NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
141 reports55,666 miles · May 1, 2013
Engine And Engine Cooling
ON NUMEROUS OCCASIONS MY 08 FORD F250 6.4 HAS HAD EXCESSIVE BLUISH WHITE SMOKE FROM THE EXHAUST WHILE DRIVING AND LASTS AROUND 20 SECONDS. DEALER WAS NOTIFIED AND SITUATION MET ALL CRITERIA OUTLINED IN TSB 11-2-2. CAC WAS REPLACED. HOWEVER, VEHICLE STILL INTERMITTENTLY HAS SAME PROBLEM. ON ONE OCCURRENCE THE SMOKE WAS SO EXCESS…
Read full complaint
ON NUMEROUS OCCASIONS MY 08 FORD F250 6.4 HAS HAD EXCESSIVE BLUISH WHITE SMOKE FROM THE EXHAUST WHILE DRIVING AND LASTS AROUND 20 SECONDS. DEALER WAS NOTIFIED AND SITUATION MET ALL CRITERIA OUTLINED IN TSB 11-2-2. CAC WAS REPLACED. HOWEVER, VEHICLE STILL INTERMITTENTLY HAS SAME PROBLEM. ON ONE OCCURRENCE THE SMOKE WAS SO EXCESSIVE THAT A MOTORCYCLE TRAVELING BEHIND ME ALMOST RAN OFF THE ROAD DUE TO VISIBILITY. FORD STATES THAT THIS IS NORMAL.
NHTSA ODI #10512134
6,240 miles · Apr 30, 2013
Engine And Engine Cooling
ON 2 OCT 2008, RADIATOR WAS DISCOVERED TO BE CRACKED AND LEAKING AT LEFT LOWER CORNER AT 6,240 MILES AND WAS REPLACED BY FORD UNDER 3YR/36000 WARRANTY. FORD INSTALLED DEGAS BOTTLE "T" FITTING TO ELIMINATE ANY FURTHER RADIATOR FAILURE. ON 12 MAR 2012, RADIATOR WAS DISCOVERED TO BE CRACKED AND LEAKING FROM LEFT LOWER CORNER AT 47…
Read full complaint
ON 2 OCT 2008, RADIATOR WAS DISCOVERED TO BE CRACKED AND LEAKING AT LEFT LOWER CORNER AT 6,240 MILES AND WAS REPLACED BY FORD UNDER 3YR/36000 WARRANTY. FORD INSTALLED DEGAS BOTTLE "T" FITTING TO ELIMINATE ANY FURTHER RADIATOR FAILURE. ON 12 MAR 2012, RADIATOR WAS DISCOVERED TO BE CRACKED AND LEAKING FROM LEFT LOWER CORNER AT 47,895 MILES. FORD SAID FAILURE WAS CAUSED DUE TO AN HYPER-EXTENDED THERMOSTAT. FORD REPLACED THERMOSTAT UNDER WARRANTY BUT WOULD NOT COVER RADIATOR UNDER WARRANTY. RADIATOR WAS REPLACED BY NON-FORD MECHANIC. ON 25 APR 2013 RADIATOR WAS DISCOVERED TO BE CRACKED AND LEAKING FROM RIGHT SIDE SEAM AT 58,520 MILES. FORD WAS CONTACTED AND OFFERED NO HELP OUTSIDE OF WARRANTY. RADIATOR WAS REPLACED BY NON-FORD MECHANIC OUTSIDE OF WARRANTY. IT DOESN'T TAKE A ROCKET SCIENTIST TO KNOW THERE IS SOMETHING SERIOUSLY WRONG WITH THE 08 F250 6.4 COOLING SYSTEMS THAT FORD FAILS TO TAKE RESPONSIBILITY FOR. I TOW A 35FT 5TH WHEEL SEVERAL TIMES A YEAR AND MY BIGGEST FEAR IS THE RADIATOR GOING OUT WHILE TOWING. IF THE RADIATOR BLEW AND THE TRUCK WENT INTO "REDUCED POWER" MODE, THERE IS A GREAT POSSIBILITY THAT A LIFE THREATENING INCIDENT COULD OCCUR, ESPECIALLY WHILE TOWING ON A STEP INCLINE. I HOPE FORD FIGURES THIS OUT SOON BEFORE SOMEONE GETS HURT.
