NHTSA owner reports · September 18, 2026 snapshot.
Visibility complaints
260 reportsClear category filter50,500 miles · Oct 7, 2008
Visibility
THE DRIVER SIDE POWER WINDOW REGULATOR HAS FAILED AND THE WINDOW WILL NOT ROLL UP. IT HAPPENED WHILE I WAS OUT OF TOWN AND IT WAS RAINING. THIS IS A HUGE SAFETY RISK. APPARENTLY, AFTER DOING VERY LITTLE RESEARCH ON THE INTERNET, THERE ARE A LOT OF FOLKS HAVING THE SAME PROBLEMS. NOT ONLY DID THIS LEAVE MY VEHICLE OPEN TO THE…
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THE DRIVER SIDE POWER WINDOW REGULATOR HAS FAILED AND THE WINDOW WILL NOT ROLL UP. IT HAPPENED WHILE I WAS OUT OF TOWN AND IT WAS RAINING. THIS IS A HUGE SAFETY RISK. APPARENTLY, AFTER DOING VERY LITTLE RESEARCH ON THE INTERNET, THERE ARE A LOT OF FOLKS HAVING THE SAME PROBLEMS. NOT ONLY DID THIS LEAVE MY VEHICLE OPEN TO THE ELEMENTS, IT ALSO LEFT IT OPEN TO ANYONE WHO WANTED TO HELP THEMSELVES TO THE VEHICLE OR IT'S CONTENTS. I AM VERY CONCERNED THAT THIS WILL HAPPEN AGAIN. *TR
NHTSA ODI #10244688
83,000 miles · Oct 3, 2008
Visibility
THE DRIVER SIDE WINDOW OF MY 2005 FORD F-150 SUPER CREW MADE A LOUD POPPING NOISE THEN FELL INTO THE DOOR, ALL WHEN I PRESSED THE BUTTON TO ROLL IT UP. IT HAD BEEN LOCKING UP FOR SEVERAL DAYS ON AND OFF. COST TO REPAIR IS ABOUT $300, SO UNTIL I CAN AFFORD IT, THE WINDOW IS HELD IN PLACE WITH VICE-GRIPS. LOCAL FORD DEALERSHIP TEL…
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THE DRIVER SIDE WINDOW OF MY 2005 FORD F-150 SUPER CREW MADE A LOUD POPPING NOISE THEN FELL INTO THE DOOR, ALL WHEN I PRESSED THE BUTTON TO ROLL IT UP. IT HAD BEEN LOCKING UP FOR SEVERAL DAYS ON AND OFF. COST TO REPAIR IS ABOUT $300, SO UNTIL I CAN AFFORD IT, THE WINDOW IS HELD IN PLACE WITH VICE-GRIPS. LOCAL FORD DEALERSHIP TELLS ME THAT HAVEN'T HEARD OF ANY SUCH PROBLEMS WITH THIS MODEL, BUT I HAVE FOUND HUNDREDS OF COMPLAINTS JUST LIKE MINE ON THE INTERNET SIMPLY BY TYPING "2005 FORD F-150 WINDOW PROBLEMS" INTO GOOGLE. *TR
NHTSA ODI #10244348
29,300 miles · Oct 2, 2008
StructureVisibility
WAS SITTING IDLE IN A PARKING LOT WHEN SUDDENLY I HEARD A LOUD POP. WHEN I STARTED TO ROLL MY WINDOW DOWN ON MY 2005 FORD F150 SUPER CAB, THE WINDOW DROPPED DOWN AND SOUNDED LIKE BROKEN GLASS. AFTER REMOVING THE PANEL I SAW THE CABLE MESSED UP. THEN AFTER GOOGLING TO FIND AN ANSWER, I DISCOVERED THAT THIS IS THE EXACT PROBLEM TH…
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WAS SITTING IDLE IN A PARKING LOT WHEN SUDDENLY I HEARD A LOUD POP. WHEN I STARTED TO ROLL MY WINDOW DOWN ON MY 2005 FORD F150 SUPER CAB, THE WINDOW DROPPED DOWN AND SOUNDED LIKE BROKEN GLASS. AFTER REMOVING THE PANEL I SAW THE CABLE MESSED UP. THEN AFTER GOOGLING TO FIND AN ANSWER, I DISCOVERED THAT THIS IS THE EXACT PROBLEM THAT DOZENS, PERHAPS HUNDREDS OF OTHERS ARE EXPERIENCING WITH THE POWER WINDOW REGULATOR. THE PLASTIC CLIP BREAKS AND THE CABLE GETS MESSED UP. FORD IS MAKING A KILLING OFF OWNERS BY USING CHEAP, BREAKABLE PARTS. THIS SHOULD BE RECALLED! I HAVE NO MONEY TO REPLACE THIS REGULATOR RIGHT NOW, SO I AM AT THE MERCY OF THE GODS IN HOPE THAT SOMEONE DOESN'T STEAL MY TRUCK, OR IT DOESN'T RAIN, SINCE WITH THIS PART BROKEN THE WINDOW WILL NOT STAY UP. PLEASE PUSH THIS THROUGH FOR A RECALL! *TR
