NHTSA owner reports · September 18, 2026 snapshot.
Power Train complaints
112 reportsClear category filter130,000 miles · Nov 29, 2016
EnginePower TrainVehicle Speed Control
TRUCK WAS BOUGHT AND I REPLACED ALL SPARK PLUGS AND EVEN HAD TO REPLACE A CLINOID BECAUSE WAS TOLD THAT WAS THE PROBLEM. ITS NOT... THERE IS A BALL VALVE IN THE TRANSMISSION THAT KEEPS THE TRUCK FROM BUILDING ENOUGH PRESSURE TO BE ABLE TO SHIFT WHICH THROWS A CODE AND SAYS MISFIRE ON 6 BEEN REPLACED TWICE NOW SO CLEARLY NOT THE …
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TRUCK WAS BOUGHT AND I REPLACED ALL SPARK PLUGS AND EVEN HAD TO REPLACE A CLINOID BECAUSE WAS TOLD THAT WAS THE PROBLEM. ITS NOT... THERE IS A BALL VALVE IN THE TRANSMISSION THAT KEEPS THE TRUCK FROM BUILDING ENOUGH PRESSURE TO BE ABLE TO SHIFT WHICH THROWS A CODE AND SAYS MISFIRE ON 6 BEEN REPLACED TWICE NOW SO CLEARLY NOT THE PROBLEM. THIS IS A MAJOR ISSUE.. TRUCK FEELS AS IF FIXING TO FIE THEN CHECK ENGINE LIGHT WILL COME ON START FLASHING BUT THROW NO CODES AND YOU CANT SPEED BACK UP BECAUSE IT FEELS LIKE YOUR TRUCK IS ABOUT TO DIE AND YOU DON'T WANT TO BLOW YOUR MOTOR.
NHTSA ODI #10928580
94,000 miles · May 26, 2016
Power TrainSteering
!. VACUUM ADVANCE CONTROL FOR FOUR WHEEL DRIVE GETS WET, LOOSES PRESSURE AND FRONT WHEELS ENGAGE SLIGHTLY, CAUSING WHEEL HUB DAMAGE. 2. STEERING BECOMES HARD, ESPECIALLY IN COLD WEATHER. HARD TO INSPECT STEERING SHAFT UNTIL IT IS DISCONNECTED FROM STEERING RACK. COMMON PROBLEM WITH MID TO LATE 2000'S FORD CROWN VIC. POLICE VEHI…
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!. VACUUM ADVANCE CONTROL FOR FOUR WHEEL DRIVE GETS WET, LOOSES PRESSURE AND FRONT WHEELS ENGAGE SLIGHTLY, CAUSING WHEEL HUB DAMAGE. 2. STEERING BECOMES HARD, ESPECIALLY IN COLD WEATHER. HARD TO INSPECT STEERING SHAFT UNTIL IT IS DISCONNECTED FROM STEERING RACK. COMMON PROBLEM WITH MID TO LATE 2000'S FORD CROWN VIC. POLICE VEHICLES. COME ON FORD, MAN UP AND MAKE THESE PROBLEMS A RECALL.
NHTSA ODI #10870924
165,000 miles · Mar 19, 2016
EnginePower Train
MY TRUCK HAS A KNOWN ISSUE WITH THE 5.4L'S CAM PHASERS. THE TRUCK MAKES A VERY LOUD NOISE AND SHAKES. TO REPAIR THIS, IT'S AROUND $3,000 AND ALSO I HAVE A KNOWN ISSUE WITH ALL 8 COILS WHICH HAD TO BE REPLACED FOR $1,200 AND A KNOWN MISFIRE. I DO NOT UNDERSTAND WHY FORD MOTOR IS AWARE OF THE ONGOING ISSUES IN THIS YEAR TRUCK A…
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MY TRUCK HAS A KNOWN ISSUE WITH THE 5.4L'S CAM PHASERS. THE TRUCK MAKES A VERY LOUD NOISE AND SHAKES. TO REPAIR THIS, IT'S AROUND $3,000 AND ALSO I HAVE A KNOWN ISSUE WITH ALL 8 COILS WHICH HAD TO BE REPLACED FOR $1,200 AND A KNOWN MISFIRE. I DO NOT UNDERSTAND WHY FORD MOTOR IS AWARE OF THE ONGOING ISSUES IN THIS YEAR TRUCK AND HAS NOT DONE ANYTHING ABOUT IT. ALSO IF THE CAM PHASERS ARE NOT REPLACED THE ENGINE WILL BLOW!
