NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
111 reportsClear category filter55,000 miles · May 19, 2009
Engine And Engine Cooling
SPARK PLUGS CANNOT BE CHANGED BECAUSE OF DESIGN OF CYLINDER HEAD. THIS IS A SPARK PLUG BREAKAGE INSIDE THE HEAD. THIS IS A COMMON OCCURRENCE ON 5.4 LITER FORD MOTORS AS REPORTED ON FORUMS AND THROUGH WORD OF MOUTH. 1998 TO 2008 MOTORS ARE NOTORIOUS LEADING CONSUMERS TO EITHER PAY HUGE REPAIR BILLS OR TRADE BEFORE THEY WISH TO TR…
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SPARK PLUGS CANNOT BE CHANGED BECAUSE OF DESIGN OF CYLINDER HEAD. THIS IS A SPARK PLUG BREAKAGE INSIDE THE HEAD. THIS IS A COMMON OCCURRENCE ON 5.4 LITER FORD MOTORS AS REPORTED ON FORUMS AND THROUGH WORD OF MOUTH. 1998 TO 2008 MOTORS ARE NOTORIOUS LEADING CONSUMERS TO EITHER PAY HUGE REPAIR BILLS OR TRADE BEFORE THEY WISH TO TRADE. ALSO, SOMEONE WISHING TO CHANGE HIS PLUGS FOR PROPER EMISSIONS OR PROPER MAINTENANCE IS JUST SCREWED. SCARED TO DEATH TO HAVE THEM CHANGED EVEN AT A DEALERSHIP. FORD MECHANICS EVEN HAVE TROUBLE.THIS IS NO FEW VEHICLES. THIS IS WIDESPREAD.
NHTSA ODI #10269436
Mileage unknown · May 17, 2009
Engine And Engine Cooling
SUDDEN ENGINE SURGES OCCURRING AT ANY TIME WEATHER MOVING OR STOPPED AT RED LIGHT OR WHILE SLOWING DOWN TO STOP. *TR
NHTSA ODI #10268946
69,500 miles · May 12, 2009
Engine And Engine Cooling
REGARDING: 2005 FORD F 150 TRUCK PURCHASED NEW FROM DEALER, HAS BEEN HAVING PROBLEMS WITH STALLING. IT HAS STALLED IN REVERSE AND WHILE DRIVING ON FREEWAY. IT IS VERY DANGEROUS. I ALMOST GOT INTO AN ACCIDENT TODAY ON THE FREEWAY, WHICH IS WHY I AM TAKING THE TIME TO LOOK INTO THIS MATTER. I ALSO KNOW A FEW PEOPLE WITH THE SAME …
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REGARDING: 2005 FORD F 150 TRUCK PURCHASED NEW FROM DEALER, HAS BEEN HAVING PROBLEMS WITH STALLING. IT HAS STALLED IN REVERSE AND WHILE DRIVING ON FREEWAY. IT IS VERY DANGEROUS. I ALMOST GOT INTO AN ACCIDENT TODAY ON THE FREEWAY, WHICH IS WHY I AM TAKING THE TIME TO LOOK INTO THIS MATTER. I ALSO KNOW A FEW PEOPLE WITH THE SAME PROBLEM AND HAVE ALSO SEEN MANY POSTINGS ONLINE FOR THIS ISSUE. MANY PEOPLE HAVE BEEN INJURED IN ACCIDENTS AND MANY TRUCKS HAVE CAUGHT ON FIRE. ALL HAVE STARTED WITH THESE SAME PROBLEMS. FORD RECOGNIZED THIS PROBLEM UNTIL THE MADE YEAR OF 2004. I DO BELIEVE IT ALSO A PROBLEM WITH 2005, AND MAYBE WITH OTHER YEARS. THIS REALLY NEEDS TO BE CHECKED INTO. I HAVE HAD MY TRUCK LOOKED AT BY A MECHANIC, AND HE IS NOT SURE OF THE PROBLEM. I SEE A LOT OF PROBLEMS WITH FORD AND FUEL INJECTORS AND CRUISE CONTROL WITH MY YEAR OF TRUCK, BUT NO RECALLS. THIS IS A SERIOUS MATTER AND I WOULD APPRECIATE THAT IT BE HANDLED RESPONSIBLY. *TR
NHTSA ODI #10268574
86,000 miles · Apr 22, 2009
Engine And Engine Cooling