NHTSA ODI #10512136
Mileage unknown · Apr 9, 2013
Engine And Engine Cooling
CPSC# I1310184A. 2008 FORD F-250. CONSUMER STATED THAT HE HAS HAD NUMEROUS PROBLEMS WITH THE COOLING SYSTEM. STATED THE RADIATOR WAS LEAKING ALSO. *LN THE CONSUMER STATED HE WAS LOOSING A GALLON OF COOLANT A WEEK. IT WAS GOING THROUGH THE AIR CHARGE AND OUT THE EXHAUST. AT 89,000 MILES, HE HAD TO PAY $ 1947.00 TO REPLACE BOTH T…
Read full complaint
CPSC# I1310184A. 2008 FORD F-250. CONSUMER STATED THAT HE HAS HAD NUMEROUS PROBLEMS WITH THE COOLING SYSTEM. STATED THE RADIATOR WAS LEAKING ALSO. *LN THE CONSUMER STATED HE WAS LOOSING A GALLON OF COOLANT A WEEK. IT WAS GOING THROUGH THE AIR CHARGE AND OUT THE EXHAUST. AT 89,000 MILES, HE HAD TO PAY $ 1947.00 TO REPLACE BOTH THE VERTICAL AND HORIZONTAL EGR COOLERS. AGAIN, DUMPING A GALLON OF COOLANT INTO THE EXHAUST SYSTEM A WEEK WHICH CAUSED SEVERE SMOKING.
NHTSA ODI #10508006
179,000 miles · Apr 1, 2013
EngineFire
TL* THE CONTACT OWNS A 2008 FORD F-250 SD. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS HE NOTICED THAT WHITE SMOKE WOULD EMIT FROM THE EXHAUST SYSTEM. THE CONTACT STATED THAT THE EXHAUST SYSTEM WAS EQUIPPED WITH A SELF-CLEANING FUNCTION HOWEVER, THE WHITE SMOKE STILL EMITTED AFTER THE FUNCTION WAS COMPLETED. THE VEHI…
Read full complaint
TL* THE CONTACT OWNS A 2008 FORD F-250 SD. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS HE NOTICED THAT WHITE SMOKE WOULD EMIT FROM THE EXHAUST SYSTEM. THE CONTACT STATED THAT THE EXHAUST SYSTEM WAS EQUIPPED WITH A SELF-CLEANING FUNCTION HOWEVER, THE WHITE SMOKE STILL EMITTED AFTER THE FUNCTION WAS COMPLETED. THE VEHICLE WAS NOT TAKEN TO THE DEALER OR AN INDEPENDENT MECHANIC. THE MANUFACTURER WAS CONTACTED AND THEY OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 179,000. THE CURRENT MILEAGE WAS APPROXIMATELY 180,000. THE VIN WAS UNAVAILABLE. *TR
NHTSA ODI #10505223
130,000 miles · Mar 1, 2013
Steering
STEERING IS HORRIBLE IN THESE TRUCKS! FORD SHOULD BE ASHAMED. THERE IS PLAY IN THE STEERING. DRIVING STRAIGHT DOWN THE ROAD THE STEERING WHEEL CAN EXHIBIT 1/4 TURN OF PLAY EITHER RIGHT OR LEFT, BUT THE TIRES AND TRUCK ARE STRAIGHT! NOW IF THAT'S NOT UNSAFE, I DON'T KNOW WHAT IS! I HAVE NO LIFT, AND STOCK TIRES. THE ALIGNMENT IS …
Read full complaint
