NHTSA owner reports · September 18, 2026 snapshot.
Service Brakes, Hydraulic complaints
90 reportsClear category filter30,173 miles · Nov 14, 2007
Service Brakes, Hydraulic
TOTAL BRAKE FAILURE, 2005 F-150 SUPERCREW, KING RANCH 4X4 OCCURRED IN TRAFFIC ON 11 NOV 2005, AT A SPEED 34 MPH. WHEN I PRESSED THE BRAKE PEDAL, THERE WERE NO BRAKES. MY WOULD HAVE WRECKED THE VEHICLE, HAD SHE BEEN DRIVING, SHE WAS HYSTERICAL WHEN THE BRAKES FAILED. I USED THE EMERGENCY BRAKE AND DOWN SHIFTED TO SLOW THE VEH…
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TOTAL BRAKE FAILURE, 2005 F-150 SUPERCREW, KING RANCH 4X4 OCCURRED IN TRAFFIC ON 11 NOV 2005, AT A SPEED 34 MPH. WHEN I PRESSED THE BRAKE PEDAL, THERE WERE NO BRAKES. MY WOULD HAVE WRECKED THE VEHICLE, HAD SHE BEEN DRIVING, SHE WAS HYSTERICAL WHEN THE BRAKES FAILED. I USED THE EMERGENCY BRAKE AND DOWN SHIFTED TO SLOW THE VEHICLE. I DIDN'T HIT THE VEHICLE IN FRONT OF ME, I MANAGED TO GET THE VEHICLE TO THE SIDE ROAD PARKING LOT. THERE WAS ABSOLUTELY NO INDICATION PRIOR TO THIS FAILURE. IT APPEARED I HAD LOST THE VACUUM BOOSTER ASSIST ON MY VEHICLE. THE VEHICLE WAS TOWED TO BEALE PKWY LINCOLN MERCURY FOR REPAIR AS IT IS UNDER FACTORY WARRANTY. THE SERVICE ADVISOR CALLED AND TOLD ME MY VEHICLE WAS READY LATE ON THE 12TH. I WENT TO THE DEALERSHIP TO PICKUP MY VEHICLE AND TALKED WITH THE MECHANIC THAT REPAIRED IT. I ASKED HIM WHAT HE DID AND HE TOLD ME HE RECONNECTED A VACUUM HOSE TO THE BACK OF THE MANIFOLD AND STATED IT HAD BLOWN OFF. I ASK HOW DID YOU SECURE IT. HE TOLD ME BY PUSHING IT BACK ONTO THE PORT IT CAME OFF OF. I ASK HIM WHY NOT INSTALL A CLAMP TO KEEP THIS FROM RECURRING. HE STATED HE WOULD HAVE TO REMOVE THE MANIFOLD TO ACCOMPLISH A CLAMP INSTALLATION. BEALE LINCOLN MERCURY REPAIRED MY VEHICLE THE BEST THEY COULD UNDER THE CIRCUMSTANCES. I FEEL THE MECHANIC SHOULD HAVE INSTALLED SOMETHING TO SECURE THE HOSE SO THIS DOESN'T HAPPEN AGAIN, BUT HE STATED HE DIDN'T THINK FORD WOULD PAY FOR REMOVING THE MANIFOLD TO INSTALL A CLAMP. I THINK FORD WOULD MUCH RATHER PAY FOR A MANIFOLD R & R INSTEAD OF A LAW SUIT FROM AN ACCIDENT, ESPECIALLY ONE WITH INJURIES OR DEATHS DUE TO A FAULTY DESIGN THAT RENDERS THE BRAKES USELESS. THIS HAS OCCURRED ON MANY OTHER F-150'S, SOME WITH ACCIDENTS INVOLVED. CHECK THE INTERNET FOR F-150 BRAKE FAILURES. FORD NEEDS TO ADDRESS THE BRAKE FAILURE ON THE F-150'S WITH 5.4L ENGINES BEFORE THERE IS MORE DAMAGE OR SERIOUS INJURIES. THIS SHOULD BE AN IMMEDIATE RECALL BY FORD. I AM NOW UNEASY DRIVING THIS VEHICLE. *TR
NHTSA ODI #10208936
53,800 miles · May 17, 2007