I HAVE A 2005 FORD F-150 (4.6L V8) AND I RECENTLY HAD A SPARK PLUG BLOW OUT OF THE ENGINE, FOR THE SECOND TIME. THE FIRST TIME IT COST ME $556.50 TO REPAIR IT. THIS TIME IT HAPPENED IN A DIFFERENT CYLINDER. THIS TIME I HAD MY 2YEAR OLD DAUGHTER WITH ME AND WAS STRANDED ALONG INTERSTATE 70 FOR OVER AN HOUR. I DIDN'T REPORT IT…
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I HAVE A 2005 FORD F-150 (4.6L V8) AND I RECENTLY HAD A SPARK PLUG BLOW OUT OF THE ENGINE, FOR THE SECOND TIME. THE FIRST TIME IT COST ME $556.50 TO REPAIR IT. THIS TIME IT HAPPENED IN A DIFFERENT CYLINDER. THIS TIME I HAD MY 2YEAR OLD DAUGHTER WITH ME AND WAS STRANDED ALONG INTERSTATE 70 FOR OVER AN HOUR. I DIDN'T REPORT IT THE FIRST TIME, BECAUSE I THOUGHT IT WAS AN ISOLATED INCIDENT. NOW AFTER SOME RESEARCH, I HAVE FOUND THAT THIS HAPPENING AROUND THE NATION. I AM NOT SURE WHY THERE HASN'T BEEN A RECALL. NOT ONLY CAN THIS BE A FIRE HAZARD, BUT IN MY CASE, MY DAUGHTER AND I WERE STRANDED ALONG SIDE A VERY BUSY HIGHWAY. *TR
NHTSA ODI #10266438
45,000 miles · Apr 21, 2009
Engine And Engine Cooling
MY TRUCK IS A 2005 FORD F-150 WITH 45,000 MILES NO PRIOR PROBLEMS SERVICED AS PER THE FORD RECOMMENDATIONS AS WELL AS REGULAR OIL CHANGES. WHILE ON VACATION GETTING OFF THE FREEWAY OFF RAMP IN RENO NEVADA AND COMING TO A STOP AT A RED LIGHT MY CAR STARTED TO SHAKE AND SPUTTER AS IF IT WAS GOING TO TURN OFF AND THE CHECK EN…
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MY TRUCK IS A 2005 FORD F-150 WITH 45,000 MILES NO PRIOR PROBLEMS SERVICED AS PER THE FORD RECOMMENDATIONS AS WELL AS REGULAR OIL CHANGES. WHILE ON VACATION GETTING OFF THE FREEWAY OFF RAMP IN RENO NEVADA AND COMING TO A STOP AT A RED LIGHT MY CAR STARTED TO SHAKE AND SPUTTER AS IF IT WAS GOING TO TURN OFF AND THE CHECK ENGINE LIGHT WAS ON. AFTER THE LIGHT TURNED GREEN I PROCEEDED THROUGH THE GREEN LIGHT AND PARKED THE TRUCK IN A SAFE SPOT OFF THE STREET. I TURNED OFF THE ENGINE AND LIFTED THE HOOD AND THERE WAS A SMALL ODDER OF GAS FUMES. SEEING THAT I NEEDED TO GET TO A SAFE AREA I SLOWLY DROVE THE TRUCK TO A HOTEL. THE NEXT DAY ON MONDAY AT A SLOW SPEED NO MORE THAN 25 MILES PER HR. I DROVE THE TRUCK TO THE FORD DEALERSHIP WHERE I SPOKE WITH A FORD SERVICE ADVISOR. THE FORD SERVICE ADVISOR TOLD ME THAT THERE WAS A (FUEL INJECTOR NOTICE) FOR THIS YEAR MAKE AND MODEL FORD TRUCK. HE ALSO SAID THAT THERE COULD BE A POSSIBILITY THAT OTHER ENGINE PROBLEMS COULD INCUR AS A RESULT OF THE BAD FUEL INJECTOR. HE SAID THAT THERE COULD BE A POSSIBILITY THAT MY MOTOR COULD (HYDROLOCK) AND CAUSE OTHER PROBLEMS IN THE ENGINE AND THAT THERE WAS ALSO A POSSIBILITY THAT MY CATALYTIC CONVERTER COULD BE DAMAGED. AFTER RECEIVING THIS INFO I LEFT THE DEALERSHIP THEY SHUTTLED ME BACK TO MY HOTEL. LATER THAT DAY THEY DIAGNOSED THE PROBLEM. THIS IS THE EXPLANATION OF WHAT THE DEALERSHIP SAID WAS WRONG WITH MY TRUCK: (1)BAD FUEL INJECTOR. (2)BENT ROD. (3)BENT VALVE SPRING (4)SCORED VALVE HEAD (5)POSSIBLE BAD CATALYTIC CONVERTER ESTIMATED DAMAGE $4,300 AND IF CATALYTIC CONVERTER WAS DAMAGED $5,100. *TR
