NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
77 reportsClear category filter93,000 miles · Jul 8, 2011
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD F-150. THE CONTACT STATED THAT THE SPARK PLUGS FRACTURED WHEN A MECHANIC ATTEMPTED TO REMOVE AND REPLACE THEM. AN AUTHORIZED DEALER WAS NOTIFIED AND INFORMED THE CONTACT THAT HE WOULD HAVE TO PAY ADDITIONAL COSTS TO HAVE THE VEHICLE REPAIRED DUE TO THE SPARK PLUGS BREAKING. THE MANUFACTURER WAS M…
Read full complaint
TL* THE CONTACT OWNS A 2006 FORD F-150. THE CONTACT STATED THAT THE SPARK PLUGS FRACTURED WHEN A MECHANIC ATTEMPTED TO REMOVE AND REPLACE THEM. AN AUTHORIZED DEALER WAS NOTIFIED AND INFORMED THE CONTACT THAT HE WOULD HAVE TO PAY ADDITIONAL COSTS TO HAVE THE VEHICLE REPAIRED DUE TO THE SPARK PLUGS BREAKING. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE, BUT OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 93,000. ..UPDATED 09/15/11 *BF UPDATED 09/26/11
NHTSA ODI #10410988
91,000 miles · Jul 7, 2011
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD F-150. THE CONTACT STATED WHILE HAVING A TUNE-UP PERFORMED AT THE DEALER, ONE OF THE SPARK PLUGS BECAME LODGED IN THE CYLINDER HEAD. THE DEALER ADVISED THAT THE CYLINDER HEAD WOULD BE SENT OUT TO HAVE THE SPARK PLUG MACHINED OUT. THE VEHICLE WAS LEFT WITH THE DEALER WHERE THE CONTACT WAS AWAIT…
Read full complaint
TL* THE CONTACT OWNS A 2006 FORD F-150. THE CONTACT STATED WHILE HAVING A TUNE-UP PERFORMED AT THE DEALER, ONE OF THE SPARK PLUGS BECAME LODGED IN THE CYLINDER HEAD. THE DEALER ADVISED THAT THE CYLINDER HEAD WOULD BE SENT OUT TO HAVE THE SPARK PLUG MACHINED OUT. THE VEHICLE WAS LEFT WITH THE DEALER WHERE THE CONTACT WAS AWAITING REPAIRS. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 91,000.
NHTSA ODI #10410844
Mileage unknown · Jul 6, 2011
Engine And Engine Cooling
SPARK PLUGS ARE SNAPPING OFF BECAUSE OF HEAT IN THE ALUMINUM HEAD.
NHTSA ODI #10411312
58,000 miles · Mar 31, 2011
Engine And Engine Cooling
OVER A PERIOD OF 3 MONTHS, I WAS EXPERIENCING A ROUGH IDLE, LOSS OF POWER WHEN ACCELERATING ON FLAT SURFACES AS WELL AS CLIMBING HILLS. I TOOK IT TO A MECHANIC WHO SAID IT WAS 2 BAD COIL PACKS. THEY FIXED IT AND 2 WEEKS LATER SAME INCIDENT OCCURRED AND THEY REPLACED IT. DURING THIS TIME, I COULD ALWAYS SMELL THE ODOR OF GASOL…
Read full complaint
OVER A PERIOD OF 3 MONTHS, I WAS EXPERIENCING A ROUGH IDLE, LOSS OF POWER WHEN ACCELERATING ON FLAT SURFACES AS WELL AS CLIMBING HILLS. I TOOK IT TO A MECHANIC WHO SAID IT WAS 2 BAD COIL PACKS. THEY FIXED IT AND 2 WEEKS LATER SAME INCIDENT OCCURRED AND THEY REPLACED IT. DURING THIS TIME, I COULD ALWAYS SMELL THE ODOR OF GASOLINE. AFTER THE LARGE EXPENSE I WAS ASSUMING, I CALLED THE FORD DEALER WHERE I BOUGHT MY 2006 F-150 LARIAT. THE SERVICE MANAGER OF 22 YEARS APPARENTLY NEVER HEARD OF THE COIL PACK GOING BAD ALONG WITH THE SPARK PLUGS BREAKING DUE TO THIS. AFTER ARGUING FOR A WEEK WITH THEM, THEY FINALLY AGREED TO PAY FOR THE REPLACEMENT OF ALL 8 COIL PACKS. DURING THIS SEQUENCE, A COIL PACK WAS GOING BAD WEEKLY AND I HAD TO CONTINUALLY HAVE IT IN THE SHOP. FORD NEEDS TO ADDRESS THIS ISSUE AND AS I CAN SEE, THERE ARE A LOT OF THESE ISSUES OUT THERE AND FORD CONTINUES TO DISREGARD A RECALL. THERE IS A DEFINITE SAFETY ISSUE AS GASOLINE WILL EMIT FROM THE CRACK IN THE COIL PACK AND COULD CAUSE A FIRE UNDER THE RIGHT CONDITION. THIS IS UNACCEPTABLE. *TR
