NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
585 reports101,000 miles · Jul 3, 2010
Engine And Engine CoolingFire
CERTAIN FORD MAKES, MODELS AND MOTORS ARE KNOWN FOR EJECTING SPARK PLUGS WHICH DESTROYS THE IGNITION COIL AND IS A FIRE HAZARD. THEY ARE ALSO KNOWN FOR THE SPARK PLUG BREAKING WHILE TRYING TO REMOVE THEM WHICH IS A FINANCIAL BURDEN ON THE CUSTOMER AS WELL AS A RISK THE MOTOR WHILE TRYING TO RESOLVE THE ISSUE. THERE ARE TSB'…
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CERTAIN FORD MAKES, MODELS AND MOTORS ARE KNOWN FOR EJECTING SPARK PLUGS WHICH DESTROYS THE IGNITION COIL AND IS A FIRE HAZARD. THEY ARE ALSO KNOWN FOR THE SPARK PLUG BREAKING WHILE TRYING TO REMOVE THEM WHICH IS A FINANCIAL BURDEN ON THE CUSTOMER AS WELL AS A RISK THE MOTOR WHILE TRYING TO RESOLVE THE ISSUE. THERE ARE TSB'S ON THIS. I NEVER RECEIVED A LETTER FROM FORD TO GIVE ME THE HEADS UP ON THIS AND LEARNED AFTER THE FACT OF ATTEMPTING TO GET A TUNE UP.........NOW STUCK WITH TWO BROKEN SPARK PLUGS STUCK IN THE MOTOR AND HAVE NO IDEA HOW MUCH THIS IS GOING TO COST ME IN THE END. I AM WITHOUT MY TRUCK WHILE WE WAIT FOR A TOOL THAT WILL HOPEFULLY REMOVE THE BROKE OFF SLEEVES. IF IT DOESN'T WORK I WILL HAVE TO HAVE THE HEAD PULLED AND WHO KNOWS IF IT WILL NEED TO BE REPLACED. EVEN IF IT REMOVES IT, I WON'T KNOW UNTIL SOMETHING HAPPENS IF IT ENDS UP CAUSING DAMAGE TO MY ENGINE. I HAVE HAD BAD EXPERIENCES WITH FORD - TWO VEHICLES NOW. THEY DO NOT BACK UP THEIR KNOWN DEFECTS. MY FIRST PROBLEM WITH THIS F150 (TRITON) WAS WHEN THE COMPUTER SHUT DOWN LEAVING ME STRANDED IN ANOTHER STATE BECAUSE THE WIRES WERE RUBBING AGAINST THE STEERING COLUMN BRACKET. I PUT A LOT OF MILES ON SO IT WAS IN EXTENDED WARRANTY AND THE DEDUCTIBLE PAID THE REPAIR. FORD HAD NO INTENTION OF TAKING RESPONSIBILITY FOR IT EVEN THOUGH IT WOULD HAVE NORMALLY BEEN UNDER ORIGINAL WARRANTY EXCEPT FOR THE MILES I PUT ON A VEHICLE. THERE WAS NO ROADSIDE SERVICE IN THE AREA I WAS IN AND I GOT STUCK WITH ALL KINDS OF EXPENSES FROM IT. SEEMS OUR AMERICAN MANUFACTURERS SHOULD BE HELD ACCOUNTABLE FOR THEIR MULTIPLE KNOWN DEFECTS AS WELL AS OUR FOREIGN MANUFACTURERS. I AM ONLY ANSWERING YES TO THE FIRE BECAUSE I AM AWARE THAT OTHERS HAVE HAD THIS AS A PROBLEM. I HAVE NOT HAD A FIRE YET, BUT WE ARE NOT DONE TRYING TO RESOLVE THE PROBLEM. *TR
NHTSA ODI #10341327
30,000 miles · Jun 30, 2010
TiresCrash