NHTSA ODI #10266192
82,000 miles · Apr 2, 2009
Engine And Engine CoolingFire
TL*THE CONTACT OWNS A 2005 FORD F-150. WHILE DRIVING APPROXIMATELY 45 MPH, THE CONTACT NOTICED THAT THE TEMPERATURE WARNING INDICATOR WAS ILLUMINATED ON THE INSTRUMENT PANEL, WHICH MEANT THAT THE VEHICLE WAS OVERHEATING. HE ALSO NOTICED SMOKE AND WATER EMANATING FROM THE VEHICLE. IF THE VEHICLE WOULD HAVE STALLED WHILE DRIVIN…
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TL*THE CONTACT OWNS A 2005 FORD F-150. WHILE DRIVING APPROXIMATELY 45 MPH, THE CONTACT NOTICED THAT THE TEMPERATURE WARNING INDICATOR WAS ILLUMINATED ON THE INSTRUMENT PANEL, WHICH MEANT THAT THE VEHICLE WAS OVERHEATING. HE ALSO NOTICED SMOKE AND WATER EMANATING FROM THE VEHICLE. IF THE VEHICLE WOULD HAVE STALLED WHILE DRIVING, HE COULD HAVE BEEN SERIOUSLY INJURED IN A CRASH. THE VEHICLE WAS TOWED TO A LOCAL DEALER AND THEY REPLACED THE WATER PUMP AT THE COST OF $300. IMMEDIATELY AFTER THE REPAIR, HE NOTICED THAT THE VEHICLE IDLED ROUGHLY. HE TOOK THE VEHICLE BACK TO THE DEALER AND THEY STATED THAT THE ENGINE NEEDED TO BE REPLACED AT THE COST OF $5,000. THE VEHICLE HAS NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 82,000.
NHTSA ODI #10264005
53,900 miles · Mar 21, 2009
Engine And Engine CoolingPower Train
WHILE DRIVING, THE VACUUM SOLENOID FOR THE 4 WHEEL DRIVE TRIES TO ENGAGE THE 4 WHEEL DRIVE - EVEN AT HIGHWAY SPEEDS- RESULTING IN A HORRIBLE SOUND. THE SOUND WAS "LIKE I HAD RUN OVER A SHOPPING CART OR HIT SOMETHING IN THE ROAD AND WAS DRAGGING IT UNDER THE TRUCK". THIS HAPPENED 5 TIMES IN TWO DAYS IN LESS THAN 30 MILES OF TOT…
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WHILE DRIVING, THE VACUUM SOLENOID FOR THE 4 WHEEL DRIVE TRIES TO ENGAGE THE 4 WHEEL DRIVE - EVEN AT HIGHWAY SPEEDS- RESULTING IN A HORRIBLE SOUND. THE SOUND WAS "LIKE I HAD RUN OVER A SHOPPING CART OR HIT SOMETHING IN THE ROAD AND WAS DRAGGING IT UNDER THE TRUCK". THIS HAPPENED 5 TIMES IN TWO DAYS IN LESS THAN 30 MILES OF TOTAL DRIVING. THE NOISE IS SO LOUD AND ALARMING THAT IT MADE ME IMMEDIATELY APPLY THE BRAKES AND PULL TO THE SIDE OF THE ROAD BECAUSE I THOUGHT I HAD HIT SOMETHING/SOMEONE. AT FIRST I WONDERED IF MY MUFFLER OR DRIVE SHAFT OR SOME OTHER PART HAD FALLEN OFF OF THE TRUCK. THIS "FALSE ENGAGEMENT" OF THE 4 WHEEL DRIVE HAPPENS WITHOUT ANY WARNING IN ALL KIDS OF DRIVING CONDITIONS (SLOW, FAST, BREAKING OR ACCELERATING). A NEW, REDESIGNED (NOW HAS A COVER ON IT TO KEEP MOISTURE OUT- WHICH WAS CAUSING THE FAILURE) VACUUM SOLENOID WAS INSTALLED ON TRUCK - A $27.00 PART. DEALERSHIP KEPT OLD PART. TECH. AT DEALER TOLD ME THAT THIS PART WILL GO BAD AT SOME POINT AND NEED REPLACING ON ALL THE TRUCKS WITH THE PART. HE SAID "NOT IF BUT WHEN". FORD KNEW ABOUT THE PROBLEM - HENCE THE REDESIGNED PART. FORD HAS NOT NOTIFIED OWNERS OF THIS PART AND IT'S IMPENDING FAILURE. *TR
