NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
31 reportsClear category filter31,500 miles · Apr 21, 2010
Engine And Engine CoolingFire
AFTER PARKING MY FORD F-350 CREW CAB 4X4 WITH A V-10 ENGINE, I EXITED THE VEHICLE AND CIRCLED AROUND TO THE PASSENGER SIDE WHERE I NOTICED FROM THE CORNER OF MY EYE FLAMES IN THE R FRONT WHEEL WELL. BEHIND THE TIRE. I IMMEDIATELY WENT INSIDE THE BUILDING AND SUMMONED HELP AND A FIRE EXTINGUISHER (ABC) . MYSELF AND SECURITY PERSO…
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AFTER PARKING MY FORD F-350 CREW CAB 4X4 WITH A V-10 ENGINE, I EXITED THE VEHICLE AND CIRCLED AROUND TO THE PASSENGER SIDE WHERE I NOTICED FROM THE CORNER OF MY EYE FLAMES IN THE R FRONT WHEEL WELL. BEHIND THE TIRE. I IMMEDIATELY WENT INSIDE THE BUILDING AND SUMMONED HELP AND A FIRE EXTINGUISHER (ABC) . MYSELF AND SECURITY PERSONNEL DID NOT OPEN THE HOOD. WE DIRECTED THE FIRE EXT. INTO THE WHEEL WELL AND THERE WAS A SORT OF BACKLASH AND WITH SECONDS A PAINT BUBBLING HOT SPOT APPEARED ON THE HOOD. WE IMMEDIATELY CONTACTED THE FIRE DEPARTMENT WHO RESPONDED. WITHIN MINUTES THE ENGINE COMPARTMENT WAS COMPLETELY ENGULFED IN FLAMES AND THERE WAS FLAMING UNDER THE ENGINE AS WELL. WE CLEARED THE AREA OF ONLOOKERS AS FIREMAN FOUGHT THE BLAZE. THERE WERE NO INJURIES TO MYSELF, THE SECURITY GUARD WHO RESPONDED, FIREMEN OR ONLOOKERS. *TR
NHTSA ODI #10326750
15,000 miles · Jan 8, 2010
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2008 FORD F350. WHENEVER THE CONTACT STARTED THE IGNITION THERE WAS A GENERATION OF EXCESSIVE EXHAUST FUMES. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR INSPECTION. THE TECHNICIAN WAS UNABLE TO LOCATE THE FAILURE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER ON THIRTEEN SEPARATE OCCASIONS FOR THE IDE…
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TL*THE CONTACT OWNS A 2008 FORD F350. WHENEVER THE CONTACT STARTED THE IGNITION THERE WAS A GENERATION OF EXCESSIVE EXHAUST FUMES. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR INSPECTION. THE TECHNICIAN WAS UNABLE TO LOCATE THE FAILURE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER ON THIRTEEN SEPARATE OCCASIONS FOR THE IDENTICAL FAILURES WHICH THERE WERE NO RESOLUTIONS. THE VEHICLE HAS NOT BEEN REPAIRED FOR THE MALFUNCTION. THE CONTACT HAD CONCERNS OF THE SAFETY RISK INVOLVED. THE FAILURE MILEAGE WAS 15,000.
