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2008 Ford Edge

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2008 Ford Edge do not stand out strongly from the model-year median of 724.

About this comparison →

When problems were reported

Mileage at the reported incident

664 reports with mileage · 455 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Air Bags. Review the 437 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 277 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 158 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

39 crash reports15 fire reports23 injury reports

Engine complaints

91 reports
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Mileage unknown · Feb 24, 2026
Engine

The internal water pump failed on my 2008 Ford Edge (3.5L V6), allowing coolant to leak into the engine oil. This caused catastrophic engine damage and complete engine failure. The water pump is internally mounted and driven by the timing chain. When it fails, coolant contaminates the oil, destroying the engine without adequate …

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The internal water pump failed on my 2008 Ford Edge (3.5L V6), allowing coolant to leak into the engine oil. This caused catastrophic engine damage and complete engine failure. The water pump is internally mounted and driven by the timing chain. When it fails, coolant contaminates the oil, destroying the engine without adequate warning. There was no external leak prior to failure. This is a known issue affecting many Ford vehicles with this engine design.

NHTSA ODI #11720256

Mileage unknown · Jan 28, 2026
Engine

I am reporting what I believe to be mileage roll back and fraud. The vehicle was bought from a private seller and upon submitting paperwork to the DMV, it was found that the mileage on the car's odometer was less than the mileage on the car's title information.

NHTSA ODI #11713843

Mileage unknown · Mar 28, 2025
EngineVehicle Speed Control

When I accelerate, my car jerks or the shifting is not smooth anymore. Others have been quoted over $9k to fix this issue.

NHTSA ODI #11651357

130,000 miles · Sep 5, 2023
Engine

The contact owns a 2008 Ford Edge. The contact stated that while driving at an undisclosed speed, the contact stated that the vehicle had been misfiring. The vehicle was taken to an independent mechanic where it was diagnosed with failed programmable module installation (PMI) that needed to be replaced. The vehicle was repaired.…

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The contact owns a 2008 Ford Edge. The contact stated that while driving at an undisclosed speed, the contact stated that the vehicle had been misfiring. The vehicle was taken to an independent mechanic where it was diagnosed with failed programmable module installation (PMI) that needed to be replaced. The vehicle was repaired. The contact stated that the PMI had experienced the failure for a second time. The manufacturer was not made aware of the failure. The failure mileage was approximately 130,000.

NHTSA ODI #11542729

Mileage unknown · Aug 16, 2023
EngineFuel System, Gasoline

The contact owns a 2008 Ford Edge. The contact stated while driving at an undisclosed speed, the vehicle started to jerk, and the contact became aware of a burning odor. The contact pulled over off the roadway. The check engine warning light intermittently illuminated. The vehicle was taken to an independent mechanic to be diagn…

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The contact owns a 2008 Ford Edge. The contact stated while driving at an undisclosed speed, the vehicle started to jerk, and the contact became aware of a burning odor. The contact pulled over off the roadway. The check engine warning light intermittently illuminated. The vehicle was taken to an independent mechanic to be diagnosed. The contact was informed that the water pump had failed. The water pump was replaced however, the failure recurred. The vehicle was taken back to the independent mechanic where it was diagnosed and determined that the brakes had failed and needed to be replaced; however, the failure recurred. The check engine warning light illuminated, and the low oil pressure warning light illuminated. The contact stated that after a week, the failure recurred, and the vehicle failed to shift into the intended gear. Additionally, the contact stated that the vehicle hesitated and stalled. The vehicle was towed to the independent mechanic where it was diagnosed that the engine failed and needed to be replaced. Additionally, the contact stated that she was informed by the dealer of the NHTSA Campaign Number 14V682000 (Fuel System, Gasoline). The vehicle was not repaired. The dealer nor the manufacturer were notified of the failure. The failure mileage was unavailable.

