IllustrationOdometer Fraud. The contact purchased a 2008 Ford F-250. The contact discovered that there was a mileage discrepancy after the purchase. The vehicle was an independent dealer sale. At the time of the purchase, the mileage was 88,000. It was later discovered, after checking the Carfax report, that the mileage was 182,000.
2008 Ford F-250
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2008 Ford F-250 do not stand out strongly from the model-year median of 119.
About this comparison →How this year compares
Owner complaints by model year
Compare all F-250 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
200–25K
4025–50K
2250–75K
1675–100K
34100–150K
28150K+
160 reports with mileage · 35 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.
- Steering. Review the 80 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Suspension. Review the 35 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Engine. Review the 18 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
10 crash reports4 fire reports3 injury reports
Electrical System complaints
12 reportsI have a 2008 ford f250 with 60,000 miles I bought it used about 7 years ago I only drive it to pull my trailer camping also I don't drive it much hoping a engine light will come on my vehicle has unintended acceleration it happen when I come to a stop light and my vehicle will unexpectedly tug forward to 0…
Read full complaint
I have a 2008 ford f250 with 60,000 miles I bought it used about 7 years ago I only drive it to pull my trailer camping also I don't drive it much hoping a engine light will come on my vehicle has unintended acceleration it happen when I come to a stop light and my vehicle will unexpectedly tug forward to 0 to 60 mpg I have to push on my brakes and turn off the key and turn back on sometimes 6 times before it goes back to normal I called the dealer to get answer where I live in California and they said they cant diagnose it unless it duplicates its self and they will charge me $200 plus if they cant find the problem I did research and found 4 vehicles the same year that had this problem and there is a recall on some of these vehicle with the same problem with the same motor and year same electronic gas pedal but they are the expedition and other makes anyways this problem has almost cause me to get in plenty accidents I had the gas pedal and electronic sensor replace throttle body and both sensors replace and still have the problem the ford dealer are saying they never heard of this issue but I google unintended acceleration and see cars of all makes and model with this drive by wire electronic situation all I want is to get it fixed doing my research its a software issue in the computer
The contact owns a 2008 Ford F-250. The contact stated while driving 30 mph, he started to smell smoke inside the vehicle, which caused him to get a headache. The contact stated no warning light was illuminated. The contact continued driving to his residence. Upon inspecting the vehicle, the contact open the hood and saw fire in…
Read full complaint
The contact owns a 2008 Ford F-250. The contact stated while driving 30 mph, he started to smell smoke inside the vehicle, which caused him to get a headache. The contact stated no warning light was illuminated. The contact continued driving to his residence. Upon inspecting the vehicle, the contact open the hood and saw fire in the engine compartment. The contact stated the check engine warning light was illuminated after the fire was located. The contact extinguished the fire with nearby water. The contact stated he did not call the fire department or the police department to file a report. The contact stated no one was injured or sought medical attention. The vehicle was not drivable. The vehicle was not diagnosed or repaired. A dealer was not contacted. The manufacturer had not been informed of the failure. The failure mileage was approximately 276,000.
My truck is having the same issues as listed in the recalls but isn’t on the recall list. Running rough dash board turns off and loses power to the cab. Low voltage light comes on but batteries and alternator test fine. Factory installed lift blocks have cracked and caused can bushings to fail.
WHILE DRIVING AT NIGHT THE VEHICLE LIGHTS WENT OUT, NO HIGH BEAMS, NO DRIVING LIGHTS AT ALL, NO BLINKERS ETC. THE FLASHERS WORKED ONLY WHILE THE VEHICLE WAS RUNNING, TURNED OFF THE VEHICLE AND IT CONTINUED TO RUNTURNED KEY BACK ON AND TURNED FLASHERS OFF AND SPUTTERED AND DIED, BUT THEN ONLY THE MIRROR AND TAIL LIGHT FLASHERS W…
Read full complaint
WHILE DRIVING AT NIGHT THE VEHICLE LIGHTS WENT OUT, NO HIGH BEAMS, NO DRIVING LIGHTS AT ALL, NO BLINKERS ETC. THE FLASHERS WORKED ONLY WHILE THE VEHICLE WAS RUNNING, TURNED OFF THE VEHICLE AND IT CONTINUED TO RUNTURNED KEY BACK ON AND TURNED FLASHERS OFF AND SPUTTERED AND DIED, BUT THEN ONLY THE MIRROR AND TAIL LIGHT FLASHERS WORKED, NOTHING IN THE FRONT WORKED. WHEN ATTEMTED TO CHECK TO SEE IF LIGHTS WOULD COME ON OR FLASHERS THE WRENCH ICON WOULD APPEAR, ALL INSTRUMENT WARNING CAME ON TO CHECK BREAK SYSYTEM BUT STILL NO LIGHTS OR FLASHER. THIS WAS AN ETREMELY DANGEROUS SITUATION DUE TO THE FACT WE WERE IN A DARK RURAL AREA ON A 2 LANE HWY AND COULD NOT SEE A THING. THE VEHICLE INTERMITITNGLY WILL NOT START AND WE HAD TO HAVE IT TOWED HOME. ALSO BACK UP SENSOR WILL NOT WORK PROPERLY AT TIMES, THE SOONEST WE CAN GET VEHICLE YO YHE SHOP IS NEXT TUESDAY.
