED TO US THAT THE GAS TANK IS A DESIGN DEFAULT BY FORD AND NO DAMAGE WAS DONE TO THE TANK BY US. *TR
NHTSA ODI #10640437
102,654 miles · Sep 29, 2014
Fuel/propulsion System
I NOTICE A STRONG GAS SMELL. THE MECHANIC TOLD ME THE SEAM OF THE TANK IS LEAKING. I HAVE OWNED MULTIPLE (OVER 20) FORDS THOUGH OUT THE YEARS AND I HAVE NEVER HAD A TANK RUST OUT IN 7 YEARS. THE REPAIR COST IS OUTRAGEOUS IF YOU CAN FIND A TANK (RIGHT NOW I CAN NOT FIND A TANK FOR UNDER $2000). IT LOOKS LIKE I AM NOT THE ONLY …
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I NOTICE A STRONG GAS SMELL. THE MECHANIC TOLD ME THE SEAM OF THE TANK IS LEAKING. I HAVE OWNED MULTIPLE (OVER 20) FORDS THOUGH OUT THE YEARS AND I HAVE NEVER HAD A TANK RUST OUT IN 7 YEARS. THE REPAIR COST IS OUTRAGEOUS IF YOU CAN FIND A TANK (RIGHT NOW I CAN NOT FIND A TANK FOR UNDER $2000). IT LOOKS LIKE I AM NOT THE ONLY PERSON HAVING THIS PROBLEM. THIS SHOULD BE A RECALL ITEM. *TR
NHTSA ODI #10639989
88,450 miles · Sep 26, 2014
Fuel/propulsion System
I NOTICED A SMELL OF GAS FOR TWO DAYS AFTER COMPLETELY FILLING MY GAS TANK THE LAST TIME. IT LASTED FOR 3 DAYS BEFORE I DECIDED TO TAKE IT IN TO HAVE IT LOOKED AT. I WAS THEN TOLD I HAVE TWO HOLES IN THE TOP OF MY GAS TANK AND IT WOULD BE AROUND $1800 TO BE REPLACED. ALTHOUGH, THAT ISN'T AN OPTION AT THE MOMENT BECAUSE THE REPLA…
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I NOTICED A SMELL OF GAS FOR TWO DAYS AFTER COMPLETELY FILLING MY GAS TANK THE LAST TIME. IT LASTED FOR 3 DAYS BEFORE I DECIDED TO TAKE IT IN TO HAVE IT LOOKED AT. I WAS THEN TOLD I HAVE TWO HOLES IN THE TOP OF MY GAS TANK AND IT WOULD BE AROUND $1800 TO BE REPLACED. ALTHOUGH, THAT ISN'T AN OPTION AT THE MOMENT BECAUSE THE REPLACEMENT TANKS ARE ON BACK ORDER SINCE THIS ISSUE IS OCCURRING SO FREQUENTLY AND THEY HAVE NO SPECIFIC DATE OF WHEN ONE WILL BE AVAILABLE. NOW I AM NERVOUS TO DRIVE MY CAR DUE TO CONCERN OF FIRE, BUT AM FACED WITH THE UNCERTAINTY OF HOW LONG I WILL BE WAITING UNTIL A GAS TANK BECOMES AVAILABLE. *TR
NHTSA ODI #10639443
931,017 miles · Sep 25, 2014
Fuel/propulsion System
SMELLED GAS IN GARAGE. CHECKED LEAKING. PULLED OUT ON DRIVE . SAW LEAKING AGAIN. TOOK TO MECHANIC AND HE VERIFIED THE SEAM ON THE TANK HAD A LEAK. TOLD NOT TO SET IN GARAGE OR DRIVE UNTIL FIXED. DANGEROUS. *TR
NHTSA ODI #10639146
108,000 miles · Sep 19, 2014
Fuel/propulsion System
TL* THE CONTACT OWNS A 2007 FORD EDGE. THE CONTACT STATED THAT FUEL WAS LEAKING FROM THE SEAMS OF THE TANK. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 108,000.
