NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
117 reportsClear category filter52,863 miles · Sep 5, 2014
EngineFuel/propulsion System
THE VEHICLE BEGAN TO SMELL LIKE RAW FUEL, PARTICULARLY AT STOP SIGNS OR INTERSECTIONS. THE SMELL APPEARED TO BE COMING FROM THE ENGINE BAY. UPON DISASSEMBLY OF THE INTAKE COMPONENTS OF THE ENGINE TO EXPOSE THE FUEL INJECTION SYSTEM, IT WAS EVIDENT THAT THE FUEL RAIL HAD BEGUN LEAKING RAW FUEL INSIDE THE ENGINE BAY. THE FUEL R…
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THE VEHICLE BEGAN TO SMELL LIKE RAW FUEL, PARTICULARLY AT STOP SIGNS OR INTERSECTIONS. THE SMELL APPEARED TO BE COMING FROM THE ENGINE BAY. UPON DISASSEMBLY OF THE INTAKE COMPONENTS OF THE ENGINE TO EXPOSE THE FUEL INJECTION SYSTEM, IT WAS EVIDENT THAT THE FUEL RAIL HAD BEGUN LEAKING RAW FUEL INSIDE THE ENGINE BAY. THE FUEL RAIL DEVELOPED A SPECK OF CORROSION ABOUT 2-3MM IN DIAMETER ON THE TOP SURFACE OF THE RAIL. THE CORROSION EVIDENTLY PENETRATED THE ENTIRE RAIL AND BECAME A PINHOLE LEAK. RAW FUEL WAS SEEN LEAKING UP AND OUT OF THE PINHOLE. THIS HAPPENED ON THE PASSENGER SIDE FUEL RAIL, WHICH IS POSITIONED INCHES AWAY FROM THE HIGH VOLTAGE COIL PACK, AND ABOVE THE EXHAUST MANIFOLD AS WELL. CALLED FORD CUSTOMER SERVICE HOTLINE AND WAS TOLD THERE IS NO RECALL FOR IT, NO EXTENDED WARRANTY PROGRAM, NO ASSISTANCE WHATSOEVER. ORDERED A NEW FUEL RAIL THROUGH LOCAL FORD DEALER FOR $500 DOLLARS (4 TIMES WHAT A TYPICAL FUEL RAIL COSTS); PART HAS NOT BEEN SHIPPED, DEALER UNSURE IF FORD HAS ANY IN STOCK OR IS EVEN MAKING THE PART. TRUCK HAS BEEN INOPERABLE FOR OVER A WEEK WITH NO WAY TO FIX IT. *TR
NHTSA ODI #10631145
122,000 miles · Aug 12, 2014
Engine
THE NUMBER 3 SPARK PLUG BLEW LOOSE. THE FIRST TIME IT HAPPENED IT WAS JUST STARTED AND IDLING. IT GOT FIXED WITH A REPAIR KIT AND THEN IT HAPPENED AGAIN THE NEXT WEEK. IT WOULDN'T BE A HUGE CONCERN BUT THERE ARE MULTIPLE THINGS THAT COULD HAPPEN AND CAUSE SERIOUS INJURY AND OR A FATALITY. *TR
NHTSA ODI #10621586
69,995 miles · Aug 7, 2014
EnginePower Train
TRUCK WENT INTO "LIMP" MODE ON START UP. VERY DIFFICULT TO GET HOME IN TRAFFIC. "FIX" WAS NEW THROTTLE BODY FROM FLECTHER FORD. $582.38. SEEMS TO BE AN ONGOING PROBLEM WITH FORD. *TR
NHTSA ODI #10620677
273,000 miles · Aug 5, 2014
Engine
AT 58,000 MILES ENGINE MALFUNCTION DUE TO A BROKEN VALVE SPRING. AT 101,879 MILE STARTED TO MAKE A LOUD RATTLING AT STARTUP AND SUBSIDED UNTIL THE ENGINE WAS WARMED UP. THIS CONTINUED UNTIL I REACHED 273,000 MILES AND THE ENGINE JUST STOPPED DUE TO OIL STARVATION AND CAM PHASER FAILURES. OIL WAS CHANGED AS REQUIRED THROUGH OUT O…
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AT 58,000 MILES ENGINE MALFUNCTION DUE TO A BROKEN VALVE SPRING. AT 101,879 MILE STARTED TO MAKE A LOUD RATTLING AT STARTUP AND SUBSIDED UNTIL THE ENGINE WAS WARMED UP. THIS CONTINUED UNTIL I REACHED 273,000 MILES AND THE ENGINE JUST STOPPED DUE TO OIL STARVATION AND CAM PHASER FAILURES. OIL WAS CHANGED AS REQUIRED THROUGH OUT OWNERSHIP. *TR
NHTSA ODI #10618905
128,000 miles · Aug 4, 2014
Engine
WHILE AT IDLE MY ENGINE STARTED TO TICK,SO I TOOK IT TO THE MECHANIC AND HE TOLD ME I HAD A BAD LASH ADJUSTER,AND IT WAS VERY COMMON FOR THIS TO HAPPEN WITH THE 5,4L 3VALVE ENGINE,SO I WENT ONLINE TO SEE IF I COULD FIND ANY INFO ABOUT MY ISSUE AND IT SEAMS THAT THOUSAND OF PEOPLE ARE HAVING THE SAME ISSUE,AND HOW FORD WILL NOT R…
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WHILE AT IDLE MY ENGINE STARTED TO TICK,SO I TOOK IT TO THE MECHANIC AND HE TOLD ME I HAD A BAD LASH ADJUSTER,AND IT WAS VERY COMMON FOR THIS TO HAPPEN WITH THE 5,4L 3VALVE ENGINE,SO I WENT ONLINE TO SEE IF I COULD FIND ANY INFO ABOUT MY ISSUE AND IT SEAMS THAT THOUSAND OF PEOPLE ARE HAVING THE SAME ISSUE,AND HOW FORD WILL NOT RECALL THE MOTORS FOR REPAIR OF A MAJOR DEFECT TO THAT TYPE OF ENGINE,THE MECHANIC TOLD ME TO DRIVE IT UNTIL IT DIES,BECAUSE THE COST WILL BE THE SAME TO REPAIR OR REPLACE THE ENGINE,POWERTRAIN.COM SELLS THE UPGRADED ENGINE WHICH CORRECTS THE THREE MAJOR ISSUES WITH THIS ENGINE,WHICH ARE,LASH ADJUSTERS,CAM PHASERS,AND THE SPARK PLUG TREADS STRIPPING OUT OF THE HEADS,WHY HAS FORD BEEN ABLE TO HIDE THIS FOR SO LONG. *TR
NHTSA ODI #10618809
181,000 miles · Jun 28, 2014
Air BagsEngineCrash