WHILE DRIVING THE ENGINE LIGHT CAME ON, THEN THE BATTERY LIGHT INTERMITTENTLY ILLUMINATED, THEN IT JUST DIED. IT CRANKED BUT WOULDN'T START. TOOK IT TO MY MECHANIC TO WHICH HE SAID THE ENTIRE CAB HAD TO BE REMOVED (PER FORD CONSULTANT) TO REPAIR ELECTRICAL SHORT. $$$$$$ I CANT AFFORD THIS! THOUSANDS OF DOLLARS!
THE WIRES SUPPLYING POWER TO THE HIGH PRESSURE OIL PUMP FRAYED. THIS WAS CAUSED BY THE WIRES NOT BEING PROPERLY PROTECTED BY FORD (ACCORDING TO THE FORD DEALERSHIP). ONCE THE SHORT IN THE WIRE OCCURRED, MY TRUCK IMMEDIATELY SHUT OFF IN THE MIDDLE OF THE HIGHWAY. I WAS GOING 65 MPH AND LUCKILY NO ONE WAS BEHIND ME. OTHERWISE …
Read full complaint
THE WIRES SUPPLYING POWER TO THE HIGH PRESSURE OIL PUMP FRAYED. THIS WAS CAUSED BY THE WIRES NOT BEING PROPERLY PROTECTED BY FORD (ACCORDING TO THE FORD DEALERSHIP). ONCE THE SHORT IN THE WIRE OCCURRED, MY TRUCK IMMEDIATELY SHUT OFF IN THE MIDDLE OF THE HIGHWAY. I WAS GOING 65 MPH AND LUCKILY NO ONE WAS BEHIND ME. OTHERWISE I WOULD HAVE BEEN IN A SERIOUS ACCIDENT SINCE MY TRUCK WAS SHUT DOWN IN THE MIDDLE OF THE ROAD. *TR
A WEEK AFTER I BOUGHT THE TRUCK THE TRANSMISSION WENT OUT THEN ITS HAD COUNTLESS ELECTRICAL PROBLEMS ITS BEEN TO 2 FORD DEALERS IT WAS AT ONE FOR 7 MONTHS AND THE OTHER FOR 3 AND A CHEVY DEALER NOONE CAN FIX MY TRUCK ITS HAD 3 TRANSMISSIONS PUT IN IT 1000S OF DOLLARS LATER AND I HAVEN'T BEEN ABLE TO DRIVE MY TRUCK IN 2 AND A HAL…
Read full complaint
A WEEK AFTER I BOUGHT THE TRUCK THE TRANSMISSION WENT OUT THEN ITS HAD COUNTLESS ELECTRICAL PROBLEMS ITS BEEN TO 2 FORD DEALERS IT WAS AT ONE FOR 7 MONTHS AND THE OTHER FOR 3 AND A CHEVY DEALER NOONE CAN FIX MY TRUCK ITS HAD 3 TRANSMISSIONS PUT IN IT 1000S OF DOLLARS LATER AND I HAVEN'T BEEN ABLE TO DRIVE MY TRUCK IN 2 AND A HALF YEARS FORD IS UNWILLING TO DO ANYTHING WITH IT. THEY CANT FIND THE PROBLEM AND GIVE UP AND TELL ME TO COME GET THE TRUCK I STILL OWE15 000 ON THE TRUCK. *TR
I WAS DRIVING OUR 2008 F-250 2WD AN AS I APPLIED THE BRAKES TO TURN, LOST POWER STEERING AND BRAKES. THIS HAD OCCURRED A FEW TIMES BEFORE BUT I COULD NOT IDENTIFY THE PROBLEM. THE PROBLEM WAS INTERMITTENT AND ALTHOUGH A NEAR SERIOUS ACCIDENT OCCURRED, NO PROBLEM COULD BE FOUND. I WAS PLANNING TO TAKE IT TO A LOCAL DEALER OVER TH…
Read full complaint
