NHTSA owner reports · September 18, 2026 snapshot.
Service Brakes, Hydraulic complaints
90 reportsClear category filter5,000 miles · Sep 7, 2006
Fuel System, GasolineParking BrakeService Brakes, Hydraulic
2005 F150 RWD VEHICLE HAS BEEN INTO FORD REPAIR 3 TIMES FOR BRAKES (PARKING BRAKE, ABS). ONE OCCASION THE TEMPERATURE OF THE LT REAR HUB WAS 385 DEGREES F BY INFERRED THERMOMETER. ANOTHER OCCASION RT REAR WAS TOO HOT TO TOUCH AFTER SITTING FOR AN HOUR. THIS VEHICLE HAS ALUMINUM RIMS THAT THE DEALER STATES SHOW NO DAMAGE. ALSO U…
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2005 F150 RWD VEHICLE HAS BEEN INTO FORD REPAIR 3 TIMES FOR BRAKES (PARKING BRAKE, ABS). ONE OCCASION THE TEMPERATURE OF THE LT REAR HUB WAS 385 DEGREES F BY INFERRED THERMOMETER. ANOTHER OCCASION RT REAR WAS TOO HOT TO TOUCH AFTER SITTING FOR AN HOUR. THIS VEHICLE HAS ALUMINUM RIMS THAT THE DEALER STATES SHOW NO DAMAGE. ALSO UNKNOWN IS WHAT THIS TEMPERATURE MAY HAVE CAUSED TO THE REAR BEARINGS, SEALS AND OTHER BRAKE COMPONENTS (CALIPERS). ABS LIGHT INTERMITTENT ON AND DRIVEABLITY WAS INTOLERABLE WITH SHAKING AND VIBRATION. FUEL CONSUMPTION GOT WORSE BY 30%. VEHICLE TAKEN TO DEALER AND PARTS WERE REPLACED (ROTOR, ABS SENSOR, PARKING BRAKE REATTACHED) , PARKING BRAKES WAS FOUND DISCONNECTED IN THE SEMI LOCKED POSITION ON THE SECOND RETURN, MISSED ON FIRST RETURN. UNABLE TO GET OLD PARTS. *NM
NHTSA ODI #10167621
14,250 miles · Sep 7, 2006
Service Brakes, HydraulicVehicle Speed Control
DT*: THE CONTACT STATED THE VEHICLE HAD AN IMPROPER BRAKE ADJUSTMENT WHICH MADE THE SLACK ADJUSTER LENGTH DIFFERENT ON EACH SIDE OF AN AXLE. THE DEALERSHIP DID NOT FIND ANY PROBLEM AND THE CONTACT REQUESTED THAT THE BRAKE CHAMBERS BE REPLACED AND EACH OF THE SERVICE CHAMBERS MUST BE OF THE SAME SIZE ACROSS THE VEHICLE'S AXLES. …
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DT*: THE CONTACT STATED THE VEHICLE HAD AN IMPROPER BRAKE ADJUSTMENT WHICH MADE THE SLACK ADJUSTER LENGTH DIFFERENT ON EACH SIDE OF AN AXLE. THE DEALERSHIP DID NOT FIND ANY PROBLEM AND THE CONTACT REQUESTED THAT THE BRAKE CHAMBERS BE REPLACED AND EACH OF THE SERVICE CHAMBERS MUST BE OF THE SAME SIZE ACROSS THE VEHICLE'S AXLES. UPDATED 10/18/2006 - THE BRAKE PEDAL TRAVELS PAST THE ACCELERATOR PEDAL AND HAS CAUSED TROUBLE WHILE THE CONSUMER ATTEMPTS TO STOP THE VEHICLE. THE CONSUMER HAS INADVERTENTLY IT BOTH PEDALS AT THE SAME TIME. *NM
NHTSA ODI #10167619
10,000 miles · Sep 1, 2006
Service Brakes, HydraulicCrash
DT*: THE CONTACT STATED WHILE ON A HILL APPLYING BRAKE PRESSURE AT 8MPH , THE BRAKE PEDAL DROPPED TO THE FLOORBOARD AND THERE WAS A LOSS OF ALL BRAKING POWER. THE VEHICLE WAS PLACED IN NEUTRAL WHICH ALLOWED THE VEHICLE TO ROLL DOWNHILL AND STRIKE A FENCE. THE SEATBELT WAS WORN AND NO INJURIES WERE SUSTAINED. HOWEVER, THE WAS …
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DT*: THE CONTACT STATED WHILE ON A HILL APPLYING BRAKE PRESSURE AT 8MPH , THE BRAKE PEDAL DROPPED TO THE FLOORBOARD AND THERE WAS A LOSS OF ALL BRAKING POWER. THE VEHICLE WAS PLACED IN NEUTRAL WHICH ALLOWED THE VEHICLE TO ROLL DOWNHILL AND STRIKE A FENCE. THE SEATBELT WAS WORN AND NO INJURIES WERE SUSTAINED. HOWEVER, THE WAS MINOR DAMAGE TO THE VEHICLE. THE POLICE WAS NOT ALERTED. THE VEHICLE WAS TOWED TO THE DEALER WHO DETERMINED THE MASTER CYLINDER WAS INOPERATIVE. THE MASTER CYLINDER REPLACEMENT CORRECTED THE BRAKING PROBLEM. THE MANUFACTURER WAS NOT ALERTED.
