NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
141 reports26,000 miles · Oct 4, 2012
Service Brakes
AFTER A 10 MILE TRIP , GOT TO MY HOME AND REAR DRIVER BRAKE WAS SMOKING. I HAD CONTINUALLY COMPLAINED TO LOCAL FORD DEALERSHIP ABOUT EXCESSIVE HEAT I.E. YOU COULD HEAR CRACKLING AFTER PARKING THE VEHICLE. I BOUGHT A CENTEC HAND LASER HEAT TEMPERATURE LCD GUN AND DEMONSTRATED TO THE FORD SERVICE MANAGER THAT ALL DISCS HAD EX…
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AFTER A 10 MILE TRIP , GOT TO MY HOME AND REAR DRIVER BRAKE WAS SMOKING. I HAD CONTINUALLY COMPLAINED TO LOCAL FORD DEALERSHIP ABOUT EXCESSIVE HEAT I.E. YOU COULD HEAR CRACKLING AFTER PARKING THE VEHICLE. I BOUGHT A CENTEC HAND LASER HEAT TEMPERATURE LCD GUN AND DEMONSTRATED TO THE FORD SERVICE MANAGER THAT ALL DISCS HAD EXCESSIVE HEAT. THEY CLAIMED THEY SERVICED THE BRAKES. CONTINUALLY BLAMED THE NEW YORK WINTER AND SALT. SINCE I GOT MY LAST SERVICE SATISFACTION SURVEY SHORTLY AFTER THIS SMOKING INCIDENT, I WROTE THAT FORD SHOULD RECALL THESE TRUCKS FOR THIS PROBLEM SINCE THE DEALERSHIPS EITHER CANNOT FIX THE PROBLEM OR WAIT TILL THE WARRANTY IS UP(IS FORD ITSELF COVERING UP?) I REPLACED THE CALIPER MYSELF IN MY YARD SINCE I FELT IT WAS UNSAFE. THE PISTONS IN THESE CALIPERS FREEZE UP DUE TO A MANUFACTURER DEFECT. *TR
NHTSA ODI #10478567
70,000 miles · Sep 18, 2012
Engine And Engine CoolingPower TrainFire
TL* THE CONTACT OWNS A 2008 FORD F-250 SD. WHILE DRIVING APPROXIMATELY 50 MPH, THE TURBO ENGINE STALLED WITH AN ILLUMINATION OF A WARNING INDICATOR. THE VEHICLE BEGAN TO PERFORM ROUGHLY WITH SMOKE AND FLAMES EMITTING FROM THE EXHAUST. WHEN THE ENGINE WAS TURNED OFF THE FLAMES WERE NO LONGER VISIBLE. THE VEHICLE WAS TOWED TO AN A…
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TL* THE CONTACT OWNS A 2008 FORD F-250 SD. WHILE DRIVING APPROXIMATELY 50 MPH, THE TURBO ENGINE STALLED WITH AN ILLUMINATION OF A WARNING INDICATOR. THE VEHICLE BEGAN TO PERFORM ROUGHLY WITH SMOKE AND FLAMES EMITTING FROM THE EXHAUST. WHEN THE ENGINE WAS TURNED OFF THE FLAMES WERE NO LONGER VISIBLE. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER WHO STATED THE TURBO CHARGER WOULD NEED TO BE REPLACED AND INCLUDING OTHER DEFECTIVE PARTS. THE FAILURE WAS RELATED TO THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER 07V139000 (POWER TRAIN: AUTOMATIC TRANSMISSION: CONTROL MODULE (TCM, PCM)). THE CONTACT EXPERIENCED THE IDENTICAL DEFECT AS STATED IN THE RECALL. THE MANUFACTURER WAS NOTIFIED AND THEY INFORMED THE CONTACT THAT THE VIN WAS NOT INCLUDED IN THE RECALL. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 70,000. UPDATED 11/01/12*LJ
NHTSA ODI #10475851
39,000 miles · Jul 8, 2012
Engine
I NOTICED THAT SOMETHING WAS DRIPPING FROM THE FRONT END OF MY TRUCK AND SUSPECTED THAT THE RADIATOR WAS LEAKING. I TOOK IT TO THE DEALERSHIP TO DIAGNOSE THE PROBLEM. I ALSO GAVE THEM SEVERAL TSBSS CONCERNING THE RADIATOR LEAK TO MAKE THEM AWARE THAT THIS IS A KNOWN PROBLEM TO FORD. OBVIOUSLY THEY CALLED ME BACK AND SAID THAT TH…