I WAS DRIVING OUR 2008 F-250 2WD AN AS I APPLIED THE BRAKES TO TURN, LOST POWER STEERING AND BRAKES. THIS HAD OCCURRED A FEW TIMES BEFORE BUT I COULD NOT IDENTIFY THE PROBLEM. THE PROBLEM WAS INTERMITTENT AND ALTHOUGH A NEAR SERIOUS ACCIDENT OCCURRED, NO PROBLEM COULD BE FOUND. I WAS PLANNING TO TAKE IT TO A LOCAL DEALER OVER THE WEEKEND. THE NEXT DAY I WAS PULLING INTO MY DRIVEWAY AND THE TRUCK ENGINE DIED AND WOULD NOT START. WE HAD IT TOWED TO THE DEALER FOR A DIAGNOSIS. IT WAS DISCOVERED THAT THE HIGH PRESSURE FUEL PUMP COVER GASKET WHICH INCLUDES A WIRING HARNESS NEEDS REPLACED DUE TO WIRE ABRASION AND A SHORTED WIRE. IN ADDITION, THE CAB OF THE TRUCK WILL NEED TO BE REMOVED TO CORRECT THE PROBLEM. I UNDERSTAND THAT THE REPLACEMENT PART HAS BEEN RE-ENGINEERED TO INCLUDE A GUARD TO PROTECT THE WIRE FROM ABRASION. FROM INTERNET RESEARCH I HAVE FOUND SEVERAL SIMILAR INSTANCES, WITH SOME VEHICLES LOSING POWER WHILE IN MOTION. THIS IS EXTREMELY DANGEROUS. THE DEALER ACKNOWLEDGED THAT THIS IS A RECURRING ISSUE WITH THIS MODEL OF TRUCK AND THEY HAVE MADE SEVERAL SIMILAR REPAIRS. AS A SAFETY PROFESSIONAL FOR OVER 30 YEARS, THIS IS VERY UNNERVING TO SAY THE LEAST. HIGHWAY CRASHES OCCUR FAR TOO OFTEN DUE TO HUMAN ERROR WITHOUT HAVING KNOWN MANUFACTURER DEFECTS ADDING TO THE PROBLEM. WHEN A TRUSTED MANUFACTURER DISCOVERS AN ENGINEERING ISSUE BUT FAILS TO INFORM OWNERS OR CORRECT THE PROBLEM, THIS ADDS UNNECESSARY DANGER FOR UNSUSPECTING MOTORISTS,OUR FAMILIES AND THE PUBLIC. I TRUST THAT THIS WILL BE INVESTIGATED FULLY. *TT
2008 FORD F250 - ALTERNATOR WENT UP ON TRUCK AFTER 41,690 MILES, THIS ALSO BURNED UP THE BATTERY, NOW THE STARTER HAS GONE UP IN THE TRUCK. GOT THE TRUCK STARTED TO TAKE HOME, TRUCK DIED. THERE IS NO POWER, LIGHTS ANYTHING AT ALL. TRUCK HAS BEEN OUT OF SERVICE FOR ALMOST 2 WEEKS. *TR
Official recalls
508V191000 · Fuel System, Gasoline:delivery
Apr 25, 2008
FORD IS RECALLING 64,754 MY 2008 F-250 AND F-350 SINGLE REAR WHEEL, 4X4, 156 INCH WHEEL BASE PICK UP TRUCKS EQUIPPED WITH A TWO PIECE DRIVE SHAFT FOR FAILING TO CONFORM TO THE FUEL SPILLAGE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 301, "FUEL SYSTEM INTEGRITY." DURING A 30 MPH FRONTAL IMPACT INTO A RIGID BARRIER, THE FUEL TANK CAN MOVE FORWARD AND CONTACT A FRAME CROSS MEMBER, POTENTIALLY CAUSING DAMAGE TO THE FUEL DELIVERY MODULE WHICH CAN RESULT IN FUEL SPILLAGE.