NHTSA ODI #10167241
10,217 miles · Jul 31, 2006
Service Brakes, Hydraulic
BRAKE FAILURE. *NM
NHTSA ODI #10164046
7,550 miles · Jul 28, 2006
Service Brakes, Hydraulic
WHILE COMING TO A STOP OCCASIONALLY THE BRAKE PEDAL HAS A LOSS OF PRESSURE FEEL AND THE BRAKE PEDAL GOES TO THE FLOOR. ON THE 26TH OF JULY I TOOK THE VEHICLE TO POWER FORD IN VALENCIA CA. AND THEY STATED THEY COULD NOT FIND A PROBLEM. IT IS MY BELIEF THE VACUUM BRAKE BOOSTER IS LEAKING PRESSURE WHEN THE AMBIENT TEMPERATURE IS HI…
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WHILE COMING TO A STOP OCCASIONALLY THE BRAKE PEDAL HAS A LOSS OF PRESSURE FEEL AND THE BRAKE PEDAL GOES TO THE FLOOR. ON THE 26TH OF JULY I TOOK THE VEHICLE TO POWER FORD IN VALENCIA CA. AND THEY STATED THEY COULD NOT FIND A PROBLEM. IT IS MY BELIEF THE VACUUM BRAKE BOOSTER IS LEAKING PRESSURE WHEN THE AMBIENT TEMPERATURE IS HIGH, BOTH TIMES THIS OCCURRED THE OUTSIDE TEMPERATURE WAS ABOVE 110 DEGREES. *JB
NHTSA ODI #10163795
Mileage unknown · Jun 29, 2006
Service Brakes, Hydraulic
DT*: THE CONTACT STATED AFTER RELEASING THE EMERGENCY BRAKES FROM THE VEHICLE IN PREPERATION TO DRIVE, THE EMERGENCY BRAKES WOULD STICK IN PLACE. THIS CAUSED THE VEHICLE TO TRAVEL WITH THE EMERGNECY BRAKES APPIED GENERATING PRESSURE TOWARD THE TIRES WHICH CAUSED THEM TO RUN HOT AND BURN. THE BURNING RELEASED A BURNING TIRE ODOR…
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DT*: THE CONTACT STATED AFTER RELEASING THE EMERGENCY BRAKES FROM THE VEHICLE IN PREPERATION TO DRIVE, THE EMERGENCY BRAKES WOULD STICK IN PLACE. THIS CAUSED THE VEHICLE TO TRAVEL WITH THE EMERGNECY BRAKES APPIED GENERATING PRESSURE TOWARD THE TIRES WHICH CAUSED THEM TO RUN HOT AND BURN. THE BURNING RELEASED A BURNING TIRE ODOR. THE DEALERS DETERMINED THERE WOULD BE A CHARGE FOR ANY SERVICE EVEN THOUGH VEHICLE WAS UNDER WARRANTY. NO REPAIRS WERE DONE.