STEERING IS HORRIBLE IN THESE TRUCKS! FORD SHOULD BE ASHAMED. THERE IS PLAY IN THE STEERING. DRIVING STRAIGHT DOWN THE ROAD THE STEERING WHEEL CAN EXHIBIT 1/4 TURN OF PLAY EITHER RIGHT OR LEFT, BUT THE TIRES AND TRUCK ARE STRAIGHT! NOW IF THAT'S NOT UNSAFE, I DON'T KNOW WHAT IS! I HAVE NO LIFT, AND STOCK TIRES. THE ALIGNMENT IS STRAIGHT. I HAVE FOUND NUMEROUS COMPLAINTS ON FORUMS OF STEERING GEAR PROBLEMS. I HAD MY STEERING LOOKED AT AND MECHANICS ARE CLUELESS. THIS IS A FORD TRUCK PROBLEM THAT HAS BEEN AN ISSUE FOR YEARS. STEERING SHOULD BE TIGHT AND PRECISE NOT SLOPPY. I AM BEGGING THE NHTSA TO AT LEAST LOOK INTO THESE, THIS MATTER IS WORTHY OF YOUR TIME AND I AM SURE AN INVESTIGATION WILL REVEAL NUMEROUS COMPLAINTS OF STEERING BOXES THAT GO LOOSE OR WEAR PREMATURELY AND STEERING COMPONENTS THAT BREAK. I AM SURE FORD HAS RECORDS OF THOUSANDS OF COMPLAINTS AND REPAIRS ON THIS BECAUSE ITS BEEN A PROBLEM FOR YEARS AND CONTINUES TO BE A PROBLEM. *TR
NHTSA ODI #10500992
44,000 miles · Feb 13, 2013
Fuel System, DieselFuel/propulsion SystemSteering
THE STEERING WHEEL STARTED TO GET SOME PLAY WHILE DRIVING DOWN THE INTERSTATE. THE STEERING EVENTUALLY WENT COMPLETELY OUT. THE STEERING WHEEL WOULD SPIN FREELY WITHOUT THE WHEELS MOVING WHATSOEVER. *TR
NHTSA ODI #10497982
107,000 miles · Dec 28, 2012
Engine
EXHAUST LEAK FROM BEHIND THE TURBO. EXHAUST ENTERS THE INSIDE OF THE CAB. SEEMS TO BE A COMMON PROBLEM. EXPENSIVE TO FIX. MUST REMOVE CAB FROM FRAME TO REPAIR. HAZARDOUS FUMES ENTER VEHICLE CAUSING HEADACHES. DEALER IS ACTING LIKE THIS IS RARE BUT IN SEARCHING THE WEB I HAVE SEEN NUMEROUS COMPLAINTS OF THE SAME PROBLEM I AM HAVI…
Read full complaint
EXHAUST LEAK FROM BEHIND THE TURBO. EXHAUST ENTERS THE INSIDE OF THE CAB. SEEMS TO BE A COMMON PROBLEM. EXPENSIVE TO FIX. MUST REMOVE CAB FROM FRAME TO REPAIR. HAZARDOUS FUMES ENTER VEHICLE CAUSING HEADACHES. DEALER IS ACTING LIKE THIS IS RARE BUT IN SEARCHING THE WEB I HAVE SEEN NUMEROUS COMPLAINTS OF THE SAME PROBLEM I AM HAVING. *TR ## VIN FAILED ##
NHTSA ODI #10490351
14,545 miles · Nov 30, 2012
Power Train
TL*THE CONTACT OWNS A 2008 FORD F-250 SD. THE CONTACT STATED THAT HE RECEIVED NOTIFICATION OF A MANUFACTURER'S RECALL AND TOOK THE VEHICLE TO THE DEALER FOR RECALIBRATION. AFTER THE RECALL SERVICE, THE CONTACT WAS DRIVING APPROXIMATELY 50-60 MPH WHEN THE TRANSMISSION STARTED TO SLIP. THE VEHICLE WAS TAKEN BACK TO THE DEALER WHE…
Read full complaint
TL*THE CONTACT OWNS A 2008 FORD F-250 SD. THE CONTACT STATED THAT HE RECEIVED NOTIFICATION OF A MANUFACTURER'S RECALL AND TOOK THE VEHICLE TO THE DEALER FOR RECALIBRATION. AFTER THE RECALL SERVICE, THE CONTACT WAS DRIVING APPROXIMATELY 50-60 MPH WHEN THE TRANSMISSION STARTED TO SLIP. THE VEHICLE WAS TAKEN BACK TO THE DEALER WHERE THEY ADVISED THE CONTACT THAT HE WOULD HAVE TO DRIVE THE VEHICLE AROUND FOR A WHILE UNTIL IT FUNCTIONED NORMALLY. THE MANUFACTURER WAS CONTACTED AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 14,545. THE CURRENT MILEAGE WAS APPROXIMATELY 17,344. THE CONSUMER STATED WHILE DRIVING AT