Service Brakes, Hydraulic
TL*THE CONTACT OWNS A 2005 FORD F-150. WHILE DRIVING THE CONTACT DEPRESSED THE BRAKE PEDAL BUT THE VEHICLE FAILED TO STOP. HE LITERALLY HAD TO APPLY ALL OF HIS WEIGHT ON THE BRAKE PEDAL IN ORDER TO STOP THE VEHICLE. THE DEALER STATED THAT THE FAILURE WAS CAUSED BY THE VACUUM HOSES. THE CURRENT AND FAILURE MILEAGES WERE 53,80…
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TL*THE CONTACT OWNS A 2005 FORD F-150. WHILE DRIVING THE CONTACT DEPRESSED THE BRAKE PEDAL BUT THE VEHICLE FAILED TO STOP. HE LITERALLY HAD TO APPLY ALL OF HIS WEIGHT ON THE BRAKE PEDAL IN ORDER TO STOP THE VEHICLE. THE DEALER STATED THAT THE FAILURE WAS CAUSED BY THE VACUUM HOSES. THE CURRENT AND FAILURE MILEAGES WERE 53,800. THE DEALER STATED THAT THE REPLACEMENT HOSE IS DESIGNED DIFFERENT FROM THE ORIGINAL WHICH THE CONSUMER THINKS FORD IS AWARE OF THIS PROBLEM WITH THE BRAKE HOSE. UPDATED 06/08/07 *TR
NHTSA ODI #10191015
39,000 miles · May 3, 2007
Service Brakes, Hydraulic
AT 15,000 AND 30,000 MILE SCHEDULED MAINTENANCES A BRAKE HOSE INSPECTED SHOULD BE DONE. IN OUR CASE IT WAS COMPLETED AND ACCORDING TO THE DEALERSHIP THERE WERE NO FOUND PROBLEMS. HOWEVER, WHEN WE WERE DRIVING AROUND A CURVE AND THERE WAS A TEENAGER ON A FOUR WHEELER ON OUR SIDE OF THE ROAD AND WE BRAKED TO AVOID THE CHILD ...W…
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AT 15,000 AND 30,000 MILE SCHEDULED MAINTENANCES A BRAKE HOSE INSPECTED SHOULD BE DONE. IN OUR CASE IT WAS COMPLETED AND ACCORDING TO THE DEALERSHIP THERE WERE NO FOUND PROBLEMS. HOWEVER, WHEN WE WERE DRIVING AROUND A CURVE AND THERE WAS A TEENAGER ON A FOUR WHEELER ON OUR SIDE OF THE ROAD AND WE BRAKED TO AVOID THE CHILD ...WE HAD NO BRAKES ON OUR 2005 F-150 SUPERCREW. WE WERE ABLE TO AVOID INJURIES WITH OUR FAMILY INSIDE THE VEHICLE AND THE CHILD WE ALMOST HIT DUE TO THE BRAKE FAILURE. UPON TOWING THE VEHICLE IN THEY SAID THAT THE BRAKE HOSE INTO THE INTAKE WAS WORN AND BLEW OFF WHEN WE DEPRESSED THE BRAKE FAST. I ASKED WHY THIS WASN'T CHECKED AND THEY SAID BECAUSE IT WAS TOO HARD TO GET TO FOR A PHYSICAL INSPECTION DURING MAINTENANCE. THE SERVICE TECH ALSO SAID HE HAS SEEN THIS WITH SEVERAL F150'S. I SEE THIS AS BEING A SERIOUS DANGER FOR THESE BRAKE HOSES TO BLOW OFF AND NOT BE WHERE THEY CAN BE CHECKED. WE ARE PAYING FOR MAINTENANCE THAT IS NOT BEING DONE NOT TO MENTION PEOPLES LIVES ARE AT STAKE. *TR
NHTSA ODI #10189639
17,945 miles · Apr 30, 2007
Service Brakes, Hydraulic