NHTSA ODI #10850589
90,000 miles · Oct 20, 2015
Power Train
REAR END SHAKING WHILE DRIVING DOWN ROAD ABOUT 60MPH. GETTING OFF GAS NOR PUTTING VEHICLE IN NEUTRAL WOULD NOT STOP SHAKING. HAD TO COME TO COMPLETE STOP BEFORE STARTING AGAIN TO MAKE VEHICLE DRIVE PROPERLY.
NHTSA ODI #10783704
92,000 miles · Sep 24, 2015
Power Train
METAL SCRAPING SOUND FROM REAR END. MECHANIC HAS CHECKED AND SAYS PINION, BEARINGS, RING GEAR HAVE FAILED. LOOKS LIKE ITS A COMMON FAILURE. 9.75 RING GEAR, 3.55 RATIO
NHTSA ODI #10776513
40,020 miles · Jul 14, 2015
Power Train
I WAS DRIVING AND HEARD A SOUND COME FROM MY ENGINE COMPARTMENT. I DIDN'T LOSE POWER, BUT PULLED OVER TO LOOK UNDER THE HOOD. NOT NOTICING ANYTHING OBVIOUS I CHECKED THE FLUID LEVELS AND NOTICED THAT MY TRANSMISSION FLUID WAS LOW. IT HAD BEEN CHECKED TWO MONTHS PRIOR DURING OIL CHANGE. I HAD NO VISIBLE SIGNS OF LEAKS. I FOUND A…
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I WAS DRIVING AND HEARD A SOUND COME FROM MY ENGINE COMPARTMENT. I DIDN'T LOSE POWER, BUT PULLED OVER TO LOOK UNDER THE HOOD. NOT NOTICING ANYTHING OBVIOUS I CHECKED THE FLUID LEVELS AND NOTICED THAT MY TRANSMISSION FLUID WAS LOW. IT HAD BEEN CHECKED TWO MONTHS PRIOR DURING OIL CHANGE. I HAD NO VISIBLE SIGNS OF LEAKS. I FOUND A FORUM ON THE INTERNET THAT TALKED ABOUT TRANSMISSION FLUID GOING FROM THE TRANSMISSION TO THE TRANSFER CASE, BUT UNABLE TO RETURN. THEY HAD A $20 SEAL REPLACED UNDER WARRANTY. THE FORUM HAD STATED THAT THIS WAS A KNOWN CONDITION BUT NOTHING WAS BEING DONE BY FORD MOTOR COMPANY. A MECHANIC HAD SAID THAT IT ONLY EFFECTED 17-18% OF VEHICLES MANUFACTURED BETWEEN 2004-2008. I CALLED TWO LOCAL DEALERSHIPS AND THEY KNEW THE PROBLEM BUT SAID THAT THERE WAS NO RECALL ON IT. IT TAKES APPROXIMATELY 3 HOURS TO CHANGE, BY DROPPING THE TRANSFER CASE AND REPLACING THE SEAL. I CALLED FORD MOTOR COMPANY REPRESENTATIVE AND WAS TOLD THAT THERE WASN'T A RECALL AND THAT THEY COULDN'T HELP. I FEEL THAT THIS COULD RESULT IN A PREMATURE FAILURE OF THE TRANSMISSION AND POSSIBLY A CATASTROPHIC EVENT. I WAS TOLD BY FMC REP THAT SHOULD A RECALL OCCUR I COULD TAKE MY RECEIPT TO A DEALERSHIP AND THAT THEY WOULD POSSIBLY REIMBURSE ME. I DON'T FEEL THAT FORD SHOULD HAVE A KNOWN CONDITION BUT DO NOTHING TO CORRECT IT. PLEASE LOOK INTO THIS FOR ME AND OTHERS UNDER THE SAME SITUATION.