TL* THE CONTACT OWNS A 2006 FORD F150. WITH CONTINENTAL TIRES, SIZE P25565R17, LINE RADIAL CONTITRAC, AND DOT A3K34SMW. THE CONTACT STATED WHILE DRIVING AT APPROXIMATELY 65MPH THE RIGHT LEFT REAR TIRE BLEW, AND THE TIRE TUBE FAILED. THE VEHICLE COLLIDED INTO A CEMENT GUARD DAMAGING THE VEHICLE REAR RIGHT END. THE CONTACT WAS NOT…
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TL* THE CONTACT OWNS A 2006 FORD F150. WITH CONTINENTAL TIRES, SIZE P25565R17, LINE RADIAL CONTITRAC, AND DOT A3K34SMW. THE CONTACT STATED WHILE DRIVING AT APPROXIMATELY 65MPH THE RIGHT LEFT REAR TIRE BLEW, AND THE TIRE TUBE FAILED. THE VEHICLE COLLIDED INTO A CEMENT GUARD DAMAGING THE VEHICLE REAR RIGHT END. THE CONTACT WAS NOT INJURED. THE VEHICLE WAS REPAIRED. THE INSURANCE COMPANY WAS INVESTIGATING THE TIRE FAILURE. THE FAILURE AND THE CURRENT MILEAGE WAS 30,000.
NHTSA ODI #10340822
68,000 miles · Jun 26, 2010
Engine And Engine Cooling
DURING ROUTINE MAINTENANCE SPARK PLUG CHANGE SIX OF THE OEM INSTALLED SPARKPLUGS BROKE OFF IN THE CYLINDER HEAD OF THE ENGINE. FORD DEALER ADMITS TO HAVING PROBLEMS WITH THIS DESIGN ENGINE AND STATES THIS OCCURS OFTEN. FORD DEALER STATED THAT FORD ADMITS AN ISSUE WITH THIS DESIGN SPARKPLUG AND HAS A TSB DETAILING THE PROCEDURE F…
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DURING ROUTINE MAINTENANCE SPARK PLUG CHANGE SIX OF THE OEM INSTALLED SPARKPLUGS BROKE OFF IN THE CYLINDER HEAD OF THE ENGINE. FORD DEALER ADMITS TO HAVING PROBLEMS WITH THIS DESIGN ENGINE AND STATES THIS OCCURS OFTEN. FORD DEALER STATED THAT FORD ADMITS AN ISSUE WITH THIS DESIGN SPARKPLUG AND HAS A TSB DETAILING THE PROCEDURE FOR BROKEN PLUG REMOVAL BUT HAS ISSUED NO FORMAL RECALL. DEALER ADVISED THAT FORD ALSO HAS A "SPECIAL TOOL" DESIGNED FOR THIS 5.4 3 VALVE SERIES MOTOR THAT IS ENGINE SPECIFIC TO REMOVE THE BROKEN PIECE OF THE SPARKPLUG BECAUSE THIS HAPPENS SO OFTEN. ALL BUT ONE OF THE BROKEN PLUGS WAS ABLE TO BE REMOVED USING A SPECIALTY TOOL PURCHASED AT AN AUTOMOTIVE PARTS STORE. FORD DEALER WAS UNABLE TO GET THE LAST BROKEN PLUG EXTRACTED FROM CYLINDER HEAD WITH THEIR "SPECIAL TOOL". ENGINE NEEDED TO BE DISSEMBLED AND CYLINDER HEAD REMOVED SO THAT THE BROKEN PIECE COULD BE EXTRACTED. THIS REPAIR COST $1708.00 TO COMPLETE. ALONG WITH $85.00 DIAGNOSTIC FEE TO TELL ME THEY COULD NOT GET THE BROKEN PIECE OUT. THE REPAIR TOOK TWO WEEKS TO HAVE COMPLETED. I FEEL THAT FORD SHOULD ISSUE A RECALL FOR THIS ISSUE AND THEY SHOULD REIMBURSE ME FOR MY COSTS DUE TO THEIR FAULTY DESIGN FLAW. *TR
NHTSA ODI #10340208
46,000 miles · Jun 25, 2010