I WAS TRAVELING SOUTH COMING TO A INTERSECTION WHEN A VEHICLE TRAVELING NORTH AND DECIDED TO TURN AND HIT ME! HE WAS TRAVEL 50 MPH. THE DRIVER RECEIVED 2 TICKETS AT CRASH SITE ALSO 1 TICKET 3 MINUTE BEFORE CRASH. I ALMOST DROVE 1/3 INTO HIS CAR. NO AIR BAG WENT OFF IN MY VEHICLE. MY HIPS HAVE BEEN HURTING EVER SINCE CRASH. ALLST…
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I WAS TRAVELING SOUTH COMING TO A INTERSECTION WHEN A VEHICLE TRAVELING NORTH AND DECIDED TO TURN AND HIT ME! HE WAS TRAVEL 50 MPH. THE DRIVER RECEIVED 2 TICKETS AT CRASH SITE ALSO 1 TICKET 3 MINUTE BEFORE CRASH. I ALMOST DROVE 1/3 INTO HIS CAR. NO AIR BAG WENT OFF IN MY VEHICLE. MY HIPS HAVE BEEN HURTING EVER SINCE CRASH. ALLSTATE FORCED ME TO SETTLE THEM. I BELIEVE IF AIRBAG WENT OFF MY HIPS WOULD BE FINE! X-RAYS SHOW THEM 1" OUT OF ALIMENT AND I NEED TO CONTINUALLY SEE A CHIROPRACTOR *TR
NHTSA ODI #10606668
Mileage unknown · Jun 18, 2014
Electrical SystemEngine
2005 FORD F-150. CONSUMER WRITES IN REGARDS TO ENGINE FAIL SAFE MODE MALFUNCTIONS CAUSES VEHICLE TO LOSE ALL POWER, BRAKES AND STEERING. CONSUMER HAS DIFFERENT VEHICLE COMPLAINT IN ARTEMIS. *SMD THE DEALER INVESTIGATED THE COMPLAINT, BUT WAS UNABLE TO IDENTIFY THE CAUSE. *JB
NHTSA ODI #10597183
68,685 miles · Jun 5, 2014
Engine
5.4L TRUCK ALWAYS MAINTAINED AND SERVICED AT FORD DEALERSHIPS. IT WAS RUNNING PERFECT UNTIL IT IMMEDIATELY BEGAN IDLING ROUGH AT A STOP. NO CHECK ENGINE LIGHT, WE JUST KNOW OUR TRUCK. TOOK IT IN FOR A TUNE-UP (REPLACED SPARK PLUGS, ETC.) AND OIL CHANGE. PERFECT BILL OF HEALTH - COULDN'T REPLICATE PROBLEM. ENGINE CHECKED OUT DIA…
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5.4L TRUCK ALWAYS MAINTAINED AND SERVICED AT FORD DEALERSHIPS. IT WAS RUNNING PERFECT UNTIL IT IMMEDIATELY BEGAN IDLING ROUGH AT A STOP. NO CHECK ENGINE LIGHT, WE JUST KNOW OUR TRUCK. TOOK IT IN FOR A TUNE-UP (REPLACED SPARK PLUGS, ETC.) AND OIL CHANGE. PERFECT BILL OF HEALTH - COULDN'T REPLICATE PROBLEM. ENGINE CHECKED OUT DIAGNOSTICALLY- PERFECT. THEY SUGGESTED IT COULD BE AN INTERMITTENT STICKING FUEL INJECTOR, SO WE WERE GOING TO GET AN ADDITIVE TO ADD TO THE FUEL TANK. DIDN'T MAKE IT THAT FAR. DROVE IT HOME - 35 MILES - GOT HOME AND ENGINE STALLED IN DRIVEWAY. TURNED BACK ON, ENGINE DIED AGAIN. LONG STORY SHORT - TOWED IT BACK TO FORD - THEY WERE ABLE TO REPLICATE THE PROBLEM - OIL PRESSURE DROPS SUDDENLY (INTERMITTENTLY)- POINTING TO CAM PHASER, TIMING AREA OF ENGINE - END RESULT - NEED NEW ENGINE - THIS ONE IS SHOT AT ONLY 68K MILES - ESTIMATED COST $7,400 PLUS TAX. EXTENDED WARRANTY EXPIRED. DID SOME INTERNET RESEARCH, APPEARS TO BE A COMMON PROBLEM. THESE 5.4L ENGINES ARE BREAKING DOWN LEFT AND RIGHT IN THESE TRUCKS. DON'T KNOW WHAT CHANGED. HAD A 1999 EXPEDITION WITH A 5.4L - GREAT VEHICLE. CONTACTED FORD CUSTOMER CARE - WAS TOLD TO KEEP ALL RECEIPTS IN THE EVENT OF A RECALL. AN ENGINE SHOULD NOT BLOW AT 68K MILES, ESPECIALLY A BUILT FORD TOUGH ENGINE. WE'VE OWNED FORDS SINCE HIGH SCHOOL AND THEY USED TO BE RELIABLE, LONG DRIVING VEHICLES. *TR
NHTSA ODI #10596310
130,000 miles · Jun 4, 2014
EnginePower Train
I BOUGHT A 2005 FORD F 150 USED NOT KNOWING ABOUT THE ENGINE AND REAR END PROBLEMS UNTIL I HEARD THE RATTLE COMING FROM UNDER THE HOOD SO I GO ASK DEALER ABOUT THIS PROBLEM HE SAID THIS TYPE ENGINE WAS FROM FORD WAS NOT GOOD LUCKY FOR ME THEY WERE REPAIRING ONE IT HAD BLOWN A SPARK PLUG OUT AND THEY WERE REPLACE PARTS FOR THE CA…
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I BOUGHT A 2005 FORD F 150 USED NOT KNOWING ABOUT THE ENGINE AND REAR END PROBLEMS UNTIL I HEARD THE RATTLE COMING FROM UNDER THE HOOD SO I GO ASK DEALER ABOUT THIS PROBLEM HE SAID THIS TYPE ENGINE WAS FROM FORD WAS NOT GOOD LUCKY FOR ME THEY WERE REPAIRING ONE IT HAD BLOWN A SPARK PLUG OUT AND THEY WERE REPLACE PARTS FOR THE CAM HE SAID GET RID OF THE TRUCK OR RUN IT TILL IT BLOWS UP IT HAS NO POWER IT STALLS IN THE MOST BAD PLACES I AM AFRAID I AM GOING TO HAVE A WRECK AND HURT SOME ONE FORD NEEDS TO RECALL THESE ENGINE AND FIX THE REAR END PROBLEM ALSO I DON'T HAVE 5 TO 8 GRAND TO FIX IT. *TR
NHTSA ODI #10596154
93,000 miles · May 21, 2014
EngineFire
