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2008 Ford F Super Duty

Owner reports · Recalls · Investigations

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How this year compares

Owner complaints by model year

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What owners reported most

All reported categories

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When problems were reported

Mileage at the reported incident

29 reports with mileage · 2 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.

  • Steering. Review the 10 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 8 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 5 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

0 crash reports0 fire reports1 injury reports

What owners actually said

31 reports
88,000 miles · Oct 17, 2013
Engine

I WAS PULLING A HORSE TRAILER UPHILL, AND ENGINE BEGAN TO OVERHEAT. A FEW DAYS LATER WHEN IN MY MECHANICS SHOP, I DISCOVERED THAT THE RADIATOR HAD CRACKED, AND SUBSEQUENT REPAIR FOR NEW COMPONENTS WAS APPX. $2K. WITHIN TWO WEEKS I BEGAN HAVING ISSUES AGAIN WITH OVERHEATING, AND UPON FURTHER RESEARCH BY MY MECHANIC, WE DISCOVER…

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I WAS PULLING A HORSE TRAILER UPHILL, AND ENGINE BEGAN TO OVERHEAT. A FEW DAYS LATER WHEN IN MY MECHANICS SHOP, I DISCOVERED THAT THE RADIATOR HAD CRACKED, AND SUBSEQUENT REPAIR FOR NEW COMPONENTS WAS APPX. $2K. WITHIN TWO WEEKS I BEGAN HAVING ISSUES AGAIN WITH OVERHEATING, AND UPON FURTHER RESEARCH BY MY MECHANIC, WE DISCOVERED THAT THE OIL COOLER, AND TWO EGR COOLERS WERE DEFECTIVE, AND THIS IN FACT HAD CAUSED THE ORIGINAL PROBLEM. MY VEHICLE WAS A COUPLE OF MONTHS OUT OF WARRANTY, AND FORD REFUSED TO CONSIDER A WARRANTY REPAIR FOR THIS ISSUE. THIS REPAIR WAS AN ADDITIONAL $5K. AFTER SPEAKING WITH SEVERAL MECHANICS, INCLUDING ONE THAT WORKS FOR A FORD DEALER, WE DISCOVERED THAT THIS IS NOT AN UNKNOWN ISSUE FOR FORD. THERE WERE PREVIOUS ISSUES WITH THE 6.0 ENGINE, WHICH DID RECEIVE A RECALL. THEY ARE NOW HAVING THE SAME ISSUES WITH THE 6.4 ENGINE, BUT AT THIS POINT HAVE BEEN UNWILLING TO ISSUE A RECALL NOTICE. MY BELIEF IS THAT FORD IS BEING UNRESPONSIVE TO AN ISSUE THEY ARE AWARE OF, AND WHICH COULD CAUSE A POTENTIAL SAFETY ISSUE EVENTUALLY WITH BREAKDOWNS ALONG ROADS AND FREEWAYS. *LN

NHTSA ODI #10548326

54,000 miles · Oct 1, 2013
Service Brakes

WHILE APPROACHING A LIGHT, THE BRAKE SYSTEM FAILED ENTIRELY. I PULLED OVER AND NOTICED OIL LEAKING FROM THE PASSENGER SIDE CALIPER. I BROUGHT THE VEHICLE HOME TO DETERMINE WHAT THE ISSUE WAS AS NOW THIS IS THE SECOND TIME THIS HAS HAPPENED. THE PREVIOUS INCIDENT WAS WITH THE FRONT CALIPER CRACKING WHICH FORD IN MCHENRY ILLINOIS …

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WHILE APPROACHING A LIGHT, THE BRAKE SYSTEM FAILED ENTIRELY. I PULLED OVER AND NOTICED OIL LEAKING FROM THE PASSENGER SIDE CALIPER. I BROUGHT THE VEHICLE HOME TO DETERMINE WHAT THE ISSUE WAS AS NOW THIS IS THE SECOND TIME THIS HAS HAPPENED. THE PREVIOUS INCIDENT WAS WITH THE FRONT CALIPER CRACKING WHICH FORD IN MCHENRY ILLINOIS REPLACED. THE CALIPER THAT FAILED THIS TIME WAS PASSENGER RIGHT REAR. THE CALIPER PISTON IS SEVERELY CRACKED. HAVE PICTURES AND THE PART STILL. I AM REQUESTING THIS CASE TO BE ESCALATED BECAUSE THIS HAS HAPPENED TWICE NOW. *TR

