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

What owners actually said

1,119 reports

15,000 miles · Jul 10, 2009

Exterior Lighting

TAIL LIGHT BULB BURNT OUT. APPEARS SOCKET IS BURNT. DEALERSHIP SAID NO PROBLEM WITH SOCKET ONLY THE BULB. I LOOKED ON LINE AND APPEARS A LOT OF PEOPLE ARE OBSERVING BURNT AND MELTED BULB SOCKETS ON A LOT OF VEHICLES. *TR

NHTSA ODI #10276305

3,300 miles · Jun 8, 2009

Power Train

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WHILE MAKING A LOW SPEED LEFT HAND TURN, THE DRIVER HEARD A LOUD BANG AND THE CARD STOPPED DEAD IN THE ROAD. UPON INVESTIGATION THE RIGHT WHEEL INCLUDING THE DISC BRAKE ROTOR, CALIPER, AND WHEEL HAS SEPARATED FROM THE TRANSAXLE. THE HALF SHAFT WAS PULLED COMPLETELY OUT OF THE TRANSAXLE AND THE WHEEL ASSEMBLY WAS HELD ONTO THE CAR BY THE BRAKE LINE AND THE SHOCK STRUT ASSEMBLY. THE LOWER CONTROL ARM WAS COMPLETELY SEPARATED FROM THE WHEEL. THE CAR WAS COMPLETELY UNDRIVABLE AT THIS POINT AND HAD TO BE TOWED. *TR

NHTSA ODI #10273143

3,000 miles · May 8, 2009

Steering

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TL*THE CONTACT OWNS A 2008 FORD EDGE. WHILE DRIVING APPROXIMATELY 60 MPH ON NORMAL ROAD CONDITIONS, THERE WAS EXCESSIVE VIBRATION AND UNINTENDED RESISTANCE WHEN THE STEERING WHEEL WAS TURNED. THE DRIVER HAD TO EXERT GREATER FORCE TO TURN THE STEERING WHEEL. THE FAILURES OCCURRED INTERMITTENTLY AND WITHOUT WARNING. THE CONTACT MADE SEVERAL ATTEMPTS TO MANEUVER THE STEERING WHEEL BEFORE IT RESUMED NORMAL OPERATION. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR DIAGNOSTIC TESTING AND THEY STATED THAT THE POWER STEERING PUMP FAILED, WHICH HAD ALREADY BEEN REPLACED TWICE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER ON SEVEN SEPARATE OCCASIONS FOR IDENTICAL FAILURES. THE RACK AND PINION WAS REPLACED TWICE, INCLUDING ALL OF THE HYDRAULIC LINES AND OIL COOLER COMPONENTS IN THE POWER STEERING SYSTEM. THE FAILURES CONTINUED WITHOUT ANY RESOLUTION. THE VEHICLE HAS NOT BEEN REPAIRED. THE FAILURE MILEAGE WAS 3,000 AND CURRENT MILEAGE WAS 13,200.

NHTSA ODI #10268190

14,000 miles · May 7, 2009

Electrical System

VEHICLE STALLS WHILE DRIVING. I HAVE OWNED THE VEHICLE 18 MONTHS. THIS HAS HAPPENED THREE TIMES. TWICE AT HIGHWAY SPEEDS AND ONCE ON A LOCAL STREET. THE FIRST EVENT THE VEHICLE HAD APPROX 2K MILES. THEN AGAIN AT APPROX 12K AND 14K. WHEN IT HAPPENS THE DASH GOES DARK, YOU LOSE ALL POWER STEERING AND BRAKES. VEHICLE CAN BE RESTAR…

