NHTSA owner reports · September 18, 2026 snapshot.
Fuel System, Gasoline complaints
36 reportsClear category filter47,000 miles · Jun 3, 2014
Fuel System, Gasoline
TL* THE CONTACT OWNS A 2007 FORD EDGE. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, FUEL FUMES WERE EMITTED INTO THE VEHICLE. LATER, THE CONTACT NOTICED THAT FUEL LEAKED ONTO THE GARAGE FLOOR. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE FUEL TANK SUFFERED FROM RUST AND CORROSION AROUND SEV…
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TL* THE CONTACT OWNS A 2007 FORD EDGE. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, FUEL FUMES WERE EMITTED INTO THE VEHICLE. LATER, THE CONTACT NOTICED THAT FUEL LEAKED ONTO THE GARAGE FLOOR. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE FUEL TANK SUFFERED FROM RUST AND CORROSION AROUND SEVERAL OF THE SEAMS. AS A RESULT, THE FUEL TANK NEEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 47,000.
NHTSA ODI #10595886
100,000 miles · May 5, 2014
Fuel System, Gasoline
THE FUEL TANK SEEMS TO BE LEAKING AT THE SEAM. FUEL IS DRIPPING TO THE GROUND. ON LINE THERE ARE SEVERAL PEOPLE THAT HAVE HAD THE SAME ISSUE. I HAVE NEVER HAD THE PROBLEM WITH CARS 3 TIMES THE AGE. COULD THIS PLEASE BE LOOKED IN TO. *TR
NHTSA ODI #10586513
120,000 miles · Apr 18, 2014
Fuel System, Gasoline
I BOUGHT THIS 2007 FORD EDGE NEW AND IT HAS BEEN KEPT IN A GARAGE THE ENTIRE TIME I HAVE OWNED IT. I NOTICED A SMELL OF GASOLINE WHILE IT WAS IN THE GARAGE AND TOOK IT TO HAVE IT LOOKED AT. WE FOUND A 2 INCH RUSTED HOLE IN THE TOP OF THE GAS TANK. FORD CLAIMS NO OTHER SIMILAR PROBLEMS HAVE BEEN REPORTED AND HAS REFUSED TO DO AN…
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I BOUGHT THIS 2007 FORD EDGE NEW AND IT HAS BEEN KEPT IN A GARAGE THE ENTIRE TIME I HAVE OWNED IT. I NOTICED A SMELL OF GASOLINE WHILE IT WAS IN THE GARAGE AND TOOK IT TO HAVE IT LOOKED AT. WE FOUND A 2 INCH RUSTED HOLE IN THE TOP OF THE GAS TANK. FORD CLAIMS NO OTHER SIMILAR PROBLEMS HAVE BEEN REPORTED AND HAS REFUSED TO DO ANYTHING ABOUT IT. ALTHOUGH I HAVE FOUND NUMEROUS FORUMS FROM PEOPLE THAT HAVE THE SAME PROBLEM. I BELIEVE THIS TO BE A MANUFACTURE DEFECT AND A POTENTIAL FIRE HAZARD. *TR
NHTSA ODI #10583601
100,000 miles · Feb 27, 2014
Fuel System, Gasoline
STRONG FUEL ODOR PRESENT INSIDE AND OUTSIDE OF THE VEHICLE. AFTER FUELING NOTICED A STEADY DRIP FROM FUEL TANK. BROUGHT VEHICLE TO PRIVATE MECHANIC AND WAS TOLD FUEL TANK NEEDED TO BE REPLACED AS IT SHOWED EVIDENCE OF CORROSION ON THE TOP OF THE TANK. FORD HAS BEEN NOTIFIED AND WILL NOT ASSIST WITH REPAIR NOR WILL THEY ADMIT …
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STRONG FUEL ODOR PRESENT INSIDE AND OUTSIDE OF THE VEHICLE. AFTER FUELING NOTICED A STEADY DRIP FROM FUEL TANK. BROUGHT VEHICLE TO PRIVATE MECHANIC AND WAS TOLD FUEL TANK NEEDED TO BE REPLACED AS IT SHOWED EVIDENCE OF CORROSION ON THE TOP OF THE TANK. FORD HAS BEEN NOTIFIED AND WILL NOT ASSIST WITH REPAIR NOR WILL THEY ADMIT IT IS A DESIGN DEFECT OR ACKNOWLEDGE OTHER COMPLAINTS FOR FAULTY FUEL TANKS. IT IS NOT NORMAL FOR A FUEL TANK TO ROT ON A 6 YEAR OLD VEHICLE.