I HAD JUST CHANGED THE OIL AND CHECKED THE FLUIDS AND HAD TO RUN SOME ERRANDS UP TOWN ABOUT A MILE AND A HALF UP THE ROAD THE ENGINE STARTED MAKING A KNOCKING NOISE, I WAS CLOSE ENOUGH TO THE GARAGE I USE SO I PULLED IN THERE TO SEE WHAT WAS GOING ON THE OIL PAN WAS ON FIRE OIL AND WHAT LOOKED LIKE ANTI FREEZE WAS COMING OUT OF …
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I HAD JUST CHANGED THE OIL AND CHECKED THE FLUIDS AND HAD TO RUN SOME ERRANDS UP TOWN ABOUT A MILE AND A HALF UP THE ROAD THE ENGINE STARTED MAKING A KNOCKING NOISE, I WAS CLOSE ENOUGH TO THE GARAGE I USE SO I PULLED IN THERE TO SEE WHAT WAS GOING ON THE OIL PAN WAS ON FIRE OIL AND WHAT LOOKED LIKE ANTI FREEZE WAS COMING OUT OF A HOLE FROM WHAT USE TO BE THE OIL PAN OR WHAT WAS LEFT OF THE PAN, THE FELLOW THAT RAN THE STATION TOLD ME IT HAD HYDRO LOCKED AND BENT A ROD AND PUSHED IT THRU THE OIL PAN, HE WENT ON TO SAY HE HAD SEEN SEVERAL OF THE 4.2 DO THIS AND IT LOOKED LIKE FORD WOULD HAVE DONE SOMETHING WHEN THEY WERE AWARE OF THE PROBLEMS WITH THE 4.2,I TALKED TO FORD ABOUT IT AND GOT THE RUN AROUND FROM THEM, JUST COULDN'T BELIEVE IT I HAD NEVER PULLED OR HAULED ANY HEAVY OBJECTS OR MISTREATED IT IN ANY WAY, DON'T UNDERSTAND WHEN THE POWERS THAT BE WERE AWARE OF THE PROBLEM WITH THIS ENGINE THE CONSUMER WAS LEFT HOLDING THE BAG TO A TUNE OF THOUSANDS OF DOLLARS IN REPAIRS, NOW GOT TO DO WITH OUT TO TRY AND SAVE THE MONEY TO GET IT FIXED, MOSTLY USED THE TRUCK TO GET MY WIFE BACK AND FORTH TO THE DR. SHE HAS M/S AND A HEART CONDITION, THE POOR ALWAYS CATCH IT IF THERE WAS ANYTHING TO FORD THEY WOULD MAKE IT GOOD AND THE SAME GOES FOR THE NHTSA THEY KNOW THE PROBLEM IS THERE JUST LOOK AT THE FORD FORMS, BUT GOD ALWAYS MAKES A WAY JUST HAVE TO WAIT AND SEE WHAT HIS PLAN ARE, ALOT OF FOLKS LIKE US HAVE NO FAMILY SO WE TAKE CARE OF OR TRUCKS, IT SURE WASN'T ABUSE THAT CAUSE THE PROBLEM. *TR
NHTSA ODI #10593142
Official recalls
3Feb 23, 2011
FORD IS RECALLING CERTAIN MODEL YEAR 2004-2006 F-150 PICK UP TRUCKS AS WELL AS CERTAIN MODEL YEAR 2006 LINCOLN MARK LT VEHICLES. IF THE CLOCKSPRING JUMPER WIRE COMES IN CONTACT WITH THE DRIVER SIDE FRONTAL AIR BAG LOWER HORN PLATE, THE WIRE INSULATION MAY BECOME CHAFED, CREATING A POTENTIAL FOR A SHORT CIRCUIT. IF THIS OCCURS THE AIR BAG WARNING LAMP MAY ILLUMINATE INDICATING THAT SERVICE IS REQUIRED.
Consequence & remedy
Consequence: THE DRIVER SIDE FRONTAL AIR BAG COULD INADVERTENTLY DEPLOY INCREASING THE RISK OF INJURY OR LOSS OF VEHICLE CONTROL IF OCCURRING WHILE IN MOTION.
Remedy: FORD WILL NOTIFY OWNERS AND INSTRUCT THEM TO TAKE THEIR VEHICLES TO A FORD OR LINCOLN/MERCURY DEALER TO HAVE A NEW CLOCKSPRING JUMPER WIRE INSTALLED THAT INCORPORATES A PROTECTIVE MESH COVER. REPAIRS WILL BE PERFORMED FREE OF CHARGE. THIS SAFETY RECALL BEGAN ON SOME VEHICLES IN MARCH 2011. THE RECALL CAMPAIGN ON THE EXPANDED POPULATION IS EXPECTED TO BEGIN ON OR ABOUT MAY 9, 2011. OWNERS MAY CONTACT THE FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.
May 7, 2008
FORD IS RECALLING 605,684 MY 2005-2006 F-150 AND LINCOLN MARK LT VEHICLES EQUIPPED WITH 5.4L 3-VALVE ENGINES. THE BRAKE BOOSTER VACUUM SUPPLY HOSE ATTACHED TO THE INTAKE MANIFOLD FITTING MAY SWELL OVER TIME AND LOSE RETENTION FORCE. THIS CONDITION COULD ALLOW THE HOSE TO BECOME DETACHED FROM THE FITTING DURING AN INTAKE MANIFOLD BACKFIRE. SHOULD THE HOSE DETACH FROM THE INTAKE MANIFOLD, SEVERAL BRAKE APPLICATIONS WITH POWER ASSIST WILL BE AVAILABLE BEFORE THE VACUUM RESERVE IS DEPLETED.
Consequence & remedy
Consequence: ONCE THE BRAKE BOOSTER VACUUM RESERVE IS DEPLETED, THE DRIVER WILL HAVE FOUNDATION BRAKE FUNCTION, BUT WITH INCREASED BRAKE PEDAL EFFORT. REDUCED VEHICLE BRAKING COULD LEAD TO A CRASH.
Remedy: DEALERS WILL REPLACE A RUBBER HOSE ON THE BRAKE BOOSTER VACUUM SUPPLY TUBE ASSEMBLY. THE RECALL BEGAN ON JUNE 27, 2008. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Feb 6, 2006
CERTAIN PICKUP TRUCKS FAIL TO COMPLY WITH EITHER THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD (FMVSS) NO. 105, 'HYDRAULIC AND ELECTRIC BRAKE SYSTEMS' OR FMVSS NO. 135, 'PASSENGER CAR BRAKE SYSTEMS.' THESE VEHICLES WERE BUILT WITH A SOFTWARE ERROR IN THE INSTRUMENT CLUSTER.
Consequence & remedy
Consequence: THIS ERROR COULD PREVENT THE ANTILOCK BRAKE SYSTEM (ABS) WARNING LIGHT FROM ILLUMINATING IF THE ABS MODULE EVER BECAME INOPERATIVE.
