NHTSA owner reports · September 18, 2026 snapshot.
Power Train complaints
11 reportsClear category filter212,425 miles · Jan 24, 2018
Power Train
TL* THE CONTACT OWNS A 2008 FORD F-350 SD. WHILE DRIVING APPROXIMATELY 10 MPH, THE CONTACT HEARD AN ABNORMAL NOISE FROM THE FRONT OF THE VEHICLE. IN ADDITION, THE VEHICLE WENT INTO LIMP MODE. A LOCAL DEALER WAS NOT CONTACTED. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE TRANSMISSION NEEDED TO …
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TL* THE CONTACT OWNS A 2008 FORD F-350 SD. WHILE DRIVING APPROXIMATELY 10 MPH, THE CONTACT HEARD AN ABNORMAL NOISE FROM THE FRONT OF THE VEHICLE. IN ADDITION, THE VEHICLE WENT INTO LIMP MODE. A LOCAL DEALER WAS NOT CONTACTED. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE TRANSMISSION NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND ADVISED THE CONTACT TO CALL NHTSA. THE APPROXIMATE FAILURE MILEAGE WAS 212,425. THE VIN WAS NOT AVAILABLE.
NHTSA ODI #11064677
95,000 miles · Nov 26, 2016
EnginePower Train
I NOTICED A PLUM OF WHITE SMOKE OUT THE TAIL PIPE. THAT INDICATED STEAM, WATER IN THE SYSTEM TO ME. ALL THE GAUGES WERE NORMAL AND I STOPPED THE VEHICLE AND CHECKED THE FLUID LEVELS. NO OBVIOUS PROBLEM. I CALLED MY LOCAL FORD DEALERSHIP AND THEY COULD NOT GET IT IN FOR 36 HOURS. I DROVE IT .4 MILES HOME AND PARKED IT. AT T…
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I NOTICED A PLUM OF WHITE SMOKE OUT THE TAIL PIPE. THAT INDICATED STEAM, WATER IN THE SYSTEM TO ME. ALL THE GAUGES WERE NORMAL AND I STOPPED THE VEHICLE AND CHECKED THE FLUID LEVELS. NO OBVIOUS PROBLEM. I CALLED MY LOCAL FORD DEALERSHIP AND THEY COULD NOT GET IT IN FOR 36 HOURS. I DROVE IT .4 MILES HOME AND PARKED IT. AT THE APPOINTED TIME I DROVE TO NORTH COUNTRY FORD. IT TOOK THEM ANOTHER DAY TO FIND THE DIESEL MECHANIC WHO COULD WORK ON THE VEHICLE. 24 HOURS LATER I AM TOLD THE ENGINE IS BLOWN; FLUID GOT INTO THE MANIFOLD AND WAS SUCKED INTO THE # 3 CYLINDER. DEPENDING ON THE AMOUNT OF PARTS THAT COULD BE SALVAGED THE COST OF REPLACEMENT COULD EXCEED $ 12,000. THIS VEHICLE HAS 95,000 MILES ON IT. IT HAS HAD TOW OTHER INCIDENTS WITH THE ENGINE AND DRIVE TRAIN: IN DECEMBER OF LAST YEAR, IN PREPARATION FOR A TRIP TO ARIZONA I HAD THE TRANSMISSION SERVICED. ABOUT 1400 MILES LATER THE TRANSMISSION BEGAN TO SLIP WHEN WE ENCOUNTERED ANY HILLS OR MOUNTAINS. I PARKED THE TRAILER AND TOOK THE TUCK TO CASSA FORD. THEY HAD THE TRUCK FOR 4 DAYS AND $ 1600.00 WORTH OF REPAIRS. I ASKED IF ANYTHING DONE AT THE TIME IT WAS SERVICE OR THE DRIVING FROM THE FIRST SIGN OF TROUBLE HAD CAUSED OR EXACERBATED THE PROBLEM. THEY SAID NO, IT WAS A PUMP PROBLEM. IN 2011, IT BEGAN TO BLOW BLACK SMOKE OUT THE TAILPIPE; THE DASH SCREEN INDICATED IT WAS CLEANING THE EXHAUST. WITHIN 5 MINUTES THE ENGINE SPUTTERED AND DIED. I CALLED FORD I WAS TOLD TO WAIT AN HOUR AND TRY TO RESTART THE VEHICLE; GIVE THE ENGINE AN OPPORTUNITY TO 'RE-SET' ITSELF. THAT DIDN'T WORK! A TOW WAS SENT AND THE VEHICLE TOWED TO NELSON FORD DEALER IN FERGUS FALLS, MINNESOTA. IT WAS A FAILED EGR VALVE. THE REPAIR WAS COVERED UNDER WARRANTY.