NHTSA ODI #10244270
41,000 miles · Sep 30, 2008
Visibility
I HAVE A 2005 F150 FORD FX4 , AND TWO FRONT WINDOWS FELL INTO THE DOOR WITHIN THREE MONTHS. I HAVE BEEN TOLD THIS IS VERY COMMON PROBLEM FOR THIS TRUCK, THAT THE POWER WINDOW REGULATORS ARE FAULTY. WHEN THESE WINDOWS FALL INSIDE THE DOOR I AM LEFT SCARED AND VERY UNSAFE. I HAVE RESEARCHED THIS PROBLEM AND FOUND COMPLAINTS ALL OV…
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I HAVE A 2005 F150 FORD FX4 , AND TWO FRONT WINDOWS FELL INTO THE DOOR WITHIN THREE MONTHS. I HAVE BEEN TOLD THIS IS VERY COMMON PROBLEM FOR THIS TRUCK, THAT THE POWER WINDOW REGULATORS ARE FAULTY. WHEN THESE WINDOWS FALL INSIDE THE DOOR I AM LEFT SCARED AND VERY UNSAFE. I HAVE RESEARCHED THIS PROBLEM AND FOUND COMPLAINTS ALL OVER ABOUT THIS SAME PROBLEM. WHAT DOES IT TAKE FOR SOMEONE TO ADDRESS THIS PROBLEM? *TR
NHTSA ODI #10244073
31,088 miles · Sep 22, 2008
Visibility
I HAD AN INCIDENT WITH MY 2005 FORD F-150 WINDOW REGULATOR IN WHICH THE PASSENGER SIDE WINDOW JUST DROPPED DOWN INSIDE THE DOOR WHILE THE VEHICLE WAS PARKED IN MARCH OF 2008. BECAUSE IT WAS STILL UNDER WARRANTY, I TOOK IT BACK TO THE DEALER AND THEY REPLACED THE WINDOW REGULATOR. I ASKED THE SERVICE MANAGER WHAT CAUSED THE WIN…
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I HAD AN INCIDENT WITH MY 2005 FORD F-150 WINDOW REGULATOR IN WHICH THE PASSENGER SIDE WINDOW JUST DROPPED DOWN INSIDE THE DOOR WHILE THE VEHICLE WAS PARKED IN MARCH OF 2008. BECAUSE IT WAS STILL UNDER WARRANTY, I TOOK IT BACK TO THE DEALER AND THEY REPLACED THE WINDOW REGULATOR. I ASKED THE SERVICE MANAGER WHAT CAUSED THE WINDOW JUST TO DROP DOWN INSIDE THE DOOR WHILE THE VEHICLE WAS PARKED AND HE STATED THAT THEY WERE HAVING PROBLEMS WITH THE WINDOW REGULATORS IN THE '04 AND '05 F-150'S. AT THAT TIME I TOLD HIM THAT I WANTED THE OTHER WINDOW REGULATORS REPLACED. HE ASKED IF I HAD ANY PROBLEMS WITH THE OTHER ONES AND I REPLIED THAT I HAD NOT YET. HE SAID THERE WAS NOTHING THEY COULD DO. I EXPLAINED MY CONCERN BEING THAT THE TRUCK WOULD BE OUT OF WARRANTY IN 3 MONTHS AND THAT I WANTED IT TO BE FIXED WHILE STILL UNDER WARRANTY. HE TOLD ME THAT IF I DID HAVE A PROBLEM AND IT WAS DUE TO FAULTY EQUIPMENT, THEY WOULD REPLACE IT. TWENTY FOUR DAYS AFTER MY WARRANTY EXPIRED THE DRIVER SIDE WINDOW DROPPED DOWN INSIDE THE DOOR WHILE DRIVING ON THE ROAD. I WAS NOT WINDING IT UP OR DOWN, IT JUST DROPPED DOWN INSIDE THE DOOR WITH A LOUD CRASH. IT SCARED THE HECK OUT OF ME AND I ALMOST HIT THE MEDIAN GUARD RAIL. I PULLED OFF THE ROAD TO SEE WHAT HAPPENED. I COULD SEE THE TOP OF THE WINDOW THROUGH THE OPENING AND FIGURED IT WAS THE PROBLEM WITH THIS WINDOW REGULATOR. WHEN I CALLED THE DEALERSHIP, THEY STATED THAT BECAUSE THE TRUCK WAS OUT OF WARRANTY, THERE WAS NOTHING THEY COULD DO. I EXPLAINED THAT THIS IS FAULTY EQUIPMENT AND THEY TOLD ME TO TAKE IT UP WITH FORD. I HAVE WRITTEN FORD CUSTOMER SERVICE ON TEN DIFFERENT OCCASIONS AND ONLY EVER RECEIVED ONE RESPONSE. THEY ASKED WHAT I WANTED DONE AND I REPLIED THAT I JUST WANTED IT REPLACED. IT HAS BEEN ALMOST 2 MONTHS NOW AND I HAVE RECEIVED NO OTHER RESPONSES FROM FORD AND MY WINDOW IS STILL NOT FIXED. I HAVE HAD TO DRIVE IN RAIN AND 110 DEGREE TEMPERATURES WITHOUT A DRIVER'S SIDE WINDOW. WINDOW REGULATOR PROBLEM. *TR