NHTSA ODI #10161059
3,600 miles · Jun 15, 2006
Service Brakes, HydraulicSuspension
HAD MY F150 FOR LESS THAN 3 MONTHS WHEN NOTICED THE VIBRATION WHEN APPLYING THE BRAKES, ALSO HAS ROUGH IDLE, AND ROUGH SUSPENSION. TOOK TO DEALER THEY STATED NOTHING WRONG... WELL NOW ITS BEEN ABOUT 9 MONTH AND THE VIBRATION HAS GOTTEN SO BAD THAT WHEN BRAKES ARE APPLIED YOU GET THE STEERING WHEEL SHAKING ALONG WITH THE TRUCK. A…
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HAD MY F150 FOR LESS THAN 3 MONTHS WHEN NOTICED THE VIBRATION WHEN APPLYING THE BRAKES, ALSO HAS ROUGH IDLE, AND ROUGH SUSPENSION. TOOK TO DEALER THEY STATED NOTHING WRONG... WELL NOW ITS BEEN ABOUT 9 MONTH AND THE VIBRATION HAS GOTTEN SO BAD THAT WHEN BRAKES ARE APPLIED YOU GET THE STEERING WHEEL SHAKING ALONG WITH THE TRUCK. AGAIN I TOOK TO THE DEALER NOW THEY TELL ME MY ROTORS ARE WARPED AND I NEED AN ALIGNMENT AND NEW TIRES CAUSE IT ATE THE TREAD OFF THE INSIDE OF THE TIRES, AND THEY WANT TO CHARGE ME $400.00. I TALKED TO THE TIRE WARRANTY DEPARTMENT HE EVEN SAID THAT IT SHOULDN'T BE HAPPENING ALONG WITH MANY OTHERS. BUT FORD SERVICE SAYS IT NORMAL.....NOW I AM DRIVING A TRUCK WITH KIDS THAT IS UNSAFE. ARE THEY WANTING FOR PEOPLE TO DIE BEFORE THEY CORRECT THIS PROBLEM?? *JB
NHTSA ODI #10159968
2,000 miles · May 15, 2006
Service Brakes, HydraulicCrash
THE ACCIDENT HAPPENED DECEMBER 19, 2005: CAUSE: BRAKE FAILURE. WE WERE STOPPED AT A RED LIGHT AND I WAS HOLDING PRESSURE ON THE BRAKE PEDAL WHEN IT COLLAPSED TO THE FLOOR AND ROLLED IN TO THE CAR IN FRONT OF US. AT THAT TIME THERE WAS ONLY 2000 MILES ON THE PICK-UP. I WASN'T SURE WHAT HAPPENED UNTIL WE WERE AT ANOTHER STOP L…
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THE ACCIDENT HAPPENED DECEMBER 19, 2005: CAUSE: BRAKE FAILURE. WE WERE STOPPED AT A RED LIGHT AND I WAS HOLDING PRESSURE ON THE BRAKE PEDAL WHEN IT COLLAPSED TO THE FLOOR AND ROLLED IN TO THE CAR IN FRONT OF US. AT THAT TIME THERE WAS ONLY 2000 MILES ON THE PICK-UP. I WASN'T SURE WHAT HAPPENED UNTIL WE WERE AT ANOTHER STOP LIGHT AND IT HAPPENED AGAIN, BUT THIS TIME I PUMPED THE BRAKE PEDAL UNTIL I HAD PRESSURE. WE RETURNED HOME IN MARCH AND I WENT TO THE DEALER WHOM WE PURCHASED IT FROM (VALU FORD AT ELBOW LAKE, MINNESOTA) AND TOLD THEM OF THE PROBLEM. HE TRIED IT AND SAID HE COULD NOT FIND A PROBLEM. I GOT INTO THE PICK-UP AND SHOWED HIM HOW THE MASTER CYLINDER COLLAPSES WHEN PRESSURE IS HELD ON IT. HE TRIED ANOTHER PICK-UP SAME YEAR AND SAID THAT'S THE WAY ITS SUPPOSED TO BE??? I WENT TO ANOTHER FORD DEALER IN ALEXANDRIA (JUETTNER MOTORS) AND TOLD HIM WHAT HAPPENED AND WHAT I WANTED DONE AND THEY TOLD ME MY INSURANCE COMPANY SHOULD TAKEN CARE OF THE PROBLEM AND DIDN'T EVEN CHECK THE BRAKES. I HAVE TAKEN THE PICK-UP TO 5 DIFFERENT INDEPENDENT