Remedy: DEALERS WILL RECALIBRATE THE INSTRUMENT CLUSTER IN THESE VEHICLES. THE RECALL BEGAN ON FEBRUARY 27, 2006. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
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
3EA10001 · Inadvertent Airbag Deployment
Opened Jan 13, 2010 · Closed Apr 25, 2011
Status: closed (inferred from source dates) · Air Bags; Air Bags:frontal; Air Bags:frontal:driver Side:inflator Module; Air Bags:frontal:sensor/control MODULE-INACTIVE
ODI opened this investigation based on reports of inadvertent airbag deployment.Data provided by Ford indicated that the airbag clockspring jumper wire, which is situated inside the steering wheel assembly, was installed in a manner that would allow it to rub (abrade) against a sharp metal edge on the nearby horn plate.Because the horn plate is electrically grounded the abrasion of an airbag wire on the sharp edge could cause a short circuit condition.As a result the airbag light may illuminate and/or the airbag may inadvertently deploy.Inadvertent deployments are most likely to occur during the airbag system's self-diagnostic test that initiates when the ignition switch is turned on.Ford modified the vehicle design in late January 2006 adding a protective tape over the sharp metal edge of the horn plate.Ford made additional design changes on MY 2007 vehicles to the horn plate, the clockspring jumper, and the connector layouts to further address this issue.ODI identified 318 deployment incidents with 121 alleged injury reports from subject vehicles.All but one of the incident and injury reports occurred in vehicles built before the January 2006 modification.In addition, there was one incident and alleged injury reported in the MY 2006 Mark LT vehicles that share the same design. In letters dated February 21 and April 11, 2011, Ford announced a recall of all of the approximately 1.3 million MY 2004-2006 F-150 vehicles built prior to January 24, 2006, the date the initial vehicle modification was made.In addition, approximately 14,000 MY 2006 Mark LT vehicles built prior to January 24, 2006 will also be recalled.Vehicles built after that date, which contain the modification, are not within the recall scope.Accordingly the investigation is closed.
Additional source detail variants (4)
Air Bags
ODI opened this investigation based on reports of inadvertent airbag deployment.Data provided by Ford indicated that the airbag clockspring jumper wire, which is situated inside the steering wheel assembly, was installed in a manner that would allow it to rub (abrade) against a sharp metal edge on the nearby horn plate.Because the horn plate is electrically grounded the abrasion of an airbag wire on the sharp edge could cause a short circuit condition.As a result the airbag light may illuminate and/or the airbag may inadvertently deploy.Inadvertent deployments are most likely to occur during the airbag system's self-diagnostic test that initiates when the ignition switch is turned on.Ford modified the vehicle design in late January 2006 adding a protective tape over the sharp metal edge of the horn plate.Ford made additional design changes on MY 2007 vehicles to the horn plate, the clockspring jumper, and the connector layouts to further address this issue.ODI identified 318 deployment incidents with 121 alleged injury reports from subject vehicles.All but one of the incident and injury reports occurred in vehicles built before the January 2006 modification.In addition, there was one incident and alleged injury reported in the MY 2006 Mark LT vehicles that share the same design. In letters dated February 21 and April 11, 2011, Ford announced a recall of all of the approximately 1.3 million MY 2004-2006 F-150 vehicles built prior to January 24, 2006, the date the initial vehicle modification was made.In addition, approximately 14,000 MY 2006 Mark LT vehicles built prior to January 24, 2006 will also be recalled.Vehicles built after that date, which contain the modification, are not within the recall scope.Accordingly the investigation is closed.
Air Bags:frontal:driver Side:inflator Module
ODI opened this investigation based on reports of inadvertent airbag deployment.Data provided by Ford indicated that the airbag clockspring jumper wire, which is situated inside the steering wheel assembly, was installed in a manner that would allow it to rub (abrade) against a sharp metal edge on the nearby horn plate.Because the horn plate is electrically grounded the abrasion of an airbag wire on the sharp edge could cause a short circuit condition.As a result the airbag light may illuminate and/or the airbag may inadvertently deploy.Inadvertent deployments are most likely to occur during the airbag system's self-diagnostic test that initiates when the ignition switch is turned on.Ford modified the vehicle design in late January 2006 adding a protective tape over the sharp metal edge of the horn plate.Ford made additional design changes on MY 2007 vehicles to the horn plate, the clockspring jumper, and the connector layouts to further address this issue.ODI identified 318 deployment incidents with 121 alleged injury reports from subject vehicles.All but one of the incident and injury reports occurred in vehicles built before the January 2006 modification.In addition, there was one incident and alleged injury reported in the MY 2006 Mark LT vehicles that share the same design. In letters dated February 21 and April 11, 2011, Ford announced a recall of all of the approximately 1.3 million MY 2004-2006 F-150 vehicles built prior to January 24, 2006, the date the initial vehicle modification was made.In addition, approximately 14,000 MY 2006 Mark LT vehicles built prior to January 24, 2006 will also be recalled.Vehicles built after that date, which contain the modification, are not within the recall scope.Accordingly the investigation is closed.
Air Bags:frontal
ODI opened this investigation based on reports of inadvertent airbag deployment.Data provided by Ford indicated that the airbag clockspring jumper wire, which is situated inside the steering wheel assembly, was installed in a manner that would allow it to rub (abrade) against a sharp metal edge on the nearby horn plate.Because the horn plate is electrically grounded the abrasion of an airbag wire on the sharp edge could cause a short circuit condition.As a result the airbag light may illuminate and/or the airbag may inadvertently deploy.Inadvertent deployments are most likely to occur during the airbag system's self-diagnostic test that initiates when the ignition switch is turned on.Ford modified the vehicle design in late January 2006 adding a protective tape over the sharp metal edge of the horn plate.Ford made additional design changes on MY 2007 vehicles to the horn plate, the clockspring jumper, and the connector layouts to further address this issue.ODI identified 318 deployment incidents with 121 alleged injury reports from subject vehicles.All but one of the incident and injury reports occurred in vehicles built before the January 2006 modification.In addition, there was one incident and alleged injury reported in the MY 2006 Mark LT vehicles that share the same design. In letters dated February 21 and April 11, 2011, Ford announced a recall of all of the approximately 1.3 million MY 2004-2006 F-150 vehicles built prior to January 24, 2006, the date the initial vehicle modification was made.In addition, approximately 14,000 MY 2006 Mark LT vehicles built prior to January 24, 2006 will also be recalled.Vehicles built after that date, which contain the modification, are not within the recall scope.Accordingly the investigation is closed.
