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

Mileage unknown · Apr 10, 2014

Power Train

2008 FORD EDGE. CONSUMER WRITES IN REGARDS TO POWER TRAIN MALFUNCTION. *SMD THE CONSUMER STATED TWICE THIS YEAR, SHE EXPERIENCED POWER TRAIN MALFUNCTION, WHERE THE VEHICLE LOST POWER. *JB

NHTSA ODI #10578712

40,000 miles · Apr 7, 2014

Power Train

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THE CAR SEEMS TO RUN FINE IN TOWN. IF IT IS DRIVEN ABOUT 20 MILES OR SO ON THE HIGHWAY, IT DEVELOPS THE FOLLOWING DRIVE TRAIN PROBLEM. WHEN THE VEHICLE SLOWS OR COMES TO A STOP AND THE DRIVER THEN ACCELERATES, SUCH AS WHEN DRIVING IN STOP-AND-GO TRAFFIC ON THE FREEWAY OR LEAVING A STOP LIGHT, IT SEEMS LIKE THE TRANSMISSION AND ENGINE QUIT TALKING TO EACH OTHER AND THEY COME UNCOUPLED DURING SHIFTING. SINCE THE GAS PEDAL IS DEPRESSED FOR ACCELERATING, DURING THE SHIFT, THE ENGINE RPM REVS UP TO PERHAPS 3000 AND THEN THE TRANSMISSION ABRUPTLY SHIFTS RESULTING IN A HEAVY SHOCK TO THE DRIVE LINE. IT DOES THIS BETWEEN EACH GEAR DURING ACCELERATION UPSHIFTING. IF THE VEHICLE IS STOPPED AND THE TRANSMISSION IS SHIFTED INTO REVERSE, THERE IS A DELAY AND THEN IT SHIFTS INTO REVERSE RESULTING IN A SIMILAR HEAVY SHOCK. I HAD SEVERAL OCCURRENCES WHERE I CAME OFF THE FREEWAY AND STOPPED AT THE LIGHT AND UPON ATTEMPTING TO GET GOING AGAIN, THE ENGINE WAS RUNNING AND WOULD REV UP BUT THE TRANSMISSION WAS NOT ENGAGED. I SHIFTED INTO PARK AND BACK INTO DRIVE AND THE VEHICLE FINALLY GOT GOING AGAIN WITH THE SAME SYMPTOMS NOTED ABOVE. IT SEEMS TO REACT THE SAME REGARDLESS OF WHETHER THE OD IS ENGAGED OR DISENGAGED. WE TOOK THE VEHICLE TO ONE OF THE LOCAL FORD STORES SEVERAL WEEKS AGO AND THEY SAID THEY COULD NOT RECREATE THE SYMPTOMS. I TOOK IT TO A DIFFERENT SERVICE DEPARTMENT PERHAPS A MONTH LATER AND THEY COULD NOT FIND A REAL PROBLEM BUT SAID ALL THE CODES WERE FINE. THEY DELETED THE ADAPTIVE TRANSMISSION FILES AND UPLOADED NEW FILES AND THE PROBLEM WAS FIXED EVEN THOUGH THEY WERE NOT SURE WHAT THEY DID TO FIX IT. A LENGTHY DRIVE A DAY LATER WENT WELL, NO PROBLEMS. BUT ON THE WAY INTO WORK IN ON APRIL 3RD THE SAME PROBLEMS ARE BACK. IT'S BACK IN THE SHOP AGAIN APRIL 7TH. NOT SURE WHAT'S NEXT. MAYBE THE FACTORY CAN OFFER ADVICE? THANKS *TR

