IllustrationVEHICLE LOST ACCELERATION WHEN TRYING TO PASS. ENGINE LIGHT CAME ON AND ENGINE STARTED TO SHAKE. I HAD TO TURN VEHICLE OFF AND RESTART. THIS NOW OCCURS ANYTIME I ATTEMPT TO ACCELERATE... *TR
2011 Ford F-150
Owner reports · Recalls · Investigations
More warning signs than most F-150 years
Owner complaints for the 2011 Ford F-150 are substantially higher than the model-year median of 676.
About this comparison →How this year compares
Owner complaints by model year
Compare all F-150 years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
3000–25K
29225–50K
35350–75K
28875–100K
381100–150K
205150K+
1,819 reports with mileage · 369 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Power Train. Review the 824 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Engine. Review the 482 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Steering. Review the 419 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
45 crash reports18 fire reports25 injury reports
Fuel/propulsion System complaints
75 reportsI WAS DRIVING AT HIGHWAY SPEED AND TRIED TO ACCELERATE QUICKLY TO PASS SOMEONE AND THE TRUCK HAD MAJOR HESITATION AND SHUDDERING. CONTINUES TO DO THIS ANYTIME YOU TRY TO RAPIDLY ACCELERATE. *TR
TL* THE CONTACT OWNS A 2011 FORD F-150. THE CONTACT STATED THAT FUEL FUMES EMITTED INTO THE VEHICLE. AFTER INSPECTING THE VEHICLE, THE CONTACT FOUND A LEAK AND NOTICED FUEL SPEWING OUT OF THE CATALYTIC CONVERTER. THE DEALER WAS CONTACTED AND MADE THE CONTACT AWARE THAT THE VEHICLE WAS NO LONGER UNDER WARRANTY. THE MANUFACTURER W…
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TL* THE CONTACT OWNS A 2011 FORD F-150. THE CONTACT STATED THAT FUEL FUMES EMITTED INTO THE VEHICLE. AFTER INSPECTING THE VEHICLE, THE CONTACT FOUND A LEAK AND NOTICED FUEL SPEWING OUT OF THE CATALYTIC CONVERTER. THE DEALER WAS CONTACTED AND MADE THE CONTACT AWARE THAT THE VEHICLE WAS NO LONGER UNDER WARRANTY. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 23,000.
ATTEMPTING TO ACCELERATE TO PASS A SLOWER VEHICLE ON THE HIGHWAY. TRUCK BEGAN SHUDDERING AND IMMEDIATELY DECELERATED TO 50MPH. WOULD NOT RESPOND FOR APPROXIMATELY 75 YARDS, THEN WOULD NOT ACCELERATE OVER 60MPH. TWO VEHICLES (ONE OF THOSE VEHICLES WAS A TRACTOR-TRAILER) FOLLOWING HAD TO TAKE EVASIVE ACTION TO AVOID REAR-END COLLI…
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ATTEMPTING TO ACCELERATE TO PASS A SLOWER VEHICLE ON THE HIGHWAY. TRUCK BEGAN SHUDDERING AND IMMEDIATELY DECELERATED TO 50MPH. WOULD NOT RESPOND FOR APPROXIMATELY 75 YARDS, THEN WOULD NOT ACCELERATE OVER 60MPH. TWO VEHICLES (ONE OF THOSE VEHICLES WAS A TRACTOR-TRAILER) FOLLOWING HAD TO TAKE EVASIVE ACTION TO AVOID REAR-END COLLISION. EXITED THE HIGHWAY, PUT THE VEHICLE IN PARK. NO WARNING LIGHTS WERE ENGAGED. WEATHER WAS SUNNY AND WARM. NOW VEHICLE IS SHIFTING VERY HARD WITH A DELAYED ENGAGEMENT BETWEEN 55-60MPH. *TR
SAME AS PREVIOUSLY REPORTED BY MANY OTHERS: MISFIRE UPON ACCELERATION UP A HILL; REPORTED TO DEALER WHO FOUND NO ERROR CODES. HAPPENED AGAIN SOON AFTER, THIS TIME ACTIVATING ENGINE WARNING LIGHT. DEALER REPLACED CYLINDER COIL; NEXT DAY, SAME TYPE OF MISFIRE OCCURRENCE. VERY UNSAFE SITUATION, COSTING ME LOTS OF TIME AND MONE…
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SAME AS PREVIOUSLY REPORTED BY MANY OTHERS: MISFIRE UPON ACCELERATION UP A HILL; REPORTED TO DEALER WHO FOUND NO ERROR CODES. HAPPENED AGAIN SOON AFTER, THIS TIME ACTIVATING ENGINE WARNING LIGHT. DEALER REPLACED CYLINDER COIL; NEXT DAY, SAME TYPE OF MISFIRE OCCURRENCE. VERY UNSAFE SITUATION, COSTING ME LOTS OF TIME AND MONEY. IN ADDITION, THIS ECCOBOOST, AS I HAVE REPORTED TO FORD SINCE IT WAS NEW, HAS NEVER ACHIEVED EVEN CLOSE TO RATED MPG, ONLY AVERAGING 14 MPG OR 40% LESS THAN ADVERTISED. VEHICLE NOW BACK AT LIVERMORE FORD, WHERE TECHNICIAN WAS ASKED BY SERVICE DEPT TO DRIVE UNIT HOME HOOKED INTO COMPUTER TO SEE IF PROBLEM CAN BE DIAGNOSED. THIS IS AN UNACCEPTABLE AND UNSAFE SITUATION. NOT HAPPY. *TR
WHILE TOWING MY CAMPER AT 60 MPH UP AN INCLINE MY 5.0L F150 BEGAN TO LOSE POWER, AS I INCREASED PRESSURE ON THE ACCELERATOR THE POWER TO THE VEHICLE DECREASED EVEN MORE. THE SERVICE ENGINE LIGHT CAME ON AND I LIMPED UP THE HILL AT A WHOPPING 20MPH ON THE INTERSTATE. ONCE ON THE DOWNGRADE THE VEHICLE CAME BACK UP TO SPEED AND T…
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WHILE TOWING MY CAMPER AT 60 MPH UP AN INCLINE MY 5.0L F150 BEGAN TO LOSE POWER, AS I INCREASED PRESSURE ON THE ACCELERATOR THE POWER TO THE VEHICLE DECREASED EVEN MORE. THE SERVICE ENGINE LIGHT CAME ON AND I LIMPED UP THE HILL AT A WHOPPING 20MPH ON THE INTERSTATE. ONCE ON THE DOWNGRADE THE VEHICLE CAME BACK UP TO SPEED AND THE SERVICE ENGINE LIGHT WENT OFF. THE TRUCK CONTINUED TO HAVE POWER ISSUES AND A KNOCKING FROM THE MOTOR WHEN I WAS CLIMBING HILLS. I TOOK THE VEHICLE TO THE FORD GARAGE AND THEY TOLD ME THERE WERE NO CODES TO TELL THEM WHAT WAS WRONG. THE VEHICLE STILL HAS THE APPARENT MISS AND KNOCKING SOUND AT CERTAIN RPM'S AND NOW HAS AN ISSUE STARTING FOR THE FIRST TIME OF THE DAY. I AGAIN TOOK IT TO THE FORD GARAGE WHEN THE STARTING ISSUE WAS HAPPENING AND THEY TOLD ME AGAIN THAT THE VEHICLE STILL HAD NO CODES TO EXPLAIN THIS PROBLEM. I TRIED ALL OF THE EASY FIXES BUT THE VEHICLE STILL HAS THE SAME STARTING AND POWER LOSS ISSUES AND FORD CAN NOT TELL ME WHAT IS GOING ON WITH MY VEHICLE. MY BEST GUESS IS A CATALYTIC CONVERTER ISSUE, BUT I CAN DO NOTHING ABOUT IT UNTIL I KNOW FOR SURE. *TR
THE ECOBOOST ENGINE FORD INTRODUCED INTO THE F150 (AND OTHER VEHICLES) IN 2011 SEEMS TO BE HAVING COMMON AND WIDESPREAD PROBLEMS, INCLUDING MY VEHICLE. I FIRST REPORTED THIS ISSUE TO THE DEALER WITH ABOUT 30,000 MILES AND NOW AGAIN AT 63,000 MILES. THE SAFETY ISSUE IS REVEALED UNDER ANY ACCELERATION "EVENT" SUCH AS HIGHWAY MERGI…