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I NOTICED THAT SOMETHING WAS DRIPPING FROM THE FRONT END OF MY TRUCK AND SUSPECTED THAT THE RADIATOR WAS LEAKING. I TOOK IT TO THE DEALERSHIP TO DIAGNOSE THE PROBLEM. I ALSO GAVE THEM SEVERAL TSBSS CONCERNING THE RADIATOR LEAK TO MAKE THEM AWARE THAT THIS IS A KNOWN PROBLEM TO FORD. OBVIOUSLY THEY CALLED ME BACK AND SAID THAT THE ENTIRE COOLING SYSTEM (RADIATOR, HOSES AND DEGAS BOTTLE) NEEDED REPLACEMENT, IT WASN'T UNDER WARRANTY AND I WOULD NEED TO PAY $1,776. I ONLY HAVE 39K MILES ON IT AND I NEVER THOUGHT THAT I WOULD BE REPLACING A RADIATOR THIS SOON. I HAVE ALWAYS BABIED THIS TRUCK AND MAINTAINED IT REGULARLY. I FEEL THAT FORD KNEW ABOUT THIS DESIGN FLAW AND SHOULD BE HELD ACCOUNTABLE FOR THE COSTS INCURRED BY ME TO REPAIR THE PROBLEM. WHO IS TO SAY THAT THIS MAY NOT OCCUR AGAIN DOWN THE ROAD? I HAVE READ THAT IT IS NOT UNCOMMON FOR TRUCKS NEEDING SEVERAL REPLACEMENT RADIATORS. IT'S CONCERNING TO ME THAT FORD CAN GET AWAY WITH THIS KIND OF DESIGN FLAW (OR SCAM) WITHOUT ANY REPERCUSSION FROM OUR GOVERNMENT. *TR
NHTSA ODI #10464620
128,000 miles · Jun 14, 2012
Engine And Engine Cooling
LIFTERS AND CAM HAVE FAILED. AND HAS TRASHED THE MOTOR. HAVE ASKED FOR HELP FROM FORD AND THEY HAVE DENIED CLAIM. THE PROBLEM WITH THIS IS THAT $55,000.00 TRUCK THAT IS ADVERTISED TO BE SUPER DUTY AND SHOULD LAST 400000 TO 500000 MILES WITH ONLY MINER ENGINE REPAIRS, THIS SHOULD NOT BE HAPPENING. FORD KNOWS FOR A FACT THAT THEY …
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LIFTERS AND CAM HAVE FAILED. AND HAS TRASHED THE MOTOR. HAVE ASKED FOR HELP FROM FORD AND THEY HAVE DENIED CLAIM. THE PROBLEM WITH THIS IS THAT $55,000.00 TRUCK THAT IS ADVERTISED TO BE SUPER DUTY AND SHOULD LAST 400000 TO 500000 MILES WITH ONLY MINER ENGINE REPAIRS, THIS SHOULD NOT BE HAPPENING. FORD KNOWS FOR A FACT THAT THEY HAVE A FAULTY MOTOR AND FAULTY INTERNAL PARTS ON ALL THE 2008 THRU 2010 6.4 L DIESEL MOTORS. THAT'S WHY THEY DESIGNED A NEW MOTOR AND ARE SUING NAVISTAR THE ENGINE DESIGNER. NOW YOU CAN GO ALL OVER THE INTERNET AND FIND THOUSANDS OF CUSTOMERS WITH THE SAME PROBLEMS AND MORE. FORD KNOWS THAT THE LIFTERS WILL FAIL AT SOME PREMATURE POINT, AND THE ROCKER ARMS WILL BREAK. ONE OF THE PROBLEMS IS THAT THERE IS SO MUCH BACK PRESSURE ON THE MOTOR DUE TOO THE PARTICULATE FILTER. THAT HAS EVEN BEEN RE-DEIGNED IN THERE NEW 6.7 MOTOR. WHY IS THERE NOT A RECALL ON THIS MOTOR OR SOME KIND OF MANDATORY RETROFIT OR FINANCIAL AID TO FIX THESE PROBLEMS. ON ANOTHER NOTE I HAVE ALL MOST HAD A LEAST 8 HEAD ON COLLISIONS FROM LOST POWER DUE TO THE EGR COOLERS FAILING OR THE PARTICULATE FILTER CLOGGING UP. THIS IS A COMMON PROBLEM WITH THIS ENGINE ALSO YOU CAN BE IN GREAT DANGER WHEN TRYING TO PASS SOMEONE. I HOPE TO HEAR FROM SOME ONE SOON.. THANK YOU IN THIS MATTER. HOW CAN FORD TURN THEIR BACKS ON LOYAL AMERICANS.......
