NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
111 reportsClear category filter22,000 miles · Nov 25, 2008
Engine And Engine CoolingCrash
SLOWING TO A STOP AT LIGHT. WAS GONG ABOUT 25. ALMOST AT COMPLETE STOP, WHEN ENGINE WENT TO ALMOST FULL THROTTLE. I PUSHED BRAKE HARDER BUT STILL DROVE INTO THE PARKED CAR IN FRONT OF ME. NO DAMAGE DONE, JUST A VERY HARD BUMP. TURNED KEY OFF, PUT IN PARK. CAR IN FRONT OF ME DROVE AHEAD AND PARKED TO SIDE OF ROAD. I STARTED THE E…
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SLOWING TO A STOP AT LIGHT. WAS GONG ABOUT 25. ALMOST AT COMPLETE STOP, WHEN ENGINE WENT TO ALMOST FULL THROTTLE. I PUSHED BRAKE HARDER BUT STILL DROVE INTO THE PARKED CAR IN FRONT OF ME. NO DAMAGE DONE, JUST A VERY HARD BUMP. TURNED KEY OFF, PUT IN PARK. CAR IN FRONT OF ME DROVE AHEAD AND PARKED TO SIDE OF ROAD. I STARTED THE ENGINE AND IT IMMEDIATELY WENT TO VERY HIGH THROTTLE. TURNED KEY OFF, WAITED 20 SECONDS, TRIED AGAIN. AND IT WAS OK. I PULLED AHEAD AND OFF TO SIDE TO TALK TO OTHER PERSON INVOLVED. AFTER 15 MINS I CALMED DOWN AND WENT HOME. *TR
NHTSA ODI #10249762
52,700 miles · Nov 18, 2008
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2005 FORD F-150. ON TWO SEPARATE OCCASIONS, THE VEHICLE MISFIRES AND LOSES POWER, BUT DOES NOT HAVE TO BE RESTARTED. THE DEALER STATED THAT THE SPARK PLUGS MAY NEED TO BE CHANGED; HOWEVER, THEY MAY BREAK OFF IN THE PROCESS. THE CURRENT MILEAGE WAS 52,838 AND FAILURE MILEAGE WAS 52,700.
NHTSA ODI #10249088
Mileage unknown · Nov 10, 2008
Engine And Engine CoolingSuspension
I BOUGHT A TRUCK AT SELINSGROVE FORD ABOUT A MONTH AGO. THE NIGHT I GOT IT HOME I NOTICED IT SOUNDED LIKE A DIESEL.. THAT WAS FINE THEN WHEN YOU GET UP TO ABOUT 55MPH ITS HAS A BAD SHIMMY AND I HAD IT BACK A COUPLE OF DIFFERENT TIME AND THEY SAY THEY DON'T KNOW WHAT TO DO ABOUT IT NOW. IT HAD TO BE WRECKED OR SOMETHING BECAUSE…
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I BOUGHT A TRUCK AT SELINSGROVE FORD ABOUT A MONTH AGO. THE NIGHT I GOT IT HOME I NOTICED IT SOUNDED LIKE A DIESEL.. THAT WAS FINE THEN WHEN YOU GET UP TO ABOUT 55MPH ITS HAS A BAD SHIMMY AND I HAD IT BACK A COUPLE OF DIFFERENT TIME AND THEY SAY THEY DON'T KNOW WHAT TO DO ABOUT IT NOW. IT HAD TO BE WRECKED OR SOMETHING BECAUSE THERE WAS A CREASE ON THE BUMPER AND THE DRIVERS SIDE DOOR NEEDED ADJUSTED. *TR
NHTSA ODI #10248398
63,000 miles · Nov 9, 2008
Engine And Engine Cooling
I HAVE A 2005 FORD WITH THE 5.4 LT. ENGINE. AT THE 63,000 MILE MARK I DECIDED TO REPLACE THE SPARK PLUGS DUE TO SLIGHT IDLE PROBLEM. AFTER SPENDING $102.00 ON A NEW SET OF SPARK PLUGS I RAN INTO THE PROBLEM OF THE SPARK PLUG'S LOWER HALF BREAKING INSIDE THE CYLINDER HEAD, IT TOOK ME TWO DAYS TO COMPLETE THE REPLACEMENT DUE TO A …