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THE ECOBOOST ENGINE FORD INTRODUCED INTO THE F150 (AND OTHER VEHICLES) IN 2011 SEEMS TO BE HAVING COMMON AND WIDESPREAD PROBLEMS, INCLUDING MY VEHICLE. I FIRST REPORTED THIS ISSUE TO THE DEALER WITH ABOUT 30,000 MILES AND NOW AGAIN AT 63,000 MILES. THE SAFETY ISSUE IS REVEALED UNDER ANY ACCELERATION "EVENT" SUCH AS HIGHWAY MERGING, PASSING, TOWING ETC. UNDER ACCELERATION THE VEHICLE "CHOKES" AND WILL NOT ACCELERATE AS THE DRIVER & PASSENGERS EXPERIENCE THE VEHICLE STALLING, SHUDDERING OR BUCKING. THIS IS OFTEN DESCRIBED AS THE VEHICLE GOING INTO "LIMP MODE" OPERATING ON FEWER THAN ALL CYLINDERS. THE PROBLEMS APPEAR TO STEM FROM DYSFUNCTIONAL INTERCOOLER OPERATION ON THIS TWIN TURBO ENGINE. THERE ARE TWO DIFFERENT SCENARIOS DESCRIBED IN F150 BLOGS. ONE, MOST COMMON, IS THAT THE COOLING OF THE AIR VIA THE INTERCOOLER CAUSES CONDENSATION TO ACCUMULATE INSIDE THE AIR INTAKE. WHEN THE DRIVER ACCELERATES, THE INCREASE IN AIR VOLUME DRAWS THE MOISTURE INTO THE FUEL DELIVERY SYSTEM AND CAUSES THE ENGINE TO MISFIRE, WHICH THE DRIVER EXPERIENCES AS AN ENGINE STALL, BUCKING OR SHUDDERING. THE SECOND SCENARIO REPORTED IS THAT THERE IS AN OVERHEATING OF AIR INTO THE FUEL DELIVER SYSTEM WHICH CAUSES EARLY DETONATION OF THE FUEL MIXTURE IN THE CYLINDERS CAUSING ROUGHLY THE SAME SYMPTOMS. MY VEHICLE REPAIRS ARE COSTING ME ALMOST $700.00 - WHICH WOULD BE MORE IF I DID NOT HAVE AN EXTENDED WARRANTY. THE DEALER IS REPLACING 6 SPARK PLUGS, 4 COIL BOOTS THAT HAVE OVERHEATED AND CRACKED, INSTALLING A NEW INTERCOOLER SHIELD - NONE OF WHICH THEY ARE STANDING BY AS A DEALER COVERED EXPENSE. FORD NEEDS TO BE HELD ACCOUNTABLE FOR THIS DEFECTIVE DESIGN FOR BOTH CONSUMER SAFETY AND FINANCIAL REASONS. SOMEONE MAY BE KILLED TRYING TO PASS OR ENTER A HIGHWAY AS THEIR VEHICLE SUDDENLY LOOSES POWER. *TR
THERE IS A PROBLEM WITH THE ENGINE MISFIRING AT MODERATE TO HARD ACCELERATION. THIS REALLY BOTHERS ME. AS I HAVE TALKED WITH FORD MECHANICS I HAVE BEEN TOLD THAT FORD HAS NO FIX FOR THIS PROBLEM. FROM WHAT I HAVE READ AND STUDIED, THIS IS A PROBLEM WITH CONDENSATION IN THE INTERCOOLER MAKING ITS WAY TO HE INJECTORS. ONCE YOU…
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THERE IS A PROBLEM WITH THE ENGINE MISFIRING AT MODERATE TO HARD ACCELERATION. THIS REALLY BOTHERS ME. AS I HAVE TALKED WITH FORD MECHANICS I HAVE BEEN TOLD THAT FORD HAS NO FIX FOR THIS PROBLEM. FROM WHAT I HAVE READ AND STUDIED, THIS IS A PROBLEM WITH CONDENSATION IN THE INTERCOOLER MAKING ITS WAY TO HE INJECTORS. ONCE YOU PUT YOUR FOOT ON THE GAS PEDAL TO ACCELERATE YOU EXPERIENCE A SOMETIMES VIOLENT STUTTER AND THE VEHICLE NOT ACCELERATING BUT INSTEAD SOUNDING LIKE IT'S GOING TO EXPLODE. I HAVE ALSO HEARD THIS HAPPENS WHEN ITS HUMID OUTSIDE. REGARDLESS, ONE DAY I'M GOING TO NEED TO ACCELERATE AWAY OR FROM SOMETHING AND THE TRUCK IS GOING TO FAIL, CAUSING ME TO GET HIT OR KILLED. I HAVE FOUND FIXES TO THE PROBLEMS INCLUDING A FULL RACE INTERCOOLER, PLUGS AND WIRES, HOWEVER I DON'T THINK I SHOULD HAVE TO SPEND OVER $1000 FOR SOMETHING FORD RELEASED KNOWING IT WASN'T READY, OR UP TO PAR. I'VE OWNED MY VEHICLE FOR OVER A YEAR NOW AND ITS 0% BETTER EVEN USING TOP OCTANE FUEL. PLEASE HELP... *TR
WATER FROM THE CAC WAS INGESTED INTO THE ENGINE CAUSING A MISFIRE. THIS IS THE 8TH TIME IT HAS HAPPENED TO ME. I HAVE HAD ALL TSB'S COMPLETED BY FORD AND THE ISSUE STILL PERSISTS. THE ECOBOOST ENGINES ARE UNSAFE. THIS LOSS OF POWER WHILE MERGING HAS CAUSES ME TO NARROWLY ESCAPE ACCIDENTS 2 OUT OF THE 8 INCIDENTS. I NOTICED …
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WATER FROM THE CAC WAS INGESTED INTO THE ENGINE CAUSING A MISFIRE. THIS IS THE 8TH TIME IT HAS HAPPENED TO ME. I HAVE HAD ALL TSB'S COMPLETED BY FORD AND THE ISSUE STILL PERSISTS. THE ECOBOOST ENGINES ARE UNSAFE. THIS LOSS OF POWER WHILE MERGING HAS CAUSES ME TO NARROWLY ESCAPE ACCIDENTS 2 OUT OF THE 8 INCIDENTS. I NOTICED THAT THE NHTSA CLOSED AN INVESTIGATION INTO THE ECOBOOST ISSUES EARLIER THIS YEAR. I'M SUGGESTING THAT THE NHTSA RE-OPEN THAT INVESTIGATION. THE TSB'S ARE NOT FIXING THESE ISSUES AND IT IS ONLY A MATTER IF TIME BEFORE SOMEONE IS SERIOUSLY INJURED. PLEASE CONTACT ME WITH ANY QUESTIONS. *TR
AS I WAS MERGING ONTO THE HIGHWAY, I HAD TO ACCELERATE TO AVOID A SEMI WHO WAS APPROACHING IN THE RIGHT LANE. I HARD ACCELERATED, BUT THE TRUCK STARTED SHAKING AND THE CHECK ENGINE LIGHT BEGAN FLASHING. I HAD LOST ALL ACCELERATION AND WAS FORCED TO PUT MY FLASHERS ON AND MERGE TO THE BREAK-DOWN LANE TO AVOID BEING RUN COMPLETE…
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AS I WAS MERGING ONTO THE HIGHWAY, I HAD TO ACCELERATE TO AVOID A SEMI WHO WAS APPROACHING IN THE RIGHT LANE. I HARD ACCELERATED, BUT THE TRUCK STARTED SHAKING AND THE CHECK ENGINE LIGHT BEGAN FLASHING. I HAD LOST ALL ACCELERATION AND WAS FORCED TO PUT MY FLASHERS ON AND MERGE TO THE BREAK-DOWN LANE TO AVOID BEING RUN COMPLETELY OFF THE HIGHWAY. THE TRUCK SHOOK VIOLENTLY WHILE IN 6TH GEAR AND I HAD TO MANUALLY SHIFT TO 5TH GEAR TO STOP THE TRUCK FROM VIBRATING APART. LESS THAN 10 MINUTES LATER (WHILE DRIVING DOWN THE HIGHWAY IN 5TH GEAR) THE CHECK ENGINE LIGHT TURNED OFF AND THE TRUCK WAS ABLE TO BE SHIFTED BACK INTO 6TH WITHOUT ANY VIBRATION. THIS LACK OF ACCELERATION IS EXTREMELY DANGEROUS AND HAS HAPPENED MORE TIMES THAN I CAN COUNT. ABOVE WAS ONLY AN EXPLANATION OF THE LAST OCCURRENCE. THE TRUCK HAS BEEN SERVICED (UNDER WARRANTY) WHERE ISSUE WAS DISCUSSED WITH FORD, BUT THEY WERE UNABLE TO "REPRODUCE" THE PROBLEM... *TR
Official recalls
619V075000 · Power Train:automatic Transmission; Power Train:automatic Transmission:control Module (tcm/pcm/tecm)
Feb 11, 2019
Ford Motor Company (Ford) is recalling certain 2011-2013 F-150 vehicles equipped with a 6-speed automatic transmission. The transmission may unexpectedly downshift into first gear, regardless of vehicle speed.