NHTSA ODI #10298742
50,000 miles · Oct 13, 2009
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2008 FORD F350. AFTER TURNING THE ENGINE OFF HE HEARD A HISSING SOUND. UPON FURTHER INSPECTION, HE NOTICED THAT THE RADIATOR WAS LEAKING FLUID. HIS CAT DIED FROM DRINKING THE FLUID. THE DEALER WAS NOTIFIED AND A TECHNICIAN CONCLUDED THAT THE REPAIRS WOULD BE COVERED UNDER THE WARRANTY. THE FAILURE MILEAGE…
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TL* THE CONTACT OWNS A 2008 FORD F350. AFTER TURNING THE ENGINE OFF HE HEARD A HISSING SOUND. UPON FURTHER INSPECTION, HE NOTICED THAT THE RADIATOR WAS LEAKING FLUID. HIS CAT DIED FROM DRINKING THE FLUID. THE DEALER WAS NOTIFIED AND A TECHNICIAN CONCLUDED THAT THE REPAIRS WOULD BE COVERED UNDER THE WARRANTY. THE FAILURE MILEAGE WAS 50000. THE CURRENT MILEAGE WAS 65000. UPDATED 11/03/09 *BF THE CONSUMER STATED THERE WAS A LEAK IN 3 DIFFERENT PLACES. UPDATED 11/04/09*JB
NHTSA ODI #10287212
70,000 miles · Jun 29, 2009
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING 55 MPH, THE ENGINE TEMPERATURE BEGAN TO RISE AND THE ENGINE POWER DECREASED. SEVERAL MONTHS PRIOR TO THE FAILURE, THE VEHICLE DISPLAYED THE SAME SYMPTOMS AND WAS SERVICED BY THE DEALER. THE CAUSE OF THE FAILURE HAS NOT BEEN DIAGNOSED BY THE DEALER. THE CURRENT AND FAILURE …
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TL*THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING 55 MPH, THE ENGINE TEMPERATURE BEGAN TO RISE AND THE ENGINE POWER DECREASED. SEVERAL MONTHS PRIOR TO THE FAILURE, THE VEHICLE DISPLAYED THE SAME SYMPTOMS AND WAS SERVICED BY THE DEALER. THE CAUSE OF THE FAILURE HAS NOT BEEN DIAGNOSED BY THE DEALER. THE CURRENT AND FAILURE MILEAGES WERE 70,000.
NHTSA ODI #10275225
2,500 miles · Nov 12, 2008
Air BagsEngine And Engine CoolingSteeringCrashInjury
JUNE 25, 2007, WE WERE IN MONTANA AND HAD JUST COME DOWN FROM APPROX. 14,000 FT. PASS, CLOSED SUN ROOF ON OUR 2008 FORD F350 CREWCAB DIESEL, ALL 4 OCCUPANTS (3 ADULTS & 1 CHILD) FELL ASLEEP @ 2:00 PM IN THE AFTERNOON. PASSENGER WOKE AS WE WERE GOING OFF THE PAVEMENT, TRIED TO PUT TRUCK BACK ON PAVEMENT BUT FRONT OF TRUCK WOULD N…
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JUNE 25, 2007, WE WERE IN MONTANA AND HAD JUST COME DOWN FROM APPROX. 14,000 FT. PASS, CLOSED SUN ROOF ON OUR 2008 FORD F350 CREWCAB DIESEL, ALL 4 OCCUPANTS (3 ADULTS & 1 CHILD) FELL ASLEEP @ 2:00 PM IN THE AFTERNOON. PASSENGER WOKE AS WE WERE GOING OFF THE PAVEMENT, TRIED TO PUT TRUCK BACK ON PAVEMENT BUT FRONT OF TRUCK WOULD NOT GET UNDER CONTROL, HIT MAIL BOXES AND VEERED TO LEFT (STILL UNABLE TO CONTROL) NOT SPEEDING, HIT HEAD ON INTO TREES, ROLLED TO ROOF. AIR BAGS DID NOT DEPLOY ON EITHER SIDE, DRIVER SIDE (FRONT AND BACK) ROOF CRUSHED TO TOP AND INTO FRONT DRIVERS SEAT AND ALMOST TO FRAME OF WINDOW IN THE BACK SEAT. WHY OR WHAT CAUSED US ALL TO FALL ASLEEP AFTER CLOSING SUN ROOF, WHY WERE WE NOT ABLE TO CONTROL FRONT OF TRUCK (TOO HEAVY?), WHY DID AIR BAGS NOT DEPLOY AND WHY DID ROOF CRUSH SO FAR ON A ROLL TO ROOF, WE DID NOT ROLL COMPLETELY OVER. TRUCK WAS TOTALED. NO DEATHS OCCURRED, DRIVER RESULTED IN A BROKEN NECK AND PASSENGERS WITH RIB AND NECK INJURIES. *TR