NHTSA ODI #10546446

72,000 miles · Aug 19, 2013
Steering

WHILE MAKING A TURN IN MY 08 F250 I HEARD A CLICK AND MY TRUCK NO LONGER WILL COME BACK STRAIGHT AFTER A TURN. IT WILL EITHER PULL HARD RIGHT OR LEFT. I HAVE TO STOP ON THE SIDE OF THE ROAD AND TURN THE WHEEL BOTH DIRECTIONS TO GET THE TRUCK TO DRIVE STRAIGHT AGAIN. NEARLY DROVE INTO ONCOMING TRAFFIC AND THEN OFF THE ROAD THE FI…

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WHILE MAKING A TURN IN MY 08 F250 I HEARD A CLICK AND MY TRUCK NO LONGER WILL COME BACK STRAIGHT AFTER A TURN. IT WILL EITHER PULL HARD RIGHT OR LEFT. I HAVE TO STOP ON THE SIDE OF THE ROAD AND TURN THE WHEEL BOTH DIRECTIONS TO GET THE TRUCK TO DRIVE STRAIGHT AGAIN. NEARLY DROVE INTO ONCOMING TRAFFIC AND THEN OFF THE ROAD THE FIRST TIME IT HAPPENED. IT NOW HAPPENS EVERY TIME I DRIVE. FORD TOLD ME IT WOULD BE COVERED UNDER WARRANTY, BUT THE PART WAS ON BACK ORDER. I FOLLOWED UP THE FOLLOWING WEEK WITH NO RESPONSE. IT TOOK ME GOING TO THE FORD DEALERSHIP FOR THEM TO TELL ME THE BACKORDER IS 120 DAYS! I EXPLAINED ITS UNACCEPTABLE AND THE TRUCK ISN'T SAFE TO DRIVE. THEY TOLD ME THEY COULD TRY AND AFTERMARKET STEERING BOX. AFTER TWO WEEKS THEY SCHEDULED MY APPT. ONLY TO TELL ME AT 4:45PM ON FRIDAY THAT THE PART THEY ORDERED WON'T FIT AND THEIR GIVING ME MY TRUCK BACK WITH THE ORIGINAL FAULTY PART. AFTER I HAVE RESEARCHED THIS I HAVE FOUND NUMEROUS COMPLAINTS FOR THE SAME PROBLEM. I SPOKE WITH MY FORD DEALERSHIP TODAY ONLY TO BE TOLD THEY HAVE NO RESPONSE FOR ME OTHER THAN WAITING 120 DAYS MINIMUM FOR A STEERING BOX. LOVE HAVING A $60,000 DEATH TRAP IN THE DRIVEWAY. BY THE WAY I ALSO HAVE HAD WHAT PEOPLE CALL THE DEATH SHAKE IN THE TRUCK HAPPEN WELL OVER A DOZEN TIMES. I THOUGHT IT WAS BAD SHOCKS AND TIRES. THEY HAVE ALL BEEN REPLACED AND IT CONTINUES TO HAPPEN. I WON'T LET MY KIDS DRIVE WITH ME IN THE TRUCK ANYMORE AS A RESULT. EVEN IF THEY FIX THE STEERING BOX BY CHRISTMAS (4 MONTHS AWAY) I DON'T FEEL SAFE DRIVING IT ANYMORE. I LOVE THIS TRUCK, BUT REFUSE TO DIE IN IT. *TR

NHTSA ODI #10536200

Mileage unknown · May 14, 2013
Steering

NO ACCIDENT HAS OCCURRED YET BUT I AM CONCERNED. I HAVE HAD A PROBLEM WITH "MEMORY STEER" ON MY 2008 FORD F-250 SUPER DUTY SINCE THERE WAS LESS THAN 40,000 MILES. IT NOW HAS 49,000 MILES AND I HAVE TO MUSCLE THE STEERING INTO A TURN THEN I HAVE TO MUSCLE IT BACK OUT AGAIN. EVERY OTHER VEHICLE I DRIVE WANTS TO RETURN TO CENTER…

