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2008 Ford F-350 Sd

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2008 Ford F-350 Sd do not stand out strongly from the model-year median of 73.

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How this year compares

Owner complaints by model year

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Counts vary with age, sales and reporting. They are not failure rates.

What owners reported most

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When problems were reported

Mileage at the reported incident

94 reports with mileage · 7 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 25 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 21 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Suspension. Review the 13 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

7 crash reports4 fire reports2 injury reports

Steering complaints

25 reports
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125,000 miles · Feb 11, 2019
Steering

TL* THE CONTACT OWNS A 2008 FORD F-350 SD. WHILE DRIVING APPROXIMATELY 12 MPH, THE STEERING FAILED WITHOUT WARNING. THE CONTACT STATED THAT THE STEERING WHEEL BECAME DETACHED FROM THE STEERING BOX. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE STEERING BOX NEEDED TO BE REPLACED. THE VEHICLE WAS…

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TL* THE CONTACT OWNS A 2008 FORD F-350 SD. WHILE DRIVING APPROXIMATELY 12 MPH, THE STEERING FAILED WITHOUT WARNING. THE CONTACT STATED THAT THE STEERING WHEEL BECAME DETACHED FROM THE STEERING BOX. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE STEERING BOX NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. BOB BELL FORD WAS CONTACTED BY PHONE AT 410-766-3600 (LOCATED AT 7125 RITCHIE HWY, GLEN BURNIE, MD 21061). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 125,000.

NHTSA ODI #11176185

128,000 miles · Jul 25, 2018
SteeringSuspension

THE 2008, AS WELL AS OTHER YEARS OF THE FORD F-350 ARE KNOWN TO HAVE A PROBLEM WITH A FRONT-END SHIMMY OR "DEATH WOBBLE". I HAVE HAD SEVERAL THOUSAND DOLLARS OF WORK DONE TO MY F-350 IN ORDER TO RESOLVE THE DEATH WOBBLE PROBLEM. THE REPAIRS WORK FOR A TIME AND THEN, WITHOUT WARNING, THE DEATH WOBBLE RETURNS. THE FACT THAT THIS …

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THE 2008, AS WELL AS OTHER YEARS OF THE FORD F-350 ARE KNOWN TO HAVE A PROBLEM WITH A FRONT-END SHIMMY OR "DEATH WOBBLE". I HAVE HAD SEVERAL THOUSAND DOLLARS OF WORK DONE TO MY F-350 IN ORDER TO RESOLVE THE DEATH WOBBLE PROBLEM. THE REPAIRS WORK FOR A TIME AND THEN, WITHOUT WARNING, THE DEATH WOBBLE RETURNS. THE FACT THAT THIS CAN OCCUR WITHOUT WARNING, AT HIGH SPEEDS, BY DRIVING OVER A VERY SMALL BUMP IN THE ROAD, MAKES THIS AN EXTRAORDINARILY DANGEROUS PROBLEM. I DON'T THINK I CAN ADEQUATELY DESCRIBE THE EXTREME NATURE OF THE DEATH WOBBLE. THE FRONT-END OF THE TRUCK IS BOUNCING LEFT AND RIGHT, THE ENTIRE VEHICLE IS TWISTING AND ROLLING, THE STEERING WHEEL IS BARELY CONTROLLABLE, ANYTHING LOOSE IN THE PASSENGER COMPARTMENT GOES FLYING AND KEEPING THE VEHICLE IN ITS LANE IS NOT ALWAYS POSSIBLE. REDUCING SPEED AS QUICKLY AS POSSIBLE IS THE ONLY RECOURSE AND THIS POSES A DANGER PARTICULARLY WHEN ON A HEAVILY TRAFFICKED HIGHWAY. THIS PROBLEM HAS BEEN KNOWN ABOUT FOR A LONG TIME AND FORD WILL NOT TAKE ANY RESPONSIBILITY. EVEN AFTER SPENDING THOUSANDS OF DOLLARS ON COMPLETE FRONT-END REBUILDS, AND IMPECCABLE MAINTENANCE, THE PROBLEM WILL SUDDENLY REOCCUR. THE DESIGN OF THIS FRONT-END IS FAULTY AND VEHICLE OWNERS SHOULD NOT CONTINUE TO BE RESPONSIBLE FOR THE COSTS OF MAINTAINING THIS FAULTY DESIGN AND BEING EXPOSED TO GREAT RISK.