NHTSA ODI #10567217
89,000 miles · Feb 7, 2014
Fuel System, Gasoline
I WAS JUST DRIVING DOWN THE ROAD AND HEARD A LOUD NOISE AND DAYS LATER STARTED SMELLING GAS AND LOOKED UNDERNEATH THE VEHICLE ONLY TO DISCOVER THAT THE GAS TANK SPLIT AND STARTED LEAKING.....CONTACTED FORD MOTOR COMPANY AND THEY REFUSE TO FIX IT OR RECALL IT. I CAN'T AFFORD TO GET A NEW TANK THAT COST $2,300 AND FORD RECALLED …
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I WAS JUST DRIVING DOWN THE ROAD AND HEARD A LOUD NOISE AND DAYS LATER STARTED SMELLING GAS AND LOOKED UNDERNEATH THE VEHICLE ONLY TO DISCOVER THAT THE GAS TANK SPLIT AND STARTED LEAKING.....CONTACTED FORD MOTOR COMPANY AND THEY REFUSE TO FIX IT OR RECALL IT. I CAN'T AFFORD TO GET A NEW TANK THAT COST $2,300 AND FORD RECALLED THE 2008 MODELS FOR THIS REASON BUT REFUSED TO RECALL THE 2007 MODELS....I AM VERY ANGRY BECAUSE AS IT IS I AM GETTING ABOUT 10 MILE TO THE GALLON ON GAS AND ONLY ABLE TO PUT ABOUT 4 GALLONS IN THE TANK AT A TIME AND DRIVE AROUND EVERY DAY WORRYING IF I WOULD EVER GET INTO AN ACCIDENT GOD FORBID I WOULD MAYBE BLOW UP BECAUSE OF THE LEAKING GAS TANK ON THIS VEHICLE... *TR
NHTSA ODI #10563364
141,000 miles · Jan 6, 2014
Fuel System, GasolinePower Train
GAS TANK SEAL CORRODED. MECHANIC WAS INSPECTING CAR WHEN HE FOUND THAT BESIDES THE TRANSMISSION TRANSFER CASE NEEDED TO BE REPLACED, THE GAS TANK WAS LEAKING GAS. IT APPEARS THE SEAL IS CORRODED. I WAS TOLD THAT THE NEW TANK WAS APPROXIMATELY 1500. (JUST THE PART) AND ABOUT 600. IN LABOR. I FEEL THAT THIS SHOULD BE REPAIRED …
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GAS TANK SEAL CORRODED. MECHANIC WAS INSPECTING CAR WHEN HE FOUND THAT BESIDES THE TRANSMISSION TRANSFER CASE NEEDED TO BE REPLACED, THE GAS TANK WAS LEAKING GAS. IT APPEARS THE SEAL IS CORRODED. I WAS TOLD THAT THE NEW TANK WAS APPROXIMATELY 1500. (JUST THE PART) AND ABOUT 600. IN LABOR. I FEEL THAT THIS SHOULD BE REPAIRED FREE OF CHARGE BY FORD, THIS SHOULD NOT HAPPEN ON A VEHICLE THAT IS ONLY 6 YEARS OLD. I CAN ONLY PUT ABOUT 5 GALLONS OF GAS IN, NOT TO EXCEED JUST UNDER THE HALF TANK MARK. ALSO, CANNOT PARK CAR ON ANYTHING BUT A LEVEL SURFACE. *TR
NHTSA ODI #10558690
103,000 miles · Dec 19, 2013
Fuel System, Gasoline
2007 FORD EDGE HAS A GAS TANK LEAK PROBLEM. NOTICE A STRONG GAS SMELL AROUND VEHICLE AND TOOK IT TO A FORD DEALER. MECHANIC FOUNDED GAS LEAKING FROM THE GAS TANK (UNSAFE TO DRIVE, POTENTIAL FIRE HAZARD). *TR
NHTSA ODI #10556630
121,000 miles · Nov 9, 2013
Fuel System, Gasoline
AFTER DRIVING THE VEHICLE FOR APPROXIMATELY 80 MILES ONE SATURDAY MORNING, MY WIFE PARKED IN THE GARAGE AS USUAL. I ENTERED THE GARAGE AFTER THE CAR SAT FOR ABOUT AN HOUR AND DETECTED THE SMELL OF GASOLINE. PROCEEDED TO INSPECT THE VEHICLE AND DETERMINED THAT THE SMELL WAS COMING FROM ENGINE COMPARTMENT. I CONTINUED TO INVEST…