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NO ACCIDENT HAS OCCURRED YET BUT I AM CONCERNED. I HAVE HAD A PROBLEM WITH "MEMORY STEER" ON MY 2008 FORD F-250 SUPER DUTY SINCE THERE WAS LESS THAN 40,000 MILES. IT NOW HAS 49,000 MILES AND I HAVE TO MUSCLE THE STEERING INTO A TURN THEN I HAVE TO MUSCLE IT BACK OUT AGAIN. EVERY OTHER VEHICLE I DRIVE WANTS TO RETURN TO CENTER OR A NEUTRAL POSITION ONCE I'M THROUGH THE TURN. I TOOK IT TO A FORD DEALER A COUPLE YEARS AGO TO ASK WHAT WAS CAUSING THIS ISSUE AND THEY SAID IT COULD BE THE STEERING BOX OR POWER STEERING PUMP. NOW I SEE THAT THE NHTSA IS INVESTIGATING THE FORD F-250 FOR STEERING FAILURES AND WANT TO CONFIRM IF THE VEHICLE IS SAFE OR UNSAFE TO DRIVE. I DRIVE INFREQUENTLY BUT WHEN I DO, IT IS AT HIGHWAY SPEEDS...NOT A TIME WHEN THE STEERING SHOULD FAIL. IF THE NHTSA WOULD LIKE MORE INFORMATION ABOUT THE SYMPTOMS MY F-250 IS EXHIBITING FOR THEIR INVESTIGATION, PLEASE FEEL FREE TO CONTACT ME. *TR

NHTSA ODI #10511865

40,000 miles · Feb 13, 2013
Engine And Engine CoolingFuel System, DieselPower Train

THE FUEL TANK LINING IS FAILING SO WE TOOK THE TRUCK INTO THE DEALERSHIP. THE CORRODING FUEL TANK LINER HAS GUMMED UP OUR FUEL FILTER. WHILE AT THE SHOP LOOKING AT THIS THE DEALERSHIP MECHANIC QUICKLY POINTED OUT THAT OUR RADIATOR HAS A LEAK. HE MENTIONED THAT IT WAS A COMMON PROBLEM AND NOT COVERED BY WARRANTY. AFTER LOOKING IN…

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THE FUEL TANK LINING IS FAILING SO WE TOOK THE TRUCK INTO THE DEALERSHIP. THE CORRODING FUEL TANK LINER HAS GUMMED UP OUR FUEL FILTER. WHILE AT THE SHOP LOOKING AT THIS THE DEALERSHIP MECHANIC QUICKLY POINTED OUT THAT OUR RADIATOR HAS A LEAK. HE MENTIONED THAT IT WAS A COMMON PROBLEM AND NOT COVERED BY WARRANTY. AFTER LOOKING INTO IT FURTHER WE FOUND OUT THAT IT IS A COMMON PROBLEM AMONG FORD SUPERDUTY F450. THIS IS THE SECOND TRUCK (F450) THAT THIS HAS HAPPENED TO AND IT COST ~$1,600.00 TO FIX. FORD REFUSES TO COVER THIS BUT THE DEALERSHIP KNOWS ITS A COMMON PROBLEM. *TR

NHTSA ODI #10497995

121,800 miles · Jan 26, 2013
Steering

I TOOK MY VEHICLE IN FOR REGULAR SERVICE TO THE LOCAL FORD DEALER AND ASKED ABOUT A FRONT END ALIGNMENT BECAUSE I HAD NOTICED THAT WHEN DRIVING STRAIGHT MY STEERING WHEEL HAD TO BE TURNED ABOUT 30 DEGREES COUNTER CLOCKWISE. CUSTOMER SERVICE REP TOLD ME THAT MY VEHICLE WAS INDEED OUT OF ALIGNMENT BUT BARLEY AND GAVE ME THE OPTIO…