NHTSA ODI #11113591

52,500 miles · May 13, 2017
Steering

STEERING GEARBOX FAILED. STEERING FELT VERY LOOSE, PULLED INTO PARKING LOT. STEERING WOULD TURN RIGHT BUT WOULD NOT TURN TO THE LEFT.COULD HEAR A CRUNCHING OR POPPING NOISE WHEN ATTEMPTING TOP TURN LEFT. HAD VEHICLE TOWED TO LOCAL REPAIR SHOP THAT FOUND THE STEERING GEARBOX FAILED INTERNALLY.

NHTSA ODI #10985553

Mileage unknown · Mar 9, 2017
SteeringSuspension

TL* THE CONTACT OWNS A 2008 FORD F-350 SD. THE CONTACT STATED THAT THE VEHICLE EXPERIENCED A RANDOM DEATH WOBBLE ASSOCIATED WITH THE STEERING AND SUSPENSION. A DEALER PERFORMED EXTENSIVE REPAIRS, BUT THE CONDITION CONTINUED. THE DEALER AND THE MANUFACTURER FAILED TO PROVIDE A REMEDY. THE VEHICLE WAS UNABLE TO BE SAFELY DRIVEN DU…

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TL* THE CONTACT OWNS A 2008 FORD F-350 SD. THE CONTACT STATED THAT THE VEHICLE EXPERIENCED A RANDOM DEATH WOBBLE ASSOCIATED WITH THE STEERING AND SUSPENSION. A DEALER PERFORMED EXTENSIVE REPAIRS, BUT THE CONDITION CONTINUED. THE DEALER AND THE MANUFACTURER FAILED TO PROVIDE A REMEDY. THE VEHICLE WAS UNABLE TO BE SAFELY DRIVEN DUE TO A STRONG VIBRATION FROM THE STEERING, WHICH ALSO CAUSED THE SUSPENSION TO BE UNSTABLE. THE VEHICLE WAS PARKED AT THE CONTACT'S RESIDENCE. THE FAILURE MILEAGE WAS NOT AVAILABLE.

NHTSA ODI #10959732

110,000 miles · Jul 15, 2016
Steering

TL* THE CONTACT OWNS A 2008 FORD F-350 SD. WHILE DRIVING VARIOUS SPEEDS, THE BRAKE PEDAL WAS DEPRESSED AND THE POWER STEERING LOST POWER AND BECAME DIFFICULT TO OPERATE. THE VEHICLE WAS DIAGNOSED BY AN INDEPENDENT MECHANIC WHO STATED THAT A BOLT IN THE POWER STEERING MECHANISM FRACTURED AND NEEDED TO BE REPAIRED. THE VEHICLE WAS…

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TL* THE CONTACT OWNS A 2008 FORD F-350 SD. WHILE DRIVING VARIOUS SPEEDS, THE BRAKE PEDAL WAS DEPRESSED AND THE POWER STEERING LOST POWER AND BECAME DIFFICULT TO OPERATE. THE VEHICLE WAS DIAGNOSED BY AN INDEPENDENT MECHANIC WHO STATED THAT A BOLT IN THE POWER STEERING MECHANISM FRACTURED AND NEEDED TO BE REPAIRED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 110,000. UPDATED 09/06/16*LJ UPDATED 09/08/16.*JB