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NHTSA ODI #10267930

8,900 miles · Mar 19, 2009

Service Brakes, HydraulicCrashInjury

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SITTING AT RED LIGHT , FOOT ON BRAKE, MY 2009 FORD EDGE WITH LESS THAN 9000 MILES ACCELERATES ON ITS OWN SENDING ME INTO THE CAR IN FRONT, HER INTO THE INTERSECTION AVOID HER I TURN, MY CAR WILL NOT STOP I PUT IT PARK, STILL WILL NOT STOP, PUT ON EMERGENCY BRAKE, FINALLY STOPS. MUCH TRAUMA ENSUES INCLUDING OTHER DRIVER GOING TO HOSPITAL, PHYSICAL PAIN AND ANXIETY ON MY PART ,ANSWERING POLICE QUESTIONS, ETC. I STILL HAVE NO CAR AS I WILL NOT DRIVE THAT DEATH TRAP AND IT STILL SITS AT THE DEALERSHIP. THEY HAVE NOT BEEN MUCH HELP. I AM HAVING TO FIGHT FORD MOTOR CO. AND THAT IS A NIGHTMARE. THEY HAVE JERKED ME AROUND, DELAYED THEIR RESPONSES AND I GUESS WISH I WOULD GO AWAY. I HAVE DONE RESEARCH AND NOW KNOW THAT THIS IS NOT THE FIRST TIME THIS HAS HAPPENED. I T IS CALLED UNINTENDED ACCELERATION AND THEY KNOW IT IS REAL ! I AM NOW WORKING WITH AN ATTORNEY BUT IT NEVER SHOULD HAVE COME TO THIS. I SIMPLY ASKED THAT THEY CANCEL OUR LEASE WITH NO FINANCIAL PENALTY, AND LET ME WORK WITH MY DEALER ON GETTING A SAFE CAR. IS THERE NO JUSTICE FOR ME ? *TR

NHTSA ODI #10262467

10,908 miles · Mar 17, 2009

SteeringSuspensionWheels

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EVENTS LEADING UP TO FAILURE: WAS DRIVING CAR AT A VERY SLOW RATE OF SPEED (LESS THAN 5 MPH) MAKING A RIGHT HAND TURN INTO A COMMERCIAL SHOPPING CENTER. FAILURE: UPON MAKING TURN, I HEARD A "POP" NOISE. AFTER TRYING TO ACCELERATE THE VEHICLE, IT WOULD NOT MOVE. I GOT OUT OF THE CAR AND NOTICED THAT THE WHEEL HAD BECOME DETACHED FROM THE AXLE AND WAS ONLY ATTACHED TO THE VEHICLE BY THE STRUT. BEARINGS HAD FALLEN OUT OF THE RELATED COMPONENTS AND THE WHEEL WAS AT APPROXIMATELY A 60% ANGLE WITH THE PAVEMENT (OTHER WHEEL WAS FINE AND WAS PERPENDICULAR TO PAVEMENT). CORRECTION OF FAILURE: TOWING TRUCK RESPONDED AND THE VEHICLE IS CURRENTLY BEING SERVICED UNDER THE MANUFACTURERS WARRANTY. INITIAL REPORT FROM THE SERVICE TEAM IS THAT IT IS MOST LIKELY MANUFACTURER DEFECT. I HAVE BEEN TOLD THAT ALL PARTS RELATED IN ACCIDENT WILL BE REPLACED OR REFURBISHED TO MAINTAIN 100% WORKING ORDER. *TR