NHTSA ODI #10461797
104,000 miles · May 1, 2012
Steering
2008 FORD F-250 SUPERDUTY DRIVING AT 40-70 MPH STRAIGHT OR TURNING (IE: ON A FREEWAY FLY-OVER). THE FRONT-END SHAKES/SHIMMIES WHEN YOU HIT A BUMP, POTHOLE, OR SURFACE THAT IS UNEVEN TO THE POINT YOU LOSE CONTROL OF VEHICLE. HAPPENS MOST ALL THE TIME IF ON FLY-OVER, AND ON STRAIGHT ROADS SOMETIMES. HIT A MINOR SEAM IN THE PAVED R…
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2008 FORD F-250 SUPERDUTY DRIVING AT 40-70 MPH STRAIGHT OR TURNING (IE: ON A FREEWAY FLY-OVER). THE FRONT-END SHAKES/SHIMMIES WHEN YOU HIT A BUMP, POTHOLE, OR SURFACE THAT IS UNEVEN TO THE POINT YOU LOSE CONTROL OF VEHICLE. HAPPENS MOST ALL THE TIME IF ON FLY-OVER, AND ON STRAIGHT ROADS SOMETIMES. HIT A MINOR SEAM IN THE PAVED ROAD AND THE FRONT END STARTED TO WOBBLE (KNOWN ON MANY INTERNET SITES AT THE "FORD DEATH WOBBLE." THERE WAS A FORD TECHNICAL SERVICE BULLETIN ISSUED FOR THIS PROBLEM THAT DEALS WITH THE STEERING GEARBOX NEEDING REPLACEMENT. SEEMS THAT THIS A REAL SAFETY HAZARD WITH NO RECALLS ON THIS PART MALFUNCTIONING. *JS
NHTSA ODI #10456980
55,000 miles · Apr 17, 2012
Service Brakes, HydraulicSteering
SLOWING DOWN TO EXIT HIGHWAY AND LOST ALL POWER STEERING AND POWER BRAKES AS IF THE TRUCK SHUT OFF, BUT IT WAS STILL RUNNING. *JS
NHTSA ODI #10455488
40,200 miles · Apr 16, 2012
Steering
TL* THE CONTACT OWNS A 2008 FORD F-250 SD. WHILE DRIVING APPROXIMATELY 50 MPH, THE CONTACT NOTICED THAT THE VEHICLE WOULD NOT IMMEDIATELY RESPOND WHEN THE STEERING WHEEL WAS TURNED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR A DIAGNOSIS. THE MECHANIC STATED THAT THE STEERING BOX WOULD HAVE TO BE REPLACED. THE MECHANIC …
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TL* THE CONTACT OWNS A 2008 FORD F-250 SD. WHILE DRIVING APPROXIMATELY 50 MPH, THE CONTACT NOTICED THAT THE VEHICLE WOULD NOT IMMEDIATELY RESPOND WHEN THE STEERING WHEEL WAS TURNED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR A DIAGNOSIS. THE MECHANIC STATED THAT THE STEERING BOX WOULD HAVE TO BE REPLACED. THE MECHANIC COULD NOT REPLACE OR REBUILD THE STEERING BOX BECAUSE THE PARTS WERE UNAVAILABLE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 40,200. UPDATED 6/4/12 *CN THE REPAIR WAS FINALLY MADE ON 04/18/12 AT A COST OF $531.13
NHTSA ODI #10455389
114,000 miles · Nov 10, 2011
Fuel System, Gasoline