NHTSA ODI #10885140

115,000 miles · Apr 19, 2016
Air BagsSteering

TL* THE CONTACT OWNS A 2008 FORD F-350 SD. WHILE THE VEHICLE WAS PARKED, THE STEERING WHEEL BECAME STUCK FOR TWO MINUTES AND THEN FAILED TO MOVE. THE AIR BAG WARNING LIGHT ILLUMINATED. THE CONTACT ATTEMPTED TO DRIVE THE VEHICLE AND THE STEERING WHEEL FAILED TO TURN. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE MANUFACTURER WA…

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TL* THE CONTACT OWNS A 2008 FORD F-350 SD. WHILE THE VEHICLE WAS PARKED, THE STEERING WHEEL BECAME STUCK FOR TWO MINUTES AND THEN FAILED TO MOVE. THE AIR BAG WARNING LIGHT ILLUMINATED. THE CONTACT ATTEMPTED TO DRIVE THE VEHICLE AND THE STEERING WHEEL FAILED TO TURN. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 115,000.

NHTSA ODI #10860415

98,500 miles · Nov 25, 2014
Steering

WHILE TURNING SHARP LEFT AT A TRAFFIC SIGNAL, THE TRUCK DID NOT WANT TO CORRECT BACK STRAIGHT. I FORCED IT BACK TO STRAIGHT AND CONTINUED ON. WHILE CONTINUING TO DRIVE, THE TRUCK WOULD TRACK LEFT AND THEN TRACK RIGHT. I TURNED THE STEERING WHEEL QUICKLY AND IT STRAIGHTENED BACK UP. THE TRUCK IS AT A PRIVATE REPAIR SHOP WITH THE …

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WHILE TURNING SHARP LEFT AT A TRAFFIC SIGNAL, THE TRUCK DID NOT WANT TO CORRECT BACK STRAIGHT. I FORCED IT BACK TO STRAIGHT AND CONTINUED ON. WHILE CONTINUING TO DRIVE, THE TRUCK WOULD TRACK LEFT AND THEN TRACK RIGHT. I TURNED THE STEERING WHEEL QUICKLY AND IT STRAIGHTENED BACK UP. THE TRUCK IS AT A PRIVATE REPAIR SHOP WITH THE TECHNICIAN UNABLE TO FIND ANYTHING BROKEN. HE SUGGESTED THAT IT MAY BE THE POWER STEERING BOX. *TR

NHTSA ODI #10660879

44,000 miles · Sep 30, 2014
EngineSteering

ON SEPTEMBER 30, 2014, MY WIFE WAS ON HER WAY TO COLUMBUS, OHIO IN HER 2008 FORD F350 SUPER DUTY TURBO DIESEL TRUCK (VIN# [XXX]) WITH 44,000 MILES. SHE'S PULLING HER 2014 26? LAKOTA TWO HORSE TRAILER WITH LIVING QUARTERS WITH HER SHOW HORSE IN THE BACK. THE UNEXPECTED HAPPEN WHILE SHE WAS ON MD-51N NEAR CUMBERLAND, MARYLAND HEAD…

