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

Power Train complaints

193 reports

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Mileage unknown · Mar 17, 2009

Power Train

WHEN I AM ON AN INCLINE AND I TAKE MY FOOT OFF OF THE GAS MY CAR WILL ROLL BACKWARDS. I TOOK IT TO THE DEALERSHIP TO BE FIXED BECAUSE I HEARD THERE WAS A TSA FOR IT. THEY SAID IT WAS NORMAL TO ROLL BACKWARDS AND THAT I NEEDED TO KEEP MY FOOT ON THE BRAKE. I HAVE ALMOST HIT ANOTHER VEHICLE BECAUSE OF IT ROLLING BACKWARDS. THIS SH…

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NHTSA ODI #10262101

15,347 miles · Feb 25, 2009

Power Train

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MY 2007 FORD EDGE IS NOW IN THE PROCESS OF HAVING A TRANSMISSION LEAK REPAIRED DUE TO FAULTY AXLE SEALS (SO I'M TOLD) FOR THE FOURTH TIME IN 18 MONTHS. I WAS INFORMED BY A SERVICE MANAGER THAT MY EDGE IS NOT THE FIRST HE HAS SEEN TO HAVE THIS PROBLEM. ALSO FORD HAS STOPPED SHIPPING REPLACEMENT SEALS BECAUSE THEY ARE NO BETTER THAN THE ORIGINALS. FORD'S STANCE SEEMS TO BE THAT THERE IS NO MAJOR PROBLEM, THE VEHICLE WAS JUST REPAIRED IN JANUARY OF THIS YEAR FOR THE SAME PROBLEM. THE PROBLEM FIRST APPEARED IN DECEMBER OF 07, I TOOK DELIVERY IN AUGUST OF 07. THE VEHICLE WAS ALSO REPAIRED IN 08 FOR THIS PROBLEM. *TR

NHTSA ODI #10259920

19,000 miles · Jan 14, 2009

EquipmentPower Train

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BURNING SMELL ORIGINATING FROM FAILED SEAL (NOW ON NATIONAL BACKORDER THIS PAST YEAR) IN PTU ASSEMBLY ON MOST FORD EDGE AND MERCURY MKX MODELS. I'VE HAD MY VEHICLE IN THE SHOP 3 TIMES OVER THE PAST YEAR AND THEY DO NOT HAVE REPLACEMENT PTU ASSEMBLIES IN STOCK AS THE COMPANY WHO MADE THEM ARE NOW OUT OF BUSINESS. TRANSMISSION FLUID LEAKS FROM PTU ASSEMBLY ONTO EXHAUST, INTO VENTS AND INTO OUR LUNGS. VEHICLE IS STILL IN THE SERVICE AREA AT MIDWAY FORD IN ROSEVILLE, MN. THEY SAY I CAN DRIVE IT UNTIL THEY FIND A PART, HOWEVER IT IS WINTER AND THAT IS NOT AN OPTION AS THE WINDOWS MUST REMAIN OPEN. MORE INFO AT -> HTTP://WWW.FORDEDGEFORUM.COM/INDEX.PHP?SHOWTOPIC=1654&ST=140. *TR

NHTSA ODI #10255012

12,000 miles · Dec 23, 2008

Power Train

POWER TRANSFER UNIT LEAKING ONTO EXHAUST CAUSING A BURNING RUBBER SMELL INTO THE CABIN WHEN STOPPED. OCCURS AFTER DRIVING VEHICLE FOR 10-15MIN. TOOK VEHICLE TO DEALERSHIP SEALS REPLACED APPROXIMATELY 2 WEEKS AGO(12-8-08). SMELL RESOLVED. YESTERDAY SMELL RETURNED (12-22-08). BELIEVE SMELL IS FROM LEAKING SEALS AGAIN. LEAKING ONTO…