Consequence & remedy
Consequence: Unexpectedly downshifting into first gear may result in a loss of vehicle control, increasing the risk of a crash.
Remedy: Ford will notify owners, and dealers will reprogram the powertrain control module, free of charge. The recall began March 4, 2019. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S07.
Additional source detail variants (2)
Power Train:automatic Transmission:control Module (tcm/pcm/tecm)
Ford Motor Company (Ford) is recalling certain 2011-2013 F-150 vehicles equipped with a 6-speed automatic transmission. The transmission may unexpectedly downshift into first gear, regardless of vehicle speed.
Consequence: Unexpectedly downshifting into first gear may result in a loss of vehicle control, increasing the risk of a crash.
Remedy: Ford will notify owners, and dealers will reprogram the powertrain control module, free of charge. The recall began March 4, 2019. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S07.
Power Train:automatic Transmission
Ford Motor Company (Ford) is recalling certain 2011-2013 F-150 vehicles equipped with a 6-speed automatic transmission. The transmission may unexpectedly downshift into first gear, regardless of vehicle speed.
Consequence: Unexpectedly downshifting into first gear may result in a loss of vehicle control, increasing the risk of a crash.
Remedy: Ford will notify owners, and dealers will reprogram the powertrain control module, free of charge. The recall began March 4, 2019. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S07.
16V248000 · Power Train:automatic Transmission
Apr 27, 2016
Ford Motor Company (Ford) is recalling certain model year 2011-2012 Ford F-150 trucks, 2012 Ford Expedition, Lincoln Navigator, and Ford Mustang vehicles. The affected vehicles are equipped with an automatic transmission that may unexpectedly downshift to first gear, regardless of vehicle speed.
Consequence & remedy
Consequence: An unexpected downshift into first gear can cause the vehicle to slow down suddenly without warning and the rear tires may slide or lock, increasing the risk of a crash.
Remedy: Ford will notify owners, and dealers will reprogram the powertrain control module with updated software, free of charge. The recall began on September 19, 2016. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 16S19.
12V190000 · Exterior Lighting:back Up Lights; Power Train:automatic Transmission:control Module (tcm/pcm/tecm)
May 3, 2012
FORD IS RECALLING CERTAIN MODEL YEAR 2011-2012 FORD F-150, 2012 EXPEDITION AND LINCOLN NAVIGATOR, AND 2012-2013 MUSTANG VEHICLES, FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NOS. 102, "TRANSMISSION SHIFT LEVER SEQUENCE, STARTER INTERLOCK, AND TRANSMISSION BRAKING EFFECT" AND 108 LAMPS, REFLECTIVE DEVICES AND ASSOCIATED EQUIPMENT. THESE VEHICLES MAY HAVE A TRANSMISSION RANGE SENSOR (TRS) THAT WAS CALIBRATED OUT OF SPECIFICATION FOR REVERSE GEAR.
Consequence & remedy
Consequence: IF THIS CONDITION EXISTS, THE TRANSMISSION MAY NOT GO INTO REVERSE OR WHEN THE DRIVER PUSHES THE SHIFT LEVER IN THE REVERSE R POSITION AND THE VEHICLES TRANSMISSION DOES GO IN REVERSE, THE R MAY NOT ILLUMINATE ON THE DASHBOARD OF THE F-150, EXPEDITION, OR NAVIGATOR MODELS AND/OR THE BACKUP LAMP ON THE REAR OF THE F-150, EXPEDITION, NAVIGATOR, OR MUSTANG VEHICLES MAY NOT ILLUMINATE. THESE CONDITIONS INCREASE THE RISK OF A CRASH OR A PEDESTRIAN BEING STRUCK DUE TO THE VEHICLES NOT SIGNALING IT IS IN REVERSE.
Remedy: FORD WILL NOTIFY OWNERS, AND DEALERS WILL INSPECT AND REPLACE THE TRS AS NECESSARY, FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JUNE 11, 2012. OWNERS MAY CONTACT FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.
Additional source detail variants (2)
Exterior Lighting:back Up Lights
FORD IS RECALLING CERTAIN MODEL YEAR 2011-2012 FORD F-150, 2012 EXPEDITION AND LINCOLN NAVIGATOR, AND 2012-2013 MUSTANG VEHICLES, FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NOS. 102, "TRANSMISSION SHIFT LEVER SEQUENCE, STARTER INTERLOCK, AND TRANSMISSION BRAKING EFFECT" AND 108 LAMPS, REFLECTIVE DEVICES AND ASSOCIATED EQUIPMENT. THESE VEHICLES MAY HAVE A TRANSMISSION RANGE SENSOR (TRS) THAT WAS CALIBRATED OUT OF SPECIFICATION FOR REVERSE GEAR.
Consequence: IF THIS CONDITION EXISTS, THE TRANSMISSION MAY NOT GO INTO REVERSE OR WHEN THE DRIVER PUSHES THE SHIFT LEVER IN THE REVERSE R POSITION AND THE VEHICLES TRANSMISSION DOES GO IN REVERSE, THE R MAY NOT ILLUMINATE ON THE DASHBOARD OF THE F-150, EXPEDITION, OR NAVIGATOR MODELS AND/OR THE BACKUP LAMP ON THE REAR OF THE F-150, EXPEDITION, NAVIGATOR, OR MUSTANG VEHICLES MAY NOT ILLUMINATE. THESE CONDITIONS INCREASE THE RISK OF A CRASH OR A PEDESTRIAN BEING STRUCK DUE TO THE VEHICLES NOT SIGNALING IT IS IN REVERSE.
Remedy: FORD WILL NOTIFY OWNERS, AND DEALERS WILL INSPECT AND REPLACE THE TRS AS NECESSARY, FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JUNE 11, 2012. OWNERS MAY CONTACT FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.
Power Train:automatic Transmission:control Module (tcm/pcm/tecm)
FORD IS RECALLING CERTAIN MODEL YEAR 2011-2012 FORD F-150, 2012 EXPEDITION AND LINCOLN NAVIGATOR, AND 2012-2013 MUSTANG VEHICLES, FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NOS. 102, "TRANSMISSION SHIFT LEVER SEQUENCE, STARTER INTERLOCK, AND TRANSMISSION BRAKING EFFECT" AND 108 LAMPS, REFLECTIVE DEVICES AND ASSOCIATED EQUIPMENT. THESE VEHICLES MAY HAVE A TRANSMISSION RANGE SENSOR (TRS) THAT WAS CALIBRATED OUT OF SPECIFICATION FOR REVERSE GEAR.
Consequence: IF THIS CONDITION EXISTS, THE TRANSMISSION MAY NOT GO INTO REVERSE OR WHEN THE DRIVER PUSHES THE SHIFT LEVER IN THE REVERSE R POSITION AND THE VEHICLES TRANSMISSION DOES GO IN REVERSE, THE R MAY NOT ILLUMINATE ON THE DASHBOARD OF THE F-150, EXPEDITION, OR NAVIGATOR MODELS AND/OR THE BACKUP LAMP ON THE REAR OF THE F-150, EXPEDITION, NAVIGATOR, OR MUSTANG VEHICLES MAY NOT ILLUMINATE. THESE CONDITIONS INCREASE THE RISK OF A CRASH OR A PEDESTRIAN BEING STRUCK DUE TO THE VEHICLES NOT SIGNALING IT IS IN REVERSE.
Remedy: FORD WILL NOTIFY OWNERS, AND DEALERS WILL INSPECT AND REPLACE THE TRS AS NECESSARY, FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JUNE 11, 2012. OWNERS MAY CONTACT FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.
11V582000 · Power Train:automatic Transmission
Dec 8, 2011
FORD IS RECALLING CERTAIN MODEL YEAR 2011 F-150 VEHICLES MANUFACTURED FROM SEPTEMBER 9, 2011, THROUGH SEPTEMBER 22, 2011, AND MODEL YEAR 2012 F-250, F-350, F-450 AND F-550 HEAVY DUTY VEHICLES MANUFACTURED FROM SEPTEMBER 12, 2011, THROUGH SEPTEMBER 22, 2011. THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NUMBER 114, THEFT PROTECTION. THE TRANSMISSION CAN BE SHIFTED OUT OF THE PARK POSITION WITHOUT PRESSING THE BRAKE PEDAL DUE TO BRAKE SHIFT INTERLOCK SWITCH PROBLEM.
Consequence & remedy
Consequence: THIS WILL ALLOW THE OPERATOR TO INADVERTENTLY SHIFT THE VEHICLE INTO GEAR WITHOUT THE BRAKE PEDAL BEING DEPRESSED, INCREASING THE RISK OF A CRASH OR INJURY TO A NEARBY PEDESTRIAN.