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD F-150. WHILE ATTEMPTING TO REPLACE THE SPARK PLUGS IN THE ENGINE, THE CONTACT NOTICED THAT FOUR OF THE SPARK PLUGS WERE WEDGED INTO THE HEAD GASKET AND COULD NOT BE REMOVED. THE VEHICLE WAS NOT DIAGNOSED AND THERE WERE NO PRIOR WARNINGS. THE CURRENT AND FAILURE MILEAGES WAS 46,000. UPDATED 11/0…
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TL* THE CONTACT OWNS A 2006 FORD F-150. WHILE ATTEMPTING TO REPLACE THE SPARK PLUGS IN THE ENGINE, THE CONTACT NOTICED THAT FOUR OF THE SPARK PLUGS WERE WEDGED INTO THE HEAD GASKET AND COULD NOT BE REMOVED. THE VEHICLE WAS NOT DIAGNOSED AND THERE WERE NO PRIOR WARNINGS. THE CURRENT AND FAILURE MILEAGES WAS 46,000. UPDATED 11/08/10 * BF UPDATED 11/10/10*JB
NHTSA ODI #10339987
30,037 miles · Jun 14, 2010
Air BagsInjury
INADVERTENT AIRBAG DEPLOYMENT WHILE STOPPED, NO COLLISION OR INCIDENT ON MY 2006 F-150 TRUCK. *TR
NHTSA ODI #10336319
54,000 miles · Jun 11, 2010
Power TrainSuspension
TL* THE CONTACT OWNS A 2006 FORD F-150. WHILE TRAVELING IN 4-WHEEL DRIVE AT 30-50 MPH THERE WAS AN UNUSUAL CLUNKING NOISE COMING FROM UNDER THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED AND THERE WERE NO PRIOR WARNINGS. THE CURRENT AND FAILURE MILEAGES WERE 54,000. UPDATED 8/2/10 *CN THE CONSUMER STATED THE VEHICLE PULLED SEVERLY …
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TL* THE CONTACT OWNS A 2006 FORD F-150. WHILE TRAVELING IN 4-WHEEL DRIVE AT 30-50 MPH THERE WAS AN UNUSUAL CLUNKING NOISE COMING FROM UNDER THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED AND THERE WERE NO PRIOR WARNINGS. THE CURRENT AND FAILURE MILEAGES WERE 54,000. UPDATED 8/2/10 *CN THE CONSUMER STATED THE VEHICLE PULLED SEVERLY TO THE LEFT AND RIGHT. UPDATED 08/09/10*JB
NHTSA ODI #10335874
47,000 miles · May 25, 2010
Power Train
GLAZE ON REAR END CLUTCH CAUSING TRUCK TO DRIVE INCORRECTLY...CONTACTED COMPANY AND THEY HAD A POSSIBLE RESOLUTION THAT DIDN'T WORK....WORRIED THAT THE REAR END WILL LOCK UP WHEN DRIVING CAUSING A WRECK!! *TR
NHTSA ODI #10332241
44,058 miles · May 22, 2010
Service Brakes, Hydraulic
BRAKES FAILED ON PICKUP WHILE DRIVING. REPAIR SHOP DETERMINED MASTER CYLINDER WAS FAULTY. *TR
NHTSA ODI #10331768
45,300 miles · Apr 26, 2010
Engine And Engine Cooling
MY 2006 FORD F-150 HAD A SPARK PLUG BROKE OFF AND NOW THE ONLY WAY TO FIX THIS IS TO REMOVE THE HEAD APPROX 3000.00 TO CORRECT. FORD SAYS THEY ARE AWARE OF THE PROBLEM BUT THEY REFUSE TO DO ANYTHING ABOUT IT. THE VEHICLE ONLY HAS 45,000 MILES AND THE TRUCK IS NOW NON DRIVABLE. WHY AREN'T THEY BEING HELD ACCOUNTABLE FOR SOMETHING…