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I TOOK MY VEHICLE IN FOR REGULAR SERVICE TO THE LOCAL FORD DEALER AND ASKED ABOUT A FRONT END ALIGNMENT BECAUSE I HAD NOTICED THAT WHEN DRIVING STRAIGHT MY STEERING WHEEL HAD TO BE TURNED ABOUT 30 DEGREES COUNTER CLOCKWISE. CUSTOMER SERVICE REP TOLD ME THAT MY VEHICLE WAS INDEED OUT OF ALIGNMENT BUT BARLEY AND GAVE ME THE OPTION TO LEAVE AS IS OR REPAIR...PERMISSION TO REPAIR AND COMPLETED, ON MY WAY HOME I NOTICED THAT THE STEERING WHEEL WAS AGAIN NOT CORRECT AND HANDLING HAD NOT IMPROVED AND DECIDED I NEEDED TO RETURN WHEN I HAD TIME OFF FROM WORK TO GET REALIGNED AND RECHECKED. A FEW DAYS LATER WHILE ON MY STREET, PULLING INTO MY DRIVEWAY I HAD LOST ALL STEERING AND WHILE ATTEMPTING TO REGAIN CONTROL I HEARD A LOUD POP IN OR ABOUT MY STEERING WHEEL AREA AND MY HORN WENT OFF TILL I UNHOOKED THE BATTERY. VEHICLE WAS TOWED TO A 4 X 4 REPAIR SHOP AND I WAS INFORMED THAT THE STEERING GEAR BOX HAD FAILED AND THE CLOCKWORK SPRING MECHANISM HAD FAILED AS WELL, PROBABLY WHILE TRYING TO REGAIN CONTROL. THE REPAIR SHOP ALSO TOLD ME THAT THIS HAS HAPPENED TO OTHER VEHICLES AND THAT A SERVICE BULLETIN WAS ISSUED WITH TECH SPECS ABOUT IT ( REPAIRMAN WAS A FORMER FORD MECHANIC) TOTAL COST OF REPAIRS AND LABOR WAS $1225.39. NOT INCLUDING ORIGINAL $69.95 ALIGNMENT FROM FORD. CONTACTED FORD MOTOR COMPANY AND EXPLAINED TO THE CUSTOMER SERVICE REP OF THE INCIDENT AND COST OF REPAIRS...WAS TOLD THEY COULD NOT FIND ANY RECORDS OF SUCH INCIDENTS, SERVICE BULLETINS NOR RECALLS, SO THEY WOULD NOT OFFER REIMBURSEMENT OF ANY KIND. I WOULD LIKE FORD TO ACKNOWLEDGE THIS INFERIOR PART AND PERFORM A SAFETY RECALL, HAD I BEEN DRIVING ON THE INTERSTATE THIS INCIDENT MAY HAVE PROVED TO BE FATAL TO MYSELF, MY FAMILY AND THOSE IN THE LANES AROUND ME. *TR

NHTSA ODI #10494795

79,300 miles · Oct 27, 2012
Engine

THE RADIATOR IS LEAKING WERE THE SIDE TANKS ARE ATTACHED TO THE CORE AND BOTH THE UPPER AND LOWER RADIATOR HOSES ARE LEAKING. WHEN I HAD THE PICKUP IN THE DEALERSHIP FOR SERVICE I WAS ADVISED THAT THERE WAS UPGRADED RADIATOR HOSES AVAILABLE. THE DEALERSHIP RECOMMENDED I REPLACE THEM TO PREVENT HOSE FAILURE. THIS WOULD BE AT MY …