NHTSA ODI #10248644
54,000 miles · Nov 10, 2008
Engine And Engine Cooling
RADIATOR LEAK. *TR
NHTSA ODI #10248262
53,000 miles · Sep 23, 2008
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING APPROXIMATELY 55 MPH, PRESSURE WAS APPLIED TO THE ACCELERATOR PEDAL WITHOUT POWER ASSISTANCE. THE CONTACT NOTICED EXCESSIVE SMOKE COMING FROM THE EXHAUST PIPE. IN ADDITION, THE VEHICLE HESITATED AND IDLED ROUGHLY. THERE WERE NO WARNING LIGHTS ILLUMINATED ON THE INSTRUMENT …
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TL*THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING APPROXIMATELY 55 MPH, PRESSURE WAS APPLIED TO THE ACCELERATOR PEDAL WITHOUT POWER ASSISTANCE. THE CONTACT NOTICED EXCESSIVE SMOKE COMING FROM THE EXHAUST PIPE. IN ADDITION, THE VEHICLE HESITATED AND IDLED ROUGHLY. THERE WERE NO WARNING LIGHTS ILLUMINATED ON THE INSTRUMENT PANEL. THE CONTACT PULLED OVER TO THE SIDE OF THE ROAD AN TURNED OFF THE ENGINE. AFTER FIVE MINUTES, THE ENGINE WAS ABLE TO BE RESTARTED. THE CONTACT OBSERVED THAT THE FAILURE OCCURRED MORE FREQUENTLY IN RAINY WEATHER CONDITIONS AND AT ANY GIVEN SPEED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR A DIAGNOSTIC, BUT NO FAILURES WERE FOUND. HOWEVER, THE COMPUTERIZED SYSTEM WAS REPROGRAMMED AND THE MOTOR WAS REPLACED AT 53,000 MILES. ON 12 SEPARATE OCCASIONS, THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR IDENTICAL FAILURES, BUT THERE WERE NO RESOLUTIONS. THE VEHICLE HAS NOT BEEN REPAIRED. THE FAILURE MILEAGE WAS 33,000 AND CURRENT MILEAGE WAS 73,400. UPDATED 10-29-08 *BF UPDATED 10/30/08. *JB
NHTSA ODI #10243260
47,000 miles · Aug 27, 2008
Engine And Engine CoolingFire
TL*THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING 60 MPH, THE CONTACT HEARD A LOUD BANGING NOISE COMING FROM THE FRONT END OF THE VEHICLE. HE NOTICED SMOKE COMING FROM THE REAR OF THE VEHICLE. HE PULLED THE VEHICLE OVER AND NOTICED SMOKE COMING FROM THE HOOD OF THE VEHICLE. ALSO, THE CONTACT NOTICED A VAST AMOUNT OF OIL O…
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TL*THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING 60 MPH, THE CONTACT HEARD A LOUD BANGING NOISE COMING FROM THE FRONT END OF THE VEHICLE. HE NOTICED SMOKE COMING FROM THE REAR OF THE VEHICLE. HE PULLED THE VEHICLE OVER AND NOTICED SMOKE COMING FROM THE HOOD OF THE VEHICLE. ALSO, THE CONTACT NOTICED A VAST AMOUNT OF OIL ON THE GROUND WHERE THE VEHICLE WAS PARKED. THE VEHICLE WAS TAKEN TO THE DEALER AND THEY STATED THAT THE ENGINE NEEDED TO BE REPLACED. PRIOR TO THE WARNING, THE CONTACT COULD SMELL OIL BURNING WHILE DRIVING THE VEHICLE. THE CURRENT AND FAILURE MILEAGES WERE 47,000.