NHTSA ODI #10637570
103,000 miles · Sep 16, 2014
Fuel/propulsion System
I WAS SMELLING FUEL EVERYTIME I WALKED AROUND MY CAR. I HAD MY BOYFRIEND LOOK AT IT AND HE SAID THAT THE SEALS ON THE FUEL TANK ARE CORRODED AND THAT I WOULD NEED A NEW FUEL TANK. AFTER CALLING FORD, WHICH CHOOSES NOT TO DO ANYTHING ABOUT THIS, IT IS GOING TO COST CLOSE TO $2,700 TO HAVE IT REPLACED. I DRIVE MY CHILDREN AROUND I…
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I WAS SMELLING FUEL EVERYTIME I WALKED AROUND MY CAR. I HAD MY BOYFRIEND LOOK AT IT AND HE SAID THAT THE SEALS ON THE FUEL TANK ARE CORRODED AND THAT I WOULD NEED A NEW FUEL TANK. AFTER CALLING FORD, WHICH CHOOSES NOT TO DO ANYTHING ABOUT THIS, IT IS GOING TO COST CLOSE TO $2,700 TO HAVE IT REPLACED. I DRIVE MY CHILDREN AROUND IN THIS VEHICLE. FORD REFUSES TO LIST THIS AS A RECALL. WHY??? MOST PEOPLE WHO DRIVE THIS TYPE OF CAR, HAS A FAMILY OR CHILDREN. IT IS VERY SCARY TO THINK THAT MY CAR COULD POSSIBLY CATCH ON FIRE, OR WORSE. *TR
NHTSA ODI #10633565
103,000 miles · Sep 13, 2014
Fuel/propulsion System
I RECENTLY PURCHASED A 2007 FORD EDGE SEL AWD. I HAVE HAD NO PROBLEMS WITH THE VEHICLE UNTIL THIS PAST THURSDAY (09/11/2014) WHEN I PUT $40.00 WORTH OF GAS IN IT WHEN IT WAS CLOSE TO EMPTY. AFTER PUTTING IN $40.00 WORTH OF GAS, IT GAVE ME A APPROXIMATELY 3/4 TANK OF GAS. I THEN PARKED IT AT MY PLACE OF WORK (NO INCLINE OF ANY …
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I RECENTLY PURCHASED A 2007 FORD EDGE SEL AWD. I HAVE HAD NO PROBLEMS WITH THE VEHICLE UNTIL THIS PAST THURSDAY (09/11/2014) WHEN I PUT $40.00 WORTH OF GAS IN IT WHEN IT WAS CLOSE TO EMPTY. AFTER PUTTING IN $40.00 WORTH OF GAS, IT GAVE ME A APPROXIMATELY 3/4 TANK OF GAS. I THEN PARKED IT AT MY PLACE OF WORK (NO INCLINE OF ANY SORT) AND STARTED TO SMELL GAS. THE TANK IS LEAKING ON THE PASSENGER SIDE UNDERNEATH. AFTER WORK, I DROVE HOME (MAYBE 10 MILES) AND HAVE NOT EVEN MOVED THE VEHICLE UNTIL TODAY (09/13/2014) AND ONLY HAVE 1/4 TANK OF GAS LEFT. NOT ONLY IS IT LEAKING GAS BUT THE INSIDE OF THE VEHICLE WREAKS. I HAVE A 2 MONTH OLD CHILD WHO I AM AFRAID TO TAKE IN THE VEHICLE NOW BECAUSE THE SMELL IS SO STRONG. THIS ISSUE NEEDS TO BE RESOLVED AS I AM NOT THE ONLY PERSON WHO HAS COMPLAINED ABOUT THIS SITUATION. I SEE THAT 2008 FORD EDGE MODELS HAVE BEEN RECALLED DUE TO THE SAME PROBLEM. I REFUSE TO SPEND CLOSE TO $2000.00 TO FIX THE PROBLEM. THANK YOU. *TR
NHTSA ODI #10632968
113,000 miles · Sep 9, 2014
Fuel/propulsion System
FOR SEVERAL DAYS PRIOR TO AND AFTER FILLING THE GAS TANK, THERE WAS A STRONG SMELL OF GASOLINE WHILE DRIVING, WHILE PARKED IN GARAGE AND WHILE PARKED IN LOT. DEALERSHIP NOTED THAT THE GAS TANK HAD COMPLETELY RUSTED AND WAS LEAKING AT THE SEAM. (ALTHOUGH I DO LIVE IN A NORTHERN STATE, THE VEHICLE HAS BEEN GARAGED DURING WINTER, W…