GARAGES AND THEY HAVE ALL SAID THE MASTER CYLINDER SHOULD NOT COLLAPSE WHEN PRESSURE IS HELD ON THE PEDAL. I WENT BACK TO THE DEALER AND ASK IF THEY COULD HAVE A COMPANY TECH EXPLAIN TO ME WHY THE MASTER CYLINDER COLLAPSES WHEN PRESSURE IS HELD ON THE PEDAL. I HAVE HEARD NOTHING FROM THEM. I FEEL VERY STRONGLY THAT FORD HAS A PROBLEM WITH THEIR MASTER CYLINDER AND SHOULD BE FIXED. I COMPLAINED TO FORD AGAIN AND ASK THEM TO HAVE SOME ONE EXPLAIN TO ME WHY THE BRAKES SHOULD COLLAPSE WHEN PRESSURE IS HELD ON THEM. THEY SENT OUT AN INDEPENDENT SOURCE AND HE HAD THE PICK-UP FOR ABOUT THREE HOURS AND SENT A REPORT BACK TO FORD SAYING THAT THE ELECTRIC BRAKES FOR THE CAMPER WERE THE PROBABLE CAUSE?? THERE IS NO HYDRAULICS INVOLVED WITH THE ELECTRIC BRAKES. NOTHING HAS BEEN DONE TO FIX THE PROBLEM.. *JB
NHTSA ODI #10157606
Mileage unknown · May 11, 2006
Service Brakes, Hydraulic
AT 20,000 MILES I TOOK MY 2005 F150 SUPERCREW XLT 4X4 INTO FIRESTONE, TO HAVE THE BRAKES CHECKED. THE TECHNICIAN INFORMED ME THAT THERE APPEARED TO BE NOTHING WRONG WITH THE PADS, AS I STILL HAD ABOUT 65-70% LEFT ON THEM. HOWEVER THERE WAS AN ISSUE WITH THE ROTORS. HE STATED THEY WERE WARPED. KNOWING THIS IS NOT NORMAL, I ASKED …
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AT 20,000 MILES I TOOK MY 2005 F150 SUPERCREW XLT 4X4 INTO FIRESTONE, TO HAVE THE BRAKES CHECKED. THE TECHNICIAN INFORMED ME THAT THERE APPEARED TO BE NOTHING WRONG WITH THE PADS, AS I STILL HAD ABOUT 65-70% LEFT ON THEM. HOWEVER THERE WAS AN ISSUE WITH THE ROTORS. HE STATED THEY WERE WARPED. KNOWING THIS IS NOT NORMAL, I ASKED IF THIS WAS A COMMON THING ON THE NEW MODEL FORDS. AND HE STATED THAT THEY HAVE HAD A LOT OF THEM IN FOR THE EXACT SAME THING, WARPED ROTORS. I TOLD HIM TO PUT THE TRUCK BACK TOGETHER AND WOULD TAKE TO FORD. HE STATED THAT THE REASON THEY WERE WARPING, WAS BECAUSE OF A DESIGN DEFECT WHICH DID NOT ALLOW THEM TO GET ENOUGH AIR TO COOL, AND IF BRAKES WERE APPLIED HARD, THEN CAUSED THEM TO WARP. I TOOK THE TRUCK TO FORD DEALERSHIP ( JENKINS AND WYNNE IN CLARKSVILLE, TN.) INFORMED THE SERVICE WRITER. AS I WAS SPEAKING TO HIM, A TECH FROM THE SHOP WALKED IN, AND SAID THERE WAS A BIG PROBLEM WITH THEM. THEY TOOK MY TRUCK INTO THE SHOP, AND AFTER A DAY INFORMED ME THAT MY TRUCK HAD THE "NEW AND IMPROVED BRAKES" ALREADY INSTALLED. I ASKED HOW THEY COULD BE NEW AND IMPROVED IF DOING THE SAME AS THE OLD STYLE. THEY STATED THEY WOULD TAKE CARE OF ME. WHEN I INQUIRED AS TO THE HOW? THE SERVICE WRITER STATED " WE WILL MACHINE THEM." I TOLD HIM THAT JUST MEANS THAT THEY WERE GOING TO GRIND THE ROTORS FLAT, AND THAT IT WASN'T FIXING THE ISSUE. I WOULD JUST HAVE TO HAVE A COMPLETE TOTAL BRAKE REPLACEMENT AT 40,000 MILES. HE COMMENTED THAT THERE WAS NOTHING THEY COULD