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ON SEPTEMBER 30, 2014, MY WIFE WAS ON HER WAY TO COLUMBUS, OHIO IN HER 2008 FORD F350 SUPER DUTY TURBO DIESEL TRUCK (VIN# [XXX]) WITH 44,000 MILES. SHE'S PULLING HER 2014 26? LAKOTA TWO HORSE TRAILER WITH LIVING QUARTERS WITH HER SHOW HORSE IN THE BACK. THE UNEXPECTED HAPPEN WHILE SHE WAS ON MD-51N NEAR CUMBERLAND, MARYLAND HEADING ACROSS A BRIDGE WITH HEAVY TRAFFIC AT 1230PM. THE CHECK ENGINE LIGHT CAME ON WITH THE FOLLOWING MESSAGE ?PULL OVER SAFELY?. TWENTY SECONDS (20 SECONDS) LATER, THE TRUCK COMPLETELY SHUT DOWN. WIFE WAS TRAVELING AT 70 MILES AN HOUR WHEN THE TRUCK SHUT DOWN, WHICH TURNED THE POWER STEERING OFF. THIS IS WHAT I CALL UNSAFE FOR ANYONE, ESPECIALLY WHEN PULLING A 26? HORSE TRAILER WITH AN EXTRA 1000LBS IN THE BACK WITH A HORSE. SHE WAS NOT ABLE TO GET COMPLETELY OFF THE ROAD WHICH ALMOST CAUSED A MAJOR ACCIDENT DUE TO THE VEHICLE SHUTTING DOWN ON HER. AFTER SITTING ON THE SIDE OF THE ROAD WAITING FOR AAA TO COME TOW THE VEHICLE FOR OVER 1 HOURS, THE VEHICLE STARTED BACK UP AND SHE DROVE IT TO FORD CUMBERLAND, 10335 MT SAVAGE ROAD NW, CUMBERLAND, MD WITH THE CHECK ENGINE LIGHT STILL ON WITH A POLICE ESCORT SINCE THE SHERIFF OF CUMBERLAND SAT WITH MY WIFE ON MD-51N WAITING ON AAA. THIS IS AFTER SHE WAS ALMOST HIT BY A FEDEX EIGHTEEN WHEELER DUE TO NOT BEING ABLE TO GET TO A SAFE LOCATION FOR A TRUCK AND HORSE TRAILER DUE TO THE VEHICLE SHUTTING DOWN ON HER. THE DEALERSHIP FOUND THE PROBLEM: EXHAUST SENSOR. THEY WERE ABLE TO REPAIR IT AND SHE WAS ABLE TO CONTINUE ON WITH HER TRIP. HOW CAN THIS SENSOR GO OUT ON A TRUCK WITH ONLY 44,000 MILES ON IT? HOW CAN THEY DESIGN A TRUCK TO SHUT DOWN AUTOMATICALLY WITHOUT ANY WARNING? THE DEALERSHIP TOLD MY WIFE THEY HAVE SEEN THESE SENSORS GO OUT AT 20,000 MILES BEFORE. NEEDS TO BE ADDRESS AND RECALL ISSUED BEFORE SOMEONE DIES ON THE HIGHWAY DUE TO THIS PROBLEM. HOLD FORD ACCOUNTABLE. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10640335

102,000 miles · Jun 27, 2014
SteeringStructureCrash

ON THE EVENING OF 6/13/2014, I WAS DRIVING MY 2008 FORD F-350 THROUGH THE DRIVE THROUGH LINE OF WHITE CASTLE IN COMMACK, NEW YORK, 11725. AS I WENT TO MAKE A RIGHT TURN TO FOLLOW THE DRIVE THROUGH LANE, A HEARD A METAL BREAKING SOUND FOLLOWED BY COMPLETE LOSS OF STEERING. WITHIN LESS THAN 1 SECOND FROM THIS HAPPENING, MY VEHICLE…