Air Bags:frontal:sensor/control MODULE-INACTIVE
ODI opened this investigation based on reports of inadvertent airbag deployment.Data provided by Ford indicated that the airbag clockspring jumper wire, which is situated inside the steering wheel assembly, was installed in a manner that would allow it to rub (abrade) against a sharp metal edge on the nearby horn plate.Because the horn plate is electrically grounded the abrasion of an airbag wire on the sharp edge could cause a short circuit condition.As a result the airbag light may illuminate and/or the airbag may inadvertently deploy.Inadvertent deployments are most likely to occur during the airbag system's self-diagnostic test that initiates when the ignition switch is turned on.Ford modified the vehicle design in late January 2006 adding a protective tape over the sharp metal edge of the horn plate.Ford made additional design changes on MY 2007 vehicles to the horn plate, the clockspring jumper, and the connector layouts to further address this issue.ODI identified 318 deployment incidents with 121 alleged injury reports from subject vehicles.All but one of the incident and injury reports occurred in vehicles built before the January 2006 modification.In addition, there was one incident and alleged injury reported in the MY 2006 Mark LT vehicles that share the same design. In letters dated February 21 and April 11, 2011, Ford announced a recall of all of the approximately 1.3 million MY 2004-2006 F-150 vehicles built prior to January 24, 2006, the date the initial vehicle modification was made.In addition, approximately 14,000 MY 2006 Mark LT vehicles built prior to January 24, 2006 will also be recalled.Vehicles built after that date, which contain the modification, are not within the recall scope.Accordingly the investigation is closed.
PE09046 · Inadvertent Airbag Deployment
Opened Sep 24, 2009 · Closed Jan 19, 2010
Status: closed (inferred from source dates) · Air Bags; Air Bags:frontal; Air Bags:frontal:driver Side:inflator Module; Air Bags:frontal:sensor/control MODULE-INACTIVE
FORD REPORTS THAT THE INADVERTENT AIRBAG DEPLOYMENTS ARE MOST LIKELY CAUSED BY THE AIRBAG HORN MOUNTING PLATE'S SHARP METAL EDGE THAT EVENTUALLY CAN CHAFE/CUT THE AIRBAG CLOCKSPRING JUMPER WIRE LEADING TO A SHORT-TO-GROUND CONDITION.ONE HUNDRED EIGHTY TWO (182) OF THE 230 REPORTS WERE FOR AIRBAG DEPLOYMENTS RESULTING IN 56 INJURIES WITH REMAINING 48 REPORTS FOR AN AIRBAG LIGHT ILLUMINATION CONDITION.INJURIES INCLUDE ABRASION, CONTUSION AND CUTS TO THE ARM/HAND/FACE AND/OR UPPER BODY REGIONS.ONE OWNER REPORTED A BROKEN TOOTH AND TWO OWNERS REPORTED BEING KNOCKED UNCONSCIOUS AS A RESULT OF THE AIRBAG DEPLOYMENT.IN ADDITION, MY2004 AND MY2006 F-150 VEHICLES ALSO CONTAIN THE SAME DESIGN THAT RESULTED IN AN ADDITIONAL 89 REPORTS WITH 37 AIRBAG DEPLOYMENTS AND NINE INJURIES. FORD MADE AN INTERIM DESIGN CHANGE TO THE HORN MOUNTING PLATE IN JANUARY 2006 AND THEN MAJOR CHANGES TO THE HORN MOUNTING PLATE, AIRBAG MODULE AND CLOCKSPRING JUMPER WIRE DESIGNS IN JUNE 2006 FOR THE MY2007 VEHICLES.THIS PRELIMINARY EVALUATION IS UPGRADED TO AN ENGINEERING ANALYSIS (EA10-001) TO INCLUDE MY2004-2006 F-150 VEHICLES AND TO FURTHER EVALUATE THE CONDITION.
Additional source detail variants (4)
Air Bags
FORD REPORTS THAT THE INADVERTENT AIRBAG DEPLOYMENTS ARE MOST LIKELY CAUSED BY THE AIRBAG HORN MOUNTING PLATE'S SHARP METAL EDGE THAT EVENTUALLY CAN CHAFE/CUT THE AIRBAG CLOCKSPRING JUMPER WIRE LEADING TO A SHORT-TO-GROUND CONDITION.ONE HUNDRED EIGHTY TWO (182) OF THE 230 REPORTS WERE FOR AIRBAG DEPLOYMENTS RESULTING IN 56 INJURIES WITH REMAINING 48 REPORTS FOR AN AIRBAG LIGHT ILLUMINATION CONDITION.INJURIES INCLUDE ABRASION, CONTUSION AND CUTS TO THE ARM/HAND/FACE AND/OR UPPER BODY REGIONS.ONE OWNER REPORTED A BROKEN TOOTH AND TWO OWNERS REPORTED BEING KNOCKED UNCONSCIOUS AS A RESULT OF THE AIRBAG DEPLOYMENT.IN ADDITION, MY2004 AND MY2006 F-150 VEHICLES ALSO CONTAIN THE SAME DESIGN THAT RESULTED IN AN ADDITIONAL 89 REPORTS WITH 37 AIRBAG DEPLOYMENTS AND NINE INJURIES. FORD MADE AN INTERIM DESIGN CHANGE TO THE HORN MOUNTING PLATE IN JANUARY 2006 AND THEN MAJOR CHANGES TO THE HORN MOUNTING PLATE, AIRBAG MODULE AND CLOCKSPRING JUMPER WIRE DESIGNS IN JUNE 2006 FOR THE MY2007 VEHICLES.THIS PRELIMINARY EVALUATION IS UPGRADED TO AN ENGINEERING ANALYSIS (EA10-001) TO INCLUDE MY2004-2006 F-150 VEHICLES AND TO FURTHER EVALUATE THE CONDITION.
Air Bags:frontal:driver Side:inflator Module
FORD REPORTS THAT THE INADVERTENT AIRBAG DEPLOYMENTS ARE MOST LIKELY CAUSED BY THE AIRBAG HORN MOUNTING PLATE'S SHARP METAL EDGE THAT EVENTUALLY CAN CHAFE/CUT THE AIRBAG CLOCKSPRING JUMPER WIRE LEADING TO A SHORT-TO-GROUND CONDITION.ONE HUNDRED EIGHTY TWO (182) OF THE 230 REPORTS WERE FOR AIRBAG DEPLOYMENTS RESULTING IN 56 INJURIES WITH REMAINING 48 REPORTS FOR AN AIRBAG LIGHT ILLUMINATION CONDITION.INJURIES INCLUDE ABRASION, CONTUSION AND CUTS TO THE ARM/HAND/FACE AND/OR UPPER BODY REGIONS.ONE OWNER REPORTED A BROKEN TOOTH AND TWO OWNERS REPORTED BEING KNOCKED UNCONSCIOUS AS A RESULT OF THE AIRBAG DEPLOYMENT.IN ADDITION, MY2004 AND MY2006 F-150 VEHICLES ALSO CONTAIN THE SAME DESIGN THAT RESULTED IN AN ADDITIONAL 89 REPORTS WITH 37 AIRBAG DEPLOYMENTS AND NINE INJURIES. FORD MADE AN INTERIM DESIGN CHANGE TO THE HORN MOUNTING PLATE IN JANUARY 2006 AND THEN MAJOR CHANGES TO THE HORN MOUNTING PLATE, AIRBAG MODULE AND CLOCKSPRING JUMPER WIRE DESIGNS IN JUNE 2006 FOR THE MY2007 VEHICLES.THIS PRELIMINARY EVALUATION IS UPGRADED TO AN ENGINEERING ANALYSIS (EA10-001) TO INCLUDE MY2004-2006 F-150 VEHICLES AND TO FURTHER EVALUATE THE CONDITION.