Remedy: FORD WILL NOTIFY OWNERS, AND DEALERS WILL INSPECT THE BRAKE SHIFT INTERLOCK SWITCH FUNCTION AND REPLACE THE SWITCH IF NECESSARY, FREE OF CHARGE. THE SAFETY RECALL BEGAN ON DECEMBER 22, 2011. OWNERS MAY CONTACT THE FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.
11V128000 · Electrical System:software
Feb 24, 2011
FORD IS RECALLING CERTAIN MODEL YEAR 2011 FORD F-150, F-250, F-350, F-450, F-550, EDGE, AND LINCOLN MKX TRUCKS MANUFACTURED FROM OCTOBER 25, 2010, THROUGH NOVEMBER 20, 2010. THESE VEHICLES WERE INSPECTED USING INTEGRATED DIAGNOSTIC SYSTEM (IDS) THAT HAD A CUSTOM SOFTWARE ROUTINE TO READ THE SUSPECT BODY CONTROL MODULE (BCM) SERIAL NUMBER. BASED ON THE SERIAL NUMBER THE BCM WAS EITHER NOT AFFECTED OR REPLACED. THE CUSTOM SOFTWARE ROUTINE WAS NOT READING THE CORRECT SET OF CHARACTERS, AND WAS NOT ABLE TO IDENTIFY A BCM THAT REQUIRED REPLACEMENT AFFECTED BCMS MAY HAVE THE POTENTIAL FOR AN INTERNAL SHORT.
Consequence & remedy
Consequence: IF AN ELECTRICAL SHORT DEVELOPS, AN OVERHEATING CONDITION MAY OCCUR WHICH COULD RESULT IN A VEHICLE FIRE.
Remedy: DEALER WILL INSPECT THE BODY CONTROL MODULE AND IF NECESSARY REPLACE IT FREE OF CHARGE. THE SAFETY RECALL BEGAN ON MARCH 7, 2011. OWNERS MAY CONTACT FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.
10V659000 · Structure:body
Dec 29, 2010
FORD IS RECALLING CERTAIN MODEL YEAR 2011 F-150, F-250, F-350, F-450, F-550, EDGE AND LINCOLN MKX VEHICLES. DURING A SIX-DAY PRODUCTION PERIOD, THE SUPPLIER OF THE BODY CONTROL MODULE MANUFACTURED MODULES THAT MAY HAVE THE POTENTIAL FOR AN INTERNAL SHORT.
Consequence & remedy
Consequence: IF AN ELECTRICAL SHORT DEVELOPS, AN OVERHEATING CONDITION MAY OCCUR WHICH CAN RESULT IN AN UNATTENDED VEHICLE FIRE.
Remedy: DEALER WILL REPLACE THE BODY CONTROL MODULE IF NECESSARY FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JANUARY 11, 2011. OWNERS MAY CONTACT FORD AT 1-866-436-7332.
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
4RQ17010 · Unexpected Transmission Downshift
Opened Dec 25, 2017 · Closed Oct 22, 2019
Status: closed (inferred from source dates) · Power Train:automatic Transmission; Power Train:automatic Transmission:control Module (tcm/pcm/tecm)
The Office of Defects Investigation (ODI) opened an investigation based on consumer allegations of transmissions unexpectedly downshifting to a lower gear without input from the driver on model year (MY) 2011-2013 Ford F-150, Expedition and Navigator vehicles. ODI has received 455 unique reports related to the alleged problem that were not covered under a previous recall for this issue (16V-248).Expedition and Navigator complaint rates are lower than F-150 complaints. Of those 455 reports, 34.7% claimed that the rear wheels locked up when the transmission downshifted. There were 4 accident claims with no injuries. There are many instances where drivers report leaving their lane or the road because of this issue.In response to ODI's Information Request (IR) letter, Ford Motor Company (Ford) responded with 783 unique reports related to the alleged problem. There were 6 accident claims with 3 injuries. Ford also submitted 1206 warranty claims related to transmission downshifting failures. The failure can occur at any time, but typically at higher speed, and include symptoms such as sudden transmission downshifting, loss of speedometer, erratic shifting of transmission, and transmission stuck in one gear. The failures typically occur without warning and may result in the rear wheels momentarily locking up. The driver often had to fully stop the vehicle and restart it to get the vehicle to shift properly.On February 2nd, 2019 Ford notified ODI that it would conduct a safety recall (19V-075) to remedy transmission downshifting failures on all 2011-2013 F-150 vehicles. Ford will also offer extended warranties to 2011-2013 Expedition and Navigator vehicles with the same issue. Per Ford, some vehicles may experience an intermittent loss of Transmission Output Speed Sensor (OSS) signal to the Powertrain Control Module (PCM), potentially resulting in a temporary unintended downshift into first gear. Ford will reprogram the PCM with software that will prevent an unintended downshift into first gear and illuminate the Malfunction Indicator Light in the event of an intermittent OSS signal loss.The recall action initiated by the manufacturer appears to address the safety risks of concern to ODI.Accordingly, the investigation is closed.The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the identification (ODI) numbers found in the attached list.
Additional source detail variants (2)
Power Train:automatic Transmission:control Module (tcm/pcm/tecm)
The Office of Defects Investigation (ODI) opened an investigation based on consumer allegations of transmissions unexpectedly downshifting to a lower gear without input from the driver on model year (MY) 2011-2013 Ford F-150, Expedition and Navigator vehicles. ODI has received 455 unique reports related to the alleged problem that were not covered under a previous recall for this issue (16V-248).Expedition and Navigator complaint rates are lower than F-150 complaints. Of those 455 reports, 34.7% claimed that the rear wheels locked up when the transmission downshifted. There were 4 accident claims with no injuries. There are many instances where drivers report leaving their lane or the road because of this issue.In response to ODI's Information Request (IR) letter, Ford Motor Company (Ford) responded with 783 unique reports related to the alleged problem. There were 6 accident claims with 3 injuries. Ford also submitted 1206 warranty claims related to transmission downshifting failures. The failure can occur at any time, but typically at higher speed, and include symptoms such as sudden transmission downshifting, loss of speedometer, erratic shifting of transmission, and transmission stuck in one gear. The failures typically occur without warning and may result in the rear wheels momentarily locking up. The driver often had to fully stop the vehicle and restart it to get the vehicle to shift properly.On February 2nd, 2019 Ford notified ODI that it would conduct a safety recall (19V-075) to remedy transmission downshifting failures on all 2011-2013 F-150 vehicles. Ford will also offer extended warranties to 2011-2013 Expedition and Navigator vehicles with the same issue. Per Ford, some vehicles may experience an intermittent loss of Transmission Output Speed Sensor (OSS) signal to the Powertrain Control Module (PCM), potentially resulting in a temporary unintended downshift into first gear. Ford will reprogram the PCM with software that will prevent an unintended downshift into first gear and illuminate the Malfunction Indicator Light in the event of an intermittent OSS signal loss.The recall action initiated by the manufacturer appears to address the safety risks of concern to ODI.Accordingly, the investigation is closed.The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the identification (ODI) numbers found in the attached list.
Power Train:automatic Transmission
The Office of Defects Investigation (ODI) opened an investigation based on consumer allegations of transmissions unexpectedly downshifting to a lower gear without input from the driver on model year (MY) 2011-2013 Ford F-150, Expedition and Navigator vehicles. ODI has received 455 unique reports related to the alleged problem that were not covered under a previous recall for this issue (16V-248).Expedition and Navigator complaint rates are lower than F-150 complaints. Of those 455 reports, 34.7% claimed that the rear wheels locked up when the transmission downshifted. There were 4 accident claims with no injuries. There are many instances where drivers report leaving their lane or the road because of this issue.In response to ODI's Information Request (IR) letter, Ford Motor Company (Ford) responded with 783 unique reports related to the alleged problem. There were 6 accident claims with 3 injuries. Ford also submitted 1206 warranty claims related to transmission downshifting failures. The failure can occur at any time, but typically at higher speed, and include symptoms such as sudden transmission downshifting, loss of speedometer, erratic shifting of transmission, and transmission stuck in one gear. The failures typically occur without warning and may result in the rear wheels momentarily locking up. The driver often had to fully stop the vehicle and restart it to get the vehicle to shift properly.On February 2nd, 2019 Ford notified ODI that it would conduct a safety recall (19V-075) to remedy transmission downshifting failures on all 2011-2013 F-150 vehicles. Ford will also offer extended warranties to 2011-2013 Expedition and Navigator vehicles with the same issue. Per Ford, some vehicles may experience an intermittent loss of Transmission Output Speed Sensor (OSS) signal to the Powertrain Control Module (PCM), potentially resulting in a temporary unintended downshift into first gear. Ford will reprogram the PCM with software that will prevent an unintended downshift into first gear and illuminate the Malfunction Indicator Light in the event of an intermittent OSS signal loss.The recall action initiated by the manufacturer appears to address the safety risks of concern to ODI.Accordingly, the investigation is closed.The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the identification (ODI) numbers found in the attached list.
