NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
101 reportsMileage unknown · Jun 4, 2010
SteeringVehicle Speed ControlCrashInjury
LETTER FROM SENATOR BROWN ON BEHALF OF CONSTITUENT RE HIS FORD TRUCK GAS PEDAL ACCELERATING, CAUSING HIM TO CRASH (DOT/I#2010-1130) *TGW THE CONSUMER STATED WHILE DRIVING ON A RURAL ROAD, THE STEERING LOCKED UP AND THE GAS PEDAL BECAME STUCK WHICH CAUSED THE VEHICLE TO ACCELERATE OUT OF CONTROL AND CRASH INTO AN EMBANKMENT. THE…
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LETTER FROM SENATOR BROWN ON BEHALF OF CONSTITUENT RE HIS FORD TRUCK GAS PEDAL ACCELERATING, CAUSING HIM TO CRASH (DOT/I#2010-1130) *TGW THE CONSUMER STATED WHILE DRIVING ON A RURAL ROAD, THE STEERING LOCKED UP AND THE GAS PEDAL BECAME STUCK WHICH CAUSED THE VEHICLE TO ACCELERATE OUT OF CONTROL AND CRASH INTO AN EMBANKMENT. THE CONSUMER WAS KNOCKED UNCONSCIOUS AND WHEN HE CAME TO THE ACCELERATOR PEDAL WAS PRESSED TO THE FLOOR. HE WAS ABLE TO RELEASE THE ACCELERATOR PEDAL SO HE PROCEEDED TO MOVE THE VEHICLE TO THE SIDE OF THE ROAD. AS HE DID THAT, THE STEERING LOCKED UP A SECOND TIME, SO HE TURNED OFF THE ENGINE AND WAITED FOR THE POLICE TO ARRIVE. THE CONSUMER SUFFERED A MILD CONCUSSION. THE CONSUMER STATED FORD NOR HIS INSURANCE COMPANY WERE WILLING TO PAY FOR THE REPAIRS FOR THE DEFECTIVE STEERING BOX. *JB
NHTSA ODI #10334890
21,000 miles · May 27, 2010
Tires
I HAD A CONTINENTAL CONTITRAC LT 245/75R17 121/118S TIRE WHICH DEVELOPED 5 CRACKS IN SIDE OF TREAD. WHILE DRIVING F350 TRUCK, ONE CRACK TOTALLY SEPARATED CAUSING INSTANT DEFLATION OF FRONT DRIVER SIDE TIRE. TIRE HAD APPROXIMATELY 21,000 MILES ON IT AND WAS ORIGINAL EQUIPMENT WHEN I PURCHASE TRUCK NEW IN FEB 2008. *TR
NHTSA ODI #10332529
26,050 miles · May 26, 2010
SteeringSuspensionCrash
2008 FORD F-350 SUPER DUTY TRUCK. CONSUMER STATES VEHICLE IS INHERENTLY UNSAFE BECAUSE OF A DESIGN FLAW *TGW THE CONSUMER BELIEVED THE FRONT SUSPENSION AND STEERING MECHANISMS WERE TOO LIGHT FOR THE WEIGHT OF THE TRUCK AND FOR THE TYPE OF LOAD IT WAS SUPPOSED TO HANDLE. THE CONSUMER STATED THE FRONT END WAS RATED TO CARRY 5200…
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2008 FORD F-350 SUPER DUTY TRUCK. CONSUMER STATES VEHICLE IS INHERENTLY UNSAFE BECAUSE OF A DESIGN FLAW *TGW THE CONSUMER BELIEVED THE FRONT SUSPENSION AND STEERING MECHANISMS WERE TOO LIGHT FOR THE WEIGHT OF THE TRUCK AND FOR THE TYPE OF LOAD IT WAS SUPPOSED TO HANDLE. THE CONSUMER STATED THE FRONT END WAS RATED TO CARRY 5200LBS. HOWEVER, WHEN THE TRUCK WAS EMPTY, THERE WAS ALREADY 4800LBS ON THE FRONT END. THE CONSUMER STATED THE TRUCK IS SUPPOSED TO BE A SUPER DUTY TRUCK, BUT APPARENTLY IT CAN'T CARRY ANYTHING EXCEPT A PASSENGER