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THE RADIATOR IS LEAKING WERE THE SIDE TANKS ARE ATTACHED TO THE CORE AND BOTH THE UPPER AND LOWER RADIATOR HOSES ARE LEAKING. WHEN I HAD THE PICKUP IN THE DEALERSHIP FOR SERVICE I WAS ADVISED THAT THERE WAS UPGRADED RADIATOR HOSES AVAILABLE. THE DEALERSHIP RECOMMENDED I REPLACE THEM TO PREVENT HOSE FAILURE. THIS WOULD BE AT MY COST, BUT CLEARLY ARE FACTORY DEFECTS. WHEN I HAD SEVERAL DIFFERENT LOCAL MECHANICS GIVE ME ESTIMATES AND ASKED WHAT THE PROBLEM WAS, AND TOLD THEM WHAT YEAR AND MODEL FORD I HAD THEY ALL DESCRIBED THE SAME LEAKS IN THE RADIATORS AND HOSES. SO THERE APPEARS TO BE A DEFECT WITH THE HOSES AND RADIATORS OF THESE YEAR AND MODELS OF FORDS. I CALLED MY LOCAL DEALERSHIP AND THEY SAID THESE PROBLEMS WOULD NOT BE CORRECTED BY FORD AT THIS TIME. THE ESTIMATE FOR THE REPAIRS IS $1116.46. I CONTACTED FORDS CUSTOMER SERVICE AND BROUGHT THESE PROBLEMS TO THEIR ATTENTION BUT WAS TOLD THAT FORD DID NOT HAVE ANY WARRANTY OR PROGRAMS TO RESOLVE THESE DEFECTIVE ITEMS. IT IS MY OPINION THAT IF ANY COMPANY OR BUSINESS PROVIDES DEFECTIVE WORKMANSHIP THAT IT SHOULD BE RESOLVED BY THEM. APPARENTLY THE AUTO REPAIR SHOPS AND THE DEALERSHIPS ARE AWARE OF THE PROBLEMS.[XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10482410

29,300 miles · Jan 19, 2012
Engine And Engine Cooling

TRUCK HAS DEVELOPED A RADIATOR LEAK AT 29,300 MILES. FORD WOULD ONLY COVER 3/36,000 WARRANTY. 2008 MY SUPERDUTY TRUCKS WITH THE 6.4L DIESEL ENGINES ARE NOTORIOUS FOR LEAKING RADIATORS AND OEM WILL NOT STAND BEHIND THEM. *TT

NHTSA ODI #10444501

66,000 miles · Feb 9, 2011
Electrical System

OWN A 2008 FORD F250 SUPER DUTY, WITH 5.4L ENGINE. ATTEMPTED TO CHANGE SPARK PLUGS, 2 PLUGS BROKE OFF IN ENGINE BLOCK. CALLED LOCAL FORD DEALER, WAS INFORMED PLUGS BREAKING OFF IN HEAD IS A COMMON PROBLEM. TRUCK TOWED TO DEALER, WHERE FORD TECHNICIAN ATTEMPTED TO EXTRACT BROKEN PLUGS. END OF 1 BROKEN PLUG DROPPED INTO ENGINE CY…

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OWN A 2008 FORD F250 SUPER DUTY, WITH 5.4L ENGINE. ATTEMPTED TO CHANGE SPARK PLUGS, 2 PLUGS BROKE OFF IN ENGINE BLOCK. CALLED LOCAL FORD DEALER, WAS INFORMED PLUGS BREAKING OFF IN HEAD IS A COMMON PROBLEM. TRUCK TOWED TO DEALER, WHERE FORD TECHNICIAN ATTEMPTED TO EXTRACT BROKEN PLUGS. END OF 1 BROKEN PLUG DROPPED INTO ENGINE CYLINDER. WAS INFORMED BY DEALER REPAIR WILL BE ~$2,410.00, AS HEAD MUST BE REMOVED, TO RETRIEVE BROKEN PLUG END. CALLED FORD HELPLINE, AS INSTRUCTED BY SERVICE MGR. HELPLINE CONFIRMED ENGINE DESIGN AND SPARK PLUGS MAY BREAK OFF DURING ROUTINE MAINTENANCE, AND THAT `A SPECIAL TOOL IS REQUIRED.' DEALERS RECEIVED FROM FORD, A TECHNICAL SERVICE BULLETIN, ALERTING TECHS OF THE POTENTIAL PROBLEM. THE GENERAL PUBLIC, UNLESS EMPLOYED BY FORD, WASN'T MADE AWARE OF THIS `SPECIAL TOOL' REQUIREMENT. FORD MOTOR CORP. IS NOT OFFERING ANY FINANCIAL ASSISTANCE &/OR REIMBURSEMENT FOR THIS POSSIBLE SHODDY DESIGN (WHY ELSE, THEN, THE TECHNICAL SERVICE BULLETIN, AVAILABLE ONLY TO DEALERS/)OF SPARK PLUGS. THE ENGINE ISN'T CONSUMER-FRIENDLY, FOR THE CONSUMER WHO DOESN'T OR CAN'T PAY DEALER PRICES TO MAINTAIN THEIR VEHICLE. *TR

NHTSA ODI #10381268

2,300 miles · Jun 9, 2010
Suspension

I HAVE A 2008 FORD F250 AND EVERYTIME I HIT A BUMP THE FRONT END SHAKES REAL BAD . I TOOK IT TO THE DEALER MANY OF TIMES THEY SAID NOTHING WAS WRONG .THEY JUST TOLD ME MY AIR PRESSURE WAS LOW. I EVEN CHANGE THE TIRES AND IT STILL DOSE IT. HELP PLEASE THANK YOU *TR

NHTSA ODI #10335535

Official recalls

0

No recalls in this snapshot.