NHTSA ODI #10262623
57,958 miles · Jan 21, 2009
Engine And Engine Cooling
ENGINE SHUT DOWN WHILE DRIVING 30 MPH THIS HAPPENED TWICE DEALER SCANNED FOR CODE AND FOUND CODE P2104 IDLE AIR CONTROL VALVE STUCK CLOSED REPLACED BODY AND MOTOR ASSEMBLY 6036 WP94 NO CHARGE UNDER WARRANTY RECALL REPLACE SWITCH 6306 WP94 AND VACUUM TEBE 6L3Z*9W431*A. *TR
NHTSA ODI #10255898
46,475 miles · Dec 10, 2008
Engine And Engine CoolingPower Train
5.4L, SUPERCREW-- ENGINE WAS REPLACED BY FORD AT 38,000 MILES (AFTER COMPLAINT TO FORD CUST SVC) DUE TO INJECTOR FAILURE AND CYLINDER HYDRA-LOCK. NOW AT 46,000 MILES, COMPLETE TRANSMISSION FAILURE. ONLY USED FOR DAILY DRIVER, NO TOWING, NEVER OFF-ROAD. TRANSMISSION FAILED ON INITIAL START ON 60 DEGREE MORNING, NO PRE-FAILURE …
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5.4L, SUPERCREW-- ENGINE WAS REPLACED BY FORD AT 38,000 MILES (AFTER COMPLAINT TO FORD CUST SVC) DUE TO INJECTOR FAILURE AND CYLINDER HYDRA-LOCK. NOW AT 46,000 MILES, COMPLETE TRANSMISSION FAILURE. ONLY USED FOR DAILY DRIVER, NO TOWING, NEVER OFF-ROAD. TRANSMISSION FAILED ON INITIAL START ON 60 DEGREE MORNING, NO PRE-FAILURE INDICATORS. PAID $2800 FOR TRANSMISSION REBUILD. I HAVE NOTICED A FAIRLY LARGE NUMBER OF PROBLEMS REPORTED ON SUB-STANDARD FACTORY TRANSMISSION AND ENGINE PARTS ON FORD TRUCKS. *TR
NHTSA ODI #10251265
18,000 miles · Dec 4, 2008
Electrical SystemEngine And Engine Cooling
TL*THE CONTACT OWNS A 2005 FORD F-150. WHILE DRIVING 55 MPH, THE VEHICLE STALLED WHEN THE BRAKE PEDAL WAS DEPRESSED. WHEN THE FAILURE OCCURRED, THE CHECK ENGINE INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE DEALER REPAIRED THE FAILURE AND THEY STATED THAT THE SENSORS FAILED; HOWEVER, THE FAILURE STILL PERSISTS. THE VEHI…
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TL*THE CONTACT OWNS A 2005 FORD F-150. WHILE DRIVING 55 MPH, THE VEHICLE STALLED WHEN THE BRAKE PEDAL WAS DEPRESSED. WHEN THE FAILURE OCCURRED, THE CHECK ENGINE INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE DEALER REPAIRED THE FAILURE AND THEY STATED THAT THE SENSORS FAILED; HOWEVER, THE FAILURE STILL PERSISTS. THE VEHICLE WAS TAKEN TO THE DEALER APPROXIMATELY TWO TIMES. THE FORD MANUFACTURER ISSUED A RECALL FOR THE POWER BOOSTER LINE. THE VEHICLE HAS NOT BEEN TAKEN IN TO HAVE THE RECALL REPAIRED. THE FAILURE MILEAGE WAS 18,000 AND CURRENT MILEAGE WAS 35,820.
NHTSA ODI #10250757
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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