AN ESTIMATED SPEED OF 50-60 MPH AND ATTEMPTING A FORCED DOWN SHIFT, THE TRANSMISSION SHIFTED INTO 3RD GEAR INSTEAD OF 4TH GEAR CAUSING RAPID REAR WHEEL DECELERATION AND HIGH ENGINE RPM TO OCCUR. IT OCCURRED IMMEDIATELY FOLLOWING SERVICING OF THE PCM PER THE MANUFACTURER'S RECALL. THE DEALER ADVISED THE CONSUMER TO DRIVE THE VEHICLE UP TO 500 MILES WHILE THE TRANSMISSION RE-LEARN ITS SHIFT TO POINTS. AFTER COMPLYING WITH THE DEALERS REQUEST, THE CONSUMER CONTINUED TO EXPERIENCE THE PROBLEM. THE DEALER INFORMED THE CONSUMER THERE WAS NOTHING WRONG WITH THE TRANSMISSION AND IT WAS PERFORMING AS DESIGNED. UPDATED 12/19/12.. UPDATED 12/31/12 *BF UPDATED 1/3/2013 *JS
NHTSA ODI #10486552
21,000 miles · Nov 12, 2012
Service Brakes, Hydraulic
I WAS ON MY WAY TO THE BUILDING SUPPLY WITH THE TRUCK. I WAS TOWING A SMALL UTILITY TRAILER. AS I APPROACHED A FAIRLY SHARP CURVE I APPLIED THE BRAKES AND THE PEDAL WENT TO THE FLOOR. THE TRUCK BRAKES WERE GONE WITHOUT WARNING. THE TRAILER BRAKES LOCKED AND SLOWED THE VEHICLE ENOUGH TO GET SAFELY THROUGH THE TURN. I RELIED ON T…
Read full complaint
I WAS ON MY WAY TO THE BUILDING SUPPLY WITH THE TRUCK. I WAS TOWING A SMALL UTILITY TRAILER. AS I APPROACHED A FAIRLY SHARP CURVE I APPLIED THE BRAKES AND THE PEDAL WENT TO THE FLOOR. THE TRUCK BRAKES WERE GONE WITHOUT WARNING. THE TRAILER BRAKES LOCKED AND SLOWED THE VEHICLE ENOUGH TO GET SAFELY THROUGH THE TURN. I RELIED ON THE TRAILER BRAKES AND THE TRANSMISSION TO COMPLETE THE TRIP AND GET THE VEHICLE SAFELY HOME. WHEN I GOT HOME I CALLED THE DEALER AND HAD THE TRUCK TOWED THERE FOR REPAIR. THE DEALER SAID THAT THE FAILURE WAS DUE TO BADLY WORN BRAKE PADS CAUSING THE CALIPERS TO OVEREXTEND AND A CALIPER PISTON SEAL HAD FAILED. PADS ON ALL 4 WHEELS WERE BADLY WORN. IT WAS THE LEFT REAR CALIPER THAT FAILED. I DO NOT UNDERSTAND HOW THE BRAKES CAN BE THIS BADLY WORN AFTER ONLY 21,000 MILES.
NHTSA ODI #10485463
29,107 miles · Oct 4, 2012
Steering
TL* THE CONTACT OWNS A 2008 FORD F-250 SD. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 10 MPH, HE NOTICED THE STEERING WHEEL FELT LOOSE AND MOVED TO THE SIDES INDEPENDENTLY. THE VEHICLE WAS TAKEN TO THE DEALER WHO STATED THAT THE STEERING BOX NEEDED TO BE REPLACED. THE VIN WAS NOT AVAILABLE. THE VEHICLE WAS NOT REPAIRED.…
Read full complaint
TL* THE CONTACT OWNS A 2008 FORD F-250 SD. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 10 MPH, HE NOTICED THE STEERING WHEEL FELT LOOSE AND MOVED TO THE SIDES INDEPENDENTLY. THE VEHICLE WAS TAKEN TO THE DEALER WHO STATED THAT THE STEERING BOX NEEDED TO BE REPLACED. THE VIN WAS NOT AVAILABLE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 29,107.