EA15006 · Brake Vacuum Pump Failure
Opened Oct 16, 2015 · Closed Apr 28, 2016
Status: closed (inferred from source dates) · Service Brakes, Electric; Service Brakes, Hydraulic:power Assist; Service Brakes, Hydraulic:power Assist:vacuum
On February 15, 2016, Ford Motor Company initiated Customer Satisfaction Program 15N05 to extend warranty coverage for the electric vacuum pump in certain model year (MY) 2011 through 2012 Ford F-150 pickup trucks equipped with 3.5L GTDI engines.The program extends coverage for up to 10 years of service or 150,000 miles from the warranty start date of the vehicle, all vehicles are eligible for the program through July 30, 2016 regardless of mileage.Ford's program covers all repairs related to electric vacuum pump (EVP) malfunctions including excessive noise, vibration, or change in brake pedal feel while applying the brakes at cold start. Ford states that the engine intake manifold is the primary source of vacuum for the brake booster and is fully compliant to motor vehicle safety standards without the supplemental vacuum supplied by the EVP.The company also contends that failure modes related to the EVP are progressive and provide warning to operators by way of noise and vibration before an operator to experience any temporary change in brake pedal feel.ODI's analysis of warranty data found that the majority of claims involved consumer concerns with EVP noise or vibration from the left front fender area when the vehicle is first started. Continued operation in this mode with pump motor noise will eventually result in the EVP seizing or becoming non-functional.Component failure analysis indicated that Ford and its supplier, Continental, identified a pump crank drive corrosion condition due to moisture entry through the vacuum intake.Corrosion damage to EVP internal components may eventually result in a blown fuse in the power distribution box and total loss of EVP function.Analysis of consumer complaints, field reports, and warranty data related to EVP failures found thatincidents predominantly occurred in driveways and parking lots in the periods immediately after cold engine starts.Many consumers operated their vehicle for some period of time with a blown EVP fuse without realizing that the pump had failed or that the vehicle had a brake system malfunction.Consumers who did experience braking performance issues reporteda temporary hard brake pedal condition at start-up followed by more consistent normal pedal feel after few seconds.On June 22, 2015, Ford developed a remedy procedure and issued TSB 15-0105 instructing dealers to replace the vacuum pump and install a new vacuum pump harness kit. In addition to reviewing test data submitted by Ford, ODI assessed safety risks associated with the alleged defect under various operating conditions, including: 1) baseline system performance with full engine and EVP vacuum available using exemplar parts, 2) disabled EVP and booster vacuum regulated to simulate worst case conditions for engine intake manifold vacuum supply to the brake booster (approximately 300 mbar); and 3) all source vacuum to the brake booster removed and Optimized Hydraulic Braking (OHB) mode active to represent complete loss of brake booster function (note: this condition is a more severe brake boost system failure mode than the alleged defect).ODI also analyzed all complaints and warranty claims to identify incidents alleging brake system performance concerns related to EVP failures.These analyses identified no brake performance issues or resulting changes in stopping distances either on highway or city traffic conditions.Two complaints alleging EVP malfunctions caused or contributed to rear-end collisions during attempted decelerations from road speeds are not believed to be related to the alleged defect.The EVP provides supplemental vacuum during initial start-up and idle
Additional source detail variants (3)
Service Brakes, Electric
On February 15, 2016, Ford Motor Company initiated Customer Satisfaction Program 15N05 to extend warranty coverage for the electric vacuum pump in certain model year (MY) 2011 through 2012 Ford F-150 pickup trucks equipped with 3.5L GTDI engines.The program extends coverage for up to 10 years of service or 150,000 miles from the warranty start date of the vehicle, all vehicles are eligible for the program through July 30, 2016 regardless of mileage.Ford's program covers all repairs related to electric vacuum pump (EVP) malfunctions including excessive noise, vibration, or change in brake pedal feel while applying the brakes at cold start. Ford states that the engine intake manifold is the primary source of vacuum for the brake booster and is fully compliant to motor vehicle safety standards without the supplemental vacuum supplied by the EVP.The company also contends that failure modes related to the EVP are progressive and provide warning to operators by way of noise and vibration before an operator to experience any temporary change in brake pedal feel.ODI's analysis of warranty data found that the majority of claims involved consumer concerns with EVP noise or vibration from the left front fender area when the vehicle is first started. Continued operation in this mode with pump motor noise will eventually result in the EVP seizing or becoming non-functional.Component failure analysis indicated that Ford and its supplier, Continental, identified a pump crank drive corrosion condition due to moisture entry through the vacuum intake.Corrosion damage to EVP internal components may eventually result in a blown fuse in the power distribution box and total loss of EVP function.Analysis of consumer complaints, field reports, and warranty data related to EVP failures found thatincidents predominantly occurred in driveways and parking lots in the periods immediately after cold engine starts.Many consumers operated their vehicle for some period of time with a blown EVP fuse without realizing that the pump had failed or that the vehicle had a brake system malfunction.Consumers who did experience braking performance issues reporteda temporary hard brake pedal condition at start-up followed by more consistent normal pedal feel after few seconds.On June 22, 2015, Ford developed a remedy procedure and issued TSB 15-0105 instructing dealers to replace the vacuum pump and install a new vacuum pump harness kit. In addition to reviewing test data submitted by Ford, ODI assessed safety risks associated with the alleged defect under various operating conditions, including: 1) baseline system performance with full engine and EVP vacuum available using exemplar parts, 2) disabled EVP and booster vacuum regulated to simulate worst case conditions for engine intake manifold vacuum supply to the brake booster (approximately 300 mbar); and 3) all source vacuum to the brake booster removed and Optimized Hydraulic Braking (OHB) mode active to represent complete loss of brake booster function (note: this condition is a more severe brake boost system failure mode than the alleged defect).ODI also analyzed all complaints and warranty claims to identify incidents alleging brake system performance concerns related to EVP failures.These analyses identified no brake performance issues or resulting changes in stopping distances either on highway or city traffic conditions.Two complaints alleging EVP malfunctions caused or contributed to rear-end collisions during attempted decelerations from road speeds are not believed to be related to the alleged defect.The EVP provides supplemental vacuum during initial start-up and idle
Service Brakes, Hydraulic:power Assist
On February 15, 2016, Ford Motor Company initiated Customer Satisfaction Program 15N05 to extend warranty coverage for the electric vacuum pump in certain model year (MY) 2011 through 2012 Ford F-150 pickup trucks equipped with 3.5L GTDI engines.The program extends coverage for up to 10 years of service or 150,000 miles from the warranty start date of the vehicle, all vehicles are eligible for the program through July 30, 2016 regardless of mileage.Ford's program covers all repairs related to electric vacuum pump (EVP) malfunctions including excessive noise, vibration, or change in brake pedal feel while applying the brakes at cold start. Ford states that the engine intake manifold is the primary source of vacuum for the brake booster and is fully compliant to motor vehicle safety standards without the supplemental vacuum supplied by the EVP.The company also contends that failure modes related to the EVP are progressive and provide warning to operators by way of noise and vibration before an operator to experience any temporary change in brake pedal feel.ODI's analysis of warranty data found that the majority of claims involved consumer concerns with EVP noise or vibration from the left front fender area when the vehicle is first started. Continued operation in this mode with pump motor noise will eventually result in the EVP seizing or becoming non-functional.Component failure analysis indicated that Ford and its supplier, Continental, identified a pump crank drive corrosion condition due to moisture entry through the vacuum intake.Corrosion damage to EVP internal components may eventually result in a blown fuse in the power distribution box and total loss of EVP function.Analysis of consumer complaints, field reports, and warranty data related to EVP failures found thatincidents predominantly occurred in driveways and parking lots in the periods immediately after cold engine starts.Many consumers operated their vehicle for some period of time with a blown EVP fuse without realizing that the pump had failed or that the vehicle had a brake system malfunction.Consumers who did experience braking performance issues reporteda temporary hard brake pedal condition at start-up followed by more consistent normal pedal feel after few seconds.On June 22, 2015, Ford developed a remedy procedure and issued TSB 15-0105 instructing dealers to replace the vacuum pump and install a new vacuum pump harness kit. In addition to reviewing test data submitted by Ford, ODI assessed safety risks associated with the alleged defect under various operating conditions, including: 1) baseline system performance with full engine and EVP vacuum available using exemplar parts, 2) disabled EVP and booster vacuum regulated to simulate worst case conditions for engine intake manifold vacuum supply to the brake booster (approximately 300 mbar); and 3) all source vacuum to the brake booster removed and Optimized Hydraulic Braking (OHB) mode active to represent complete loss of brake booster function (note: this condition is a more severe brake boost system failure mode than the alleged defect).ODI also analyzed all complaints and warranty claims to identify incidents alleging brake system performance concerns related to EVP failures.These analyses identified no brake performance issues or resulting changes in stopping distances either on highway or city traffic conditions.Two complaints alleging EVP malfunctions caused or contributed to rear-end collisions during attempted decelerations from road speeds are not believed to be related to the alleged defect.The EVP provides supplemental vacuum during initial start-up and idle