AS I APPROACHED A STOP SIGN BRAKES FAILED TO BRAKE PROPERLY. THE BRAKES WERE TIGHT AND NO AMOUNT OF PRESSURE WOULD STOP THE TRUCK. I PUT IT IN N AND IT EVENTUALLY ROLLED TO A STOP WITH THE HELP OF GRAVITY AND THE INCLINE LEADING UP TO THE INTERSECTION. I HAD MY 2005, F150 TOWED TO THE NEAREST FORD DEALERSHIP. THE FAULTY H…
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AS I APPROACHED A STOP SIGN BRAKES FAILED TO BRAKE PROPERLY. THE BRAKES WERE TIGHT AND NO AMOUNT OF PRESSURE WOULD STOP THE TRUCK. I PUT IT IN N AND IT EVENTUALLY ROLLED TO A STOP WITH THE HELP OF GRAVITY AND THE INCLINE LEADING UP TO THE INTERSECTION. I HAD MY 2005, F150 TOWED TO THE NEAREST FORD DEALERSHIP. THE FAULTY HOSE WAS REPLACED WITH A 'REINFORCED ONE. WHICH LEAVES ME TO BELIEVE FORD HAS HAD TROUBLE WITH THIS PART PRIOR TO THIS INCIDENT. WHY ELSE WOULD THEY REPLACE THE FAULTY PART WITH THIS NEW, SO-CALLED REINFORCED ONE. THE OLD PART IS NOT AVAILABLE BECAUSE I WAS TOLD THE DEALERSHIP HAD TO SEND IT TO FORD MOTOR CO. I WONDER HOW MANY ACCIDENTS, COLLISIONS, NEAR MISSES, AND DEATHS OCCURRED BECAUSE OF BRAKE FAILURES THAT WENT UNREPORTED. HAD THIS FAILURE OCCURRED IN MARCH, JUST NORTH OF TAILGATE , ALL ON ROUTE 77, WHEN THE TRACTOR TRAILER TRUCK PULLED IN FRONT OF ME, I 'M SURE THE ACCIDENT WOULD HAVE BECOME ANOTHER STATISTIC REPORTED AS AN UNFORTUNATE FATALITY CAUSED BY A CARELESS TRUCK DRIVER. NO ONE WOULD HAVE THOUGHT TO INVESTIGATE THE BRAKES ON MY TRUCK.*AK
NHTSA ODI #10189226
318 miles · Apr 24, 2007
Service Brakes, Hydraulic
TL* THE CONTACT OWNS A 2005 FORD F-150. WHEN DEPRESSED THE BRAKES PEDAL WENT ALL THE WAY TO THE FLOORBOARD WITHOUT WARNING. THE FAILURE OCCURRED INTERMITTENTLY, AND SPEEDWAS NOT A FACTOR. THE VEHICLE WAS TAKEN TO TWO DIFFERENT FORD DEALERS, AND NEITHER ONE COULD FIND ANY FAILURES. THE MASTER CYLINDER HAD BEEN REPLACED. T…
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TL* THE CONTACT OWNS A 2005 FORD F-150. WHEN DEPRESSED THE BRAKES PEDAL WENT ALL THE WAY TO THE FLOORBOARD WITHOUT WARNING. THE FAILURE OCCURRED INTERMITTENTLY, AND SPEEDWAS NOT A FACTOR. THE VEHICLE WAS TAKEN TO TWO DIFFERENT FORD DEALERS, AND NEITHER ONE COULD FIND ANY FAILURES. THE MASTER CYLINDER HAD BEEN REPLACED. THE CURRENT MILEAGE IS 28,619, AND FAILURE MILEAGE WAS 318. *AK UPDATED 07/06/07 *TR
NHTSA ODI #10188688
64,000 miles · Mar 2, 2007
Service Brakes, Hydraulic
TL* - THE CONTACT CALLED REGARDING THE 2005 FORD F150. THE CONTACT STATED THAT WHEN ATTEMPTING TO PUT THE VEHICLE IN REVERSE THE BRAKES FAILED. THE CONTACT PULLED OVER AND TURNED THE VEHICLE OFF. THERE WERE NO WARNING INDICATORS. THE CONTACT HAD THE VEHICLE TOWED TO A FORD DEALER. WHO DIAGNOSED THE FAILURE AS BEING A RESUL…