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AFTER DRIVING THE VEHICLE FOR APPROXIMATELY 80 MILES ONE SATURDAY MORNING, MY WIFE PARKED IN THE GARAGE AS USUAL. I ENTERED THE GARAGE AFTER THE CAR SAT FOR ABOUT AN HOUR AND DETECTED THE SMELL OF GASOLINE. PROCEEDED TO INSPECT THE VEHICLE AND DETERMINED THAT THE SMELL WAS COMING FROM ENGINE COMPARTMENT. I CONTINUED TO INVESTIGATE THE SOURCE AND EVENTUALLY FOUND WHAT APPEARED TO BE FUEL SEEPING FROM THE FUEL RAIL, ALSO KNOWN AS THE FUEL SUPPLY MANIFOLD. I CONCLUDED THAT THE FUEL WAS LEAKING IN THE AREA OF THE TEST PORT WHICH IS CONNECTED TO THE RAIL. I COULD TELL THAT FUEL WAS LEAKING AT THE POINT WHERE THE TEST PORT IS CONNECTED TO THE RAIL. I HAD THE VEHICLE TOWED TO A FORD DEALER, AND I WAS TOLD THAT THE FUEL RAIL PORT WAS NOT REPAIRABLE AND A NEW FUEL RAIL WAS REQUIRED. THIS WAS A DANGEROUS SITUATION AS GASOLINE COULD HAVE LEAKED OUT ONTO VERY HOT ENGINE PARTS AND POTENTIALLY CAUSE A FIRE. *TR
NHTSA ODI #10551616
80,000 miles · Oct 20, 2013
Fuel System, Gasoline
FOR A FEW WEEKS THERE WAS A STRONG GAS SMELL ALL AROUND THE FORD EDGE. BROUGHT IT IN TO BE LOOKED AT. THEY WERE STUMPED, THE GAS TANK WAS NOT LEAKING, THERE WAS NO DAMAGE TO IT NOR ANY RUST OF ANY KIND YET THEY ALSO COULD SMELL THE GAS. AFTER TIME, THEY FOUND THAT GAS WAS SEEPING THROUGH THE SEAMS OF THE TANK. CALLED MULTIPLE FO…
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FOR A FEW WEEKS THERE WAS A STRONG GAS SMELL ALL AROUND THE FORD EDGE. BROUGHT IT IN TO BE LOOKED AT. THEY WERE STUMPED, THE GAS TANK WAS NOT LEAKING, THERE WAS NO DAMAGE TO IT NOR ANY RUST OF ANY KIND YET THEY ALSO COULD SMELL THE GAS. AFTER TIME, THEY FOUND THAT GAS WAS SEEPING THROUGH THE SEAMS OF THE TANK. CALLED MULTIPLE FORD DEALERSHIPS AND THEY SAID THEY HAVE BEEN SEEING QUITE A BIT OF THIS ON EDGES AND HAVE REPAIRED 4 WITHIN THE PAST MONTH IN OUR AREA. THEY INFORMED US HOW EXTREMELY DANGEROUS IT WAS TO CONTINUE DRIVING THE CAR, IF WE WERE IN AN ACCIDENT OR IF ANYONE THREW A LIT CIGARETTE, THE CAR COULD EXPLODE. VERY UNSAFE. WE CALLED FORD BECAUSE WE SAW MANY RECALLS ON NEWER MODELS FOR THE SAME THING. THEY DENIED THE CLAIM FOR THE 07 MODEL. WE GOT IT REPAIRED FOR $1700 AT A FORD DEALERSHIP. THEY ARE NOT OFFERING A REIMBURSEMENT FOR A MALFUNCTIONING PART AND A VERY DANGEROUS SITUATION. *TR
NHTSA ODI #10548621
84,000 miles · Sep 30, 2013
Fuel System, Gasoline
A STRONG ODOR OF GASOLINE WAS DETECTED AROUND THE VEHICLE. MECHANIC INVESTIGATED. GAS TANK HAD RUSTED THROUGH. GASOLINE WAS LEAKING. ACCORDING TO DIFFERENT BLOGS, THIS IS AN ISSUE THAT MANY OTHER OWNERS HAVE HAD WITH 2007 FORD EDGE. REPLACEMENT OF TANK IS OUTRAGEOUSLY EXPENSIVE. FORD DOES NOT HAVE A RECALL NOR A BULLETIN O…
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A STRONG ODOR OF GASOLINE WAS DETECTED AROUND THE VEHICLE. MECHANIC INVESTIGATED. GAS TANK HAD RUSTED THROUGH. GASOLINE WAS LEAKING. ACCORDING TO DIFFERENT BLOGS, THIS IS AN ISSUE THAT MANY OTHER OWNERS HAVE HAD WITH 2007 FORD EDGE. REPLACEMENT OF TANK IS OUTRAGEOUSLY EXPENSIVE. FORD DOES NOT HAVE A RECALL NOR A BULLETIN ON THE PROBLEM AND GIVE NOT MORE THAN AN APOLOGY FOR THE INCONVENIENCE. *TR
NHTSA ODI #10546225
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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