Service Brakes, Hydraulic:power Assist:vacuum
On February 15, 2016, Ford Motor Company initiated Customer Satisfaction Program 15N05 to extend warranty coverage for the electric vacuum pump in certain model year (MY) 2011 through 2012 Ford F-150 pickup trucks equipped with 3.5L GTDI engines.The program extends coverage for up to 10 years of service or 150,000 miles from the warranty start date of the vehicle, all vehicles are eligible for the program through July 30, 2016 regardless of mileage.Ford's program covers all repairs related to electric vacuum pump (EVP) malfunctions including excessive noise, vibration, or change in brake pedal feel while applying the brakes at cold start. Ford states that the engine intake manifold is the primary source of vacuum for the brake booster and is fully compliant to motor vehicle safety standards without the supplemental vacuum supplied by the EVP.The company also contends that failure modes related to the EVP are progressive and provide warning to operators by way of noise and vibration before an operator to experience any temporary change in brake pedal feel.ODI's analysis of warranty data found that the majority of claims involved consumer concerns with EVP noise or vibration from the left front fender area when the vehicle is first started. Continued operation in this mode with pump motor noise will eventually result in the EVP seizing or becoming non-functional.Component failure analysis indicated that Ford and its supplier, Continental, identified a pump crank drive corrosion condition due to moisture entry through the vacuum intake.Corrosion damage to EVP internal components may eventually result in a blown fuse in the power distribution box and total loss of EVP function.Analysis of consumer complaints, field reports, and warranty data related to EVP failures found thatincidents predominantly occurred in driveways and parking lots in the periods immediately after cold engine starts.Many consumers operated their vehicle for some period of time with a blown EVP fuse without realizing that the pump had failed or that the vehicle had a brake system malfunction.Consumers who did experience braking performance issues reporteda temporary hard brake pedal condition at start-up followed by more consistent normal pedal feel after few seconds.On June 22, 2015, Ford developed a remedy procedure and issued TSB 15-0105 instructing dealers to replace the vacuum pump and install a new vacuum pump harness kit. In addition to reviewing test data submitted by Ford, ODI assessed safety risks associated with the alleged defect under various operating conditions, including: 1) baseline system performance with full engine and EVP vacuum available using exemplar parts, 2) disabled EVP and booster vacuum regulated to simulate worst case conditions for engine intake manifold vacuum supply to the brake booster (approximately 300 mbar); and 3) all source vacuum to the brake booster removed and Optimized Hydraulic Braking (OHB) mode active to represent complete loss of brake booster function (note: this condition is a more severe brake boost system failure mode than the alleged defect).ODI also analyzed all complaints and warranty claims to identify incidents alleging brake system performance concerns related to EVP failures.These analyses identified no brake performance issues or resulting changes in stopping distances either on highway or city traffic conditions.Two complaints alleging EVP malfunctions caused or contributed to rear-end collisions during attempted decelerations from road speeds are not believed to be related to the alleged defect.The EVP provides supplemental vacuum during initial start-up and idle
PE15026 · Brake Vacuum Pump Failure
Opened Jun 22, 2015 · Closed Oct 19, 2015
Status: closed (inferred from source dates) · Service Brakes, Electric; Service Brakes, Hydraulic:power Assist; Service Brakes, Hydraulic:power Assist:vacuum
On June 22, 2015, the Office of Defects Investigations (ODI) opened Preliminary Evaluation PE15-026 to investigate incidents of increased brake pedal effort at cold start and extended stopping distance while driving in traffic, resulting from failures of the electric brake vacuum assist pump in model year (MY) 2011-2012 Ford F-150 pickup trucks equipped with 3.5L GTDI engines. In response to ODI's Information Request (IR) for PE15-026, Ford provided ODI with 396 complaints and field reports relating to incidents of increased brake pedal effort or malfunctions in the electric vacuum pump (EVP). ODI's analysis of the data provided by Ford identified 7 crashes and 1,851 warranty claims related to either a hard brake pedal condition or reduced brake effectiveness. Additionally, ODI identified one report in its database alleging an injury to an occupant of a vehicle struck in the rear by a subject F-150 vehicle with a failed EVP as documented in the police accident report referencing a dealer assessment of the pump.According to Ford, the subject vehicles utilize a traditional brake vacuum booster to provide power assist for braking and the EVP is intended to operate to maintain consistent brake pedal feel. The engine intake manifold is the primary source of vacuum for the booster and is fully compliant to motor vehicle safety standards without the EVP. Ford described the conditions related to a change in brake pedal feel as limited and temporary and provided component failure analysis showing evidence of water entry into the EVP which caused internal pump corrosion. Ford indicated that the EVP failure mode is progressive and provides warning to operators by way of noise and vibration before an operator is likely to experience any temporary change in brake pedal feel. Damage to the EVP motor bearing may eventually result in a blown EVP fuse and total loss of EVP function. Ford provided test data showing the brake pedal forces and pedal travel curves over time for 0.3g decelerations to a stop from 80kph (50mph) for: 1) normal system (full engine and EVP vacuum available); 2) Ford's approximation of worst case booster performance with EVP failure (EVP disabled and booster vacuum regulated to 300mbar to simulate cold start, all accessory loads on, and starting at 0 vacuum); and 3) with all source vacuum to the brake booster removed and Hydraulic Boost Compensation (HBC) active to represent complete loss of brake booster function. The Ford tests showed that the brake pedal forces required for achieving the 0.3g decelerations were relatively low for the normal condition, 35-40 N (8-9 lbf), increased by approximately 2-3 times normal when the EVP is disabled, 75-115 N (17-26 lbf), and increased by about 5-6 times normal for the complete brake booster failure condition, 205-215 N (46-48 lbf). This Preliminary Evaluation has been upgraded to Engineering Analysis (EA15-006) to test for EVP malfunctions under other vehicle operating conditions (e.g., low-speed driveway braking after cold-start with failed EVP), potential human factors contributions and to further assess the scope, frequency, and safety-related consequences of the alleged defect.The VOQs associated with the opening of this investigation are:10565994, 10575987, 10598351, 10604687, 10605701, 10607811, 10610491, 10615536, 10617828, 10619545, 10643075, 10650578, 10662151, 10664415, 10666988, 10668069, 10678844, 10695537, 10700874, 10706217, 10706271, 10712465, 10723033, 10723792, 10726960, 10730549, 10730721, 10730735, 10730837, 10730909, 10731008, 10731135, 10731157, 10731165, 10731395, 10731758, 10732609, 10732878, 10733375, 10733804, 10734558, 10734613, 10743859, 10744214, 10
Additional source detail variants (3)
Service Brakes, Electric
On June 22, 2015, the Office of Defects Investigations (ODI) opened Preliminary Evaluation PE15-026 to investigate incidents of increased brake pedal effort at cold start and extended stopping distance while driving in traffic, resulting from failures of the electric brake vacuum assist pump in model year (MY) 2011-2012 Ford F-150 pickup trucks equipped with 3.5L GTDI engines. In response to ODI's Information Request (IR) for PE15-026, Ford provided ODI with 396 complaints and field reports relating to incidents of increased brake pedal effort or malfunctions in the electric vacuum pump (EVP). ODI's analysis of the data provided by Ford identified 7 crashes and 1,851 warranty claims related to either a hard brake pedal condition or reduced brake effectiveness. Additionally, ODI identified one report in its database alleging an injury to an occupant of a vehicle struck in the rear by a subject F-150 vehicle with a failed EVP as documented in the police accident report referencing a dealer assessment of the pump.According to Ford, the subject vehicles utilize a traditional brake vacuum booster to provide power assist for braking and the EVP is intended to operate to maintain consistent brake pedal feel. The engine intake manifold is the primary source of vacuum for the booster and is fully compliant to motor vehicle safety standards without the EVP. Ford described the conditions related to a change in brake pedal feel as limited and temporary and provided component failure analysis showing evidence of water entry into the EVP which caused internal pump corrosion. Ford indicated that the EVP failure mode is progressive and provides warning to operators by way of noise