NHTSA ODI #10239912
60,624 miles · Jun 24, 2008
Engine And Engine CoolingCrashInjury
TL*THE CONTACT OWNS A 2008 FORD F-350. ON JUNE 4, 2008, WHILE DRIVING APPROXIMATELY 60 MPH, THE VEHICLE SUDDENLY SHUT DOWN WITHOUT WARNING. THE CONTACT TOOK THE VEHICLE TO THE DEALER AND THEY STATED THAT THE EXHAUST FILTER FAILED. THE DEALER REPLACED THE EXHAUST FILTER. ON JUNE 22, 2008, THE CONTACT'S FATHER WAS TRANSPORTING…
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TL*THE CONTACT OWNS A 2008 FORD F-350. ON JUNE 4, 2008, WHILE DRIVING APPROXIMATELY 60 MPH, THE VEHICLE SUDDENLY SHUT DOWN WITHOUT WARNING. THE CONTACT TOOK THE VEHICLE TO THE DEALER AND THEY STATED THAT THE EXHAUST FILTER FAILED. THE DEALER REPLACED THE EXHAUST FILTER. ON JUNE 22, 2008, THE CONTACT'S FATHER WAS TRANSPORTING A TRAILER AND THE VEHICLE SUDDENLY SHUT OFF WHILE ATTEMPTING TO PARK. THE TRAILER SLAMMED INTO THE VEHICLE. HIS FATHER LOST CONTROL AND SUSTAINED INJURIES TO HIS NECK AND BACK. THE VEHICLE WAS RETURNED TO THE DEALER, BUT THEY WERE UNABLE TO DIAGNOSE THE CAUSE OF THE FAILURE. THE MANUFACTURER STATED THAT THEY WERE NOT RESPONSIBLE FOR ANY OF THE DAMAGES. THE FAILURE MILEAGE WAS 60,624 AND CURRENT MILEAGE WAS 69,000.
NHTSA ODI #10232205
40,000 miles · Apr 1, 2008
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2008 FORD F-350. THE CONTACT HEARD A HUMMING NOISE COMING FROM THE POWER STEERING. HE DISCOVERED THAT THE RADIATOR FLUID WAS LOW. THE VEHICLE WAS TAKEN TO THE DEALER FOR A PRESSURE CHECK OF THE COOLING SYSTEM. THE DEALER FOUND A RADIATOR LEAK AND MADE THE REPLACEMENT. THIS IS THE SECOND TIME THE RADIAT…
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TL*THE CONTACT OWNS A 2008 FORD F-350. THE CONTACT HEARD A HUMMING NOISE COMING FROM THE POWER STEERING. HE DISCOVERED THAT THE RADIATOR FLUID WAS LOW. THE VEHICLE WAS TAKEN TO THE DEALER FOR A PRESSURE CHECK OF THE COOLING SYSTEM. THE DEALER FOUND A RADIATOR LEAK AND MADE THE REPLACEMENT. THIS IS THE SECOND TIME THE RADIATOR HAS BEEN REPLACED DUE TO THE SAME FAILURE. THE CURRENT MILEAGE WAS 40,800 AND FAILURE MILEAGE WAS 40,000.
NHTSA ODI #10223024
Official recalls
6Jul 28, 2008
KNAPHEIDE IS RECALLING 108 MY 2006-2008 PRO SERIES TRUCK BEDS EQUIPPED WITH AN ICC BUMPER WHICH INCLUDED A PROVISION FOR A BALL HITCH. THERE MAY BE AN INSUFFICIENT WELD ATTACHING THE HITCH CHANNEL TO THE SUPPORTING STRUCTURE.
Consequence & remedy
Consequence: THIS COULD RESULT IN BENDING OF THE HITCH CHANNEL OR THE HITCH COULD BE PULLED OFF THE VEHICLE, INCREASING THE RISK OF A CRASH.
Remedy: KNAPHEIDE WILL OFFER TWO REMEDIES TO ITS CUSTOMERS: (1) FOR THOSE CUSTOMERS WHO DO NOT USE THE HITCH, THE HITCH WILL BE REMOVED FROM THE TRUCK BED AND REPLACED WITH AN ICC BUMPER; OR (2) FOR THOSE CUSTOMERS WHO NEED A HITCH, A RECEIVER HITCH ASSEMBLY WILL BE ADDED TO THE EXISTING HITCH ASSEMBLY AND ALL SUSPECT WELD JOINTS WILL BE RE WELDED. THE RECALL BEGAN ON AUGUST 15, 2008. OWNERS MAY CONTACT KNAPHEIDE AT 1-877-473-5763.
Apr 25, 2008
FORD IS RECALLING 64,754 MY 2008 F-250 AND F-350 SINGLE REAR WHEEL, 4X4, 156 INCH WHEEL BASE PICK UP TRUCKS EQUIPPED WITH A TWO PIECE DRIVE SHAFT FOR FAILING TO CONFORM TO THE FUEL SPILLAGE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 301, "FUEL SYSTEM INTEGRITY." DURING A 30 MPH FRONTAL IMPACT INTO A RIGID BARRIER, THE FUEL TANK CAN MOVE FORWARD AND CONTACT A FRAME CROSS MEMBER, POTENTIALLY CAUSING DAMAGE TO THE FUEL DELIVERY MODULE WHICH CAN RESULT IN FUEL SPILLAGE.
