NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
15 reportsClear category filter130,000 miles · Dec 19, 2022
Engine And Engine Cooling
The contact owns a 2008 Ford F-250. The contact stated while driving approximately 60 MPH, the cabin began to fill up with diesel exhaust fumes and white smoke. The contact stated that "Drive Vehicle to Clean Exhaust Filter" warning light illuminated. The contact rolled down the window to relieve the cabin of exhaust fumes and s…
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The contact owns a 2008 Ford F-250. The contact stated while driving approximately 60 MPH, the cabin began to fill up with diesel exhaust fumes and white smoke. The contact stated that "Drive Vehicle to Clean Exhaust Filter" warning light illuminated. The contact rolled down the window to relieve the cabin of exhaust fumes and smoke. The contact noticed that a rubber boot around the 4WD shift lever inside the vehicle was completely melted, and only a thick plastic ring around the shift lever opening where the rubber boot was attached remained. The contact replaced the rubber boot; however, the failure reoccurred within a week after replacement. The contact had taken the vehicle to a local dealer, where it was diagnosed and determined that the exhaust pipes needed to be replaced and that the repair required the vehicle cabin to be removed. The vehicle had not been repaired. The manufacturer had not been informed of the failure. The failure mileage was approximately 130,000.
NHTSA ODI #11498062
70,000 miles · Aug 24, 2018
Engine And Engine CoolingPower TrainFire
TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING 35 MPH, WHITE SMOKE CAME OUT OF THE EXHAUST. THE CONTACT STATED THAT THE VEHICLE EXHIBITED THE SAME SYMPTOMS AS LISTED IN NHTSA CAMPAIGN NUMBER: 07V139000 (POWER TRAIN). THE VEHICLE WAS TAKEN TO COLLEY FORD (1945 AUTO CENTRE DR, GLENDORA, CA 91740, 909-592-4131) WHERE IT WAS …
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TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING 35 MPH, WHITE SMOKE CAME OUT OF THE EXHAUST. THE CONTACT STATED THAT THE VEHICLE EXHIBITED THE SAME SYMPTOMS AS LISTED IN NHTSA CAMPAIGN NUMBER: 07V139000 (POWER TRAIN). THE VEHICLE WAS TAKEN TO COLLEY FORD (1945 AUTO CENTRE DR, GLENDORA, CA 91740, 909-592-4131) WHERE IT WAS DIAGNOSED, BUT THE FAILURE COULD NOT BE DUPLICATED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 70,000.
NHTSA ODI #11122212
123,000 miles · Jul 16, 2015
Engine And Engine CoolingSteering
TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING APPROXIMATELY 60 MPH, THE STEERING WHEEL SHOOK VIOLENTLY AND WOBBLED OUT OF CONTROL. THE CONTACT HAD TO DEPRESS THE BRAKE PEDAL HARSHLY IN ORDER FOR THE FAILURE TO SEIZE. THE CONTACT STATED THAT THE WOBBLING OF THE FRONT END CAUSED THE RADIATOR TO EVENTUALLY BURST. THE FAILUR…
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TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING APPROXIMATELY 60 MPH, THE STEERING WHEEL SHOOK VIOLENTLY AND WOBBLED OUT OF CONTROL. THE CONTACT HAD TO DEPRESS THE BRAKE PEDAL HARSHLY IN ORDER FOR THE FAILURE TO SEIZE. THE CONTACT STATED THAT THE WOBBLING OF THE FRONT END CAUSED THE RADIATOR TO EVENTUALLY BURST. THE FAILURE RECURRED MULTIPLE TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO REPLACED THE TIRES AND PERFORMED AN ALL WHEEL ALIGNMENT; HOWEVER, THE FAILURE PERSISTED. THE MANUFACTURER INFORMED THE CONTACT THAT THE VIN WAS NOT INCLUDED IN ANY RECALLS. THE APPROXIMATE FAILURE MILEAGE WAS 123,000.