NHTSA ODI #10243037
14,685 miles · Sep 13, 2008
Visibility
NORMAL DRIVING WITH WINDOWS UP, HEARD LOUD BANG AND WE THOUGHT SOMEONE HAD HIT OR THROWN SOMETHING AT OUR PICKUP. THEN I NOTICED DRIVER SIDE FRONT WINDOW SLOWLY SLIDING DOWN AND FINALLY FALLING INTO DOOR. PICKUP IS FOR ALL INTENTS UNSAFE. CAN NOT PUT UP WINDOW. I SEE ON OTHER WEBSITES AND THIS ONE THAT THIS IS A VERY COMMON PRO…
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NORMAL DRIVING WITH WINDOWS UP, HEARD LOUD BANG AND WE THOUGHT SOMEONE HAD HIT OR THROWN SOMETHING AT OUR PICKUP. THEN I NOTICED DRIVER SIDE FRONT WINDOW SLOWLY SLIDING DOWN AND FINALLY FALLING INTO DOOR. PICKUP IS FOR ALL INTENTS UNSAFE. CAN NOT PUT UP WINDOW. I SEE ON OTHER WEBSITES AND THIS ONE THAT THIS IS A VERY COMMON PROBLEM, AND FORD SHOULD BE MADE TO FIX THIS WITH A SAFETY RECALL. THIS HAPPENED 2 MONTHS AFTER WARRANTY WAS UP WITH LESS THAN 15,000 MILES ON VEHICLE. TOTALLY UNACCEPTABLE. *TR
NHTSA ODI #10242088
73,350 miles · Sep 3, 2008
Visibility
2005 FORD F150 LARIAT SUPERCREW 4 DOOR TRUCK-FAILED POWER WINDOW REGULATOR ON PASSENGER SIDE DOOR. POWER WINDOW SWITCH WAS BEING USED TO RAISE WINDOW AND THE GLASS FELL INTO THE DOOR PANEL MAKING A LOUD BANG. THE NOISE WAS LOUD AND I BELIEVED THE GLASS HAD BROKEN DUE TO THE NOISE. THE WINDOW WOULD NO LONGER OPERATE. THE TRUCK I…
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2005 FORD F150 LARIAT SUPERCREW 4 DOOR TRUCK-FAILED POWER WINDOW REGULATOR ON PASSENGER SIDE DOOR. POWER WINDOW SWITCH WAS BEING USED TO RAISE WINDOW AND THE GLASS FELL INTO THE DOOR PANEL MAKING A LOUD BANG. THE NOISE WAS LOUD AND I BELIEVED THE GLASS HAD BROKEN DUE TO THE NOISE. THE WINDOW WOULD NO LONGER OPERATE. THE TRUCK IS ONLY USED FOR PLEASURE DRIVING ON OCCASION. THE WINDOWS ARE SELDOM OPERATED AS AIR-CONDITIONING IS TYPICALLY USED. , THE DEALERSHIP SERVICE DEPARTMENT IS SCHEDULED TO REPAIR THIS SECOND FAILURE IN LESS THAN ONE MONTH. PROBLEM IS NOT UNIQUE TO MY TRUCK. I HAVE FILED COMPLAINT WITH FORD. *TR
NHTSA ODI #10240847
71,000 miles · Sep 3, 2008
Visibility
2005 FORD F150 LARIAT SUPERCREW 4 DOOR TRUCK-FAILED POWER WINDOW REGULATOR ON DRIVER SIDE DOOR. POWER WINDOW SWITCH WAS BEING USED TO RAISE WINDOW AND THE GLASS FELL INTO THE DOOR PANEL MAKING A LOUD BANG. THE NOISE WAS LOUD AND I BELIEVED THE GLASS HAD BROKEN DUE TO THE NOISE. THE WINDOW WOULD NO LONGER OPERATE. THE FAILURE …