Consequence & remedy
Consequence: FUEL SPILLAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy: DEALERS WILL INSTALL A BRACKET ON THE AFFECTED VEHICLES FREE OF CHARGE. THE RECALL BEGAN ON MAY 23, 2008. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Feb 28, 2008
FORD IS RECALLING 87,515 MY 2008 F250, F-350, F-450, AND F-550 VEHICLES FOR FAILING TO COMPLY WITH ALL THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 207, "SEATING SYSTEMS." SOME 40% SPLIT AND CAPTAIN'S CHAIR DRIVER'S SEATS, EQUIPPED WITH LUMBAR SUPPORTS, MAY HAVE IMPROPER WELDS AT THE JOINT OF THE SEAT BACK PIVOT BRACKET AND THE SEAT BACK FRAME.
Consequence & remedy
Consequence: IN THE EVENT OF A CRASH, THE SEAT SIDE PIVOT BRACKET MAY CRACK OR BREAK, INCREASING THE RISK OF INJURY TO THE SEAT OCCUPANT.
Remedy: DEALERS WILL ADD A REINFORCEMENT TO THE DRIVER'S SEAT BACK FRAME ON THE 40% SPLIT OR CAPTAIN'S CHAIR SEAT EQUIPPED WITH LUMBAR SUPPORT OR, IF NECESSARY, THE SEAT BACK FRAME WILL BE REPLACED. THE RECALL BEGAN ON MARCH 28, 2008. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Nov 21, 2007
CERTAIN VEHICLES FAIL TO CONFORM TO THE REQUIREMENTS SPECIFIED IN FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 208, 'OCCUPANT CRASH PROTECTION.' THE DRIVER AIR BAG MODULE MAY NOT HAVE BEEN PROPERLY ASSEMBLED.
Consequence & remedy
Consequence: THIS CONDITION MAY PREVENT THE DRIVER AIR BAG FROM PROPERLY DEPLOYING AND REDUCE OCCUPANT PROTECTION IN THE EVENT OF A CRASH.
Remedy: DEALERS WILL REPLACE YOUR DRIVER AIR BAG MODULE FREE OF CHARGE. THE RECALL BEGAN ON NOVEMBER 20, 2007. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Mar 26, 2007
ON CERTAIN TRUCKS EQUIPPED WITH A 6.4L DIESEL ENGINE, EXCESSIVE TEMPERATURES IN THE DIESEL PARTICULATE FILTER IN THE EXHAUST SYSTEM MAY RESULT FROM EXCESS HYDROCARBONS IN THE EXHAUST.
Consequence & remedy
Consequence: LACK OF POWER OR ROUGH OPERATION, UNUSUAL NOISES FROM THE ENGINE OR EXHAUST, WHITE SMOKE FROM THE EXHAUST, AND POTENTIALLY A VISIBLE FLAME OUT THE TAILPIPE CAN OCCUR.
Remedy: DEALERS WILL REPROGRAM THE POWER TRAIN CONTROL MODULE. THE RECALL BEGAN ON APRIL 3, 2007. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Mar 26, 2007
ON CERTAIN TRUCKS EQUIPPED WITH A 6.4L DIESEL ENGINE, INSUFFICIENT CLEARANCE OF THE BATTERY POSITIVE (B+) WIRE TO THE RIGHT HAND SPLASH SHIELD BOLT MAY RESULT IN THE BATTERY B+ WIRE CONTACTING THE SPLASH SHIELD BOLT.
Consequence & remedy
Consequence: LONG TERM CONTACT COULD CAUSE WIRE CHAFE, RESULTING IN COPPER WIRE BEING EXPOSED. IF THIS CONDITION OCCURS, THE BATTERY B+ WIRE COULD SHORT TO GROUND INCREASING THE RISK OF A FIRE.