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TL* - THE CONTACT CALLED REGARDING THE 2005 FORD F150. THE CONTACT STATED THAT WHEN ATTEMPTING TO PUT THE VEHICLE IN REVERSE THE BRAKES FAILED. THE CONTACT PULLED OVER AND TURNED THE VEHICLE OFF. THERE WERE NO WARNING INDICATORS. THE CONTACT HAD THE VEHICLE TOWED TO A FORD DEALER. WHO DIAGNOSED THE FAILURE AS BEING A RESULT OF A LACK OF VACUUM IN BRAKE BOOSTER. THE FORD DEALER FOUND THAT THE INTAKE VACUUM CONNECTION FAILED BECAUSE THE HOSE HAD BECOME SOFT. THE FAILURE MILEAGE WAS 64, 277. THE DEALER HAD TO REMOVE THE THROTTLE AND FUEL RAIL TO ACCESS AND REPLACE THE HOSE. THE CURRENT MILEAGE WAS 66000.*AK UPDATED 04/05/07*JB
NHTSA ODI #10184038
26,114 miles · Dec 8, 2006
Service Brakes, Hydraulic
DT*: THE CONTACT STATED WHILE DRIVING 18 MPH, THE BRAKES FAILED. THE VEHICLE WAS TOWED TO THE SALES/SERVICE DEALER, WHO DETERMINED THE VACUUM HOSE HAD COME OFF. THE MANUFACTURER WAS NOTIFIED. UPDATED 1/19/2007 - *NM
NHTSA ODI #10175549
6,000 miles · Nov 17, 2006
Service Brakes, Hydraulic
I EXPERIENCED EXTREME FRONT BRAKE SHUDDER AFTER ONLY 6200 MILES ON THIS VEHICLE. I FEEL THAT THIS IS A SERIOUS DESIGN FAULT OF THE FRONT ROTORS. I HAD THE VEHICLE SERVICED UNDER WARRANTY AND THE FRONT ROTORS WERE CUT. I AM JUST WAITING FOR THE ROTORS TO WARP AGAIN, AND HOPEFULLY THEY WON'T CAUSE AN ACCIDENT. NO HELP FROM INQUIRI…
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I EXPERIENCED EXTREME FRONT BRAKE SHUDDER AFTER ONLY 6200 MILES ON THIS VEHICLE. I FEEL THAT THIS IS A SERIOUS DESIGN FAULT OF THE FRONT ROTORS. I HAD THE VEHICLE SERVICED UNDER WARRANTY AND THE FRONT ROTORS WERE CUT. I AM JUST WAITING FOR THE ROTORS TO WARP AGAIN, AND HOPEFULLY THEY WON'T CAUSE AN ACCIDENT. NO HELP FROM INQUIRIES WITH FORD MOTOR COMPANY ABOUT THIS PROBLEM. *NM
NHTSA ODI #10173777
Mileage unknown · Oct 28, 2006
Service Brakes, HydraulicVehicle Speed ControlCrash
WHILE TRYING TO STOP MY FORD F-150 TRUCK, I WAS ACTUALLY HITTING THE ACCELERATOR AT THE SAME TIME AS I WAS PUSHING THE BRAKE PEDAL. I COULD NOT TELL THAT IT WAS HAPPENING UNTIL IT WAS TOO LATE. AS I PSHED ON THE BRAKE THE TRUCK DID NOT SEEM TO SLOW DOWN NEARLY AS FAST AS IT SHOULD HAVE, SO I PUSHED HARDER ON THE BRAKE AND THAT…