NHTSA ODI #10393867
59,014 miles · Mar 26, 2011
Engine And Engine Cooling
I HAVE A 2006 FORD F-150 AND UPON REMOVING THE SPARK PLUGS AT 60,00 MILES, WHICH AREN'T DUE TO BE DONE UNTIL 100,00 MILES, THE SPARK PLUGS BROKE OFF IN THE HEAD. I HAVE BEEN A CERTIFIED MECHANIC IN THE PAST SO I KNOW HOW TO REMOVE SPARK PLUGS. FORD SHOULD BE ISSUING A RECALL ON THIS PROBLEM. THE PROBLEM IS DISCUSSED A LOT ON INT…
Read full complaint
I HAVE A 2006 FORD F-150 AND UPON REMOVING THE SPARK PLUGS AT 60,00 MILES, WHICH AREN'T DUE TO BE DONE UNTIL 100,00 MILES, THE SPARK PLUGS BROKE OFF IN THE HEAD. I HAVE BEEN A CERTIFIED MECHANIC IN THE PAST SO I KNOW HOW TO REMOVE SPARK PLUGS. FORD SHOULD BE ISSUING A RECALL ON THIS PROBLEM. THE PROBLEM IS DISCUSSED A LOT ON INTERNET SITES AND WELL DOCUMENTED TO BE A PROBLEM. *TR
NHTSA ODI #10392941
39,000 miles · Mar 14, 2011
Engine And Engine Cooling
2006 FORD F150 WITH 39,000 MILES ACTING FUNNY. TOOK IT TO GARAGE AND WAS CATALYTIC CONVERTER. STATED THEY WOULDN'T COVER IT BECAUSE I DROVE TO GARAGE. *TR
NHTSA ODI #10390089
68,500 miles · Mar 3, 2011
Engine And Engine Cooling
WHILE DRIVING DOWN THE ROAD THE THREADS IN THE RIGHT REAR CYLINDER HEAD OF MY 2006 FORD F150 5.4L TRITON V8 FAILED CAUSING SPARK PLUG EJECTION AND COIL DAMAGE. IT IS CURRENTLY BEING TOWED TO THE REPAIR SHOP AND, ACCORDING TO THE DEALERSHIP, THE WHOLE CYLINDER HEAD WILL HAVE TO BE REPLACED. IT IS UNKNOWN, AT THIS TIME, WHAT THE…
Read full complaint
WHILE DRIVING DOWN THE ROAD THE THREADS IN THE RIGHT REAR CYLINDER HEAD OF MY 2006 FORD F150 5.4L TRITON V8 FAILED CAUSING SPARK PLUG EJECTION AND COIL DAMAGE. IT IS CURRENTLY BEING TOWED TO THE REPAIR SHOP AND, ACCORDING TO THE DEALERSHIP, THE WHOLE CYLINDER HEAD WILL HAVE TO BE REPLACED. IT IS UNKNOWN, AT THIS TIME, WHAT THE DEALERSHIP WILL COVER AND WHAT MY EXPENSES WILL BE. *TR
NHTSA ODI #10386289
101,000 miles · Jan 28, 2011
Engine And Engine Cooling
WHAT A SHOCKER, I GO TO THE FORD DEALER FOR THE 100K TUNE UP FOR MY F-150 KING RANCH ORIGINAL COST $450. ALMOST TWO WEEKS LATER, TRUCK STILL ISN'T FINISHED COST IS AT $3, 500 STILL CAN GO. THEY DON'T KNOW YET UNTIL THEIR FINISHED PUTTING EVERYTHING BACK TOGETHER. 7 OF THE 8 PLUGS BROKE, TWO WOULD NOT COME OUT. FINALLY, THEY GOT …
Read full complaint
WHAT A SHOCKER, I GO TO THE FORD DEALER FOR THE 100K TUNE UP FOR MY F-150 KING RANCH ORIGINAL COST $450. ALMOST TWO WEEKS LATER, TRUCK STILL ISN'T FINISHED COST IS AT $3, 500 STILL CAN GO. THEY DON'T KNOW YET UNTIL THEIR FINISHED PUTTING EVERYTHING BACK TOGETHER. 7 OF THE 8 PLUGS BROKE, TWO WOULD NOT COME OUT. FINALLY, THEY GOT ONE OF THE TWO OUT. THE ONE IS SEIZED UP PRETTY GOOD. THE HAD TO TAKE THE HEAD OFF AND WAITING ON THE OUTCOME. I'M UP IN ARMS ON WHAT TO DO. I DON'T HAVE AN EXTRA $3, 000 LAYING AROUND TO PAY FOR THIS PLUS THE PRICE CAN STILL GO UP. HOW CAN THEY NOT TELL YOU THIS UP FRONT AND KEEP PADDING THE PRICE AND NOT KNOWING WHAT ITS GOING TO COST UNTIL YOU PICK YOUR VEHICLE UP. PLEASE CONTACT ME, I WOULD LIKE TO FILE A SUIT AGAINST FORD BUT NEED ASSISTANCE. I TALKED TO SOMEONE FROM FORDS FRONT OFFICE ABOUT THIS ISSUE. THEY ARE WELL AWARE OF THIS MATTER. ALL THEY SAY IS THAT ITS NOT UNDER WARRANTY AND MY VEHICLE IS OVER THE 100K MAX. COME TO FIND OUT, NO MATTER WHAT