OR TWO BEFORE THE FRONT END IS OVERLOADED. THE STEERING BOX BROKE SUDDENLY FOR THE TIME AT 26,050 MILES. WHICH CAUSED THE CONSUMER TO CRASH INTO A PARKED VEHICLE AT ABOUT 20 MPH. THE DEALER REPLACED THE STEERING BOX, BUT THE NEW ONE FAILED AT 29, 581 MILES. THE CURRENT STEERING BOX IS FEELING LOOSE AND THE TRUCK WANDERS. THE BALL JOINTS AND TIE ROD ENDS WERE REPLACED AT 38,587 MILES. THE CONSUMER ALSO STATED WHEN THE VEHICLE WAS DRIVEN OVER A BUMP, IF FELT AS THOUGH THE POWER STEERING MALFUNCTIONED FOR A FEW SECONDS. *JB
NHTSA ODI #10331743
5,000 miles · Apr 13, 2010
Electrical SystemVehicle Speed Control
I PURCHASED A 2008 FORD 350 SUPER DUTY KING RANCH WITH A 6.4L DIESEL AND STARTED HAVING THROTTLE PROBLEMS @ ABOUT 5,000 MILES. I HAD REPEATED PROBLEMS WITH THROTTLE RESPONSE. I WAS DRIVING DOWN THE HWY @ 70MPH AND THE TRUCK JUST WENT INTO IDLE MODE AND WOULD NOT RESPOND TO THE THROTTLE PEDAL. I WAS VERY LUCKY TO BE ABLE TO WE…
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I PURCHASED A 2008 FORD 350 SUPER DUTY KING RANCH WITH A 6.4L DIESEL AND STARTED HAVING THROTTLE PROBLEMS @ ABOUT 5,000 MILES. I HAD REPEATED PROBLEMS WITH THROTTLE RESPONSE. I WAS DRIVING DOWN THE HWY @ 70MPH AND THE TRUCK JUST WENT INTO IDLE MODE AND WOULD NOT RESPOND TO THE THROTTLE PEDAL. I WAS VERY LUCKY TO BE ABLE TO WEAVE THRU TRAFFIC AND PULL OVER TO THE SIDE OF THE ROAD. I SHUT THE TRUCK OFF AND SAT THERE FOR A FEW MINUTES THEN RESTARTED THE TRUCK AND DROVE OFF. ON NUMEROUS OCCASIONS I WOULD START THE TRUCK AND IT WOULD DRIVE A SHORT WAYS AND THEN KICK INTO IDLE MODE AND THE ENGINE WOULD NOT RESPOND TO THE PEDAL. I HAD THE TRUCK TOWED INTO THE FORD DEALER AND THEY SAID THEY COULD NOT DUPLICATE THE PROBLEM. THEY REPLACED THE THROTTLE PEDAL SENSOR AND GAVE IT BACK TO ME. I FILED A COMPLAINT WITH CUSTOMER SERVICE ON 6/18/2009 CASE # [XXX] AS THE PROBLEM CONTINUED TO HAPPEN. I HAD THE TRUCK TOWED IN AGAIN AND THE FORD DEALER REPLACED THE MAP SENSOR. THE PROBLEM CONTINUED TO HAPPEN AND I HAD THE TRUCK TOWED INTO THE FORD DEALER AGAIN AND LEFT IT WITH THEM. THEY CALLED ME BACK AND SAID THE TRUCK WAS READY TO PKUP. I WAS UNDER THE IMPRESSION THAT THEY HAD CHANGED A PART OR CORRECTED THE PROBLEM. I INFORMED THEM THAT I WAS GOING ON A HUNTING TRIP TO UT IN LATE DECEMBER AND WANTED TO ENSURE MY TRUCK WAS IN FACT REPAIRED. I DROVE TO ELKO NV AND SPENT THE NIGHT. THE NEXT DAY (SUNDAY) I STARTED THE TRUCK AND IT KICKED INTO IDLE MODE AND WOULD NOT RESPOND TO THE THROTTLE. I HAD IT TOWED TO THE FORD DEALER AGAIN. THE NEXT DAY THEY REFLASED THE COMPUTER IN THE TRUCK AND SAID THEY HOPED IT WOULD GET ME HOME. WHEN I RETURNED HOME I TOOK THE TRUCK INTO THE LOCAL FORD DEALER AGAIN. THEY SAID THEY COULD NOT DUPLICATE THE PROBLEM. THEY DID CHANGE OUT THE PCM AND GAVE ME BACK THE TRUCK BUT WOULD NOT CONFIRM THEY FIXED THE PROBLEM. I WAS IN CONTACT WITH FORD CUST SERVICE AND REQUESTED A BUY BACK. THEY REFUSED. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #10325384
