NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
195 reports230,000 miles · Aug 12, 2019
Air BagsCrashInjury
TL* THE CONTACT OWNED A 2008 FORD F-250. THE CONTACT STATED THAT WHILE DRIVING 30 MPH, GOT HIT BY AN EIGHTEEN WHEELER THAT RAN A STOP SIGN, STRIKING THE DRIVER SIDE. NONE OF THE AIR BAGS DEPLOYED. THE POLICE WAS PRESENT AND A REPORT NUMBER: 88163534 WAS FILED. THE CONTACT WAS TAKEN TO THE HOSPITAL BY AMBULANCE, TREATED AND RELEA…
Read full complaint
TL* THE CONTACT OWNED A 2008 FORD F-250. THE CONTACT STATED THAT WHILE DRIVING 30 MPH, GOT HIT BY AN EIGHTEEN WHEELER THAT RAN A STOP SIGN, STRIKING THE DRIVER SIDE. NONE OF THE AIR BAGS DEPLOYED. THE POLICE WAS PRESENT AND A REPORT NUMBER: 88163534 WAS FILED. THE CONTACT WAS TAKEN TO THE HOSPITAL BY AMBULANCE, TREATED AND RELEASED. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR A DIAGNOSTIC. THE VEHICLE WAS TOWED TO A PRIVATE RESIDENCE. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 230,000.
NHTSA ODI #11243200
146,000 miles · Aug 9, 2019
Steering
IT STARTS SHIMMYING BACK AND FORTH VICIOUSLY AND WILL NOT STEER. I PUT ON NEW STRUTS, STEERING GEAR BOX, SHOCKS, TIRES, AND HAVE SPENT OVER $,3, 000 IN THE PAST FEW MONTHS. I NEVER KNOW WHEN THIS WILL START AND HAVE COME CLOSE TO SEVERAL ACCIDENTS. I HAVE READ MANY LETTERS FROM PEOPLE WITH THE SAME PROBLEM IN THIS MODEL. WHY IS …
Read full complaint
IT STARTS SHIMMYING BACK AND FORTH VICIOUSLY AND WILL NOT STEER. I PUT ON NEW STRUTS, STEERING GEAR BOX, SHOCKS, TIRES, AND HAVE SPENT OVER $,3, 000 IN THE PAST FEW MONTHS. I NEVER KNOW WHEN THIS WILL START AND HAVE COME CLOSE TO SEVERAL ACCIDENTS. I HAVE READ MANY LETTERS FROM PEOPLE WITH THE SAME PROBLEM IN THIS MODEL. WHY IS THERE NO RECALL?
NHTSA ODI #11242819
240,000 miles · Jun 24, 2019
Engine
TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING 60 MPH, THE VEHICLE LOST POWER, FAILED TO ACCELERATE, THE ENGINE MADE AN ABNORMAL NOISE, AND WHITE SMOKE WAS SEEN COMING FROM THE EXHAUST PIPE. THE VEHICLE WAS NOT TAKEN TO THE DEALER OR AN INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING. THE VEHICLE WAS NOT REPAIRED. THE CONTACT…
Read full complaint
TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING 60 MPH, THE VEHICLE LOST POWER, FAILED TO ACCELERATE, THE ENGINE MADE AN ABNORMAL NOISE, AND WHITE SMOKE WAS SEEN COMING FROM THE EXHAUST PIPE. THE VEHICLE WAS NOT TAKEN TO THE DEALER OR AN INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING. THE VEHICLE WAS NOT REPAIRED. THE CONTACT STATED THAT THE FAILURE OCCURRED INTERMITTENTLY. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND REFERRED THE CONTACT TO NHTSA. THE APPROXIMATE FAILURE MILEAGE WAS 240,000.
NHTSA ODI #11222051
46,000 miles · Jun 18, 2019
Service Brakes
I HAVE 46000 MILES ON MY TRUCK AND FOUR TIMES MY REAR BRAKES HAVE LOCKED UP ON ME. I BOUGHT THE VEHICLE USED WITH 17000 MILES SO CAN NOT TELL YOU HOW MANY TIMES IT HAS HAPPENED PREVIOUSLY. IT IS NO WONDER I GOT A USED VEHICLE WITH SO LOW OF MILES. I HAVE LOST ALL FAITH IN DRIVING THIS TRUCK FOR ANY KIND OF DISTANCE. I HAVE BEEN …
Read full complaint
I HAVE 46000 MILES ON MY TRUCK AND FOUR TIMES MY REAR BRAKES HAVE LOCKED UP ON ME. I BOUGHT THE VEHICLE USED WITH 17000 MILES SO CAN NOT TELL YOU HOW MANY TIMES IT HAS HAPPENED PREVIOUSLY. IT IS NO WONDER I GOT A USED VEHICLE WITH SO LOW OF MILES. I HAVE LOST ALL FAITH IN DRIVING THIS TRUCK FOR ANY KIND OF DISTANCE. I HAVE BEEN COMPLETELY UNABLE TO MOVE STRANDED ON THE ROAD. ON ANOTHER OCCASION I HAD TO DRIVE FIFTY MILES TOWING A TRAILOR WITH VICE GRIPS CRIMPING MY BRAKE LINE AFTER I BROKE THE CALIPER FREE AND GUESS WHAT THEY ARE LOCKED UP AGAIN.THIS IS A REAL PROBLEM AND VERY DANGEROUS
NHTSA ODI #11220814
207,077 miles · Jun 2, 2019
Steering
STEERING GEAR BOX SEEMS TO HAVE BROKE. LOSE OF ALL STEERING. STEERING WHEEL SPINS AROUND BUT DOES NOT CONTROL ANYTHING NOW
NHTSA ODI #11217337
139,000 miles · Apr 7, 2019
Steering
WHILE IN MOTION, AT 30 MPH OR HIGHER, THE TRUCK WANDERS LEFT AND RIGHT. IMPOSSIBLE TO MAINTAIN STRAIGHT TRAVEL...BASICALLY NO CENTERING OF STEERING. UNSAFE AND IT APPEARS THAT YOU ARE DRIVING AS A DRUNK WOULD. ALSO, VIOLENT SHAKING OF STEERING WHEEL AFTER HITTING A BUMP AT SPEED.