Air Bags:frontal
FORD REPORTS THAT THE INADVERTENT AIRBAG DEPLOYMENTS ARE MOST LIKELY CAUSED BY THE AIRBAG HORN MOUNTING PLATE'S SHARP METAL EDGE THAT EVENTUALLY CAN CHAFE/CUT THE AIRBAG CLOCKSPRING JUMPER WIRE LEADING TO A SHORT-TO-GROUND CONDITION.ONE HUNDRED EIGHTY TWO (182) OF THE 230 REPORTS WERE FOR AIRBAG DEPLOYMENTS RESULTING IN 56 INJURIES WITH REMAINING 48 REPORTS FOR AN AIRBAG LIGHT ILLUMINATION CONDITION.INJURIES INCLUDE ABRASION, CONTUSION AND CUTS TO THE ARM/HAND/FACE AND/OR UPPER BODY REGIONS.ONE OWNER REPORTED A BROKEN TOOTH AND TWO OWNERS REPORTED BEING KNOCKED UNCONSCIOUS AS A RESULT OF THE AIRBAG DEPLOYMENT.IN ADDITION, MY2004 AND MY2006 F-150 VEHICLES ALSO CONTAIN THE SAME DESIGN THAT RESULTED IN AN ADDITIONAL 89 REPORTS WITH 37 AIRBAG DEPLOYMENTS AND NINE INJURIES. FORD MADE AN INTERIM DESIGN CHANGE TO THE HORN MOUNTING PLATE IN JANUARY 2006 AND THEN MAJOR CHANGES TO THE HORN MOUNTING PLATE, AIRBAG MODULE AND CLOCKSPRING JUMPER WIRE DESIGNS IN JUNE 2006 FOR THE MY2007 VEHICLES.THIS PRELIMINARY EVALUATION IS UPGRADED TO AN ENGINEERING ANALYSIS (EA10-001) TO INCLUDE MY2004-2006 F-150 VEHICLES AND TO FURTHER EVALUATE THE CONDITION.
Air Bags:frontal:sensor/control MODULE-INACTIVE
FORD REPORTS THAT THE INADVERTENT AIRBAG DEPLOYMENTS ARE MOST LIKELY CAUSED BY THE AIRBAG HORN MOUNTING PLATE'S SHARP METAL EDGE THAT EVENTUALLY CAN CHAFE/CUT THE AIRBAG CLOCKSPRING JUMPER WIRE LEADING TO A SHORT-TO-GROUND CONDITION.ONE HUNDRED EIGHTY TWO (182) OF THE 230 REPORTS WERE FOR AIRBAG DEPLOYMENTS RESULTING IN 56 INJURIES WITH REMAINING 48 REPORTS FOR AN AIRBAG LIGHT ILLUMINATION CONDITION.INJURIES INCLUDE ABRASION, CONTUSION AND CUTS TO THE ARM/HAND/FACE AND/OR UPPER BODY REGIONS.ONE OWNER REPORTED A BROKEN TOOTH AND TWO OWNERS REPORTED BEING KNOCKED UNCONSCIOUS AS A RESULT OF THE AIRBAG DEPLOYMENT.IN ADDITION, MY2004 AND MY2006 F-150 VEHICLES ALSO CONTAIN THE SAME DESIGN THAT RESULTED IN AN ADDITIONAL 89 REPORTS WITH 37 AIRBAG DEPLOYMENTS AND NINE INJURIES. FORD MADE AN INTERIM DESIGN CHANGE TO THE HORN MOUNTING PLATE IN JANUARY 2006 AND THEN MAJOR CHANGES TO THE HORN MOUNTING PLATE, AIRBAG MODULE AND CLOCKSPRING JUMPER WIRE DESIGNS IN JUNE 2006 FOR THE MY2007 VEHICLES.THIS PRELIMINARY EVALUATION IS UPGRADED TO AN ENGINEERING ANALYSIS (EA10-001) TO INCLUDE MY2004-2006 F-150 VEHICLES AND TO FURTHER EVALUATE THE CONDITION.
PE08001 · Loss Of Brake POWER-ASSIST
Opened Jan 8, 2008 · Closed May 9, 2008
Status: closed (inferred from source dates) · Service Brakes, Hydraulic:power Assist; Service Brakes, Hydraulic:power Assist:vacuum; Service Brakes, Hydraulic:power Assist:vacuum:hoses, Lines/piping, And Fittings
BY LETTER DATED MAY 5, 2008, FORD MOTOR COMPANY (FORD) NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA RECALL NUMBER 08V-208) TO ADDRESS A MANUFACTURING DEFECT IN APPROXIMATELY 605,684 MODEL YEAR (MY) 2005 AND 2006 FORD F-150 AND LINCOLN MARK LT VEHICLES ORIGINALLY EQUIPPED WITH THE 5.4L DISPLACEMENT, 3-VALVE PER CYLINDER, V-8 ENGINE.THE RECALLED VEHICLES WERE BUILT FROM JULY 18, 2004 THROUGH MAY 31, 2006 AT THE DEARBORN TRUCK PLANT; FROM MAY 4, 2004 THROUGH MAY 31, 2006 AT THE KANSAS CITY ASSEMBLY PLANT; AND FROM APRIL 19, 2004 THROUGH MAY 31, 2006 AT THE NORFOLK TRUCK PLANT.THE VEHICLES WERE MANUFACTURED WITH THE SAME DEFECTIVE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY UNIQUE TO THE 5.4L V-8 ENGINE.FORD F-150 VEHICLES EQUIPPED WITH OPTIONALLY AVAILABLE 4.2L V6 AND 4.6L V-8 ENGINES ARE NOT INCLUDED IN THIS RECALL ACTION BECAUSE THEY UTILIZE A DIFFERENT, ONE-PIECE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY THAT DOES NOT EXHIBIT AN APPARENT DEFECT TREND. THE RECALLED VEHICLES UTILIZE A TWO-PIECE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY COMPRISED OF A STANDPIPE ASSEMBLY AND VACUUM HOSE.THE STANDPIPE ASSEMBLY ATTACHES TO A FITTING ON THE ENGINE AIR INTAKE MANIFOLD UTILIZING A FLEXIBLE RUBBER HOSE AND PLASTIC ELBOW.THE VACUUM HOSE ATTACHES TO THE OPPOSITE END OF THE STANDPIPE ASSEMBLY AND CONNECTS TO A CHECK VALVE FITTING AT THE BRAKE BOOSTER ASSEMBLY.ACCORDING TO FORD, THE PORTION OF THE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY ATTACHED TO THE INTAKE MANIFOLD MAY SWELL OVER TIME AND LOSE RETENTION FORCE, WHICH MAY ALLOW THE HOSE TO BECOME DETACHED FROM THE INTAKE MANIFOLD.SHOULD THE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY BE DISRUPTED, APPLICATION OF THE BRAKE PEDAL MAY DEPLETE THE VACUUM RESERVE AND CONSEQUENTLY RESULT IN LOSS OF BRAKE POWER-ASSIST. TO CORRECT THE SAFETY DEFECT, FORD WILL INSTALL AN IMPROVED DESIGN BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY THAT UTILIZES A HOSE CLAMP AT THE INTAKE MANIFOLD ATTACHMENT. THIS REMEDY WILL BE PROVIDED FREE OF CHARGE FOR ALL RECALLED VEHICLES.LATER PRODUCTION FORD F-150 AND LINCOLN MARK LT VEHICLES BUILT AFTER MAY 2006 WERE MANUFACTURED WITH A HOSE CLAMP AT THE BRAKE BOOSTER VACUUM SUPPLY HOSE/INTAKE MANIFOLD ATTACHMENT AND ARE NOT AFFECTED. TO DATE, THE OFFICE OF DEFECTS INVESTIGATION (ODI) IS AWARE OF 324 NON-DUPLICATIVE COMPLAINTS AND 14 NON-INJURY CRASHES RELATED TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF 4,465 SUBJECT VEHICLES THAT EXPERIENCED ONE OR MORE WARRANTY CLAIMS TO REPAIR OR REPLACE THE SUBJECT BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY. THE ACTION TAKEN BY FORD IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Additional source detail variants (3)
Service Brakes, Hydraulic:power Assist
BY LETTER DATED MAY 5, 2008, FORD MOTOR COMPANY (FORD) NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA RECALL NUMBER 08V-208) TO ADDRESS A MANUFACTURING DEFECT IN APPROXIMATELY 605,684 MODEL YEAR (MY) 2005 AND 2006 FORD F-150 AND LINCOLN MARK LT VEHICLES ORIGINALLY EQUIPPED WITH THE 5.4L DISPLACEMENT, 3-VALVE PER CYLINDER, V-8 ENGINE.THE RECALLED VEHICLES WERE BUILT FROM JULY 18, 2004 THROUGH MAY 31, 2006 AT THE DEARBORN TRUCK PLANT; FROM MAY 4, 2004 THROUGH MAY 31, 2006 AT THE KANSAS CITY ASSEMBLY PLANT; AND FROM APRIL 19, 2004 THROUGH MAY 31, 2006 AT THE NORFOLK TRUCK PLANT.THE VEHICLES WERE MANUFACTURED WITH THE SAME DEFECTIVE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY UNIQUE TO THE 5.4L V-8 ENGINE.FORD F-150 VEHICLES EQUIPPED WITH OPTIONALLY AVAILABLE 4.2L V6 AND 4.6L V-8 ENGINES ARE NOT INCLUDED IN THIS RECALL ACTION BECAUSE THEY UTILIZE A DIFFERENT, ONE-PIECE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY THAT DOES NOT EXHIBIT AN APPARENT DEFECT TREND. THE RECALLED VEHICLES UTILIZE A TWO-PIECE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY COMPRISED OF A STANDPIPE ASSEMBLY AND VACUUM HOSE.THE STANDPIPE ASSEMBLY ATTACHES TO A FITTING ON THE ENGINE AIR INTAKE MANIFOLD UTILIZING A FLEXIBLE RUBBER HOSE AND PLASTIC ELBOW.THE VACUUM HOSE ATTACHES TO THE OPPOSITE END OF THE STANDPIPE ASSEMBLY AND CONNECTS TO A CHECK VALVE FITTING AT THE BRAKE BOOSTER ASSEMBLY.ACCORDING TO FORD, THE PORTION OF THE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY ATTACHED TO THE INTAKE MANIFOLD MAY SWELL OVER TIME AND LOSE RETENTION FORCE, WHICH MAY ALLOW THE HOSE TO BECOME DETACHED FROM THE INTAKE MANIFOLD.SHOULD THE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY BE DISRUPTED, APPLICATION OF THE BRAKE PEDAL MAY DEPLETE THE VACUUM RESERVE AND CONSEQUENTLY RESULT IN LOSS OF BRAKE POWER-ASSIST. TO CORRECT THE SAFETY DEFECT, FORD WILL INSTALL AN IMPROVED DESIGN BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY THAT UTILIZES A HOSE CLAMP AT THE INTAKE MANIFOLD ATTACHMENT. THIS REMEDY WILL BE PROVIDED FREE OF CHARGE FOR ALL RECALLED VEHICLES.LATER PRODUCTION FORD F-150 AND LINCOLN MARK LT VEHICLES BUILT AFTER MAY 2006 WERE MANUFACTURED WITH A HOSE CLAMP AT THE BRAKE BOOSTER VACUUM SUPPLY HOSE/INTAKE MANIFOLD ATTACHMENT AND ARE NOT AFFECTED. TO DATE, THE OFFICE OF DEFECTS INVESTIGATION (ODI) IS AWARE OF 324 NON-DUPLICATIVE COMPLAINTS AND 14 NON-INJURY CRASHES RELATED TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF 4,465 SUBJECT VEHICLES THAT EXPERIENCED ONE OR MORE WARRANTY CLAIMS TO REPAIR OR REPLACE THE SUBJECT BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY. THE ACTION TAKEN BY FORD IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Service Brakes, Hydraulic:power Assist:vacuum
BY LETTER DATED MAY 5, 2008, FORD MOTOR COMPANY (FORD) NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA RECALL NUMBER 08V-208) TO ADDRESS A MANUFACTURING DEFECT IN APPROXIMATELY 605,684 MODEL YEAR (MY) 2005 AND 2006 FORD F-150 AND LINCOLN MARK LT VEHICLES ORIGINALLY EQUIPPED WITH THE 5.4L DISPLACEMENT, 3-VALVE PER CYLINDER, V-8 ENGINE.THE RECALLED VEHICLES WERE BUILT FROM JULY 18, 2004 THROUGH MAY 31, 2006 AT THE DEARBORN TRUCK PLANT; FROM MAY 4, 2004 THROUGH MAY 31, 2006 AT THE KANSAS CITY ASSEMBLY PLANT; AND FROM APRIL 19, 2004 THROUGH MAY 31, 2006 AT THE NORFOLK TRUCK PLANT.THE VEHICLES WERE MANUFACTURED WITH THE SAME DEFECTIVE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY UNIQUE TO THE 5.4L V-8 ENGINE.FORD F-150 VEHICLES EQUIPPED WITH OPTIONALLY AVAILABLE 4.2L V6 AND 4.6L V-8 ENGINES ARE NOT INCLUDED IN THIS RECALL ACTION BECAUSE THEY UTILIZE A DIFFERENT, ONE-PIECE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY THAT DOES NOT EXHIBIT AN APPARENT