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I HAVE A 2005 FORD WITH THE 5.4 LT. ENGINE. AT THE 63,000 MILE MARK I DECIDED TO REPLACE THE SPARK PLUGS DUE TO SLIGHT IDLE PROBLEM. AFTER SPENDING $102.00 ON A NEW SET OF SPARK PLUGS I RAN INTO THE PROBLEM OF THE SPARK PLUG'S LOWER HALF BREAKING INSIDE THE CYLINDER HEAD, IT TOOK ME TWO DAYS TO COMPLETE THE REPLACEMENT DUE TO A FAULTY DESIGN OF THE SPARK PLUGS. THE SPARK PLUG STEEL SHELL IS MADE OF TWO PARTS A TOP HALF THAT HAS THE THREADS MADE ONTO IT AND THE LOWER HALF THAT HAS THE HOOD WERE THE GAP IS MADE BETWEEN THE ELECTRODE AND ITSELF ALLOWING FOR A SPARK TO HAPPEN. THE PROBLEM BEING IN THAT THESE TWO PARTS ARE ONLY CRIMPED TOGETHER, THE CRIMPING IS NOT STRONG ENOUGH AND THE LOWER HALF DUE TO THE CARBON BUILD UP MAINTAINS ITSELF JAMMED IN THE CYLINDER HEAD WHILE THE TOP PART SLIPS AT THE CRIMPING AREA TURNS AND IS THREADED OUT CAUSING THE SEPARATION, I WAS GOING TO WELD THE TWO PARTS TOGETHER SO THAT THE NEXT TIME I HAD TO CHANGE THE SPARK PLUGS THE LOWER HALF WOULD TURN WITH THE TOP HALF OF ALLOWING IT TO BREAK ITSELF FREE FROM THE CARBON BUILD UP AND NOT BREAK IN THE CYLINDER HEAD BUT DECIDED NOT TO GO WITH IT TOO MUCH TROUBLE I'LL GET RID OF THE TRUCK BEFORE THE SPARK PLUG NEED REPLACING. WELL WHAT I HOPE TO GET OUT OF THIS IS THAT FORD REVAMPS IT'S SPARK PLUG DESIGN BY EITHER WELDING THESE TWO PARTS TOGETHER OR MAKING THE SPARK PLUG SHELL A 1 PIECE SO THAT I DON'T HAVE THIS PROBLEM AGAIN IF I DO DECIDE TO BUY ANOTHER FORD PRODUCT AFTER THE HELL I HAD TO GO THOUGH CHANGING THESE SPARK PLUGS. *TR
NHTSA ODI #10248213
Mileage unknown · Oct 28, 2008
Engine And Engine Cooling
2004-2007 F-150 TRUCK SAY TO CHANGE THE SPARK PLUGS OUT AT 100K. THE DEALERS SAY $300 TO CHANGE BUT IF THEY SNAP OF IT COULD COST MORE? THEY ALMOST ALWAYS SNAP!!! FORD HAS A SPARK PLUG THAT SNAPS IN HALF WHEN TRYING TO CHANGE OUT DO TO CARBON BUILD UP. BAD DESIGN AND THEN IS ABOUT $88 HR FOR A TECH TO FIX. ALMOST ALL DEALERSH…
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2004-2007 F-150 TRUCK SAY TO CHANGE THE SPARK PLUGS OUT AT 100K. THE DEALERS SAY $300 TO CHANGE BUT IF THEY SNAP OF IT COULD COST MORE? THEY ALMOST ALWAYS SNAP!!! FORD HAS A SPARK PLUG THAT SNAPS IN HALF WHEN TRYING TO CHANGE OUT DO TO CARBON BUILD UP. BAD DESIGN AND THEN IS ABOUT $88 HR FOR A TECH TO FIX. ALMOST ALL DEALERSHIPS BREAK THEM AND COST THE OWNER $1000 TO $1800 FOR A SPARK PLUG CHANGE DO TO POOR DESIGN? EVERYONE IS BREAKING AND FORD IS MAKING A TON OF MONEY ON A PROBLEM THAT SHOULD BE RECALLED!!!!! IF YOU RESEARCH THIS ON THE WEB NEED I SAY NO MORE....I BOUGHT A $32,000 TRUCK THAT I CANT CHANGE THE SPARK PLUGS.. SOMETHING REALLY NEEDS TO HAPPEN. THANK YOU KEN BELK *TR
NHTSA ODI #10247097
90,000 miles · Oct 27, 2008
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2005 FORD F-150. WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE BEGAN TO JERK, BACKFIRE, AND RUN BADLY. IN ADDITION, THE CHECK ENGINE LIGHT ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE HAD TO BE TOWED TWICE. THE FUEL INJECTORS WERE CLEANED TWICE AND THE DEALER STATED THAT THE CATALYTIC CONVERTER NEEDED T…
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TL*THE CONTACT OWNS A 2005 FORD F-150. WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE BEGAN TO JERK, BACKFIRE, AND RUN BADLY. IN ADDITION, THE CHECK ENGINE LIGHT ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE HAD TO BE TOWED TWICE. THE FUEL INJECTORS WERE CLEANED TWICE AND THE DEALER STATED THAT THE CATALYTIC CONVERTER NEEDED TO BE REPLACED. THE VIN WAS UNKNOWN. THE CURRENT MILEAGE WAS 100,000 AND FAILURE MILEAGE WAS 90,000.