WARRANTY YOU HAVE, THIS PARTICULAR ISSUE HAS NO WARRANTY TO BEGIN WITH. ALL THEY WOULD DO IS OFFER ME THE "X PLAN" ON A NEW VEHICLE. NOW, WHY WOULD I WANT TO BUY A NEW VEHICLE. I'VE BEEN RAISED ON FORD VEHICLES MY ENTIRE LIFE. I MUST SAY THIS WILL BE MY LAST FORD TRUCK FOR SURE. A FRIEND OF MINE HAS A TOYOTA TRUCK AND HAS OVER 200K MILES. NEVER HAS HAD A ISSUE WITH ANYTHING. PLEASE ADVISE ON WHAT TO DO, THIS NEEDS TO STOP AND FORD NEEDS TO DO SOMETHING ABOUT THIS. BUT I HAVE A FEELING THEY WON'T OR THEY WOULD OF DONE IT ALREADY. *TR
NHTSA ODI #10379379
157,000 miles · Jan 26, 2011
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2006 FORD F150. WHILE DRIVING APPROXIMATELY 55 MPH THE ENGINE LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THAT THE OXYGEN SENSORS NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. AFTER THE VEHICLE WAS REPAIRED, THE CHECK ENGINE LIGHT ILLUMINATED AGAIN. THE VEHICLE WAS TAKE…
Read full complaint
TL*THE CONTACT OWNS A 2006 FORD F150. WHILE DRIVING APPROXIMATELY 55 MPH THE ENGINE LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THAT THE OXYGEN SENSORS NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. AFTER THE VEHICLE WAS REPAIRED, THE CHECK ENGINE LIGHT ILLUMINATED AGAIN. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THAT THE FAILURE WAS CAUSED BY THE OXYGEN SENSORS, WHICH NEEDED TO BE REPLACED A SECOND TIME. THE VEHICLE WAS REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 157,000.
NHTSA ODI #10378742
52,000 miles · Jan 21, 2011
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2006 FORD F150. THE CONTACT STATED THAT WHILE DRIVING 70 MPH THE VEHICLE STALLED. SHE WAS ABLE TO RESTART IT AND TWO ATTEMPTS. THE VEHICLE WAS TAKEN TO THE DEALER AND THEY WERE UNABLE TO DUPLICATE THE FAILURE. THE MANUFACTURER WAS NOT CONTACTED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 52,000 …
Read full complaint
TL*THE CONTACT OWNS A 2006 FORD F150. THE CONTACT STATED THAT WHILE DRIVING 70 MPH THE VEHICLE STALLED. SHE WAS ABLE TO RESTART IT AND TWO ATTEMPTS. THE VEHICLE WAS TAKEN TO THE DEALER AND THEY WERE UNABLE TO DUPLICATE THE FAILURE. THE MANUFACTURER WAS NOT CONTACTED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 52,000 AND CURRENT MILEAGE WAS 95,429. UPDATED 03/16/11 *BF UPDATED 04/25/11
NHTSA ODI #10378214
Official recalls
4Feb 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.
Nov 9, 2005
ON CERTAIN TRUCKS, PASSENGER CARS AND SPORT UTILITY VEHICLES, THE WINDSHIELD WIPER MOTOR MAY HAVE BEEN PRODUCED WITHOUT GREASE BEING APPLIED TO THE OUTPUT SHAFT GEAR.
Consequence & remedy
Consequence: AFTER A PERIOD OF CONTINUOUS USE ON THE HIGH SPEED SETTING, LACK OF GREASE ON THE OUTPUT SHAFT GEAR MAY CAUSE THE GEAR TO DISTORT OR FRACTURE DURING OPERATION RESULTING IN A LOSS OF WIPER FUNCTION. INOPERATIVE WIPERS UNDER INCLEMENT WEATHER CONDITIONS COULD CAUSE A CRASH DUE TO IMPAIRED VISIBILITY.
Remedy: DEALERS WILL INSPECT THE WIPER MOTOR FOR THE PRESENCE OF GREASE AND GREASE THE WIPER MOTOR GEARS IF NECESSARY. THE RECALL BEGAN ON NOVEMBER 22, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673 OR LINCOLN/MERCURY AT 1-800-521-4140.
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
2EA10001 · 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.
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.
Illustration