and vibration before an operator is likely to experience any temporary change in brake pedal feel. Damage to the EVP motor bearing may eventually result in a blown EVP fuse and total loss of EVP function. Ford provided test data showing the brake pedal forces and pedal travel curves over time for 0.3g decelerations to a stop from 80kph (50mph) for: 1) normal system (full engine and EVP vacuum available); 2) Ford's approximation of worst case booster performance with EVP failure (EVP disabled and booster vacuum regulated to 300mbar to simulate cold start, all accessory loads on, and starting at 0 vacuum); and 3) with all source vacuum to the brake booster removed and Hydraulic Boost Compensation (HBC) active to represent complete loss of brake booster function. The Ford tests showed that the brake pedal forces required for achieving the 0.3g decelerations were relatively low for the normal condition, 35-40 N (8-9 lbf), increased by approximately 2-3 times normal when the EVP is disabled, 75-115 N (17-26 lbf), and increased by about 5-6 times normal for the complete brake booster failure condition, 205-215 N (46-48 lbf). This Preliminary Evaluation has been upgraded to Engineering Analysis (EA15-006) to test for EVP malfunctions under other vehicle operating conditions (e.g., low-speed driveway braking after cold-start with failed EVP), potential human factors contributions and to further assess the scope, frequency, and safety-related consequences of the alleged defect.The VOQs associated with the opening of this investigation are:10565994, 10575987, 10598351, 10604687, 10605701, 10607811, 10610491, 10615536, 10617828, 10619545, 10643075, 10650578, 10662151, 10664415, 10666988, 10668069, 10678844, 10695537, 10700874, 10706217, 10706271, 10712465, 10723033, 10723792, 10726960, 10730549, 10730721, 10730735, 10730837, 10730909, 10731008, 10731135, 10731157, 10731165, 10731395, 10731758, 10732609, 10732878, 10733375, 10733804, 10734558, 10734613, 10743859, 10744214, 10
Service Brakes, Hydraulic:power Assist
On June 22, 2015, the Office of Defects Investigations (ODI) opened Preliminary Evaluation PE15-026 to investigate incidents of increased brake pedal effort at cold start and extended stopping distance while driving in traffic, resulting from failures of the electric brake vacuum assist pump in model year (MY) 2011-2012 Ford F-150 pickup trucks equipped with 3.5L GTDI engines. In response to ODI's Information Request (IR) for PE15-026, Ford provided ODI with 396 complaints and field reports relating to incidents of increased brake pedal effort or malfunctions in the electric vacuum pump (EVP). ODI's analysis of the data provided by Ford identified 7 crashes and 1,851 warranty claims related to either a hard brake pedal condition or reduced brake effectiveness. Additionally, ODI identified one report in its database alleging an injury to an occupant of a vehicle struck in the rear by a subject F-150 vehicle with a failed EVP as documented in the police accident report referencing a dealer assessment of the pump.According to Ford, the subject vehicles utilize a traditional brake vacuum booster to provide power assist for braking and the EVP is intended to operate to maintain consistent brake pedal feel. The engine intake manifold is the primary source of vacuum for the booster and is fully compliant to motor vehicle safety standards without the EVP. Ford described the conditions related to a change in brake pedal feel as limited and temporary and provided component failure analysis showing evidence of water entry into the EVP which caused internal pump corrosion. Ford indicated that the EVP failure mode is progressive and provides warning to operators by way of noise and vibration before an operator is likely to experience any temporary change in brake pedal feel. Damage to the EVP motor bearing may eventually result in a blown EVP fuse and total loss of EVP function. Ford provided test data showing the brake pedal forces and pedal travel curves over time for 0.3g decelerations to a stop from 80kph (50mph) for: 1) normal system (full engine and EVP vacuum available); 2) Ford's approximation of worst case booster performance with EVP failure (EVP disabled and booster vacuum regulated to 300mbar to simulate cold start, all accessory loads on, and starting at 0 vacuum); and 3) with all source vacuum to the brake booster removed and Hydraulic Boost Compensation (HBC) active to represent complete loss of brake booster function. The Ford tests showed that the brake pedal forces required for achieving the 0.3g decelerations were relatively low for the normal condition, 35-40 N (8-9 lbf), increased by approximately 2-3 times normal when the EVP is disabled, 75-115 N (17-26 lbf), and increased by about 5-6 times normal for the complete brake booster failure condition, 205-215 N (46-48 lbf). This Preliminary Evaluation has been upgraded to Engineering Analysis (EA15-006) to test for EVP malfunctions under other vehicle operating conditions (e.g., low-speed driveway braking after cold-start with failed EVP), potential human factors contributions and to further assess the scope, frequency, and safety-related consequences of the alleged defect.The VOQs associated with the opening of this investigation are:10565994, 10575987, 10598351, 10604687, 10605701, 10607811, 10610491, 10615536, 10617828, 10619545, 10643075, 10650578, 10662151, 10664415, 10666988, 10668069, 10678844, 10695537, 10700874, 10706217, 10706271, 10712465, 10723033, 10723792, 10726960, 10730549, 10730721, 10730735, 10730837, 10730909, 10731008, 10731135, 10731157, 10731165, 10731395, 10731758, 10732609, 10732878, 10733375, 10733804, 10734558, 10734613, 10743859, 10744214, 10
Service Brakes, Hydraulic:power Assist:vacuum
On June 22, 2015, the Office of Defects Investigations (ODI) opened Preliminary Evaluation PE15-026 to investigate incidents of increased brake pedal effort at cold start and extended stopping distance while driving in traffic, resulting from failures of the electric brake vacuum assist pump in model year (MY) 2011-2012 Ford F-150 pickup trucks equipped with 3.5L GTDI engines. In response to ODI's Information Request (IR) for PE15-026, Ford provided ODI with 396 complaints and field reports relating to incidents of increased brake pedal effort or malfunctions in the electric vacuum pump (EVP). ODI's analysis of the data provided by Ford identified 7 crashes and 1,851 warranty claims related to either a hard brake pedal condition or reduced brake effectiveness. Additionally, ODI identified one report in its database alleging an injury to an occupant of a vehicle struck in the rear by a subject F-150 vehicle with a failed EVP as documented in the police accident report referencing a dealer assessment of the pump.According to Ford, the subject vehicles utilize a traditional brake vacuum booster to provide power assist for braking and the EVP is intended to operate to maintain consistent brake pedal feel. The engine intake manifold is the primary source of vacuum for the booster and is fully compliant to motor vehicle safety standards without the EVP. Ford described the conditions related to a change in brake pedal feel as limited and temporary and provided component failure analysis showing evidence of water entry into the EVP which caused internal pump corrosion. Ford indicated that the EVP failure mode is progressive and provides warning to operators by way of noise and vibration before an operator is likely to experience any temporary change in brake pedal feel. Damage to the EVP motor bearing may eventually result in a blown EVP fuse and total loss of EVP function. Ford provided test data showing the brake pedal forces and pedal travel curves over time for 0.3g decelerations to a stop from 80kph (50mph) for: 1) normal system (full engine and EVP vacuum available); 2) Ford's approximation of worst case booster performance with EVP failure (EVP disabled and booster vacuum regulated to 300mbar to simulate cold start, all accessory loads on, and starting at 0 vacuum); and 3) with all source vacuum to the brake booster removed and Hydraulic Boost Compensation (HBC) active to represent complete loss of brake booster function. The Ford tests showed that the brake pedal forces required for achieving the 0.3g decelerations were relatively low for the normal condition, 35-40 N (8-9 lbf), increased by approximately 2-3 times normal when the EVP is disabled, 75-115 N (17-26 lbf), and increased by about 5-6 times normal for the complete brake booster failure condition, 205-215 N (46-48 lbf). This Preliminary Evaluation has been upgraded to Engineering Analysis (EA15-006) to test for EVP malfunctions under other vehicle operating conditions (e.g., low-speed driveway braking after cold-start with failed EVP), potential human factors contributions and to further assess the scope, frequency, and safety-related consequences of the alleged defect.The VOQs associated with the opening of this investigation are:10565994, 10575987, 10598351, 10604687, 10605701, 10607811, 10610491, 10615536, 10617828, 10619545, 10643075, 10650578, 10662151, 10664415, 10666988, 10668069, 10678844, 10695537, 10700874, 10706217, 10706271, 10712465, 10723033, 10723792, 10726960, 10730549, 10730721, 10730735, 10730837, 10730909, 10731008, 10731135, 10731157, 10731165, 10731395, 10731758, 10732609, 10732878, 10733375, 10733804, 10734558, 10734613, 10743859, 10744214, 10
PE13018 · Reduced Power During Hard Acceleration
Opened May 22, 2013 · Closed Apr 7, 2014
Status: closed (inferred from source dates) · Engine; Engine And Engine Cooling