NHTSA ODI #10928042
52,000 miles · Jul 3, 2013
Power TrainSteering
TL* THE CONTACT OWNS A 2008 FORD F-350 SD. THE CONTACT STATED THAT WHILE DRIVING 30 MPH, THE POWER STEERING ASSIST FAILED AS THE STEERING WHEEL SEIZED. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING, WHO STATED THAT THE GEARBOX HAD FAILED. THE VEHICLE HAD BEEN REPAIRED ONCE IN THE PAST FOR THE SAME FAILURE. THE FAILU…
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TL* THE CONTACT OWNS A 2008 FORD F-350 SD. THE CONTACT STATED THAT WHILE DRIVING 30 MPH, THE POWER STEERING ASSIST FAILED AS THE STEERING WHEEL SEIZED. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING, WHO STATED THAT THE GEARBOX HAD FAILED. THE VEHICLE HAD BEEN REPAIRED ONCE IN THE PAST FOR THE SAME FAILURE. THE FAILURE WAS REPORTED TO THE MANUFACTURER. THE FAILURE MILEAGE WAS 52,000. THE CURRENT MILEAGE WAS 70,576.
NHTSA ODI #10523110
12,000 miles · Jan 18, 2013
EnginePower TrainVehicle Speed Control
ON MULTIPLE OCCASIONS, WHEN VEHICLE IS STOPPED, WITH BRAKE DEPRESSED, THE ENGINE REVS UP AND VEHICLE WANTS TO ACCELERATE FORWARD AT A HIGH RATE OF SPEED. THE ONLY WAY TO STOP THE ACCELERATION IS TO GET THE VEHICLE TRANSITIONED IN TO PARK AND CUT THE ENGINE. THE VEHICLE HAS BEEN TO THREE DEALERS, WHOM ARE UNABLE TO DIAGNOSE AND…
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ON MULTIPLE OCCASIONS, WHEN VEHICLE IS STOPPED, WITH BRAKE DEPRESSED, THE ENGINE REVS UP AND VEHICLE WANTS TO ACCELERATE FORWARD AT A HIGH RATE OF SPEED. THE ONLY WAY TO STOP THE ACCELERATION IS TO GET THE VEHICLE TRANSITIONED IN TO PARK AND CUT THE ENGINE. THE VEHICLE HAS BEEN TO THREE DEALERS, WHOM ARE UNABLE TO DIAGNOSE AND CORRECT THE PROBLEM. FORD HAS NOT BEEN RESPONSIVE. VEHICLE IS UNSAFE TO DRIVE. *TR
NHTSA ODI #10493421
35,530 miles · Aug 27, 2010
Power Train
I HAVE A 2008 350 SUPER DUTY FORD TRUCK. I HAVE ABOUT 35,000 MILES ON THE TRUCK AND IN THOSE MILES I HAVE HAD ABOUT A DOZEN INCIDENTS WHERE THE TRUCKS AUTOMATIC TRANSMISSION DID NOT START FROM A DEAD STOP IN 1ST. GEAR. IN STEAD IT MUST HAVE STARTED IN 3RD. OR 4TH GEAR RESULTING IN WHAT WOULD BE A VERY UNDERPOWERED START. I WOULD…