NHTSA ODI #10734080
175,000 miles · Jun 2, 2015
Electrical SystemPower TrainUnknown Or OtherFire
ON THE MORNING OF MARCH 5TH 2015 I STARTED MY TRUCK TO WARM THE INSIDE AND ALSO MELT THE SNOW OFF MY WINDSHIELD. I GOT IN THE TRUCK AND BACKED OUT AWAY FROM HOUSE. DUE TO HAVING SNOW ON THE DRIVEWAY I TURNED ON THE 4 WHEEL DRIVE IN HIGH. MY FOUR WHEEL DRIVE WOULD NOT WORK SO I TRIED TO SWICTH TO 2 WHEEL DRIVE BACK TO FOUR WHEEL…
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ON THE MORNING OF MARCH 5TH 2015 I STARTED MY TRUCK TO WARM THE INSIDE AND ALSO MELT THE SNOW OFF MY WINDSHIELD. I GOT IN THE TRUCK AND BACKED OUT AWAY FROM HOUSE. DUE TO HAVING SNOW ON THE DRIVEWAY I TURNED ON THE 4 WHEEL DRIVE IN HIGH. MY FOUR WHEEL DRIVE WOULD NOT WORK SO I TRIED TO SWICTH TO 2 WHEEL DRIVE BACK TO FOUR WHEEL DRIVE BUT THE 4 WHEEL DRIVE WOULD NOT TURN ON. I GRABBED THE GEAR SHIFT TO PUT THE TRUCK BACK IN PARK WHEN I NOTICED MY GEAR SHIFT COULD FLOAT TO PARK TO 1ST GEAR FREELY AND WOULD NOT SHIFT. AT THIS TIME I NOTICED SMOKE STARTING TO COME INSIDE CAB FROM UNDER DASH AND THRU THE VENTS. I JUMPED OUT AND OPENED THE HOOD. A 1 FOOT SECTION OF A WIRING HARNES MOUNTED TO THE FIREWALL HAD CAUGHT FIRE. I MADE ATTEMPTS TO PUT OUT THE FIRE BUT WITHIN A FEW SECONDS THE ENGINE COMPARTMENT WAS ENGULFED. IN 2 TO 3 MINUTES THE ENTIRE INSIDE OF THE CAB WAS ALSO COMPLETELY ON FIRE. MY WIFE WHO WAS WATCHING ME IMMEDIATLY CALLED 911 TO GET THE FIRE DEPARTMENT. AFTER 3 MINUTES THE TRUCK WAS ALREADY A TOTAL LOSE. DUE TO THE TRUCK BEING ONLY 60' FROM MY HOUSE AND BURNING SO HOT I WAS CONCERNED ABOUT MY HOUSE CATCHING FIRE. TWO GENTLEMAN FROM THE RESCUE SQUAD ARRIVED BUT IT WAS TOO LATE FOR ANYTHING TO BE DONE. I WAS ABLE TO GET A BACKHOE AND PUT THE FIRE OUT WITH SNOW. UNFORTUNATELY I HAD LIABILITY INSURANCE ONLY WHICH MEANT A TOTAL LOSE. I NEVER DREAMED THAT THE TRUCK WOULD BURN UP SITTING IN MY DRIVEWAY!!!! I KNOW THERE HAVE BEEN SOME RECALLS FOR F150 DUE TO FIRE HAZARDS WITH THE CRUISE CONTROL FOR OTHER YEAR MODEL CLOSE TO 2005. A VEHICLE CATCHING FIRE WHILE ITS SITTING IN A DRIVEWAY RUNNING IS TOTALLY UNACCEPTABLE. THE TRUCK WAS IN EXCELLENT SHAPE AND HAD NO AFTER MARKET PARTS OR WORK PERFORMED. I HAVE NO IDEAL WHY THE WIRING HARNESS CAUGHT FIRE.
NHTSA ODI #10723002
97,500 miles · Feb 11, 2015
Power TrainSteeringSuspension
I JUST WANTED TO ADD MY VEHICLE TO THE LIST OF COMPLAINTS ABOUT THE DIFFERENTIAL. MINE MAKES NOISE AND HAS MADE NOISE FOR QUITE SOME TIME. I THOUGHT IT MIGHT BE THE TIRES OR ROTORS. I FOUND OUT THAT IT WAS COMING DIRECTLY FROM THE REAR DIFFERENTIAL. BASED ON THE COMPLAINTS I HAVE HEARD, I AM PRETTY SURE THIS IS THE SAME THING. …
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I JUST WANTED TO ADD MY VEHICLE TO THE LIST OF COMPLAINTS ABOUT THE DIFFERENTIAL. MINE MAKES NOISE AND HAS MADE NOISE FOR QUITE SOME TIME. I THOUGHT IT MIGHT BE THE TIRES OR ROTORS. I FOUND OUT THAT IT WAS COMING DIRECTLY FROM THE REAR DIFFERENTIAL. BASED ON THE COMPLAINTS I HAVE HEARD, I AM PRETTY SURE THIS IS THE SAME THING. THE NOISE SOUNDS LIKE METAL RUNNING ON METAL. I BELIEVE THIS SHOULD BE SOMETHING FORD SHOULD PAY TO FIX. IF I HAVE TO PAY FOR IT, I'M DEFINITELY NOT USING FORD. I READ THAT'S MANY PEOPLE HAVE THE SAME COMPLAINTS. THIS FAILURE IS SECURITY PUBLIC PROBLEMS, BECAUSE ACCIDENTAL OR CRASH MAY OCCUR. *TR