DEFECT TREND. THE RECALLED VEHICLES UTILIZE A TWO-PIECE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY COMPRISED OF A STANDPIPE ASSEMBLY AND VACUUM HOSE.THE STANDPIPE ASSEMBLY ATTACHES TO A FITTING ON THE ENGINE AIR INTAKE MANIFOLD UTILIZING A FLEXIBLE RUBBER HOSE AND PLASTIC ELBOW.THE VACUUM HOSE ATTACHES TO THE OPPOSITE END OF THE STANDPIPE ASSEMBLY AND CONNECTS TO A CHECK VALVE FITTING AT THE BRAKE BOOSTER ASSEMBLY.ACCORDING TO FORD, THE PORTION OF THE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY ATTACHED TO THE INTAKE MANIFOLD MAY SWELL OVER TIME AND LOSE RETENTION FORCE, WHICH MAY ALLOW THE HOSE TO BECOME DETACHED FROM THE INTAKE MANIFOLD.SHOULD THE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY BE DISRUPTED, APPLICATION OF THE BRAKE PEDAL MAY DEPLETE THE VACUUM RESERVE AND CONSEQUENTLY RESULT IN LOSS OF BRAKE POWER-ASSIST. TO CORRECT THE SAFETY DEFECT, FORD WILL INSTALL AN IMPROVED DESIGN BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY THAT UTILIZES A HOSE CLAMP AT THE INTAKE MANIFOLD ATTACHMENT. THIS REMEDY WILL BE PROVIDED FREE OF CHARGE FOR ALL RECALLED VEHICLES.LATER PRODUCTION FORD F-150 AND LINCOLN MARK LT VEHICLES BUILT AFTER MAY 2006 WERE MANUFACTURED WITH A HOSE CLAMP AT THE BRAKE BOOSTER VACUUM SUPPLY HOSE/INTAKE MANIFOLD ATTACHMENT AND ARE NOT AFFECTED. TO DATE, THE OFFICE OF DEFECTS INVESTIGATION (ODI) IS AWARE OF 324 NON-DUPLICATIVE COMPLAINTS AND 14 NON-INJURY CRASHES RELATED TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF 4,465 SUBJECT VEHICLES THAT EXPERIENCED ONE OR MORE WARRANTY CLAIMS TO REPAIR OR REPLACE THE SUBJECT BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY. THE ACTION TAKEN BY FORD IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Service Brakes, Hydraulic:power Assist:vacuum:hoses, Lines/piping, And Fittings
BY LETTER DATED MAY 5, 2008, FORD MOTOR COMPANY (FORD) NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA RECALL NUMBER 08V-208) TO ADDRESS A MANUFACTURING DEFECT IN APPROXIMATELY 605,684 MODEL YEAR (MY) 2005 AND 2006 FORD F-150 AND LINCOLN MARK LT VEHICLES ORIGINALLY EQUIPPED WITH THE 5.4L DISPLACEMENT, 3-VALVE PER CYLINDER, V-8 ENGINE.THE RECALLED VEHICLES WERE BUILT FROM JULY 18, 2004 THROUGH MAY 31, 2006 AT THE DEARBORN TRUCK PLANT; FROM MAY 4, 2004 THROUGH MAY 31, 2006 AT THE KANSAS CITY ASSEMBLY PLANT; AND FROM APRIL 19, 2004 THROUGH MAY 31, 2006 AT THE NORFOLK TRUCK PLANT.THE VEHICLES WERE MANUFACTURED WITH THE SAME DEFECTIVE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY UNIQUE TO THE 5.4L V-8 ENGINE.FORD F-150 VEHICLES EQUIPPED WITH OPTIONALLY AVAILABLE 4.2L V6 AND 4.6L V-8 ENGINES ARE NOT INCLUDED IN THIS RECALL ACTION BECAUSE THEY UTILIZE A DIFFERENT, ONE-PIECE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY THAT DOES NOT EXHIBIT AN APPARENT DEFECT TREND. THE RECALLED VEHICLES UTILIZE A TWO-PIECE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY COMPRISED OF A STANDPIPE ASSEMBLY AND VACUUM HOSE.THE STANDPIPE ASSEMBLY ATTACHES TO A FITTING ON THE ENGINE AIR INTAKE MANIFOLD UTILIZING A FLEXIBLE RUBBER HOSE AND PLASTIC ELBOW.THE VACUUM HOSE ATTACHES TO THE OPPOSITE END OF THE STANDPIPE ASSEMBLY AND CONNECTS TO A CHECK VALVE FITTING AT THE BRAKE BOOSTER ASSEMBLY.ACCORDING TO FORD, THE PORTION OF THE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY ATTACHED TO THE INTAKE MANIFOLD MAY SWELL OVER TIME AND LOSE RETENTION FORCE, WHICH MAY ALLOW THE HOSE TO BECOME DETACHED FROM THE INTAKE MANIFOLD.SHOULD THE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY BE DISRUPTED, APPLICATION OF THE BRAKE PEDAL MAY DEPLETE THE VACUUM RESERVE AND CONSEQUENTLY RESULT IN LOSS OF BRAKE POWER-ASSIST. TO CORRECT THE SAFETY DEFECT, FORD WILL INSTALL AN IMPROVED DESIGN BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY THAT UTILIZES A HOSE CLAMP AT THE INTAKE MANIFOLD ATTACHMENT. THIS REMEDY WILL BE PROVIDED FREE OF CHARGE FOR ALL RECALLED VEHICLES.LATER PRODUCTION FORD F-150 AND LINCOLN MARK LT VEHICLES BUILT AFTER MAY 2006 WERE MANUFACTURED WITH A HOSE CLAMP AT THE BRAKE BOOSTER VACUUM SUPPLY HOSE/INTAKE MANIFOLD ATTACHMENT AND ARE NOT AFFECTED. TO DATE, THE OFFICE OF DEFECTS INVESTIGATION (ODI) IS AWARE OF 324 NON-DUPLICATIVE COMPLAINTS AND 14 NON-INJURY CRASHES RELATED TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF 4,465 SUBJECT VEHICLES THAT EXPERIENCED ONE OR MORE WARRANTY CLAIMS TO REPAIR OR REPLACE THE SUBJECT BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY. THE ACTION TAKEN BY FORD IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
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