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WHILE TRYING TO STOP MY FORD F-150 TRUCK, I WAS ACTUALLY HITTING THE ACCELERATOR AT THE SAME TIME AS I WAS PUSHING THE BRAKE PEDAL. I COULD NOT TELL THAT IT WAS HAPPENING UNTIL IT WAS TOO LATE. AS I PSHED ON THE BRAKE THE TRUCK DID NOT SEEM TO SLOW DOWN NEARLY AS FAST AS IT SHOULD HAVE, SO I PUSHED HARDER ON THE BRAKE AND THAT DID NOT SEEM TO WORK PROPERLY, THEN I REALIZED THE RIGHT EDGE OF MY FOOT WAS ACTUALLY DEPRESSING THE ACCELERATOR, BUT YOU COULD NOT REALLY FEEL IT SINCE IT HAS VERY LITTLE RESISTANCE. WHEN I REALIZED WHAT WAS HAPPENING, I TRIED TO LIFT MY FOOT OFF THE ACCELRATOR, BUT TO DO SO I HAD TO RELEASE THE BRAKE A BIT. WHEN I DID THAT, THE VEHICLE LURCHED FORWARD TOWARD THE CAR IN FRONT OF ME AND HIT IT. IT HAPPENS BECAUSE AS YOU ARE HITTING THE ACCELERATOR WHILE TRYING TO BRAKE, THE ENGINE REVS UP TO HIGH RPM, AS YOU TRY TO GET YOUR FOOT OFF THE ACCELERATOR, AND RELEASE THE BRAKE A BIT, THE CAR THINKS YOU WANT TO GO FAST AND TAKES OFF BECAUSE OF THE HIGH RPM. THIS HAPPENED TO ME ABOUT TWO OR THREE WEEKS AGO, BUT IT JUST SEEMED LIKE AN ODDITY AT THE TIME SO I DID NOT REALLY THINK IT WAS A BIG DEAL. THEN IT HAPPENED TO ME AGAIN YESTERDAY WHEN I NEEDED TO STOP QUICKLY BECAUSE EVERYONE HAD SLAMMED ON THE BRAKES IN FRONT OF ME, SO WHEN I WENT TO HIT MY BRAKES, I INADVERTANTLY WAS HITTING THE ACCELERATOR AT THE SAME TIME AGAIN, ONLY THIS TIME, IT CAUSED AN ACCIDENT AS I PLOWED INTO THE CAR IN FRONT OF ME. I HAD PLENTY OF ROOM IN FRONT OF ME, AT LEAST 10 TO 15 FEET OR MORE, AND WE WERE ONLY TRAVELING BETWEEN 5 TO 10 MILES PER HOUR. I WONDER HOW MANY OTHER DRIVERS HAVE HAD THIS OCCUR TO THEM. I HAVE BEEN DRIVING VEHICLES FOR THIRTY YEARS AND HAVE NEVER HAD THIS HAPPEN TO ME UNTIL I DROVE THIS TRUCK, AND IT HAS NOW HAPPENED AT LEAST 2 TIMES IN THE LAST MONTH. I AM DRIVING THIS TRUCK SINCE AUGUST THIS YEAR. *NM
NHTSA ODI #10172027
48,000 miles · Sep 19, 2006
Service Brakes, Hydraulic
DT*: THE CONTACT STATED UPON STARTING THE VEHICLE IN THE MORNING, WITHOUT ANY WARNING SIGNAL TO INDICATE BRAKE FAILURE, THE BRAKE PEDAL WAS DEPRESSED AND WOULD NOT GO ALL THE WAY TO THE FLOOR. THE VEHICLE WAS TOWED TO THE DEALERSHIP WHO DETERMINED A VACUUM LINE HAD DISCONNECTED DUE TO OIL PRESENCE IN THE CONNECTION. THE RUBBER…
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DT*: THE CONTACT STATED UPON STARTING THE VEHICLE IN THE MORNING, WITHOUT ANY WARNING SIGNAL TO INDICATE BRAKE FAILURE, THE BRAKE PEDAL WAS DEPRESSED AND WOULD NOT GO ALL THE WAY TO THE FLOOR. THE VEHICLE WAS TOWED TO THE DEALERSHIP WHO DETERMINED A VACUUM LINE HAD DISCONNECTED DUE TO OIL PRESENCE IN THE CONNECTION. THE RUBBER HOSE WAS REPLACED. THE CONTACT DENIED ANY TRACES OF OIL IN THE SURROUNDING OF THE VACUUM HOSE CONNECTION. UPDATED 11/03/06. *JB
NHTSA ODI #10168672
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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