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I HAVE A 2008 350 SUPER DUTY FORD TRUCK. I HAVE ABOUT 35,000 MILES ON THE TRUCK AND IN THOSE MILES I HAVE HAD ABOUT A DOZEN INCIDENTS WHERE THE TRUCKS AUTOMATIC TRANSMISSION DID NOT START FROM A DEAD STOP IN 1ST. GEAR. IN STEAD IT MUST HAVE STARTED IN 3RD. OR 4TH GEAR RESULTING IN WHAT WOULD BE A VERY UNDERPOWERED START. I WOULD PRESS THE ACCELERATOR TO THE FLOOR WHICH WOULD RESULT IN THE TRANSMISSION DOWN SHIFTING AND THE WHEELS SPINNING EVEN WHEN PULLING A 5TH WHEEL TRAILER. TWICE, WHILE EMPTY, I NEARLY HAD AN ACCIDENT WHEN I NEEDED A RAPID RESPONSE TO ENTER TRAFFIC. THE LAST TIME THIS HAPPENED WAS 8/25/2010. WHEN I HAVE TAKEN THIS COMPLAINT TO A FORD DEALERSHIP, THEY SAY THEY CAN NOT FIND ANY CODES, HOWEVER THE LAST TIME THE DEALER DID A COMPUTER UPDATE ON THE TRUCK AND THAT WAS ABOUT 10 MONTHS AGO AND I THOUGHT THE PROBLEM WAS SOLVED. I MET ANOTHER PERSON WITH THE SAME POWER TRAIN AS MINE WHO HAD THE SAME PROBLEM, FINALLY HIS TRANSMISSION WENT OUT AND HAD TO BE REPLACED. I WOULD LIKE TO HAVE YOU INVESTIGATE THIS ISSUE, IT MAY SAVE A LIFE. *TR
NHTSA ODI #10352336
27,999 miles · Feb 3, 2010
Engine And Engine CoolingExterior LightingFuel System, Diesel
TL* THE CONTACT OWNS A 2008 FORD F350 SUPER DUTY TRUCK PURCHASED NEW. HE STATED AFTER HAVING A REGULAR OIL CHANGE, HE NOTICED A LARGE OIL SPILLAGE COMING FROM UNDER THE VEHICLE. THE DEALER ADVISED REPLACING THE HIGH PRESSURE FUEL PUMP. THE REPAIR CAUSED THE OIL TO LEAK WORSE. WITHIN JUST UNDER A YEAR OF THE INITIAL FAILURE, THE …
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TL* THE CONTACT OWNS A 2008 FORD F350 SUPER DUTY TRUCK PURCHASED NEW. HE STATED AFTER HAVING A REGULAR OIL CHANGE, HE NOTICED A LARGE OIL SPILLAGE COMING FROM UNDER THE VEHICLE. THE DEALER ADVISED REPLACING THE HIGH PRESSURE FUEL PUMP. THE REPAIR CAUSED THE OIL TO LEAK WORSE. WITHIN JUST UNDER A YEAR OF THE INITIAL FAILURE, THE DEALER REPLACED THE HIGH PRESSURE FUEL PUMP A SECOND TIME. SEVERAL MONTHS LATER, THE CONTACT BEGAN TO NOTICE THE OIL LEAK AGAIN. THE HIGH PRESSURE FUEL PUMP WAS REPLACED A THIRD TIME. HE ALSO STATED THE BULBS IN THE EXTERIOR LIGHTING ELEMENTS, INCLUDING HEADLIGHTS, TAIL LIGHTS AND TURN SIGNALS CONTINUED TO BLOW. THE DEALER COULD NOT IDENTIFY THE REASON WHY THEY CONTINUED TO FAIL. WHILE AT A STOP, WHILE ATTEMPTING TO ACCELERATE, THE VEHICLE WOULD NOT SHIFT INTO GEARS PROPERLY. THE VEHICLE WOULD STAY IN HIGH GEAR AND WOULD NOT DOWN SHIFT PROPERLY. THE DEALER WAS UNABLE TO DUPLICATE THE FAILURE. NO FURTHER REPAIRS WERE MADE TO DATE. THERE WERE NO RECALLS ON HIS VEHICLE. THE FAILURE AND CURRENT MILEAGES WERE UNDER 28,000.