12,000 miles · Mar 18, 2010
Tires
1. ON JULY 8TH 2009 WHILE RETURNING HOME FROM TEXAS AT THE POSTED SPEED WE EXPERIENCED A VIBRATION. I CHECKED THE INSTRUMENT PANEL FOR ANY PROBLEMS SUCH AS THE LOW TIRE INDICATOR LIGHT. SECONDS AFTER THE RIGHT SIDE REAR TIRE EXPLODED AND PULLED THE TRUCK VIOLENTLY TO THE RIGHT AS I FOUGHT TO CONTROL THE TRUCK AND BRING IT TO A S…
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1. ON JULY 8TH 2009 WHILE RETURNING HOME FROM TEXAS AT THE POSTED SPEED WE EXPERIENCED A VIBRATION. I CHECKED THE INSTRUMENT PANEL FOR ANY PROBLEMS SUCH AS THE LOW TIRE INDICATOR LIGHT. SECONDS AFTER THE RIGHT SIDE REAR TIRE EXPLODED AND PULLED THE TRUCK VIOLENTLY TO THE RIGHT AS I FOUGHT TO CONTROL THE TRUCK AND BRING IT TO A STOP. THE TREAD HAD SEPARATED FROM THE TIRE AND CAUSED EXTENSIVE DAMAGE TO RIGHT QUARTER PANEL AS WELL AS THE EXHAUST. WE RETURNED THE TRUCK TO THE DEALER AND THEY REPAIRED THE DAMAGE AND REPLACED THE CONTINENTAL TIRE. I EXPRESSED MY CONCERN OF THE REMAINING TIRES AND THEY TOLD ME THAT IT WAS AN ISOLATED INCIDENT AND SHOULDN'T HAVE ANY MORE PROBLEMS. THE TRUCK AND ORIGINAL EQUIPMENT TIRES ONLY HAD 12K MILES. 2. ON 2/12/10 WHILE DRIVING TO CAL. AGAIN @ POSTED SPEED AND NO LOW TIRE INDICATOR LIGHT ON. THE SAME CONDITIONS AS ABOVE ONLY TOWING A FIFTH WHEEL TRAILER. WE EXPERIENCED A VIBRATION AND WITH IN SECONDS THE LEFT REAR TIRE EXPLODED AND AGAIN THE TREAD SEPARATED FROM THE TIRE AND CAUSED EXTENSIVE DAMAGE TO THE LEFT QUARTER PANEL. WE WERE VERY FORTUNATE TO BRING THE RIG TO A STOP WITH OUT ROLLING OR CAUSING INJURY OR FATALITY. AGAIN I RETURNED THE TRUCK TO THE DEALER ON 2/14/10 AND THEIR IT SITS TO THIS DAY 3/17/10 AND NOTHING BUT EXCUSES. *TR
NHTSA ODI #10320595
2,285 miles · Mar 13, 2010
Suspension
2008 F-350 HAS WHAT THEY CALL THE "DEATH WOBBLE" AND HAS A CONSTANT SHAKE AT HIGHWAY SPEEDS. FORD BLAMED IT ON THE TIRES. I REPLACED TIRES WITH ONE OF THE BEST YOU CAN BUY. CONTINUED TO DO THE SAME THING. FORD BLAMED IT ON THOSE TIRES. BEEN IN FOR SERVICE 5 TIMES IN 1 YEAR. DEALERSHIP TOLD ME NOT TO COME BACK BECAUSE THEY CAN'T …
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2008 F-350 HAS WHAT THEY CALL THE "DEATH WOBBLE" AND HAS A CONSTANT SHAKE AT HIGHWAY SPEEDS. FORD BLAMED IT ON THE TIRES. I REPLACED TIRES WITH ONE OF THE BEST YOU CAN BUY. CONTINUED TO DO THE SAME THING. FORD BLAMED IT ON THOSE TIRES. BEEN IN FOR SERVICE 5 TIMES IN 1 YEAR. DEALERSHIP TOLD ME NOT TO COME BACK BECAUSE THEY CAN'T FIX IT. FORD TELLS ME TO GO BACK TO THE DEALERSHIP. SOMEDAY I'M GOING TO KILL SOMEONE OR MYSELF IN THIS TRUCK SINCE I HAVE NO CONTROL WHEN THE "DEATH WOBBLE" STARTS UNTIL I CAN SLOW DOWN TO ABOUT 20 MPH ON AN INTERSTATE HIGHWAY. UPDATED IVOQ 05/26/10