NHTSA ODI #10578053

Mileage unknown · Apr 5, 2014

Power TrainVehicle Speed Control

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MY WIFE AND I WERE DRIVING ON THE FREEWAY, WITH THE CRUISE CONTROL ON. AT RANDOM THE CARE KICKED OUT ON CRUISE AND THE SPEEDOMETER WAS NOT WORKING, WE ALSO HAD TIRE PRESSURE WARNING, ENGINE SERVICE WARNING, AIR BAG WARNING AND NO ODOMETER. WE MADE IT TO THE FREEWAY EXIST, HOWEVER WHEN WE WENT TO ACCELERATE THE CAR BARELY MOVED. THE ENGINE WOULD REV AT HIGH RPM'S BUT WOULD JUST CRAWL. WE MADE IT TO OUR HOUSE (BARELY) AND PARKED THE CAR. THE SHIFT INTO PARK WAS VERY VIOLENT AND MADE THE CARE JUMP. WITH MY FOOT ON THE BRAKE I WOULD SHIFT FROM P TO N, THEN N TO R, THEN R TO D AND SAME ORDER BACK TO PARK. EACH CHANGE WAS VERY VIOLENT. I TURNED THE ENGINE OFF, LET IT SIT FOR ABOUT 1 MINUTE, TURNED THE CAR BACK ON AND THE WARNING LIGHTS WERE GONE AND THE ODOMETER WAS BACK TO NORMAL. HOWEVER, WHEN I WENT TO DRIVE AGAIN THE SHIFT WAS STILL VIOLENT, I HAD NOT POWER (HIGH REV AND BARELY MOVED) AND NO SPEEDOMETER. THE CAR IS CURRENTLY IN MY DRIVEWAY WITH THAT BEING THE CURRENT STATE. I HAVE DONE SOME RESEARCH ONLINE AND THIS APPEAR TO BE A VERY COMMON ISSUE FOR THESE VEHICLES. *TR

NHTSA ODI #10577606

140,000 miles · Apr 2, 2014

Electrical SystemVehicle Speed ControlCrashInjury

HERE IS THE LINK TO AN EXACT DETAILED EXPLANATION. WHEN I LOST POWER MY CAR ROLLED INTO THE MIDDLE OF THE INTERSECTION AND WAS HIT. HTTP://WWW.YOUTUBE.COM/WATCH?V=LDWPAFPVU0O3. *TR

NHTSA ODI #10576977

94,000 miles · Apr 2, 2014

Suspension

NOISE COMING FROM THE RIGHT, REAR WHEEL AREA AT VARIOUS SPEEDS. SOUNDS LIKE A LIGHT RUMBLE STRIP SOUND AND A LIGHT SQUEALING/GRINDING ALSO. TOOK IT TO A LOCAL MECHANIC WHO SAYS THE BEARINGS ARE BAD. FORD NEEDS TO DO SOMETHING ABOUT THIS ISSUE. IT'S SEEMS TO BE AN EXISTING PROBLEM ON THESE EDGES AND RECURRING PROBLEMS AS WELL…

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NHTSA ODI #10576755

71,000 miles · Mar 29, 2014

Engine

EXITS OFF HIGHWAY, CAR ENGINE BEGINS TO STALL. CAR WAS TAKING TO SHOP FOR REPAIR CAR CONTINUES TO STALL, ENGINE IS IN, AND THERE IS A CODE OF A FUEL SYSTEM PROBLEM. *TR

NHTSA ODI #10575455

55,000 miles · Mar 27, 2014

Electrical SystemPower Train

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AFTER STARTING CAR, VEHICLE MADE LOUD CLUNK SOUND WHEN PUT IN REVERSE. CAR WOULD NOT ACCELERATE WITHOUT PRESSING ACCELERATOR MORE THAN USUAL AND ENGINE REVVED HIGH. DASH BOARD WENT BLANK EXCEPT FOR WRENCH SYMBOL, AIRBAG SYMBOL AND ODOMETER HAD ALL DASHES. TURNED CAR OFF, WAITED A FEW MINUTES, TURNED CAR BACK ON AND EVERYTHING WAS BACK TO NORMAL, CAR DROVE FINE. THIS HAS HAPPENED ABOUT 5 TIMES WITHIN THE PAST 3 YEARS, SEVERAL MONTHS APART. HAVE ALSO HAD TO REPLACE REAR TAIL LIGHTS MULTIPLE TIMES, SOMETIMES WITHIN 2 DAYS OF REPLACEMENT. HAVE TAKEN CAR TO FORD SERVICE, BUT THEY CAN'T PINPOINT PROBLEM. NOW CAR IS OUT OF WARRANTY. SEEMS LIKE IT COULD BE ELECTRICAL OR SENSORS. HAVE READ AND SEEN VIDEOS OF MANY OTHERS WITH THIS SAME PROBLEM WITH THIS YEAR, MAKE AND MODEL. WISH FORD WOULD HELP OWNERS LIKE OURSELVES WITH A RECALL TO FIX THIS, AS OUR LOYALTY HAS GONE AWAY WITH FRUSTRATION. HAVE JUST TODAY, 03/27/14 HAD MY CAR TOWED TO REPAIR SHOP TO CHECK TRANSMISSION. THE DASHBOARD HAS RETURNED TO NORMAL, BUT LOUD CLUNK WHEN SHIFTING AND WILL NOT ACCELERATE WITHOUT FLOORING IT. *TR