NHTSA ODI #10246779
102,000 miles · Aug 22, 2008
Engine And Engine CoolingFuel System, Gasoline
2005 FORD F-150 5.4 LITER ENGINE; ALL SERVICE WORK WAS PERFORMED AT THE RECOMMENDED SERVICE INTERVALS ON THIS VEHICLE. AT 102,000 MILES, I TOOK THE VEHICLE TO THE DEALERSHIP TO HAVE SPARK PLUGS REPLACED. (FORD RECOMMENDED 100,000 MILE TUNE-UP) THE FIRST THREE SPARK PLUGS ATTEMPTED TO BE REMOVED BY THREE DIFFERENT TECHNICIANS BR…
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2005 FORD F-150 5.4 LITER ENGINE; ALL SERVICE WORK WAS PERFORMED AT THE RECOMMENDED SERVICE INTERVALS ON THIS VEHICLE. AT 102,000 MILES, I TOOK THE VEHICLE TO THE DEALERSHIP TO HAVE SPARK PLUGS REPLACED. (FORD RECOMMENDED 100,000 MILE TUNE-UP) THE FIRST THREE SPARK PLUGS ATTEMPTED TO BE REMOVED BY THREE DIFFERENT TECHNICIANS BROKE OFF EVEN WHEN FOLLOWING THE FORD TSB PROCEEDURE. THIS TUNE UP WILL COST ME ALMOST $2,000 DUE TO THE DEFECTIVE SPARK PLUG DESIGN. FORD WILL NOT HELP WITH THE REPAIR. *TR
NHTSA ODI #10239403
40,000 miles · Aug 3, 2008
Electrical SystemEngine And Engine CoolingFuel System, Gasoline
MY TRUCK HAS 56K ON IT BOUGHT IT USED WITH 35K ON IT WHEN IT STARTS RUNS WITH HIGH IDLE AND THE TOP END TICKS REALLY BAD THE TICKING DOES NOT GO AWAY AT ALL SPEEDS AT A STOP LIGHT IT SOUNDS LIKE A DIESEL TIC TIC TIC SOUNDS LIKE A LIFTER IS STUCK. I PUT "LUCAS" IN IT TO TRY TO MAKE IT GO AWAY …
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MY TRUCK HAS 56K ON IT BOUGHT IT USED WITH 35K ON IT WHEN IT STARTS RUNS WITH HIGH IDLE AND THE TOP END TICKS REALLY BAD THE TICKING DOES NOT GO AWAY AT ALL SPEEDS AT A STOP LIGHT IT SOUNDS LIKE A DIESEL TIC TIC TIC SOUNDS LIKE A LIFTER IS STUCK. I PUT "LUCAS" IN IT TO TRY TO MAKE IT GO AWAY THEN I CHANGED THE OIL RAN ABOUT TWO WEEKS WITH NO DIFFERENCE AND CHANGED IT AGAIN AND NO CHANGE CALLED FORD DEALER THEY COULDN'T HELP THEY SAID I WOULD HAVE TAKE IT IN AND GET CHARGED $165. THEN I CHANGED THE SPARK PLUGS MAYBE A FOULED PLUG THAT WASN'T IT THERE GOES 120 BUCKS A COUPLE OF WEEKS AGO MY WIFE WAS DRIVING ON THE FREEWAY AND THE DRIVERS SIDE WINDOW FALLS THE WINDOW REGULATOR BROKE $140 REPLACED THAT ALREADY. THE PASSENGER SEAT BELT LOCKS UP SOMETIMES NOW TO THE FRONT THE STEERING WHEEL SHAKES REALLY BAD WHEN YOU APPLY THE BRAKES TURNED THE ROTORS AT NAPA $20 NEW BRAKE PADS $90 AT KRAGENS BALANCED TIRES FREE I WORK AT A TIRE SHOP SHAKING WENT AWAY FOR ABOUT