WE WHERE HAULING CATTLE DOWN THE HIGHWAY AND LOST POWER AT 2500 RPMS THIS WAS EXTREMELY DANGEROUS TO BE ON A HIGHWAY GOING 55 MPH WITH A LOAD OF CATTLE AND WITH NO WARNING THE TRUCK LOST POWER. WE TOOK THE TRUCK INTO THE FORD DEALERSHIP AND ARE NOW HAVING THE HIGH PRESSURE FUEL INJECTOR PUMP REPLACED. THE CAB OF THE TRUCK HAS T…
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WE WHERE HAULING CATTLE DOWN THE HIGHWAY AND LOST POWER AT 2500 RPMS THIS WAS EXTREMELY DANGEROUS TO BE ON A HIGHWAY GOING 55 MPH WITH A LOAD OF CATTLE AND WITH NO WARNING THE TRUCK LOST POWER. WE TOOK THE TRUCK INTO THE FORD DEALERSHIP AND ARE NOW HAVING THE HIGH PRESSURE FUEL INJECTOR PUMP REPLACED. THE CAB OF THE TRUCK HAS TO BE TAKEN OFF TO WORK ON THIS PUMP IT WILL BE AT LEAST 18 HOURS OF LABOR. FORD HAS REDESIGNED THE NEWER MOTORS SO THAT THE HIGH PRESSURE FUEL INJECTOR PUMP IS NOW IN THE FRONT OF THE MOTOR. I REALLY THINK THIS SHOULD BE A RECALL BEFORE MORE PEOPLE HAVE THIS HAPPEN TO THEM PLEASE LOOK INTO THIS... *TR
NHTSA ODI #10435125
20,000 miles · Nov 6, 2011
Engine And Engine Cooling
1/1/10 ISN'T THE FIRST SMOG-OUT, BUT DEFINITELY THE WORST & MOST DANGEROUS. WHILE DECENDING FROM THE TOP OF THE MOUNTAIN IN GATLINBURG IN BUMPER TO BUMPER TRAFFIC WHERE IT TOOK 45-60 MINS TO GO 2 MILES, THE EXHAUST CLEANING WAS BLOWING SUFFOCATING AND BLINDING BLUE SMOKE CONTINUOUSLY. THEN GOING THROUGH TOWN WHERE PEOPLE ARE W…
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1/1/10 ISN'T THE FIRST SMOG-OUT, BUT DEFINITELY THE WORST & MOST DANGEROUS. WHILE DECENDING FROM THE TOP OF THE MOUNTAIN IN GATLINBURG IN BUMPER TO BUMPER TRAFFIC WHERE IT TOOK 45-60 MINS TO GO 2 MILES, THE EXHAUST CLEANING WAS BLOWING SUFFOCATING AND BLINDING BLUE SMOKE CONTINUOUSLY. THEN GOING THROUGH TOWN WHERE PEOPLE ARE WALKING UP & DOWN BESIDE THE ROAD (STILL IN BUMPER TO BUMPER TRAFFIC) IT WAS STILL SMOGGING THE PEOPLE WALKING AND PEOPLE DRIVING BEHIND ME COULD NOT SEE. IF A MOTORCYCLE OR PERSON ENDED UP BESIDE US WHEN WE HAD TO STOP FOR TRAFFIC LIGHTS, THEY WOULD HAVE BEEN SEVERELY BURNED. IT CONTINUED TO CLEAN DOWN TO PIGEON FORGE FOR A TOTAL OF 1-1/2 TO 2 HOURS. FORD ENGINEER WAS SUPPOSED TO RECALIBRATE TO MAKE SURE IT DIDN'T CLEAN IF UNDER 35 MPH, BUT IT DOES IT ALL THE TIME, SOMETIMES DAY AFTER DAY FOR HOURS. *TR
NHTSA ODI #10434350
6,910 miles · Nov 2, 2011
Tires
ALL 4 TIRES ON MY TRUCK HAVE SUBSTANTIAL CRACKING ALL THE WAY AROUND WHERE THE TREAD IS ATTACHED TO THE TIRE CARCASS. THE TREAD HAS CRACKS IN IT AS WELL. THE TIRES HAVE BEEN IN SERVICE 30 MONTHS. *TR
NHTSA ODI #10433934
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
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