NHTSA ODI #11539000

Mileage unknown · May 20, 2023
Engine

Water pump recall class action

NHTSA ODI #11523028

Mileage unknown · Aug 20, 2022
Engine

I believe it was March,2022 or April,2022 my check engine light came On 20’ before pulling into my driveway. I called “Protect My Car” insurance protection that I have, had my Edge towed to a repair shop and they said my antifreeze was leaking into my oil, that my water pump went out and said it was my fault as I neglected takin…

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I believe it was March,2022 or April,2022 my check engine light came On 20’ before pulling into my driveway. I called “Protect My Car” insurance protection that I have, had my Edge towed to a repair shop and they said my antifreeze was leaking into my oil, that my water pump went out and said it was my fault as I neglected taking care of my vehicle and they have denied paying to fix it, even thought it is 100% covered. Not sure what to do as it only has 151,000 miles on it and the body is in good shape and clean inside. I had no idea the water pump went out. I’m not a mechanic and thought that’s why I was paying them for problems like this. I need help to get it fixed and never neglected it or drove it after check engine light came on.

NHTSA ODI #11480307

50,000 miles · Jun 22, 2021
EnginePower TrainFire

The contact owns a 2008 Ford Edge. The contact stated that while driving at various speeds the vehicle would not properly accelerate and the engine would misfire. Also on occasions, the check engine light had illuminated and the speed would not increase past 10 mph. The vehicle was taken to the local dealer who diagnosed that th…

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The contact owns a 2008 Ford Edge. The contact stated that while driving at various speeds the vehicle would not properly accelerate and the engine would misfire. Also on occasions, the check engine light had illuminated and the speed would not increase past 10 mph. The vehicle was taken to the local dealer who diagnosed that the input-out sensor in the transmission was faulty causing the ignition coil to melt. The contact indicated that the PCM was also faulty. The vehicle was repaired but the failures continued to occur. The manufacturer was notified of the failure. The failure mileage was 50,000.

NHTSA ODI #11421818

211,000 miles · Apr 27, 2021
EnginePower TrainVehicle Speed Control

HERE WE ARE YEARS LATER AND STILL THE SAME ISSUES....LOSS OF POWER WITHOUT WARNING, SHUTS OFF WITH NO WARNING. BANGS WHEN SHIFTING, VERY ROUGH SHIFTING. FEELS LIKE ITS IN 1ST GEAR AND THEN SHIFTS ROUGHLY INTO GEAR, OR I HAVE TO STOP SHUT IT OFF AND START AGAIN. I SEE ALOT OF THE SAME COMPLAINT AND NO RECALL? ITS GETTIN STUPID NO…

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HERE WE ARE YEARS LATER AND STILL THE SAME ISSUES....LOSS OF POWER WITHOUT WARNING, SHUTS OFF WITH NO WARNING. BANGS WHEN SHIFTING, VERY ROUGH SHIFTING. FEELS LIKE ITS IN 1ST GEAR AND THEN SHIFTS ROUGHLY INTO GEAR, OR I HAVE TO STOP SHUT IT OFF AND START AGAIN. I SEE ALOT OF THE SAME COMPLAINT AND NO RECALL? ITS GETTIN STUPID NOW! THIS SHOULD BE RECALLED, IT IS A SAFETY ISSUE!

NHTSA ODI #11414086

157,763 miles · Mar 1, 2021
EnginePower TrainUnknown Or Other

VEHICLE STALLED WHILE REVERSING INTO A PARKING SPOT. BARELY STARTED. STALLED A FEW SECONDS LATER AFTER COMPLETING THE REVERSE INTO PARKING SPOT. BARELY STARTED AGAIN. GOT ON THE ROAD AND DRIVING FINE A FEW HUNDRED FEET, VEHICLE STALLED ALMOST RAN INTO A GROUP OF PARKED VEHICLES. BARELY STARTED AGAIN. MADE IT TO THE HIGHWAY TO GO…

