NHTSA owner reports · September 18, 2026 snapshot.
Power Train complaints
193 reportsClear category filter125,000 miles · Mar 22, 2017
Electronic Stability Control (esc)Fuel/propulsion SystemPower Train
FORD DEALER HAS MY 2007 FORD EDGE DUE TO IT STALLING OUT WHILE DRIVING 60 MPH ON A HIGHWAY CAUSING MY ENGINE TO DIE SO I HAD TO GET TOWED HOME AND OFF OF THE HIGHWAY. THE DEALER ORIGINALLY THOUGHT IT WAS THE ELECTRONIC THROTTLE BODY BUT THEY HAVE NOW DETERMINED THAT WAS NOT THE PROBLEM. INSTEAD IT IS THE PCM WHICH IS COSTING ME …
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FORD DEALER HAS MY 2007 FORD EDGE DUE TO IT STALLING OUT WHILE DRIVING 60 MPH ON A HIGHWAY CAUSING MY ENGINE TO DIE SO I HAD TO GET TOWED HOME AND OFF OF THE HIGHWAY. THE DEALER ORIGINALLY THOUGHT IT WAS THE ELECTRONIC THROTTLE BODY BUT THEY HAVE NOW DETERMINED THAT WAS NOT THE PROBLEM. INSTEAD IT IS THE PCM WHICH IS COSTING ME OVER $1500, IF THAT EVEN FIXES THIS. PLUS I HAVE BEEN PAYING FOR A RENTAL CAR BECAUSE THE DEALERS DON'T HAVE FREE LOANER VEHICLES. SO THIS WHOLE THING IS GOING TO COST ME ABOUT $2000. NOW I HAVE BEEN RESEARCHING THIS PROBLEM, AND CAN CLEARLY TELL THIS IS NOT NORMAL WEAR AND TEAR INSTEAD IT IS A FAULTY PART THAT SO MANY OTHER OWNERS ARE EXPERIENCING. I CLEARLY SEE FORD HAS BEEN MADE AWARE OF THIS PROBLEM AND THEY SHOULD BE TAKING RESPONSIBILITY FOR THEIR MISTAKE. FORD HAS REFUSED TO ISSUE A RECALL ON THIS PROBLEM EVEN THOUGH IT IS VERY DANGEROUS AND COSTLY FOR THE VEHICLE OWNER. I HAVE NEVER OWNED A FORD BEFORE AND LIKELY WILL NOT AGAIN BECAUSE OF THIS BAD EXPERIENCE.
NHTSA ODI #10967799
125,000 miles · Mar 8, 2017
Power Train
I WAS EXITING THE FREEWAY, SLOWING DOWN ON THE RAMP, AND I LOST COMPLETE LOSS OF ACCELERATION AS I CAME TO A STOP AT THE LIGHT. UP ON GREEN SIGNAL, EVEN WITH PUSHING OF THE GAS PEDAL, MY CAR DID NOT ACCELERATE. AND IN A FEW SECONDS, THE TRANSMISSION ENGAGED VIOLENTLY WITH A HUGE NOISE AND LED TO SUDDEN ACCELERATION, FOLLOWED BY …
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I WAS EXITING THE FREEWAY, SLOWING DOWN ON THE RAMP, AND I LOST COMPLETE LOSS OF ACCELERATION AS I CAME TO A STOP AT THE LIGHT. UP ON GREEN SIGNAL, EVEN WITH PUSHING OF THE GAS PEDAL, MY CAR DID NOT ACCELERATE. AND IN A FEW SECONDS, THE TRANSMISSION ENGAGED VIOLENTLY WITH A HUGE NOISE AND LED TO SUDDEN ACCELERATION, FOLLOWED BY LOSS OF ACCELERATION AGAIN. I TRIED PUSHING THE PEDAL ONE MORE TIME BUT REALIZED THAT THERE WAS NO ACCELERATION. I THEN STOPPED AND GOT MY VEHICLE TOWED TO A FORD DEALERSHIP AND THEIR FINDING IS THAT THE TRANSMISSION NEEDS TO BE REPLACED COMPLETELY.