NHTSA ODI #10575187

60,000 miles · Mar 20, 2014

Service Brakes

BRAKES FADE, BECOME MUSHY, PEDAL GOES TO THE FLOOR. DOES NOT STOP AT LIGHTS SOMETIMES CAUSING ME TO PUT IN PARK WHILE MOVING. *TR

NHTSA ODI #10573852

35,000 miles · Mar 14, 2014

Structure

TL* THE CONTACT OWNS A 2008 FORD EDGE. THE CONTACT STATED THAT THE REAR PASSENGER'S SIDE DOOR WOULD NOT OPEN. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO STATED THAT THE ACTUATOR WOULD NEED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE CONTACT ALSO STATED THAT THE DRIVER'S DOOR AND THE REAR DRIVER'S SIDE DOOR WERE PREV…

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NHTSA ODI #10569347

111,000 miles · Mar 11, 2014

Unknown Or Other

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I HAVE A 2008 FORD EDGE. WE WERE OVER AN HOUR AWAY FROM HOME, ON A SUNDAY, WHEN WE STOPPED AT A STOP LIGHT AND WHEN I WAS TAKING OFF, THE VEHICLE WOULD REV BUT NOT GO, THEN WHEN IT DID ENGAGE, THERE WAS A HARD THUD TWICE. I WAS REALLY AFRAID THAT WE MIGHT NOT MAKE IT BACK HOME AS WELL AS MAKING IT THROUGH THE INTERSECTION. WE DID MAKE IT HOME WITHOUT FURTHER INCIDENT THAT DAY. I MADE AN APPT TO TAKE IT TO THE DEALERSHIP THAT I PURCHASED IT FROM ON WEDNESDAY. THERE WERE NO INCIDENTS UNTIL TUESDAY NIGHT WHEN WE WERE COMING HOME FROM THE GROCERY STORE. FROM A STOP AT A STOP SIGN IT DID THE SAME THING, BUT NOT A HARD. THE DEALERSHIP WAS UNABLE TO PULL ANY CODES OR GET IT TO ACT UP THAT FIRST DAY. I ASKED THEM TO KEEP IT AND TO TRY ONCE AGAIN. IT DID ACT UP FOR THE GUY, BUT THEY COULDN'T FIGURE OUT WHAT WAS GOING ON. THEY RECOMMENDED THAT I TAKE IT TO THE FORD DEALERSHIP TO SEE IF THEY COULD FIGURE IT OUT. I TOOK IT IN TODAY AND THEY CALLED TO TELL ME THAT THEY WERE UNABLE TO PULL ANY CODES OR GET IT TO ACT UP. SO NOW I AM PAYING THEM $135 JUST TO TELL ME THE SAME THING THE OTHER DEALERSHIP DIDN'T CHARGE ME FOR. ON TOP OF THAT, I DRIVE 45 MILES ROUND TRIP TO WORK 5 DAYS A WEEK AND AM AFRAID OF THIS HAPPENING ON THE BUSY INTERSTATE THAT I TRAVEL OR HAPPENING AT A BUSY INTERSECTION. I HAVE READ MANY STATEMENTS BY PEOPLE AND IT SEEMS THEY ARE HAVING THE SAME PROBLEMS WITH THE SAME RESULTS...NOTHING! FORD NEEDS TO STEP UP AND MAKE SURE THE PEOPLE WHO BUY THEIR VEHICLES ARE HAPPY AND WILL RETURN. I DON'T UNDERSTAND HOW THE SERVICE PEOPLE CAN'T FIX IT WITHOUT A CODE OR EVEN FIGURE OUT WHAT'S GOING ON. THIS IS A SCARY THING AND I DON'T HAVE THE MONEY TO PAY PEOPLE TO TELL ME NOTHING! AND THEN WHAT HAPPENS WHEN MY WARRANTY ENDS?! MY BIGGEST CONCERN IS SAFETY. THERE ARE TOO MANY PEOPLE WRITING ABOUT THE SAME THING HAPPENING. *TR

NHTSA ODI #10568592

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