NHTSA ODI #10478585
NHTSA investigations
1PE13014 · Alleged Loss Of Steering
Opened May 7, 2013 · Closed Jan 31, 2014
Status: closed (inferred from source dates) · Steering; Steering:gear Box (other Than Rack And Pinion)
The Office of DefectsInvestigation (ODI) opened PE13-014 after identifying five complaints alleging steering gear failure in model year (MY) 2008 Ford F-250 and F-350 Super Duty pick-up trucks and to evaluate the relationship between the design history of the steering gear assembly and the alleged defect.As background, ODI investigated steering gear sector shaft fractures in approximately 1.3 million MY 1999 - 2001 Ford Super Duty pick-up trucks and MY 2000 - 2001 Ford Excursion sport utility vehicles in Engineering Analysis EA01-009.The investigation determined that the sector shaft failures were the result of extraordinary, possibly multiple, impacts and not the result of fatigue.No defect in design, manufacturing or materials was identified in the sector shaft.EA01-009 was closed August 19, 2003 with 169 complaints, resulting in a rate of 12.9 incidents per 100,000 vehicles after approximately one year of service.Ford increased the diameter of the sector shaft from 1.375 inches to 1.625 inches at the start of MY 2005 production, increasing the resistance of the steering gear assembly to torsional overload by approximately 48% and changing the failure mode from sector shaft fracture to cracked or broken sector shaft gear teeth.The redesigned steering gear assembly was used in approximately 1.1 million MY 2005 through 2009 Ford Super Duty pick-up trucks, including the subject vehicles.Figure 1 shows the basic steering system design used in Ford Super Duty trucks investigated in EA01-009 and PE13-014. Figure 2 shows the locations of failures resulting from impact related torsional overloading of the sector shaft for the subject vehicles and the prior generation Ford Super Duty trucks investigated in EA01-009.Figure 3 shows an example of a failed sector shaft investigated in EA01-009 and comparisons of fracture surfaces of sector shafts failing from fatigue loading and from torsional overload.Ford provided field return part analysis of failed steering gears from MY 2005 through 2009 Super Duty trucks found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload (Figure 4).Laboratory analysis found no evidence of fatigue or material property defects in any of the fractures.Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns (Figure 5).Analysis of failures by time in service indicates a random failure pattern/distribution, consistent with incidents of impact induced overload (Figure 6). The complaint rate for the subject vehicles after approximately 5 to 6 years, 7.1 incidents per 100,000 vehicles, is lower than the rate observed in EA01-009. Furthermore, similar to the condition investigated in EA01-009, a number of incident records include evidence of impact loads (e.g., curb strikes) and several alleged crashes include incidents in which information suggests that the steering gear failure was most likely a result of crash forces, rather than the cause of the crash.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at ww
Additional source detail variants (2)
Steering
The Office of DefectsInvestigation (ODI) opened PE13-014 after identifying five complaints alleging steering gear failure in model year (MY) 2008 Ford F-250 and F-350 Super Duty pick-up trucks and to evaluate the relationship between the design history of the steering gear assembly and the alleged defect.As background, ODI investigated steering gear sector shaft fractures in approximately 1.3 million MY 1999 - 2001 Ford Super Duty pick-up trucks and MY 2000 - 2001 Ford Excursion sport utility vehicles in Engineering Analysis EA01-009.The investigation determined that the sector shaft failures were the result of extraordinary, possibly multiple, impacts and not the result of fatigue.No defect in design, manufacturing or materials was identified in the sector shaft.EA01-009 was closed August 19, 2003 with 169 complaints, resulting in a rate of 12.9 incidents per 100,000 vehicles after approximately one year of service.Ford increased the diameter of the sector shaft from 1.375 inches to 1.625 inches at the start of MY 2005 production, increasing the resistance of the steering gear assembly to torsional overload by approximately 48% and changing the failure mode from sector shaft fracture to cracked or broken sector shaft gear teeth.The redesigned steering gear assembly was used in approximately 1.1 million MY 2005 through 2009 Ford Super Duty pick-up trucks, including