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2005 FORD F150 LARIAT SUPERCREW 4 DOOR TRUCK-FAILED POWER WINDOW REGULATOR ON DRIVER SIDE DOOR. POWER WINDOW SWITCH WAS BEING USED TO RAISE WINDOW AND THE GLASS FELL INTO THE DOOR PANEL MAKING A LOUD BANG. THE NOISE WAS LOUD AND I BELIEVED THE GLASS HAD BROKEN DUE TO THE NOISE. THE WINDOW WOULD NO LONGER OPERATE. THE FAILURE WAS A TOTAL SHOCK. THE TRUCK IS ONLY USED FOR PLEASURE DRIVING ON OCCASION. THE WINDOWS ARE SELDOM OPERATED AS AIR-CONDITIONING IS TYPICALLY USED. , THE DEALERSHIP SERVICE DEPARTMENT REPAIRED REGULATOR AT A TOTAL COST OF $259.50 AND THE PROBLEM IS NOT UNIQUE TO MY TRUCK AND INDICATED I SHOULD PASS MY COMPLAINT ON TO FORD. *TR
NHTSA ODI #10240845
24,172 miles · Aug 25, 2008
Visibility
IN OCTOBER OF 2007 DURING NORMAL OPERATION OF THE VEHICLE THE RIGHT HAND PASSENGER WINDOW SUDDENLY FELL INTO THE DOOR RENDERING THE WINDOW INOPERABLE. IN DECEMBER OF 2007 THE 2ND FAILURE OF A WINDOW REGULATOR ASSEMBLY OCCURRED ON THE RIGHT HAND REAR PASSENGER WINDOW WHILE AGAIN OPERATING THE VEHICLE UNDER NORMAL DRIVING CONDIT…
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IN OCTOBER OF 2007 DURING NORMAL OPERATION OF THE VEHICLE THE RIGHT HAND PASSENGER WINDOW SUDDENLY FELL INTO THE DOOR RENDERING THE WINDOW INOPERABLE. IN DECEMBER OF 2007 THE 2ND FAILURE OF A WINDOW REGULATOR ASSEMBLY OCCURRED ON THE RIGHT HAND REAR PASSENGER WINDOW WHILE AGAIN OPERATING THE VEHICLE UNDER NORMAL DRIVING CONDITIONS. THE WINDOW, AGAIN, FELL INTO THE DOOR AND COULD NOT BE RETRIEVED. THE 3RD FAILURE OF THE WINDOW REGULATOR ASSEMBLY OCCURRED DURING AUGUST OF 2008. THIS TIME THE DRIVER'S WINDOW FELL INTO THE DOOR DURING NORMAL OPERATION OF THE VEHICLE AND WAS UNABLE TO BE RETRIEVED. ACCORDING TO THE DEALER, THE WINDOW REGULATOR ASSEMBLY WAS AT FAULT IN EACH INSTANCE. THE FIRST TWO INCIDENTS WERE COVERED UNDER THE FACTORY WARRANTY, THE THIRD INCIDENT OCCURRED (37,618 MILES) AFTER EXPIRATION OF THE FACTORY WARRANTY. EACH TIME THE VEHICLE WAS BROUGHT IN FOR REPAIRS, THE SERVICE DEPARTMENT INDICATED THAT THE FAILURE OF THE WINDOW REGULATOR HAS BEEN A FREQUENT PROBLEM SEEN WITH THIS MAKE AND MODEL. WHEN THIS FAILURE OCCURS, THE VEHICLE IS BASICALLY RENDERED INOPERABLE DUE TO INCLEMENT WEATHER, SECURITY, ETC. I AM ANTICIPATING THE FAILURE OF THE REMAINING WINDOW (LEFT HAND PASSENGER) TO OCCUR AT ANY UNKNOWN MOMENT. ALL ASSEMBLIES WERE REPLACED WITH AN IMPROVED VERSION OF THE PART, ACCORDING TO THE DEALER. NO ASSEMBLIES WERE ALLOWED TO BE REPLACED PRIOR TO ACTUAL FAILURE OF THE REGULATOR UNLESS I WAS WILLING TO PAY FULL PRICE FOR REPLACEMENT CHARGES. I BELIEVE FORD SHOULD RECALL ALL VEHICLES THAT HAVE BEEN MANUFACTURED WITH THIS DEFECTIVE REGULATOR AND REPLACE IT AT NO CHARGE WITH THE IMPROVED PART. *TR
NHTSA ODI #10239724
39,871 miles · Aug 22, 2008
Visibility
WINDOW REGULATOR-EARLY FAILURE-FORD WOULD DO NOTHING. AFTER READING MANY BLOGS-IT'S A REAL BIG PROBLEM. FORD IS CHARGING 350-OR SO TO REPAIR OVER AND OVER AGAIN,MANY PEOPLE HAVE HAD 4-6 REPAIRS ON THE SAME VEHICLE WITH 40,00 MILES ON THEM, FORD REFUSES TO STAND BEHIND. *TR
NHTSA ODI #10239392
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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