NHTSA ODI #10734536
68,000 miles · Mar 2, 2015
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2008 FORD F-250. THE CONTACT STATED THAT WHILE DRIVING AT AN UNKNOWN SPEED, THE LOW ENGINE POWER WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE RADIATOR SEAL FRACTURED AND THE HOSES WERE LEAKING. THE RADIATOR WAS REPLACED. THE MANUFACTURER WAS MADE AWARE O…
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TL* THE CONTACT OWNS A 2008 FORD F-250. THE CONTACT STATED THAT WHILE DRIVING AT AN UNKNOWN SPEED, THE LOW ENGINE POWER WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE RADIATOR SEAL FRACTURED AND THE HOSES WERE LEAKING. THE RADIATOR WAS REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 68,000.
NHTSA ODI #10691615
110,851 miles · Dec 15, 2014
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2008 FORD F-250. THE CONTACT STATED THAT THE EXHAUST MANIFOLD BOLTS WERE RUSTED AND FRACTURED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE EXHAUST MANIFOLD WAS FRACTURED AND LEAKING. THE TECHNICIAN REPLACED BOTH EXHAUST MANIFOLDS, 20 STUDS, FOUR NUTS, AND TWO GASKETS. THE MANUFACTUR…
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TL* THE CONTACT OWNS A 2008 FORD F-250. THE CONTACT STATED THAT THE EXHAUST MANIFOLD BOLTS WERE RUSTED AND FRACTURED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE EXHAUST MANIFOLD WAS FRACTURED AND LEAKING. THE TECHNICIAN REPLACED BOTH EXHAUST MANIFOLDS, 20 STUDS, FOUR NUTS, AND TWO GASKETS. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 110,851.
NHTSA ODI #10664297
24,000 miles · Sep 9, 2012
Engine And Engine Cooling
I AM FILING A COMPLAINT HERE AS FORD CUSTOMER CARE REFERENCED YOU IN ONE OF THEIR RESPONSES TO ME. MY PICKUP WITH 24,000 MILES ON IT BLEW OUT THE TANK ON THE RADIATOR. THIS COULD REFLECT AS A SAFETY ISSUE FROM BEING STRANDED. FROM TALKING TO THE SERVICE PEOPLE AT LEWIS AND CLARK FORD IN YANKTON SD WHERE I HAD TO BE TOWED TO IT S…
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I AM FILING A COMPLAINT HERE AS FORD CUSTOMER CARE REFERENCED YOU IN ONE OF THEIR RESPONSES TO ME. MY PICKUP WITH 24,000 MILES ON IT BLEW OUT THE TANK ON THE RADIATOR. THIS COULD REFLECT AS A SAFETY ISSUE FROM BEING STRANDED. FROM TALKING TO THE SERVICE PEOPLE AT LEWIS AND CLARK FORD IN YANKTON SD WHERE I HAD TO BE TOWED TO IT SOUNDS LIKE THIS IS A COMMON OCCURRENCE. I ALSO HAVE DONE A LITTLE RESEARCH ON LINE AND IN A SHORT TIME FOUND APPROXIMATELY 40 CASE SO I AM SURE THERE ARE MANY MORE. ANY HELP YOU COULD GIVE ME WITH THIS ISSUE WOULD BE APPRECIATED. *TR
NHTSA ODI #10474370
49,000 miles · Mar 22, 2012
Engine And Engine Cooling
ON MARCH 13, 2012, I FILED A COMPLAINT WITH FORD MOTOR COMPANY CUSTOMER SERVICE REGARDING A REPAIR THEY MADE TO MY TRUCK. THE CASE NUMBER IS [XXX]. I HAD TO REPLACE TWO RADIATOR HOSES COSTING ME $500. THEY WERE NOT DEFECTIVE DUE TO ABUSE OR MAINT. THEY HAD A DESIGN FLAW PER THE SERVICE TECH. I BROUGHT THE TRUCK IN FOR ONE OF…