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VEHICLE STALLED WHILE REVERSING INTO A PARKING SPOT. BARELY STARTED. STALLED A FEW SECONDS LATER AFTER COMPLETING THE REVERSE INTO PARKING SPOT. BARELY STARTED AGAIN. GOT ON THE ROAD AND DRIVING FINE A FEW HUNDRED FEET, VEHICLE STALLED ALMOST RAN INTO A GROUP OF PARKED VEHICLES. BARELY STARTED AGAIN. MADE IT TO THE HIGHWAY TO GO HOME AND WHILE DRIVING AT JUST UNDER 55MPH LIMIT VEHICLE STALLS IN THE PASSING LANE. ALMOST CAUSED A WRECK WITH SEVERAL VEHICLES INCLUDING A SEMI. DIDN'T START FOR A FEW MINUTES. VEHICLE STUTTERED TO START AND BARELY TURNED OVER. AFTER IT STARTED I SAT THERE AND WATCHED THE TACHOMETER, IT WOULD, WITHOUT MYSELF TOUCHING OR DOING ANYTHING, IDLE THEN JUMP A LITTLE AND DIP A LITTLE OVER AND OVER. THERE SEEMS TO BE NO CERTAIN SITUATION OR REASONING FOR WHEN, WHERE OR WHY IT WOULD STALL, COMPLETE RANDOMNESS! HIGHWAY DRIVING, SLOW STOP AND GO CITY DRIVING, REVERSING, IT SEEMS TO DO IT COMPLETELY RANDOMLY AND UNEXPECTEDLY BUT ALWAYS WHILE MOVING ONE DIRECTION OR THE OTHER. STRAIGHT LINE, TURNING, FAST, SLOW, DIDN'T MAKE A DIFFERENCE. FINALLY WAS ABLE TO GET OFF THE HIGHWAY, CAME INTO TOWN AND I WAS ABLE TO STOP AT ALL THE LIGHTS AND GO BUT THEN OUT OF NO WHERE AGAIN DOING CLOSE TO THE 35MPH LIMIT IT STALLS AGAIN AND THIS TIME I WAS AT A 6 WAY INTERSECTION AND ALMOST HIT ANOTHER MOVING VEHICLE. MY FAMILY WILL NOT BE RIDING IN THIS VEHICLE AGAIN UNTIL SOMETHING IS DONE! THIS IS NOT NORMAL OR SAFE! NOT FOR ME OR ANYONE ELSE ON THE ROADWAY! I HAVE NO CLUE AS TO WHAT THE ISSUE COULD BE EXCEPT THAT IT'S THE MANUFACTURERS ISSUE. IT DOESN'T MAKE ANY SINCE. VEHICLE HAS NEVER BEEN WRECKED, ABOVE AVERAGE MAINTENANCE INTERVALS, COMPLETELY MAINTAINED BUT THIS IS SOMETHING MORE THAN REGULAR 'WEAR AND TEAR' AS ONE WOULD SAY. NOT SAFE AT ALL!! COULD HAVE KILLED MYSELF, MY FAMILY OR SOMEONE ELSE WITH THIS PROBLEM!! NEEDS ATTENTION ASAP! EXTREMELY UNSAFE!

NHTSA ODI #11398586

Official recalls

6

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

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.

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.

08V301000 · Fuel System, Gasoline:storage:tank Assembly

Jul 3, 2008

FORD IS RECALLING 142 MY 2008 EDGE AND LINCOLN MKK ALL WHEEL DRIVE VEHICLES. THE FUEL TANK WELD FIXTURE MAY HAVE BEEN EXPOSED TO A CONTAMINANT DURING PRODUCTION WHICH COULD CAUSE A DIMPLE IN THE BOTTOM OF THE FUEL TANK AT A SPOT WELD.

Consequence & remedy

Consequence: THIS DIMPLE COULD RESULT IN A FUEL LEAK OR A FUEL DRIP FROM THE TANK. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE FUEL TANK FREE OF CHARGE. THE RECALL BEGAN ON JULY 11, 2008. OWNERS MAY CONTACT FORD AT 1-866-437-7332.

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

2

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