NHTSA ODI #10959683
95,000 miles · Jan 31, 2017
Power Train
PERSISTENT SMELL WHEN DRIVING AND THEN FOUND DARK "OIL" SPOTS THAT SPREAD THROUGHOUT UNDER SIDE OF THE VEHICLE AND ON MY GARAGE FLOOR AFTER BEING PARKED. BROUGHT TO FORD DEALERSHIP: PTU FAILURE IS WHAT WE ARE BEING TOLD. VERY COSTLY REPAIR/REPLACEMENT CHARGE OF PTU ASSEMBLY, APPROXIMATELY $1500. I'M PUTTING IN THIS COMPLAINT BEC…
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PERSISTENT SMELL WHEN DRIVING AND THEN FOUND DARK "OIL" SPOTS THAT SPREAD THROUGHOUT UNDER SIDE OF THE VEHICLE AND ON MY GARAGE FLOOR AFTER BEING PARKED. BROUGHT TO FORD DEALERSHIP: PTU FAILURE IS WHAT WE ARE BEING TOLD. VERY COSTLY REPAIR/REPLACEMENT CHARGE OF PTU ASSEMBLY, APPROXIMATELY $1500. I'M PUTTING IN THIS COMPLAINT BECAUSE I HAVE SEEN MANY, MANY COMPLAINTS OF OTHER PEOPLE EXPERIENCING SIMILAR ISSUE WITH THIS MAKE, MODEL AND YEAR. PLEASE CONSIDER INVESTIGATING, AND IF THIS HAPPENED TO SOMEONE ELSE PLEASE PUT IN YOUR COMPLAINT SO IT WILL GO TO INVESTIGATION, THANK YOU! *TR
NHTSA ODI #10948636
96,987 miles · Jan 20, 2017
Power Train
I WAS DRIVING DOWN THE INTERSTATE WHEN I SUDDENLY LOST POWER. I MANAGED TO SOMEHOW GET MY CAR OFF THE ROAD AND EXIT THE HIGHWAY (I WAS JUST ABOUT TO THE EXIT WHEN THIS HAPPENED). IT WAS LOOKED AT BY A FORD DEALER WHO SAID THE PCM DIED AND TOOK OUT AT LEAST THREE COIL PACKS. TOLD ME IF I DROVE IT ANY FURTHER IT WOULD LIKELY CATCH…
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I WAS DRIVING DOWN THE INTERSTATE WHEN I SUDDENLY LOST POWER. I MANAGED TO SOMEHOW GET MY CAR OFF THE ROAD AND EXIT THE HIGHWAY (I WAS JUST ABOUT TO THE EXIT WHEN THIS HAPPENED). IT WAS LOOKED AT BY A FORD DEALER WHO SAID THE PCM DIED AND TOOK OUT AT LEAST THREE COIL PACKS. TOLD ME IF I DROVE IT ANY FURTHER IT WOULD LIKELY CATCH FIRE. UP TO THIS POINT I HADN'T HAD ANY PROBLEMS WITH THIS CAR. IT WAS RUNNING FINE. THIS ALL HAPPENED SO QUICKLY AND IN SUCH A DANGEROUS LOCATION THAT IT COULD HAVE CAUSED AN ACCIDENT. UPON RESEARCHING PLACES TO FIX THE ISSUE, I NOTICED A RATHER LARGE AMOUNT OF COMPLAINTS ABOUT THIS SAME ISSUE AND THIS SAME MAKE MODEL AND CAR YEAR. EACH COMPLAINT SAID THIS HAPPENED ON THE FREEWAY. *TR
NHTSA ODI #10946720
129,000 miles · Jan 12, 2017
Power Train
WHILE DRIVING ON A FREEWAY SUDDENLY A PUNGENT SMELL FILLED THE CABIN AND THAT WAS UNBEARABLE ALONG WITH A HUGE CRACKING SOUND THAT DIDN'T STOP... TOOK THE NEXT EXIT AND STOPPED AT A PARKING SPOT. TOOK TO THE FORD DEALER THE SAME DAY AND THEY DIAGNOSED IMMEDIATELY THAT THE PTU NEEDS TO BE REPLACED AND THAT'S A KNOW ISSUE WHERE AL…
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WHILE DRIVING ON A FREEWAY SUDDENLY A PUNGENT SMELL FILLED THE CABIN AND THAT WAS UNBEARABLE ALONG WITH A HUGE CRACKING SOUND THAT DIDN'T STOP... TOOK THE NEXT EXIT AND STOPPED AT A PARKING SPOT. TOOK TO THE FORD DEALER THE SAME DAY AND THEY DIAGNOSED IMMEDIATELY THAT THE PTU NEEDS TO BE REPLACED AND THAT'S A KNOW ISSUE WHERE ALMOST ALL THE FORD EDGES OF 2007 AND 08 HAVE THE PTU ISSUE. THE SMELL IS FROM THE OIL THAT LEAKED FROM THE PTU WHICH FELL ON THE EXHAUST. PAID AROUND $1800 TO REPLACE THE PTU. I AM WONDERING WHY