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FOR SEVERAL DAYS PRIOR TO AND AFTER FILLING THE GAS TANK, THERE WAS A STRONG SMELL OF GASOLINE WHILE DRIVING, WHILE PARKED IN GARAGE AND WHILE PARKED IN LOT. DEALERSHIP NOTED THAT THE GAS TANK HAD COMPLETELY RUSTED AND WAS LEAKING AT THE SEAM. (ALTHOUGH I DO LIVE IN A NORTHERN STATE, THE VEHICLE HAS BEEN GARAGED DURING WINTER, WASHED APPROPRIATELY, WELL TAKEN CARE OF AND ROUTINE MAINTENANCE). THE DEALERSHIP CUSTOMER SERVICE AND FORD CUSTOMER SERVICE WERE EXTREMELY POOR. FORD CUSTOMER SERVICE STATED THAT THERE IS NO RECALL, THEREFORE THEY WILL NOT STAND BEHIND THEIR PRODUCT- THIS WILL NOT BE THE FIRST REVIEW THAT YOU WILL READ ABOUT THIS EXACT SAME ISSUE. AFTER DOING MORE RESEARCH, THE 2007-2009 MODELS HAVE THE SAME FUEL TANK AND THE 2008 MODEL HAS BEEN RECALLED FOR THIS ISSUE. A 7 YEAR OLD CAR SHOULD NOT HAVE TO HAVE THE GAS TANK REPLACED, ESPECIALLY WHEN THIS IS NOTED AT THE SEAM. THIS MANUFACTURER DEFECT IS A SAFETY LIABILITY THAT FORD DOES NOT WANT TO CLAIM AND REFUSES TO PUT THE SAFETY OF IT'S CUSTOMERS ABOVE THE FINANCIAL BURDEN THIS WOULD CAUSE THEM. THE FUMES ALONE ARE TOXIC AND IF THERE WAS ANY TYPE OF SPARK ON THE ROADWAY, THIS COULD RESULT IN A FIRE, ACCIDENTS AND DEATH. IT'S SAD THAT AN AMERICAN COMPANY HAS SUCH POOR CUSTOMER SERVICE AND POOR SAFETY STANDARDS. THIS WILL BE THE LAST FORD VEHICLE THAT I WILL OWN. *TR
NHTSA ODI #10631857
130,000 miles · Sep 5, 2014
Fuel/propulsion System
STARTED SMELLING GASOLINE EVERY TIME MY CAR WAS IN THE GARAGE. SEEMED TO HAPPEN RIGHT AFTER I FILLED UP. RESEARCHED INTERNET FOR "2007 FORD EDGE FUEL SMELL" AND FOUND SEVERAL COMPLAINTS AND WHAT LOOKS LIKE A VERY EXPENSIVE REPAIR (OEM FUEL TANK AVERAGES $1700 PLUS LABOR). TOOK CAR TO DEALER AND FOUND OUT THE FUEL TANK WAS DEFEC…
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STARTED SMELLING GASOLINE EVERY TIME MY CAR WAS IN THE GARAGE. SEEMED TO HAPPEN RIGHT AFTER I FILLED UP. RESEARCHED INTERNET FOR "2007 FORD EDGE FUEL SMELL" AND FOUND SEVERAL COMPLAINTS AND WHAT LOOKS LIKE A VERY EXPENSIVE REPAIR (OEM FUEL TANK AVERAGES $1700 PLUS LABOR). TOOK CAR TO DEALER AND FOUND OUT THE FUEL TANK WAS DEFECTIVE AND NEEDED REPLACEMENT. WAS TOLD BY THE DEALER THAT IT WAS NOT SAFE TO DRIVE. REQUESTING A RECALL BEFORE SOMEONE GETS KILLED. *TR
NHTSA ODI #10631056
88,000 miles · Sep 2, 2014
Fuel/propulsion System
GAS TANK IS LEAKING FROM THE TOP ONTO THE PASSENGERS SIDE OF THE VEHICLE WHEN TANK IS NEAR FULL. NOTICED LEAK ABOUT A WEEK AGO. *TR
NHTSA ODI #10629997
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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