NHTSA ODI #11194425
30,000 miles · Apr 4, 2019
Service Brakes
WHILE IN MOTION, MORE OFTEN ON HOT DAYS, THE BRAKE CALIPERS, IN BOTH THE FRONT AND BACK, LOCK UP AND THE TRUCK NEEDS TO BE LEFT STATIONARY UNTIL THEY RELEASE. THE BRAKE PADS, CALIPERS, AND ROTORS HAVE BEEN CHANGED NUMEROUS TIMES. FORD WILL NOT TAKE CREDIT FOR FAULTY CALIPERS WHEN I EXPLAINED THE PROBLEM AT 30,000 ORIGINAL MILES…
Read full complaint
WHILE IN MOTION, MORE OFTEN ON HOT DAYS, THE BRAKE CALIPERS, IN BOTH THE FRONT AND BACK, LOCK UP AND THE TRUCK NEEDS TO BE LEFT STATIONARY UNTIL THEY RELEASE. THE BRAKE PADS, CALIPERS, AND ROTORS HAVE BEEN CHANGED NUMEROUS TIMES. FORD WILL NOT TAKE CREDIT FOR FAULTY CALIPERS WHEN I EXPLAINED THE PROBLEM AT 30,000 ORIGINAL MILES. WHEN I ASKED AN EXPERIENCED LOCAL MECHANIC ABOUT THE PROBLEM, HE EXPLAINED THAT FORD USED TWO DIFFERENT TYPES OF METALS IN THEIR CALIPERS SO THEY EXPAND AND CONTRACT AT DIFFERENT RATES, CAUSING THEM TO LOCK UP.
NHTSA ODI #11193847
80,000 miles · Feb 5, 2019
Engine
EXCESSIVE BLOWBY POLLUTING ENGINE. #8 AND #6 CYLINDERS, RINGS HEAVILY WORN OR DAMAGED DUE TO DIESEL REGEN CONTAMINATING LUBRICATION AND GETTING IN CRANKCASE. THIS IS A VERY WELL KNOWN AND UNACCEPTABLE ISSUE CAUSING SCORED ENGINE BLOCKS AND FAILURE OF ENGINE AND DPF AND EGRS.
NHTSA ODI #11174452
200,000 miles · Jan 22, 2019
Power Train
TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING APPROXIMATELY 65 MPH, A POPPING NOISE SUDDENLY OCCURRED. THE VEHICLE BEGAN TO LOSE POWER AND WOULD NOT ACCELERATE PAST 30 MPH. THE VEHICLE WAS TOWED TO RED MCCOMBS FORD (8333 I10, SAN ANTONIO, TX) WHERE IT WAS DIAGNOSED THAT THE PARTICULATE FILTER WAS FAULTY AND NEEDED TO BE …
Read full complaint
TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING APPROXIMATELY 65 MPH, A POPPING NOISE SUDDENLY OCCURRED. THE VEHICLE BEGAN TO LOSE POWER AND WOULD NOT ACCELERATE PAST 30 MPH. THE VEHICLE WAS TOWED TO RED MCCOMBS FORD (8333 I10, SAN ANTONIO, TX) WHERE IT WAS DIAGNOSED THAT THE PARTICULATE FILTER WAS FAULTY AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED, BUT NO ASSISTANCE WAS OFFERED. THE CONTACT WAS INFORMED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 07V139000 (POWER TRAIN). THE FAILURE MILEAGE WAS 200,000. *TT*JB
NHTSA ODI #11171431
92,000 miles · Jan 3, 2019
Air Bags
TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING 30 MPH, THE AIR BAG WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO FUTURE FORD LINCOLN OF CONCORD (2285 DIAMOND BLVD, CONCORD, CA 94520. 888-415-4242), BUT WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMAT…
Read full complaint
TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING 30 MPH, THE AIR BAG WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO FUTURE FORD LINCOLN OF CONCORD (2285 DIAMOND BLVD, CONCORD, CA 94520. 888-415-4242), BUT WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 92,000.
NHTSA ODI #11164767
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
Illustration