Consequence & remedy
Consequence: FUEL SPILLAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy: DEALERS WILL INSTALL A BRACKET ON THE AFFECTED VEHICLES FREE OF CHARGE. THE RECALL BEGAN ON MAY 23, 2008. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
08V096000 · Seats
Feb 28, 2008
FORD IS RECALLING 87,515 MY 2008 F250, F-350, F-450, AND F-550 VEHICLES FOR FAILING TO COMPLY WITH ALL THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 207, "SEATING SYSTEMS." SOME 40% SPLIT AND CAPTAIN'S CHAIR DRIVER'S SEATS, EQUIPPED WITH LUMBAR SUPPORTS, MAY HAVE IMPROPER WELDS AT THE JOINT OF THE SEAT BACK PIVOT BRACKET AND THE SEAT BACK FRAME.
Consequence & remedy
Consequence: IN THE EVENT OF A CRASH, THE SEAT SIDE PIVOT BRACKET MAY CRACK OR BREAK, INCREASING THE RISK OF INJURY TO THE SEAT OCCUPANT.
Remedy: DEALERS WILL ADD A REINFORCEMENT TO THE DRIVER'S SEAT BACK FRAME ON THE 40% SPLIT OR CAPTAIN'S CHAIR SEAT EQUIPPED WITH LUMBAR SUPPORT OR, IF NECESSARY, THE SEAT BACK FRAME WILL BE REPLACED. THE RECALL BEGAN ON MARCH 28, 2008. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
07V541000 · Air Bags:frontal:driver Side:inflator Module
Nov 21, 2007
CERTAIN VEHICLES FAIL TO CONFORM TO THE REQUIREMENTS SPECIFIED IN FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 208, 'OCCUPANT CRASH PROTECTION.' THE DRIVER AIR BAG MODULE MAY NOT HAVE BEEN PROPERLY ASSEMBLED.
Consequence & remedy
Consequence: THIS CONDITION MAY PREVENT THE DRIVER AIR BAG FROM PROPERLY DEPLOYING AND REDUCE OCCUPANT PROTECTION IN THE EVENT OF A CRASH.
Remedy: DEALERS WILL REPLACE YOUR DRIVER AIR BAG MODULE FREE OF CHARGE. THE RECALL BEGAN ON NOVEMBER 20, 2007. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
07V139000 · Power Train:automatic Transmission:control Module (tcm/pcm/tecm)
Mar 26, 2007
ON CERTAIN TRUCKS EQUIPPED WITH A 6.4L DIESEL ENGINE, EXCESSIVE TEMPERATURES IN THE DIESEL PARTICULATE FILTER IN THE EXHAUST SYSTEM MAY RESULT FROM EXCESS HYDROCARBONS IN THE EXHAUST.
Consequence & remedy
Consequence: LACK OF POWER OR ROUGH OPERATION, UNUSUAL NOISES FROM THE ENGINE OR EXHAUST, WHITE SMOKE FROM THE EXHAUST, AND POTENTIALLY A VISIBLE FLAME OUT THE TAILPIPE CAN OCCUR.
Remedy: DEALERS WILL REPROGRAM THE POWER TRAIN CONTROL MODULE. THE RECALL BEGAN ON APRIL 3, 2007. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
07V140000 · Electrical SYSTEM:12V/24V/48V Battery
Mar 26, 2007
ON CERTAIN TRUCKS EQUIPPED WITH A 6.4L DIESEL ENGINE, INSUFFICIENT CLEARANCE OF THE BATTERY POSITIVE (B+) WIRE TO THE RIGHT HAND SPLASH SHIELD BOLT MAY RESULT IN THE BATTERY B+ WIRE CONTACTING THE SPLASH SHIELD BOLT.
Consequence & remedy
Consequence: LONG TERM CONTACT COULD CAUSE WIRE CHAFE, RESULTING IN COPPER WIRE BEING EXPOSED. IF THIS CONDITION OCCURS, THE BATTERY B+ WIRE COULD SHORT TO GROUND INCREASING THE RISK OF A FIRE.
Remedy: DEALERS WILL INSPECT THE BATTERY B+ WIRE LOCATION AND, IF NECESSARY, REPOSITION THE WIRE. THE RECALL BEGAN ON APRIL 3, 2007. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
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
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