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MY 2006 FORD F-150 HAD A SPARK PLUG BROKE OFF AND NOW THE ONLY WAY TO FIX THIS IS TO REMOVE THE HEAD APPROX 3000.00 TO CORRECT. FORD SAYS THEY ARE AWARE OF THE PROBLEM BUT THEY REFUSE TO DO ANYTHING ABOUT IT. THE VEHICLE ONLY HAS 45,000 MILES AND THE TRUCK IS NOW NON DRIVABLE. WHY AREN'T THEY BEING HELD ACCOUNTABLE FOR SOMETHING WHEN THEY KNOW IT IS A PROBLEM WITH THIS STYLE VEHICLE. *TR
NHTSA ODI #10327545
55,000 miles · Apr 11, 2010
Visibility
BOTH DRIVER AND PASSENGER SIDE REVIEW MIRRORS ARE NOT STATIONARY. THEY ARE LOOSE AND PIVOT WHEN CLOSING A DOOR. DRIVER'S SIDE ALSO VIBRATES WHILE DRIVING MAKING IT DIFFICULT TO SEE OUT OF. THIS HAS BEEN REPORTED TO FORD DEALERSHIP WHERE THEY STATED "IT IS JUST A POOR DESIGN WITH A 'BREAK-AWAY FEATURE' THAT APPEARS TO HAVE BEE…
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BOTH DRIVER AND PASSENGER SIDE REVIEW MIRRORS ARE NOT STATIONARY. THEY ARE LOOSE AND PIVOT WHEN CLOSING A DOOR. DRIVER'S SIDE ALSO VIBRATES WHILE DRIVING MAKING IT DIFFICULT TO SEE OUT OF. THIS HAS BEEN REPORTED TO FORD DEALERSHIP WHERE THEY STATED "IT IS JUST A POOR DESIGN WITH A 'BREAK-AWAY FEATURE' THAT APPEARS TO HAVE BEEN 'OVERWORN' BY PREVIOUS OWNER, POSSIBLY DUE TO USE OF THINNER GASKETS IN MIRROR ASSEMBLY". WHEN ASKED ABOUT LONGEVITY AND ANTICIPATED LIFESPAN OF MIRRORS PRIOR TO FAILURE DUE TO WEAR, THEY STATED IT WAS NOT A WEAR-PART, HOWEVER, THEY ALSO DENIED IT BEING DEFECTIVE AND QUOTED ME $1200 FOR PARTS AND LABOR TO REPLACE. WARRANTY WOULD NOT COVER SINCE THE DEFECT WAS MECHANICAL AND NOT ELECTRICAL. THE DEALERSHIP ALSO STATED THE MIRRORS THAT WOULD BE INSTALLED WOULD BE EXACTLY THE SAME AND THERE WAS NO GUARANTEE THIS WOULD NOT HAPPEN AGAIN. I WAS UNABLE TO GET A CORRECTIVE ACTION OR REASONING WHY MY PARTICULAR MIRRORS ARE NOT SATISFACTORY, BUT I HAVE HEARD THIS IS NOT A NEW PROBLEM FOR THIS VEHICLE. LOOKING AT BOTH OF MY MIRRORS, IT IS OBVIOUS THEY SHOULD HAVE SOME SORT OF LOCKING MECHANISM (SNAP-IN-PLACE DESIGN) LIKE MOST VEHICLES. THERE HAS NOT BEEN ANY ACCIDENT INVOLVED WITH THIS SAFETY ISSUE. THIS IS TO DOCUMENT A KNOWN PROBLEM FOR AWARENESS PURPOSES AND TO POTENTIALLY RECEIVE A CORRECTIVE ACTION FOR MY FAULTY MIRRORS. THIS ISSUE HAS BEEN ON-GOING, AND AN ARBITRARY INCIDENT DATE HAS BEEN ASSIGNED. *TR
NHTSA ODI #10324971
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.
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