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NHTSA ODI #10252625

10 miles · Dec 14, 2008

Power Train

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MY 2007 FORD EDGE ALL WHEEL DRIVE HAS A LEAKING PROBLEM FROM THE TRANSFER CASE. IT HAS HAD THIS PROBLEM SINCE THE DAY IT WAS NEW. SEVERAL VISITS TO THE DEALER I WAS TOLD IT IS NOT LEAKING ALTHOUGH THERE WAS ALWAYS OIL ON MY DRIVE. I OWN AN AUTO REPAIR SHOP SO I HAD IT IN THE SHOP AND KNEW WITHOUT A DOUBT IT WAS LEAKING. WHAT MAKES IT DANGEROUS IS THE LEAK DRIPS DIRECTLY ON THE EXHAUST PIPE WHICH IS RIGHT BELOW THE TRANSFER CASE. YOU CAN SMELL BURNING OIL AND IT SMOKES A LOT OF TIMES WHEN STOPPING AT STOP SIGNS. THE DEALER HAS WENT AS FAR AS REPLACING THE TRANSFER CASE. THAT FIXED THE PROBLEM FOR A FEW MONTHS BUT THE LEAK ALWAYS COMES BACK. I HAVE RESEARCHED THE PROBLEM AND ON FORDEDGEFORUM.COM HAVE FOUND MANY OWNERS HAVING THE SAME PROBLEM. I AM AFRAID FORD IS NOT ABLE TO FIND A PERMANENT FIX FOR THE PROBLEM AND SOMEONE IS GOING TO GET BURNED. I HAVE READ OF THESE VEHICLES CATCHING ON FIRE BUT HAVE NOT HEARD THE CAUSE. THIS LEAK COULD BE CAUSING IT. IN MY OWN REPAIR SHOP I HAVE NOTICED CUSTOMER VEHICLES HAVE THE SAME LEAK AS MINE. SOMETHING NEEDS TO BE DONE ABOUT IT. THIS AFFECTS THE 2007 AND 2008 FORD EDGE AND LINCOLN MKX MODELS THAT ARE ALL WHEEL DRIVE AND HAVE A TRANSFER CASE OR "PTU UNIT." *TR

NHTSA ODI #10251711

Mileage unknown · Jul 22, 2008

Power Train

AUTOMATIC TRANSMISSION WILL NOT HOLD VEHICLE IN PLACE ON EVEN SLIGHT INCLINE. I.E. VEHICLE IN DRIVE FACING UPHILL WHEN STOPPED AND BRAKE RELEASED VEHICLE WILL ROLL BACKWARD DOWN HILL. VEHICLE FACING DOWNHILL WITH TRANSMISSION IN REVERSE WILL ROLL FORWARD WHEN BRAKE IS RELEASED. *TR

NHTSA ODI #10235252

14,000 miles · Apr 28, 2008

Power Train

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WHEN THE EDGE IS IN DRIVE AND STOPPED ON AN INCLINE IT WILL ROLL BACKWARD WHEN YOU RELEASE THE BRAKE. IT DOESN'T JUST ROLL BACK A LITTLE....IT WILL CONTINUE TO ROLL BACK UNTIL YOU GIVE IT SOME GAS OR STEP ON THE BRAKE. THE FIRST TIME IT HAPPENED I ALMOST ROLLED BACK INTO THE CAR BEHIND ME. I HAVE NEVER EXPERIENCED THIS ROLLBACK IN AN AUTOMATIC VEHICLE. I READ ON THE INTERNET THAT THERE WAS A TSB FOR THIS AND TOOK MY EDGE IN TO HAVE IT "REFLASHED" (AS RECOMMENDED ON A FORD EDGE FORUM) BUT WAS TOLD BY THE DEALER THAT THERE WAS NO FIX (AND NO SUCH TSB) FOR IT AND THAT THIS IS NORMAL. I FEEL IT IS A DANGER AND SHOULD BE CORRECTED OR AT THE VERY LEAST MENTIONED IN THE OWNERS MANUAL. *TR

NHTSA ODI #10225988

Mileage unknown · Apr 18, 2008

Power Train

FORD IN TEXAS. DEALERSHIP CLAIMS THEY CAN NOT DUPLICATE CONCERNS AND WILL NOT GIVE ANY TYPE OF DOCUMENT THAT I BOUGHT EDGE IN FOR CONCERNS UNLESS THEY ARE ABLE TO DUPLICATE 1ST. I FEEL I WAS SOLD A LEMON AND FORD DOES NOT WANT TO DO WARRANTY WORK. . ONE ISSUE MY EDGE WILL ROLL BACK WHILE DRIVING ON AN INCLINE SIMILAR TO ON…