NHTSA ODI #10319436
9,585 miles · Mar 4, 2010
Fuel System, Gasoline
NORMAL DRIVING, ACCELERATING TO SPEED LIMIT. THROTTLE STUCK WIDE OPEN AND WOULD NOT RETURN TO IDLE. DEALER REPLACE GAS PEDAL. HAVE OLD PART. *TR
NHTSA ODI #10316753
30,000 miles · Mar 4, 2010
Service Brakes, HydraulicFire
INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6) 2008 F-350 SUPER DUTY TRUCK [XXX] FRONT CALIPER LOCKUP OVERHEAT, SMOKE AND FAILURE. VEHICLE HAS 29,000 MILES, ALL REQUIRED FACTORY MAINTENANCE REQUIREMENTS MET AT OR BEFORE REQUIRED INTERVALS. NORMAL DRIVE OF 14 MILES AVERAGING 50-60 MP…
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INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6) 2008 F-350 SUPER DUTY TRUCK [XXX] FRONT CALIPER LOCKUP OVERHEAT, SMOKE AND FAILURE. VEHICLE HAS 29,000 MILES, ALL REQUIRED FACTORY MAINTENANCE REQUIREMENTS MET AT OR BEFORE REQUIRED INTERVALS. NORMAL DRIVE OF 14 MILES AVERAGING 50-60 MPH, WITH FINAL 1/2 MIL PORTION AT AIRPORT AND AT 25-30 MPH. FRONT LEFT (DRIVER) SIDE CALIPER FAILS TO RELEASE, DRIVE OF 1/8 MILE TO PARKING LOT REVEALED SMOKING AND LOCKED CALIPER. NO PREVIOUS BRAKE ISSUES. 900 MILE FREEWAY ROUND TRIP (450 MI PER DAY)( COMPLETED WITHIN THE PREVIOUS 3 DAYS ALL WITH NO ISSUES. DEALER IS REPLACING CALIPER, DISC AND PADS UNDER WARRANTY. CAUSE OF FAILURE IS NOT RELEASED TO OWNER AS DEALER IS REQUIRED TO SEND DEFECTIVE CALIPER TO FORD FOR ANALYSIS.. ALL THREE REMAINING CALIPERS ARE OF THE SAME TYPE. *TR
NHTSA ODI #10316749
18,000 miles · Mar 3, 2010
Steering
I HAVE A 2008 FORD F-350 DUALLY THAT WHEN HITTING A DIP/BUMP IN THE ROAD AT SPEEDS ABOVE ABOUT 35, THE ENTIRE FRONT END SHAKES/SHIMMYS SO BAD THAT YOU CAN'T EVEN CONTROL IT! I RECEIVED A LETTER IN THE MAIL FROM FORD IN APRIL 2009 BASICALLY SAYING WHEN IT HAPPENS SLOW DOWN. THE DEALER REFUSES TO DO ANYTHING. SOMEONE IS GOING T…
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I HAVE A 2008 FORD F-350 DUALLY THAT WHEN HITTING A DIP/BUMP IN THE ROAD AT SPEEDS ABOVE ABOUT 35, THE ENTIRE FRONT END SHAKES/SHIMMYS SO BAD THAT YOU CAN'T EVEN CONTROL IT! I RECEIVED A LETTER IN THE MAIL FROM FORD IN APRIL 2009 BASICALLY SAYING WHEN IT HAPPENS SLOW DOWN. THE DEALER REFUSES TO DO ANYTHING. SOMEONE IS GOING TO GET KILLED IF THIS IS NOT FIXED. *TR
NHTSA ODI #10316308
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
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