the subject vehicles.Figure 1 shows the basic steering system design used in Ford Super Duty trucks investigated in EA01-009 and PE13-014. Figure 2 shows the locations of failures resulting from impact related torsional overloading of the sector shaft for the subject vehicles and the prior generation Ford Super Duty trucks investigated in EA01-009.Figure 3 shows an example of a failed sector shaft investigated in EA01-009 and comparisons of fracture surfaces of sector shafts failing from fatigue loading and from torsional overload.Ford provided field return part analysis of failed steering gears from MY 2005 through 2009 Super Duty trucks found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload (Figure 4).Laboratory analysis found no evidence of fatigue or material property defects in any of the fractures.Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns (Figure 5).Analysis of failures by time in service indicates a random failure pattern/distribution, consistent with incidents of impact induced overload (Figure 6). The complaint rate for the subject vehicles after approximately 5 to 6 years, 7.1 incidents per 100,000 vehicles, is lower than the rate observed in EA01-009. Furthermore, similar to the condition investigated in EA01-009, a number of incident records include evidence of impact loads (e.g., curb strikes) and several alleged crashes include incidents in which information suggests that the steering gear failure was most likely a result of crash forces, rather than the cause of the crash.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at ww
Steering:gear Box (other Than Rack And Pinion)
The Office of DefectsInvestigation (ODI) opened PE13-014 after identifying five complaints alleging steering gear failure in model year (MY) 2008 Ford F-250 and F-350 Super Duty pick-up trucks and to evaluate the relationship between the design history of the steering gear assembly and the alleged defect.As background, ODI investigated steering gear sector shaft fractures in approximately 1.3 million MY 1999 - 2001 Ford Super Duty pick-up trucks and MY 2000 - 2001 Ford Excursion sport utility vehicles in Engineering Analysis EA01-009.The investigation determined that the sector shaft failures were the result of extraordinary, possibly multiple, impacts and not the result of fatigue.No defect in design, manufacturing or materials was identified in the sector shaft.EA01-009 was closed August 19, 2003 with 169 complaints, resulting in a rate of 12.9 incidents per 100,000 vehicles after approximately one year of service.Ford increased the diameter of the sector shaft from 1.375 inches to 1.625 inches at the start of MY 2005 production, increasing the resistance of the steering gear assembly to torsional overload by approximately 48% and changing the failure mode from sector shaft fracture to cracked or broken sector shaft gear teeth.The redesigned steering gear assembly was used in approximately 1.1 million MY 2005 through 2009 Ford Super Duty pick-up trucks, including the subject vehicles.Figure 1 shows the basic steering system design used in Ford Super Duty trucks investigated in EA01-009 and PE13-014. Figure 2 shows the locations of failures resulting from impact related torsional overloading of the sector shaft for the subject vehicles and the prior generation Ford Super Duty trucks investigated in EA01-009.Figure 3 shows an example of a failed sector shaft investigated in EA01-009 and comparisons of fracture surfaces of sector shafts failing from fatigue loading and from torsional overload.Ford provided field return part analysis of failed steering gears from MY 2005 through 2009 Super Duty trucks found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload (Figure 4).Laboratory analysis found no evidence of fatigue or material property defects in any of the fractures.Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns (Figure 5).Analysis of failures by time in service indicates a random failure pattern/distribution, consistent with incidents of impact induced overload (Figure 6). The complaint rate for the subject vehicles after approximately 5 to 6 years, 7.1 incidents per 100,000 vehicles, is lower than the rate observed in EA01-009. Furthermore, similar to the condition investigated in EA01-009, a number of incident records include evidence of impact loads (e.g., curb strikes) and several alleged crashes include incidents in which information suggests that the steering gear failure was most likely a result of crash forces, rather than the cause of the crash.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at ww
Illustration