On May 22, 2013, the Office of Defects Investigation (ODI) opened PE13-018 to investigate 95 complaints alleging incidents of reduced engine power during hard accelerations in model year (MY) 2011 through 2013 Ford F-150 trucks.ODI was aware of three technical service bulletins (TSBs) issued by Ford for a condition that was related to moisture accumulation in the Charge Air Cooler (CAC) for the turbochargers.A Preliminary Evaluation was opened to gather information to assess whether the subject vehicles contain a safety related defect.The subject vehicles are powered by Ford?s 3.5L EcoBoost engine which uses twin turbochargers to obtain a balance of fuel economy and engine power based on the driver?s demand.When the driver requests more power from the engine, as in accelerating to pass, merge, ascend hills or haul a load the two turbochargers will spin up compressing the air which is then used to increase the power created by the combustion in the engine.The compressed air, which gains heat by the compression process, is passed through a Charge Air Cooler (CAC) which is designed to lower the temperature of the air in order to make the combustion process even more efficient (Figures 1 and 2).In response to ODI?s Information Request letter, Ford indicated that a misfire condition could occur after steady-speed operation under significantly humid and rainy conditions.Ford?s analysis found that under those conditions, condensation could form and accumulate on the inside of the CAC tubes which could then be ingested into the engine during particularly hard acceleration near wide-open throttle.An engine misfire of up to three cylinders could occur if the amount of condensed water released from the CAC exceeded the engine?s operating threshold for water ingestion.Ford noted that due to regulations set by the EPA, the powertrain software would disable up to two of the misfiring cylinders for no more than 30 seconds and until the driver tips out the throttle in order to protect the catalytic converter from damage. Ford?s testing of this condition on the subject vehicles showed that a vehicle experiencing such a condition would continue to maintain its speed as well as accelerate, albeit at a lower rate than expected by the driver.Similar results were obtained in testing done by NHTSA?s Vehicle Research and Testing Center in East Liberty, Ohio (Figure 6).In an ongoing process to address the problem Ford issued a series of TSBs where a deflector shield was installed onto the CAC (Figures 3, 4 and 5).In January 2014 Ford indicated that its data shows that the TSBs have been effective in resolving the problem, that for the MY 2013 vehicles their remedy is 100% effective and the latest TSBs for MY 2011 ? 2012 are 95% effective.The 525 complaints to ODI and the total 4,120 unique VIN complaints listed in the Failure Report are incidents of alleged reduced power or driveability symptoms and not all are necessarily related to the condition created by water ingestion.Reduced power conditions can occur for a variety of reasons including faults with ignition coils, spark plugs, a catalytic converter, the throttle body, turbocharger, fuel pump/filter, powertrain control module (hardware or software) or transmission shifting problems.Ford also noted that in a large number of warranty claims on the subject vehicles, the CAC was replaced or a TSB procedure was performed when the symptoms exhibited were inconsistent with a CAC water ingestion related issue.Given these circumstances, further use of the agency resources in this matter does not appear to be warranted.Accordingly, this investigation is closed.The closing of
Additional source detail variants (2)
Engine And Engine Cooling
On May 22, 2013, the Office of Defects Investigation (ODI) opened PE13-018 to investigate 95 complaints alleging incidents of reduced engine power during hard accelerations in model year (MY) 2011 through 2013 Ford F-150 trucks.ODI was aware of three technical service bulletins (TSBs) issued by Ford for a condition that was related to moisture accumulation in the Charge Air Cooler (CAC) for the turbochargers.A Preliminary Evaluation was opened to gather information to assess whether the subject vehicles contain a safety related defect.The subject vehicles are powered by Ford?s 3.5L EcoBoost engine which uses twin turbochargers to obtain a balance of fuel economy and engine power based on the driver?s demand.When the driver requests more power from the engine, as in accelerating to pass, merge, ascend hills or haul a load the two turbochargers will spin up compressing the air which is then used to increase the power created by the combustion in the engine.The compressed air, which gains heat by the compression process, is passed through a Charge Air Cooler (CAC) which is designed to lower the temperature of the air in order to make the combustion process even more efficient (Figures 1 and 2).In response to ODI?s Information Request letter, Ford indicated that a misfire condition could occur after steady-speed operation under significantly humid and rainy conditions.Ford?s analysis found that under those conditions, condensation could form and accumulate on the inside of the CAC tubes which could then be ingested into the engine during particularly hard acceleration near wide-open throttle.An engine misfire of up to three cylinders could occur if the amount of condensed water released from the CAC exceeded the engine?s operating threshold for water ingestion.Ford noted that due to regulations set by the EPA, the powertrain software would disable up to two of the misfiring cylinders for no more than 30 seconds and until the driver tips out the throttle in order to protect the catalytic converter from damage. Ford?s testing of this condition on the subject vehicles showed that a vehicle experiencing such a condition would continue to maintain its speed as well as accelerate, albeit at a lower rate than expected by the driver.Similar results were obtained in testing done by NHTSA?s Vehicle Research and Testing Center in East Liberty, Ohio (Figure 6).In an ongoing process to address the problem Ford issued a series of TSBs where a deflector shield was installed onto the CAC (Figures 3, 4 and 5).In January 2014 Ford indicated that its data shows that the TSBs have been effective in resolving the problem, that for the MY 2013 vehicles their remedy is 100% effective and the latest TSBs for MY 2011 ? 2012 are 95% effective.The 525 complaints to ODI and the total 4,120 unique VIN complaints listed in the Failure Report are incidents of alleged reduced power or driveability symptoms and not all are necessarily related to the condition created by water ingestion.Reduced power conditions can occur for a variety of reasons including faults with ignition coils, spark plugs, a catalytic converter, the throttle body, turbocharger, fuel pump/filter, powertrain control module (hardware or software) or transmission shifting problems.Ford also noted that in a large number of warranty claims on the subject vehicles, the CAC was replaced or a TSB procedure was performed when the symptoms exhibited were inconsistent with a CAC water ingestion related issue.Given these circumstances, further use of the agency resources in this matter does not appear to be warranted.Accordingly, this investigation is closed.The closing of
Engine
On May 22, 2013, the Office of Defects Investigation (ODI) opened PE13-018 to investigate 95 complaints alleging incidents of reduced engine power during hard accelerations in model year (MY) 2011 through 2013 Ford F-150 trucks.ODI was aware of three technical service bulletins (TSBs) issued by Ford for a condition that was related to moisture accumulation in the Charge Air Cooler (CAC) for the turbochargers.A Preliminary Evaluation was opened to gather information to assess whether the subject vehicles contain a safety related defect.The subject vehicles are powered by Ford?s 3.5L EcoBoost engine which uses twin turbochargers to obtain a balance of fuel economy and engine power based on the driver?s demand.When the driver requests more power from the engine, as in accelerating to pass, merge, ascend hills or haul a load the two turbochargers will spin up compressing the air which is then used to increase the power created by the combustion in the engine.The compressed air, which gains heat by the compression process, is passed through a Charge Air Cooler (CAC) which is designed to lower the temperature of the air in order to make the combustion process even more efficient (Figures 1 and 2).In response to ODI?s Information Request letter, Ford indicated that a misfire condition could occur after steady-speed operation under significantly humid and rainy conditions.Ford?s analysis found that under those conditions, condensation could form and accumulate on the inside of the CAC tubes which could then be ingested into the engine during particularly hard acceleration near wide-open throttle.An engine misfire of up to three cylinders could occur if the amount of condensed water released from the CAC exceeded the engine?s operating threshold for water ingestion.Ford noted that due to regulations set by the EPA, the powertrain software would disable up to two of the misfiring cylinders for no more than 30 seconds and until the driver tips out the throttle in order to protect the catalytic converter from damage. Ford?s testing of this condition on the subject vehicles showed that a vehicle experiencing such a condition would continue to maintain its speed as well as accelerate, albeit at a lower rate than expected by the driver.Similar results were obtained in testing done by NHTSA?s Vehicle Research and Testing Center in East Liberty, Ohio (Figure 6).In an ongoing process to address the problem Ford issued a series of TSBs where a deflector shield was installed onto the CAC (Figures 3, 4 and 5).In January 2014 Ford indicated that its data shows that the TSBs have been effective in resolving the problem, that for the MY 2013 vehicles their remedy is 100% effective and the latest TSBs for MY 2011 ? 2012 are 95% effective.The 525 complaints to ODI and the total 4,120 unique VIN complaints listed in the Failure Report are incidents of alleged reduced power or driveability symptoms and not all are necessarily related to the condition created by water ingestion.Reduced power conditions can occur for a variety of reasons including faults with ignition coils, spark plugs, a catalytic converter, the throttle body, turbocharger, fuel pump/filter, powertrain control module (hardware or software) or transmission shifting problems.Ford also noted that in a large number of warranty claims on the subject vehicles, the CAC was replaced or a TSB procedure was performed when the symptoms exhibited were inconsistent with a CAC water ingestion related issue.Given these circumstances, further use of the agency resources in this matter does not appear to be warranted.Accordingly, this investigation is closed.The closing of