NHTSA ODI #10262091

65 miles · Mar 16, 2009

Air BagsCrashInjury

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I WAS INVOLVED IN A LATERAL COLLISION TO THE DRIVER'S SIDE/DOOR AT AN ALLEGED 25 MPH WHEN A SUBJECT DRIVING A 97 CHEVY CAVALIER, FAILED TO STOP AT A RED TRAFFIC SIGNAL AT AN INTERSECTION. SUBJECT HAD A HIGH LEVEL OF INTOXICATION (.175 BAC) & IMPAIRED JUDGMENT; HE CONTINUED TO ACCELERATE THROUGH THE INTERSECTION STRIKING MY VEHICLE IN THE DRIVER'S SIDE DOOR. I WAS THE SOLE OCCUPANT AND DRIVER OF THE 2008 FORD EDGE. THE CRASH FORCES DID PUSH ME THROUGH THE INTERSECTION WHERE MY VEHICLE CAME TO REST SEVERAL YARDS FROM THE POINT OF IMPACT. I WAS NOT ABLE TO OPEN MY DRIVER'S SIDE WINDOW OR DRIVER'S SIDE DOOR, SEVERAL EMERGENCY PERSONNEL PULLED AND PRIED ON THE DOOR UNTIL IT OPENED TO FREE ME. THE POLICE REPORT INDICATES THAT THERE WAS NO AIRBAG DEPLOYMENT; THE OFFICER WHO CAME TO THE HOSPITAL TO FOLLOW UP ALSO VOICED HIS DISBELIEF THAT THE AIRBAGS DID NOT DEPLOY. THE PROPERTY DAMAGE APPRAISERS REPORT SPECIFICALLY STATES THAT THE SIDE IMPACT AIRBAGS DID NOT DEPLOY ALSO. THERE WAS REPLACEMENT OF THE ENTIRE LEFT SIDE FROM BUMPER TO BUMPER. INCLUDES REPLACING THE L STEERING TIE ROD, L CENTER PILLAR & ROCKER, L CTR PILLAR REINFORCEMENT, L FRT SEAT ASSEMBLY, BOTH DOORS, FENDERS, UNDERBODY REPAIR, SEATBELT, ALLOY WHEEL/TIRE, AND TRANSMISSION PROBLEMS. I'M AN OCCUPANT PROTECTION COORDINATOR & CHILD PASSENGER SAFETY TECH/INSTRUCTOR, AND IN CORRESPONDENCE WITH MY COLLEAGUES IN THE SAFETY INDUSTRY, WE'RE ALL SHOCKED AT THE INOPERABILITY OF MY SIDE IMPACT AIRBAGS. I ONLY HAD ABOUT 6500 MILES ON THE VEHICLE AT THE TIME OF THE CRASH. I WAS TRANSPORTED BY SQUAD AND TREATED FOR INJURIES TO THE ENTIRE LEFT SIDE OF MY BODY (SPECIFICALLY MY HEAD, SHOULDER, ELBOW, HIP,) AND THE RIGHT SIDE OF MY NECK. I'M STILL IN NEED OF AND RECEIVING MEDICAL TREATMENTS FOR THE INJURIES CAUSED BY THIS CRASH. I FIELD A COMPLAINT WITH FORD IN OCT 08 AND SUBMITTED THE CLAIM TO FORD (01/18/09). NO ACKNOWLEDGEMENT OR RESPONSE TO MY CLAIM HAS BEEN RECEIVED TO DATE. *TR

NHTSA ODI #10262062

21,500 miles · Mar 15, 2009

Air BagsCrashInjury

I WAS HIT BY AN ONCOMING VEHICLE DOING ABOUT 50-60 MPH ON THE SURFACE STREETS WHEN HE HIT ME HEAD ON. THE FRONT PART OF MY 2008 FORD EDGE SEL WAS TOTALED, AND THE GUYS GREEN MINIVAN WAS TOTALED IN THE FRONT TOO. MY AIRBAGS DID NOT DEPLOY. MY AIRBAGS DID NOT DEPLOY. I CAN NOT BELIEVE THIS. *TR

NHTSA ODI #10261885

1,000 miles · Dec 2, 2008

Wheels

TL*THE CONTACT OWNS A 2008 FORD EDGE. THE VEHICLE HAS 20 INCH WHEELS. THE CONTACT STATED THAT THE WHEEL ASSEMBLY MAKES A LOUD NOISE. THE FAILURE WAS REPAIRED, BUT THE NOISE STILL PERSISTS. THE FAILURE MILEAGE WAS 1,000 AND CURRENT MILEAGE WAS 9,200. UPDATED 12/30/08 *CN UPDATED 12/30/08. *JB

NHTSA ODI #10250499

900 miles · Dec 1, 2008

Fuel System, Gasoline

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TL*THE CONTACT OWNS A 2008 FORD EDGE. WHILE DRIVING 10-20 MPH, THE CONTACT HEARD BANGING NOISES COMING FROM THE FUEL TANK. THE DEALER STATED THAT THE BAFFLES INSIDE THE TANK WERE NOT LARGE ENOUGH TO HOLD THE CAPACITY OF THE BAG THAT HOLDS THE GAS. THE GAS TANK WAS REPLACED, BUT THE NEW TANK HAS NOT RESOLVED THE ISSUE. THE VEHICLE IS CURRENTLY AT THE DEALER. THE CONTACT DOES NOT FEEL SAFE DRIVING THE VEHICLE BECAUSE THE BAG COULD BURST IN THE GAS TANK AND CAUSE A FUEL LEAK. THE CURRENT MILEAGE WAS 2,100 AND FAILURE MILEAGE WAS 900.

NHTSA ODI #10250430

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.

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

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