THERE IS NO RECALL AS IT SEEM TO HAPPEN FOR MOST OF THE EDGES. CALLED THE FORD CORPORATE CUSTOMER CARE TO REPORT THE ISSUE AND THEY DIDN'T CARE TO LISTEN AND ASKED TO DEAL WITH THE LOCAL DEALERS. DIDN'T EXPECT THIS FROM FORD AND I WOULD REQUEST NHTSA ODI TEAM TO LOOK INTO THIS ISSUE AND FLAG THIS AS RECALL AS THIS COULD CREATE A SERIOUS CRASH WHEN IT HAPPENS ON A FREEWAY AS IT COULD SLOW DOWN THE VEHICLE SUDDENLY AND THINK ABOUT THE CONDITION OF THE INFANTS WHO COULD INHALE THE GASES. I LITERALLY HAD ISSUE INHALING FOR NEXT COUPLE OF DAYS AS THE SMELL WAS THAT BAD WHEN IT LEAKED. *TR
NHTSA ODI #10944686
180,000 miles · Dec 29, 2016
Power Train
TL* THE CONTACT OWNS A 2007 FORD EDGE. WHILE DRIVING 60 MPH, THE PCM MALFUNCTIONED AND THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO BE REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 180,000. THE VIN WAS NOT AVAILABLE. UPDATED 05/31/17*LJ *TR
NHTSA ODI #10938543
116,000 miles · Nov 18, 2016
Power Train
TL* THE CONTACT OWNS A 2007 FORD EDGE. THE CONTACT STATED THAT THE TRANSMISSION FAILED WHILE DRIVING APPROXIMATELY 45 MPH. THE VEHICLE EMITTED A LOUD NOISE UNDER THE HOOD AND THE WRINGER AND AIR BAG WARNING INDICATORS ILLUMINATED. THE CONTACT WAS ABLE TO COAST THE VEHICLE ONTO THE ROAD SHOULDER THE VEHICLE WAS RESTARTED AND RET…
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TL* THE CONTACT OWNS A 2007 FORD EDGE. THE CONTACT STATED THAT THE TRANSMISSION FAILED WHILE DRIVING APPROXIMATELY 45 MPH. THE VEHICLE EMITTED A LOUD NOISE UNDER THE HOOD AND THE WRINGER AND AIR BAG WARNING INDICATORS ILLUMINATED. THE CONTACT WAS ABLE TO COAST THE VEHICLE ONTO THE ROAD SHOULDER THE VEHICLE WAS RESTARTED AND RETURNED TO NORMAL. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS 116,000. UPDATED 02/21/17*LJ
NHTSA ODI #10926966
Mileage unknown · Nov 18, 2016
Power Train
DURING LEFT TURNS ENGINE RPM'S DROP AND BRAKE PEDAL SOFTENS AND FLUCTUATES. CITY STREETS .. LEFT TURNS
NHTSA ODI #10926862
97,000 miles · Nov 17, 2016
EnginePower Train
TL* THE CONTACT OWNS A 2007 FORD EDGE. WHILE OPERATING THE VEHICLE, A BURNING CHEMICAL ODOR WAS PRESENT AND A GRINDING NOISE WAS HEARD COMING FROM THE ENGINE. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE POWER TRANSFER CASE WAS FAULTY AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURE…
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TL* THE CONTACT OWNS A 2007 FORD EDGE. WHILE OPERATING THE VEHICLE, A BURNING CHEMICAL ODOR WAS PRESENT AND A GRINDING NOISE WAS HEARD COMING FROM THE ENGINE. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE POWER TRANSFER CASE WAS FAULTY AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 97,000.
NHTSA ODI #10926730
40,000 miles · Sep 29, 2016
Electrical SystemPower Train
DEFECTIVE POWER CONTROL MODULE ON FORD FROM THESE YEARS CAUSES ENGINE TO STALL, RUN POORLY AND CAUSE ELECTRICAL PROBLEMS AFFECTING THE STEERING, BRAKES AND TRANSMISSION. THIS EXTREMELY COMMON FORD DEFECT CAN CREATE A POTENTIALLY DEADLY VEHICLE CONTROL FAILURE AT HIGHWAY SPEED.
NHTSA ODI #10910606
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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