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ON THE EVENING OF 6/13/2014, I WAS DRIVING MY 2008 FORD F-350 THROUGH THE DRIVE THROUGH LINE OF WHITE CASTLE IN COMMACK, NEW YORK, 11725. AS I WENT TO MAKE A RIGHT TURN TO FOLLOW THE DRIVE THROUGH LANE, A HEARD A METAL BREAKING SOUND FOLLOWED BY COMPLETE LOSS OF STEERING. WITHIN LESS THAN 1 SECOND FROM THIS HAPPENING, MY VEHICLE COLLIDED WITH A CINDER BLOCK WALL CAUSING SIGNIFICANT FRONT END DAMAGE TO THE BUMPER, FENDER AND HEADLIGHT. THERE WERE NO INJURIES TO MYSELF OR ANY PASSENGERS AS WELL AS THE WALL HAD MINIMAL DAMAGE. I HAD A POLICE REPORT FILED WITH THE SUFFOLK COUNTY POLICE DEPARTMENT. THE REPORT CORROBORATES MY STATEMENT OF COMPLETE STEERING LOSS AS THE DIRECT RESULT OF THE ACCIDENT. THE VEHICLE WAS TOWED TO MY MECHANIC, NORTH SHORE FIRESTONE IN COMMACK. UPON INVESTIGATION THEY DETERMINED THE GEARS INSIDE OF THE STEERING BOX COMPLETELY FAILED. THEY COULD BE OF FURTHER ASSISTANCE DETAILING WHAT THE INTERNALS OF THE STEERING BOX LOOKED LIKE IF NEEDED. THEY ALSO INFORMED ME THERE IS A 2 MONTH BACK LOG ON THE REPLACEMENT FOR THIS PART. BEING THAT THERE IS A REPLACEMENT BACKLOG, FORD MUST KNOW THERE IS A DESIGN FLAW. THIS PART NEEDS TO BE REDESIGNED TO STAND UP TO THE DIFFICULT TASK OF GETTING WHITE CASTLE! THIS FAILURE NOT ONLY CAUSED DAMAGE TO MY TRUCK COSTING OVER $5,000, BUT THIS WILL CAUSE MY INSURANCE TO GO UP AS WELL. IF THIS CAUSES ME TO BE DROPPED FROM MY INSURANCE, I WILL HAVE MAJOR PROBLEMS BEING THAT ALL OF MY JOBS REQUIRE ME TO HAVE TRANSPORTATION. PLEASE HAVE FORD FIX THIS PROBLEM SO NO ONE ELSE IS INVOLVED IN AN ACCIDENT. I WAS LUCKY I WAS GOING AT A LOW SPEED, BUT THE NEXT PERSON MAY NOT BE AS LUCKY AS I WAS. *TR

NHTSA ODI #10606385

40,000 miles · May 18, 2014
SteeringSuspension

I HAVE A 2008 F350 SINGLE REAR WHEEL!!!! DEATH WOBBLE WITH MY FRIENDS BOSTON WHALER GOING DOWN 495 TO THE CAPE!!!! HAD THE TRUCK FOR FOUR YEARS!!! REPLACED 2 STEERING SHOCKS,TIEROD ENDS!! TIRES!! 2 FRONT ALIGNMENTS!!! TRUCK IS A PIECE OF [XXX]!!!!!!!!!!!!!!!!!! I HAVE HAD A 1978 F150,1979 F250,1988 F150,1995 F150,1996 F250,1999…

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I HAVE A 2008 F350 SINGLE REAR WHEEL!!!! DEATH WOBBLE WITH MY FRIENDS BOSTON WHALER GOING DOWN 495 TO THE CAPE!!!! HAD THE TRUCK FOR FOUR YEARS!!! REPLACED 2 STEERING SHOCKS,TIEROD ENDS!! TIRES!! 2 FRONT ALIGNMENTS!!! TRUCK IS A PIECE OF [XXX]!!!!!!!!!!!!!!!!!! I HAVE HAD A 1978 F150,1979 F250,1988 F150,1995 F150,1996 F250,1999 F350 AND LOVED ALL OF THEM AND GOT THIS 2008 F350 AND NEVER HAD A WORSE CONTROLLING TRUCK IN MY LIFE AND I HAVE BEAN A MECHANIC FOR 30!!!! I REPEAT 30 YEARS AND WHAT A [XXX] BOX FRONT END WOW!!!! FORD PLEASE HAVE A RECALL BEFORE YOU KILL SOMEBODY IN THE TRUCK OR HITTING SOME ONE!!!!!!!!! INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR UPDATED 11/18/2014 *JS

NHTSA ODI #10592301

Official recalls

0

No recalls in this snapshot.

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

1

PE13014 · 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