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

1

PE13014 · Alleged Loss Of Steering

Opened May 7, 2013 · Closed Jan 31, 2014

Status: closed (inferred from source dates) · Steering; Steering:gear Box (other Than Rack And Pinion)

The Office of DefectsInvestigation (ODI) opened PE13-014 after identifying five complaints alleging steering gear failure in model year (MY) 2008 Ford F-250 and F-350 Super Duty pick-up trucks and to evaluate the relationship between the design history of the steering gear assembly and the alleged defect.As background, ODI investigated steering gear sector shaft fractures in approximately 1.3 million MY 1999 - 2001 Ford Super Duty pick-up trucks and MY 2000 - 2001 Ford Excursion sport utility vehicles in Engineering Analysis EA01-009.The investigation determined that the sector shaft failures were the result of extraordinary, possibly multiple, impacts and not the result of fatigue.No defect in design, manufacturing or materials was identified in the sector shaft.EA01-009 was closed August 19, 2003 with 169 complaints, resulting in a rate of 12.9 incidents per 100,000 vehicles after approximately one year of service.Ford increased the diameter of the sector shaft from 1.375 inches to 1.625 inches at the start of MY 2005 production, increasing the resistance of the steering gear assembly to torsional overload by approximately 48% and changing the failure mode from sector shaft fracture to cracked or broken sector shaft gear teeth.The redesigned steering gear assembly was used in approximately 1.1 million MY 2005 through 2009 Ford Super Duty pick-up trucks, including the subject vehicles.Figure 1 shows the basic steering system design used in Ford Super Duty trucks investigated in EA01-009 and PE13-014. Figure 2 shows the locations of failures resulting from impact related torsional overloading of the sector shaft for the subject vehicles and the prior generation Ford Super Duty trucks investigated in EA01-009.Figure 3 shows an example of a failed sector shaft investigated in EA01-009 and comparisons of fracture surfaces of sector shafts failing from fatigue loading and from torsional overload.Ford provided field return part analysis of failed steering gears from MY 2005 through 2009 Super Duty trucks found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload (Figure 4).Laboratory analysis found no evidence of fatigue or material property defects in any of the fractures.Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns (Figure 5).Analysis of failures by time in service indicates a random failure pattern/distribution, consistent with incidents of impact induced overload (Figure 6). The complaint rate for the subject vehicles after approximately 5 to 6 years, 7.1 incidents per 100,000 vehicles, is lower than the rate observed in EA01-009. Furthermore, similar to the condition investigated in EA01-009, a number of incident records include evidence of impact loads (e.g., curb strikes) and several alleged crashes include incidents in which information suggests that the steering gear failure was most likely a result of crash forces, rather than the cause of the crash.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.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 monitor this issue and reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at ww

Additional source detail variants (2)