NHTSA ODI #10304285
19,499 miles · Jun 19, 2009
Power Train
I WAS NOTIFIED BY FORD THAT MY 2008 F-350 6.4 DIESEL PICKUP HAD TWO RECALL NOTICES TO BE PERFORMED. ON 1.29.08 I TOOK THE TRUCK TO CAPISTRANO FORD AND THEY PERFORMED RECALL 08B06 AND RECALL 08B07. SINCE THEN THE AUTOMATIC TRANSMISSION HAS NOT PERFORMED THE SAME. I PULL A FIFTH WHEEL TRAILER. THE DRY WEIGHT OF THE TRAILER IS ABO…
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I WAS NOTIFIED BY FORD THAT MY 2008 F-350 6.4 DIESEL PICKUP HAD TWO RECALL NOTICES TO BE PERFORMED. ON 1.29.08 I TOOK THE TRUCK TO CAPISTRANO FORD AND THEY PERFORMED RECALL 08B06 AND RECALL 08B07. SINCE THEN THE AUTOMATIC TRANSMISSION HAS NOT PERFORMED THE SAME. I PULL A FIFTH WHEEL TRAILER. THE DRY WEIGHT OF THE TRAILER IS ABOUT 9000LBS. WHEN GOING DOWNHILL THE AUTOMATIC TRANSMISSION NO LONGER DOWNSHIFTS TO ASSIST IN BRAKING AND DOWNHILL SPEED CONTROL. THE TRANSMISSION IS EQUIPPED WITH A TOW/ HAUL SETTING ON THE END OF THE SHIFT LEVER. BEFORE THE RECALL THIS FEATURE WORKED GREAT. AS YOU START DOWN A HILL, TAKING YOUR FOOT OFF THE GAS THE TRUCK WILL COAST AND THEN BEGIN TO PICK UP SPEED. WHEN THE TRANSMISSION SENSED THE INCREASE IN SPEED WHILE COASTING, THE TRANSMISSION WOULD AUTOMATICALLY DOWNSHIFT. IT WOULD DO THIS AT ANY SPEED. AFTER THE RECALL, THE TRANSMISSION WILL NOT DOWNSHIFT UNTIL LONG AFTER IT HAS ANY AFFECT ON BRAKING OR SPEED CONTROL. WHILE BRAKING, SOMETIMES HARD IF IT IS A STEEP HILL, THE TRANSMISSION WILL DOWNSHIFT AND THE TRUCK WILL SHUTTER. IT IS A SHORT BURST THAT IS VERY NOTICEABLE AND OBVIOUSLY NOT NORMAL.THE SHUTTER NEVER HAPPENED BEFORE THE RECALL. I HAVE TAKEN IN BACK TO FORD TWICE AND THEY SAY THAT THE TRANSMISSION CONTROL MODULE (TCM) WAS REPROGRAMMED AS PART OF RECALL 08B07 BUT THEY CAN NOT CHANGE IT BACK TO THE ORIGINAL PROGRAM. IN SHORT, FORD WILL NOT DO ANYTHING ABOUT THIS. THE OPERATIONAL SAFETY OF THE VEHICLE, WHILE TOWING LOADS THAT THE TRUCK IS DESIGNED TO TOW, HAS BEEN COMPROMISED. FORD SAYS THEY CAN NOT DO ANYTHING ABOUT IT. IS ANYONE ELSE HAVING THIS PROBLEM? ACCORDING TO FORD THIS COMPLAINT HAS NOT BEEN MADE. IF I'M THE ONLY ONE HAVING THE PROBLEM, THEN FORD SHOULD FIX MY TRUCK. *TR
NHTSA ODI #10274297
Mileage unknown · Feb 6, 2009
Engine And Engine CoolingFuel System, DieselPower Train
2MONTHS INTO MY "NEW" VEHICLE THE RADIATOR CRACKED AND OVER HEATED ; THE BACK GLASS LEAKS WITH WATER EVERY TIME IT RAINS , MOTOR REVES UP OUT OF CONTROL , NOW MOTOR HAS BLOWN OIL INTO RADIATOR AND ALL OVER DRIVEWAY DEEMING VEHICLE UNDRIVEABLE. *TR
NHTSA ODI #10257752
27,500 miles · Oct 30, 2008
Power TrainFire
TRUCK CAUGHT ON FIRE WHILE DRIVEING DOWN RAOD
NHTSA ODI #10247289
4,501 miles · Mar 12, 2008
Power Train
WHEN TRUCK GOES INTO REGENERATION MODE(ON DRIVE OR REVERSE) IT IS SOMETIMES VERY HARD TO KEEP IT UNDER CONTROL...IT WANTS TO ACCELERATE--- NORMALLY IT GOES UP TO 1200 TO 1300 RPM BUT ON 2 OR 3 TIMES ITS GONE UP TO 1500, 1 TIME IT WENT UP TO 2300 RPM ( THAT'S NOT SAVE )--------2 TIMES ENGINE LOST POWER WHILE DRIVING AT 65-70 MPH.…
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WHEN TRUCK GOES INTO REGENERATION MODE(ON DRIVE OR REVERSE) IT IS SOMETIMES VERY HARD TO KEEP IT UNDER CONTROL...IT WANTS TO ACCELERATE--- NORMALLY IT GOES UP TO 1200 TO 1300 RPM BUT ON 2 OR 3 TIMES ITS GONE UP TO 1500, 1 TIME IT WENT UP TO 2300 RPM ( THAT'S NOT SAVE )--------2 TIMES ENGINE LOST POWER WHILE DRIVING AT 65-70 MPH...TRUCK MAKES A LOUD METAL TO METAL NOISE WHEN YOU GO FROM DRIVE TO REVERSE AND WHEN YOU START MOVING... *TR
NHTSA ODI #10220877
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