DO. I ASKED IF THIS WAS NORMAL FOR TRUCKS TO BE COMING IN WITH WARPED ROTORS AT 20,000 MILES, AND HE JUST SHRUGGED HIS SHOULDERS. I ASKED HIM, WHAT ARE WE AS TRUCK OWNERS SUPPOSED TO DO, REPLACE THE ROTORS EVERY 30-40,000 MILES. AGAIN HE JUST SHRUGGED AND SAID THERE WAS NOTHING HE COULD DO. AFTER THEY GROUND THE ROTORS, AND PUT THE TRUCK BACK TOGETHER, LESS THAN 500 MILES THEY STARTED DOING THE SAME THING, AND I ALMOST HAD AN ACCIDENT. THEY WILL "PULSE AND THE VEHICLE WILL LURCH" *JB
NHTSA ODI #10157269
2,000 miles · May 3, 2006
Service Brakes, HydraulicCrash
MAY 2, 2006 THE ACCIDENT HAPPENED DECEMBER 19, 2005: CAUSE: BREAK FAILURE. WE WERE STOP AT A RED LIGHT AND I WAS HOLDING PRESSURE ON THE BREAK PEDAL AND IT COLLAPSED TO THE FLOOR AND ROLLING IN T…
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MAY 2, 2006 THE ACCIDENT HAPPENED DECEMBER 19, 2005: CAUSE: BREAK FAILURE. WE WERE STOP AT A RED LIGHT AND I WAS HOLDING PRESSURE ON THE BREAK PEDAL AND IT COLLAPSED TO THE FLOOR AND ROLLING IN TO THE CAR IN FRONT OF US. AT THAT TIME THERE WAS ONLY 2000 MILES ON THE PICK-UP. I WASN'T SURE WHAT HAPPENED UNTIL WE WERE AT ANOTHER STOP LIGHT AND IT HAPPENED AGAIN, BUT THIS TIME I PUMPED THE BREAK PEDAL TILL I HAD PRESSURE. WE RETURNED HOME IN MARCH AND I WENT TO THE DEALER WHOM WE PURCHASED IT FROM (VALU FORD AT ELBOW LAKE, MINNESOTA) AND TOLD THEM OF THE PROBLEM. HE TRIED IT AND SAID HE COULD NOT FIND A PROBLEM. I GOT INTO THE PICK-UP AND SHOWED HIM HOW THE MASTER CYLINDER COLLAPSES WHEN PRESSURE IS HELD ON IT. HE TRIED ANOTHER PICK-UP SAME YEAR AND SAID THAT??S THE WAY ITS SUPPOSED TO BE??? I WENT TO ANOTHER FORD DEALER IN ALEXANDRIA (JUETTNER MOTORS) AND TOLD HIM WHAT HAPPENED AND WHAT I WANTED DONE AND THEY TOLD ME MY INSURANCE COMPANY SHOULD TAKE CARE OF THE PROBLEM AND DIDN'T EVEN CHECK THE BREAKS. I HAVE TAKEN THE PICK-UP TO 5 DIFFERENT INDEPENDENT GARAGES AND THEY HAVE ALL SAID THE MASTER CYLINDER SHOULD NOT COLLAPSE WHEN PRESSURE IS HELD ON THE PEDAL. I WENT BACK TO THE DEALER AND ASK IF THEY COULD HAVE A COMPANY TECH EXPLAIN TO ME WHY THE MASTER CYLINDER COLLAPSES WHEN PRESSURE IS HELD ON THE PEDAL. I HAVE HEARD NOTHING FROM THEM. I FEEL VERY STRONGLY THAT FORD HAS A PROBLEM WITH THEIR MASTER CYLINDER AND SHOULD BE FIXED. I COMPLAINED TO FORD AGAIN AND ASK THEM TO HAVE SOME ONE EXPLAIN TO ME WHY THE BREAKS SHOULD COLLAPSE WHEN PRESSURE IS HELD ON THEM. THEY SENT OUT A INDEPENDENT SOURCE AND HE HAD THE PICK-UP FOR ABOUT THREE HOURS AND SENT A REPORT BACK TO FORD SAYING THAT THE ELECTRIC BREAKS FOR THE CAMPER WERE THE PROBABLE CAUSE?? THERE IS NO HYDRAULICS INVOLVED WITH THE ELECTRIC BREAKS. *NM
NHTSA ODI #10156669
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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