Steering

The Office of DefectsInvestigation (ODI) opened PE13-014 after identifying five complaints alleging steering gear failure in model year (MY) 2008 Ford F-250 and F-350 Super Duty pick-up trucks and to evaluate the relationship between the design history of the steering gear assembly and the alleged defect.As background, ODI investigated steering gear sector shaft fractures in approximately 1.3 million MY 1999 - 2001 Ford Super Duty pick-up trucks and MY 2000 - 2001 Ford Excursion sport utility vehicles in Engineering Analysis EA01-009.The investigation determined that the sector shaft failures were the result of extraordinary, possibly multiple, impacts and not the result of fatigue.No defect in design, manufacturing or materials was identified in the sector shaft.EA01-009 was closed August 19, 2003 with 169 complaints, resulting in a rate of 12.9 incidents per 100,000 vehicles after approximately one year of service.Ford increased the diameter of the sector shaft from 1.375 inches to 1.625 inches at the start of MY 2005 production, increasing the resistance of the steering gear assembly to torsional overload by approximately 48% and changing the failure mode from sector shaft fracture to cracked or broken sector shaft gear teeth.The redesigned steering gear assembly was used in approximately 1.1 million MY 2005 through 2009 Ford Super Duty pick-up trucks, including the subject vehicles.Figure 1 shows the basic steering system design used in Ford Super Duty trucks investigated in EA01-009 and PE13-014. Figure 2 shows the locations of failures resulting from impact related torsional overloading of the sector shaft for the subject vehicles and the prior generation Ford Super Duty trucks investigated in EA01-009.Figure 3 shows an example of a failed sector shaft investigated in EA01-009 and comparisons of fracture surfaces of sector shafts failing from fatigue loading and from torsional overload.Ford provided field return part analysis of failed steering gears from MY 2005 through 2009 Super Duty trucks found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload (Figure 4).Laboratory analysis found no evidence of fatigue or material property defects in any of the fractures.Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns (Figure 5).Analysis of failures by time in service indicates a random failure pattern/distribution, consistent with incidents of impact induced overload (Figure 6). The complaint rate for the subject vehicles after approximately 5 to 6 years, 7.1 incidents per 100,000 vehicles, is lower than the rate observed in EA01-009. Furthermore, similar to the condition investigated in EA01-009, a number of incident records include evidence of impact loads (e.g., curb strikes) and several alleged crashes include incidents in which information suggests that the steering gear failure was most likely a result of crash forces, rather than the cause of the crash.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.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 monitor this issue and reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at ww

Steering:gear Box (other Than Rack And Pinion)

The Office of DefectsInvestigation (ODI) opened PE13-014 after identifying five complaints alleging steering gear failure in model year (MY) 2008 Ford F-250 and F-350 Super Duty pick-up trucks and to evaluate the relationship between the design history of the steering gear assembly and the alleged defect.As background, ODI investigated steering gear sector shaft fractures in approximately 1.3 million MY 1999 - 2001 Ford Super Duty pick-up trucks and MY 2000 - 2001 Ford Excursion sport utility vehicles in Engineering Analysis EA01-009.The investigation determined that the sector shaft failures were the result of extraordinary, possibly multiple, impacts and not the result of fatigue.No defect in design, manufacturing or materials was identified in the sector shaft.EA01-009 was closed August 19, 2003 with 169 complaints, resulting in a rate of 12.9 incidents per 100,000 vehicles after approximately one year of service.Ford increased the diameter of the sector shaft from 1.375 inches to 1.625 inches at the start of MY 2005 production, increasing the resistance of the steering gear assembly to torsional overload by approximately 48% and changing the failure mode from sector shaft fracture to cracked or broken sector shaft gear teeth.The redesigned steering gear assembly was used in approximately 1.1 million MY 2005 through 2009 Ford Super Duty pick-up trucks, including the subject vehicles.Figure 1 shows the basic steering system design used in Ford Super Duty trucks investigated in EA01-009 and PE13-014. Figure 2 shows the locations of failures resulting from impact related torsional overloading of the sector shaft for the subject vehicles and the prior generation Ford Super Duty trucks investigated in EA01-009.Figure 3 shows an example of a failed sector shaft investigated in EA01-009 and comparisons of fracture surfaces of sector shafts failing from fatigue loading and from torsional overload.Ford provided field return part analysis of failed steering gears from MY 2005 through 2009 Super Duty trucks found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload (Figure 4).Laboratory analysis found no evidence of fatigue or material property defects in any of the fractures.Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns (Figure 5).Analysis of failures by time in service indicates a random failure pattern/distribution, consistent with incidents of impact induced overload (Figure 6). The complaint rate for the subject vehicles after approximately 5 to 6 years, 7.1 incidents per 100,000 vehicles, is lower than the rate observed in EA01-009. Furthermore, similar to the condition investigated in EA01-009, a number of incident records include evidence of impact loads (e.g., curb strikes) and several alleged crashes include incidents in which information suggests that the steering gear failure was most likely a result of crash forces, rather than the cause of the crash.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.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 monitor this issue and reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at ww