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NHTSA ODI #10224962

Mileage unknown · Mar 31, 2008

Power TrainSeatsService Brakes, HydraulicInjury

2007 FORD EDGE WITH SEVERAL PROBLEMS. CONSUMER STATES THAT THE VEHICLE IS A LEMON. HERE ARE SOME OF THE CAR'S PROBLEMS REAR BRAKE LIGHTS FILL WITH WATER WHEN IT RAINS. SEAT BROKE, SCREW STICKS UP AND CUT A CHILD'S FOOT, BRAKES FAILED AND MORE. *KB THE PIN IN THE GEAR SHIFT DID NOT ENGAGE PROPERLY, LEAVING THE CONSUMER UNABLE T…

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NHTSA ODI #10222852

150 miles · Feb 21, 2008

Exterior LightingPower TrainSeatsInjury

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TL*THE CONTACT OWNS A 2007 FORD EDGE. WHEN THE VEHICLE WAS PURCHASED, THE FRONT PASSENGER SEAT FAILED. THE VEHICLE WAS AT THE DEALER FOR THREE WEEKS TO REPAIR THE SEAT. THE BOLTS IN THE SEAT WERE VISIBLE AND INJURED ONE OF THE PASSENGERS. THE DEALER REPLACED THE SCREWS AND COVERED THEM WITH A RUBBER SEAL; HOWEVER, THEY CONTINUE TO FALL OFF AND EXPOSE THE SCREWS. AT 150 MILES, THE LINING IN THE MOONROOF FELL OFF OF THE VEHICLE AND WAS REPLACED BY THE DEALER. SIX MONTHS LATER, WHILE DRIVING APPROXIMATELY 5 MPH, THE CONTACT HEARD A LOUD GRINDING SOUND WHEN HE DEPRESSED THE BRAKE PEDAL. THE DEALER DIAGNOSED THE FAILURE AND STATED THAT THE BRAKES WERE CORRODED. THE BRAKES WERE REPLACED AND THE ROTORS WERE CLEANED. THE FRONT AND REAR WINDOWS DO NOT GRIP OR SEAL PROPERLY WHEN THEY ARE ROLLED UP OR DOWN. THE DEALER DIAGNOSED THE WINDOW FAILURE ON FOUR OCCASIONS AND EVENTUALLY STATED THAT THEY HAD TO CHANGE THE PAPER ON THE ROLLERS. THE TWO REAR EXTERIOR LIGHTS CONTINUE TO FILL UP WITH WATER. THE DEALER DIAGNOSED THE FAILURE ON THREE OCCASIONS AND REPLACED THE TAIL LIGHTS; HOWEVER, THE FAILURE CONTINUED. THERE SEEMS TO BE A DESIGN FAILURE. ON SEVERAL OCCASIONS, THE GEAR SHIFT FAILED TO ENGAGE IN PARK, DRIVE, AND REVERSE. A PASSENGER HAD TO STOP TRAFFIC SINCE THE GEAR SHIFT WAS LOCKED IN REVERSE. THE FAILURE RECURRED ON FEBRUARY 20, 2008; HOWEVER, THE DEALER STATED THAT THE EARLIEST THEY COULD SCHEDULE AN APPOINTMENT WOULD BE ON MARCH 1, 2008. THE FAILURE OCCURS INTERMITTENTLY AND HAS BEEN IN THE REPAIR SHOP EVERY OTHER WEEK SINCE IT WAS PURCHASED. THE CONTACT IS THE ORIGINAL OWNER. THE DEALER HAS OFFERED NO ASSISTANCE IN REPLACING THE VEHICLE. THE CONTACT WAS ADVISED TO ONLY HAVE THE VEHICLE SERVICED BY A DEALER THAT IS ONE OR MORE HOURS AWAY FROM HER RESIDENCE. THE FAILURE MILEAGE WAS 150 AND CURRENT MILEAGE WAS 8,000. UPDATED 3/25/08 *CN

NHTSA ODI #10219464

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