NHTSA ODI #10682846
65,000 miles · Jan 17, 2015
Electrical SystemEnginePower Train
2005 F150 GOES INTO "FAIL SAFE MODE" AND SHUTS DOWN WHILE DRIVING. IT ONLY OCCURRED ONCE PER YEAR STARTING AT 65,000 MILES, BUT NOW HAPPENS EVERY 3-4 WEEKS AT 114,000 MILES. ONCE THE ENGINE SHUTS DOWN, I PUT THE TRANSMISSION INTO NEUTRAL WHILE COASTING AND IT RESTARTS EASILY. THE ENGINE LIGHT ILLUMINATES FOR 3-4 DAYS AND THEN…
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2005 F150 GOES INTO "FAIL SAFE MODE" AND SHUTS DOWN WHILE DRIVING. IT ONLY OCCURRED ONCE PER YEAR STARTING AT 65,000 MILES, BUT NOW HAPPENS EVERY 3-4 WEEKS AT 114,000 MILES. ONCE THE ENGINE SHUTS DOWN, I PUT THE TRANSMISSION INTO NEUTRAL WHILE COASTING AND IT RESTARTS EASILY. THE ENGINE LIGHT ILLUMINATES FOR 3-4 DAYS AND THEN TURNS OFF. IN RESEARCHING THE ISSUE, IT SEEMS TO BE A RATHER COMMON PROBLEM WITH THIS VEHICLE AND IS USUALLY CAUSED BY A FAULTY THROTTLE BODY. FORD STATES THAT THEY ARE AWARE OF THE PROBLEM. *TR
NHTSA ODI #10676255
85,000 miles · Jan 12, 2015
EnginePower Train
I OWN THE ABOVE MENTION VEHICLE, THERE WAS NO DISCLOSURE TO ME AT THE TIME OF PURCHASE OF A VERY SERIOUS DESIGN FLAW WITH THE SPARK PLUGS THAT COULD AND LIKELY WILL BREAK OFF IN THE ENGINE DURING REPLACEMENT AND THE EXTREME COST IN CHANGING THESE PLUGS AROUND 900 TO 1000 DOLLARS IF NO PLUGS BREAK OFF AND EVEN MORE IN THE PLUGS D…
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I OWN THE ABOVE MENTION VEHICLE, THERE WAS NO DISCLOSURE TO ME AT THE TIME OF PURCHASE OF A VERY SERIOUS DESIGN FLAW WITH THE SPARK PLUGS THAT COULD AND LIKELY WILL BREAK OFF IN THE ENGINE DURING REPLACEMENT AND THE EXTREME COST IN CHANGING THESE PLUGS AROUND 900 TO 1000 DOLLARS IF NO PLUGS BREAK OFF AND EVEN MORE IN THE PLUGS DO BREAK OFF OR HEADS HAVE TO REMOVED TO EXTRACT THE PLUGS EVEN WORSE PIECES OF PRSHELL COULD FALL INTO THE ENGINE CYLINDER AND CAUSE ENGINE DAMAGE TO AROUND 8000 DOLLARS NOW THAT I AWARE OF THE EXTREME COST 3 OR 4 TIMES THE AMOUNT FOR ROUTINE MAINTENANCE OF CHANGING SPARK PLUGS IN THESE FORD VEHICLES FORD IS NO HELP AT ALL SAYING ITS NOT A SAFETY ISSUE I CANT HELP IT THE DESIGN FLAW WITH THESE LONG 2 PIECE PLUGS IS SO SERIOUS AND THE PRICE GOUGING OF THE CONSUMER FOR THE COST TO CHANGE SPARK PLUGS IS SO EXPENSIVE AND SO BAD I STRONGLY FEEL THAT THE FEDERAL GOV SHOULD STEP INTO THE MATTER AND HELP THE CONSUMERS OUT AND NOT ALLOW FORD TO GET BY WITH THIS EXTREME BAD DESIGN FLAW AND THE OUTRAGEOUS COST THEY ARE CHARGING AND THE FED GOV SHOULD FORCE FORD TO RECALL ALL AFFECTED VEHICLES AND MANDATE THAT FORD EAT THE COST OF CHANGING THESE SPARK PLUGS AND PUT IN THE NEWLY DEVELOPED PLUGS THAT ARE NOT PRONE TO BECOME SEIZED TO THE ENGINE AND FORD SHALL DO SO AT NO COST TO THE CONSUMER SAFETY OR NOT IT IS JUST UNBELIEVABLE THEY CAN GET BY WITH SUCH A SERIOUS DESIGN FLAW WITH SUCH A HIGH EXPENSE TO THE CONSUMER FOR SOMETHING THAT IS SUPPOSED TO BE ROUTINE. *TR
NHTSA ODI #10671828
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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