THREE DAYS 350 MILES LATER THE SHAKING IS BACK WITH A VENGEANCE CHECKED THE BALANCING ON THE TIRES THEY WERE GOOD ROTORS ARE OUT OF SHAPE AGAIN STILL ON THERE NOW AND THE SHAKING IS GETTING WORSE I CANT AFFORD THEM RIGHT NOW SO THEY WILL STAY THERE HOOKED UP THE SNAP ON EHTOS COMPUTER TO IT AND REGISTERS THAT TWO SENSORS HAVE AN OPEN CIRCUIT BUT NO EXPLANATION FOR TOP END NOISE INJECTORS MIGHT BE BAD. *TR
NHTSA ODI #10236779
43,143 miles · Jul 21, 2008
Engine And Engine Cooling
ADVISED THAT THE 2005 F-150 5.4 TRITON ENGINE HAS A HISTORY OF SPARK PLUGS SEIZING IN THE ENGINE AND RECOMMENDED THAT THE PLUGS BE REPLACED. FORD SAYS THE PLUGS WILL LAST FOR 100,000 MILES. TSB 08-7-6 ISSUED BY FORD TO ADDRESS PROBLEM. HAD PLUGS REPLACED AT 43,123 MILES AND HAD THREE FROZEN OR SEIZED COSTING OVER $300.00 IN L…
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ADVISED THAT THE 2005 F-150 5.4 TRITON ENGINE HAS A HISTORY OF SPARK PLUGS SEIZING IN THE ENGINE AND RECOMMENDED THAT THE PLUGS BE REPLACED. FORD SAYS THE PLUGS WILL LAST FOR 100,000 MILES. TSB 08-7-6 ISSUED BY FORD TO ADDRESS PROBLEM. HAD PLUGS REPLACED AT 43,123 MILES AND HAD THREE FROZEN OR SEIZED COSTING OVER $300.00 IN LABOR. FORD KNOWS OF PROBLEM AND HAS NOT ISSUED A RECALL TO CORRECT DESIGN FLAW. READ MANY OTHER SIMILAR STORIES ON INTERNET WHERE CITIZENS ARE PAYING THOUSANDS OF DOLLARS TO GET THE PLUGS OUT AND VEHICLE BACK IN OPERATION. *TR
NHTSA ODI #10235212
Mileage unknown · Jun 2, 2008
Engine And Engine CoolingFire
AT 2:.00 AM THE MORNING OF APRIL 24, 2008 WE WERE AWAKENED BY OUR SERIOUSLY AGITATED DOG, TO FIND OUR 2005 FORD F150 ENGULFED BY FLAMES AND TO SOON SEE OUR OTHER TWO VEHICLES AND OUR HOME DESTROYED BY FIRE. A TOTAL OF FOUR INVESTIGATORS HAVE CONCLUDED THAT THE CAUSE OF THE FIRE IS THE FORD F150. THE TRUCK IS PRESENTLY UNDER LOC…
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AT 2:.00 AM THE MORNING OF APRIL 24, 2008 WE WERE AWAKENED BY OUR SERIOUSLY AGITATED DOG, TO FIND OUR 2005 FORD F150 ENGULFED BY FLAMES AND TO SOON SEE OUR OTHER TWO VEHICLES AND OUR HOME DESTROYED BY FIRE. A TOTAL OF FOUR INVESTIGATORS HAVE CONCLUDED THAT THE CAUSE OF THE FIRE IS THE FORD F150. THE TRUCK IS PRESENTLY UNDER LOCK AND KEY AND THE INVESTIGATION CONTINUES TO FIND THE EXACT COMPONENT. *TR
NHTSA ODI #10229513
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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