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ON MARCH 13, 2012, I FILED A COMPLAINT WITH FORD MOTOR COMPANY CUSTOMER SERVICE REGARDING A REPAIR THEY MADE TO MY TRUCK. THE CASE NUMBER IS [XXX]. I HAD TO REPLACE TWO RADIATOR HOSES COSTING ME $500. THEY WERE NOT DEFECTIVE DUE TO ABUSE OR MAINT. THEY HAD A DESIGN FLAW PER THE SERVICE TECH. I BROUGHT THE TRUCK IN FOR ONE OF THEM WAS LEAKING. THEY REPLACED BOTH FOR THEY SAID THAT THE OTHER ONE WAS GOING TO LEAK EVENTUALLY. THEY WERE REPLACED WITH A NEWLY DESIGNED HOSE TO PREVENT THE LEAKING. THE TECH STATED THAT THEY HAVE HAD TO REPLACE MANY ON THIS MODEL AND YEAR TRUCK. I REALIZE THE TRUCK WAS PAST THE 3 YEAR/36000 MILE WARRANTY; HOWEVER IT SHOULD HAVE BEEN COVERED UNDER THE POWER TRAIN WARRANTY OR FORD SHOULD HAVE COVERED THE COST. IT WAS A MANUFACTURE DESIGN FLAW AND COULD HAVE BLOWN OUT ON THE ROAD CAUSING A BREAK DOWN AND HIGHWAY SAFETY HAZARD. ALL I'M ASKING FOR IS THAT FORD ACKNOWLEDGE THE PROBLEM AND A RECALL BE MANDATED FOR THE VEHICLE. THE DEALERSHIP SAID THAT WAS THE ONLY WAY I COULD BE REIMBURSED. SHOULD YOU REQUIRE ANY ADDITIONAL INFORMATION PLEASE LET ME KNOW. I'M SURE OTHER OWNERS HAVE HAD THIS SAME ISSUE. ALSO, I HAVE IN MY POSSESSION THE TWO DEFECTIVE AND DESIGN FLAWED RADIATOR HOSES. I MADE THE DEALERSHIP GIVE THEM TO ME. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #10452694
44,000 miles · Jan 4, 2012
Engine And Engine Cooling
THIS VEHICLE SINCE THE LAST PCM UPDATE WHEN IT GOES INTO "CLEAN EXHAUST FILTER" MODE WILL SHOOT OUT HEAVY SMOKE FOR 2 MILES. THIS IS AN ENVIRONMENTAL POLLUTION AND ALSO A SAFETY HAZARD FOR DRIVERS BEHIND THE VEHICLE. THIS PROBLEM HAS BEEN ONGOING FOR MONTHS. DEALER STATES IT IS"NORMAL". *TR
NHTSA ODI #10442352
48,668 miles · Jan 3, 2012
Engine And Engine Cooling
RADIATOR HAS FAILED FOUR TIMES. THE FOURTH TIME IT FAILED IT WAS OUT OF WARRANTY. FORD REFUSES TO ACKNOWLEDGE THE DEFECT. *TR
NHTSA ODI #10442277
53,129 miles · Nov 15, 2010
Engine And Engine Cooling
WE OWN A FORD 2008 F250 SUPER DUTY CREWCAB SRW. TOOK IT IN FOR A OIL LEAK AND DEALER FOUND THE RADIATOR HAD ' C/S VEHICLE HAS COOLANT LEAKS. RADIATOR & TOP & LEFT LOWER RADIATOR HOSE FAULTY LEAKING COOLANT' THE RADIATOR FROM THE MANUFACTURE WAS REPLACED IN APRIL 2009. THIS WILL BE THE 3RD RADIATOR REPLACED. DEALER IS NOW CHARGI…
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WE OWN A FORD 2008 F250 SUPER DUTY CREWCAB SRW. TOOK IT IN FOR A OIL LEAK AND DEALER FOUND THE RADIATOR HAD ' C/S VEHICLE HAS COOLANT LEAKS. RADIATOR & TOP & LEFT LOWER RADIATOR HOSE FAULTY LEAKING COOLANT' THE RADIATOR FROM THE MANUFACTURE WAS REPLACED IN APRIL 2009. THIS WILL BE THE 3RD RADIATOR REPLACED. DEALER IS NOW CHARGING US $1,233.31 FOR THE REPLACEMENT OF THE 3RD ONE. OUR SON WHO HAS A F350 HAS HAD 3 RADIATORS REPLACED. IS THIS SOMETHING THE CONSUMER NEEDS TO BE PAYING FOR THE LENGTH OF THE OWNING A FORD TRUCK AND IS IT COMMON TO HAVE A RADIATOR REPLACED EVERY YEAR. *TR
NHTSA ODI #10365760
Official recalls
5Apr 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.
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.
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.
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.
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
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