Remedy: DEALERS WILL INSPECT THE BATTERY B+ WIRE LOCATION AND, IF NECESSARY, REPOSITION THE WIRE. THE RECALL BEGAN ON APRIL 3, 2007. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
1PE13014 · Alleged Loss Of Steering
Opened May 7, 2013 · Closed Jan 31, 2014
Status: closed (inferred from source dates) · Steering; Steering:gear Box (other Than Rack And Pinion)
The Office of DefectsInvestigation (ODI) opened PE13-014 after identifying five complaints alleging steering gear failure in model year (MY) 2008 Ford F-250 and F-350 Super Duty pick-up trucks and to evaluate the relationship between the design history of the steering gear assembly and the alleged defect.As background, ODI investigated steering gear sector shaft fractures in approximately 1.3 million MY 1999 - 2001 Ford Super Duty pick-up trucks and MY 2000 - 2001 Ford Excursion sport utility vehicles in Engineering Analysis EA01-009.The investigation determined that the sector shaft failures were the result of extraordinary, possibly multiple, impacts and not the result of fatigue.No defect in design, manufacturing or materials was identified in the sector shaft.EA01-009 was closed August 19, 2003 with 169 complaints, resulting in a rate of 12.9 incidents per 100,000 vehicles after approximately one year of service.Ford increased the diameter of the sector shaft from 1.375 inches to 1.625 inches at the start of MY 2005 production, increasing the resistance of the steering gear assembly to torsional overload by approximately 48% and changing the failure mode from sector shaft fracture to cracked or broken sector shaft gear teeth.The redesigned steering gear assembly was used in approximately 1.1 million MY 2005 through 2009 Ford Super Duty pick-up trucks, including the subject vehicles.Figure 1 shows the basic steering system design used in Ford Super Duty trucks investigated in EA01-009 and PE13-014. Figure 2 shows the locations of failures resulting from impact related torsional overloading of the sector shaft for the subject vehicles and the prior generation Ford Super Duty trucks investigated in EA01-009.Figure 3 shows an example of a failed sector shaft investigated in EA01-009 and comparisons of fracture surfaces of sector shafts failing from fatigue loading and from torsional overload.Ford provided field return part analysis of failed steering gears from MY 2005 through 2009 Super Duty trucks found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload (Figure 4).Laboratory analysis found no evidence of fatigue or material property defects in any of the fractures.Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns (Figure 5).Analysis of failures by time in service indicates a random failure pattern/distribution, consistent with incidents of impact induced overload (Figure 6). The complaint rate for the subject vehicles after approximately 5 to 6 years, 7.1 incidents per 100,000 vehicles, is lower than the rate observed in EA01-009. Furthermore, similar to the condition investigated in EA01-009, a number of incident records include evidence of impact loads (e.g., curb strikes) and several alleged crashes include incidents in which information suggests that the steering gear failure was most likely a result of crash forces, rather than the cause of the crash.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at ww
Additional source detail variants (2)
Steering
The Office of DefectsInvestigation (ODI) opened PE13-014 after identifying five complaints alleging steering gear failure in model year (MY) 2008 Ford F-250 and F-350 Super Duty pick-up trucks and to evaluate the relationship between the design history of the steering gear assembly and the alleged defect.As background, ODI investigated steering gear sector shaft fractures in approximately 1.3 million MY 1999 - 2001 Ford Super Duty pick-up trucks and MY 2000 - 2001 Ford Excursion sport utility vehicles in Engineering Analysis EA01-009.The investigation determined that the sector shaft failures were the result of extraordinary, possibly multiple, impacts and not the result of fatigue.No defect in design, manufacturing or materials was identified in the sector shaft.EA01-009 was closed August 19, 2003 with 169 complaints, resulting in a rate of 12.9 incidents per 100,000 vehicles after approximately one year of service.Ford increased the diameter of the sector shaft from 1.375 inches to 1.625 inches at the start of MY 2005 production, increasing the resistance of the steering gear assembly to torsional overload by approximately 48% and changing the failure mode from sector shaft fracture to cracked or broken sector shaft gear teeth.The redesigned steering gear assembly was used in approximately 1.1 million MY 2005 through 2009 Ford Super Duty pick-up trucks, including the subject vehicles.Figure 1 shows the basic steering system design used in Ford Super Duty trucks investigated in EA01-009 and PE13-014. Figure 2 shows the locations of failures resulting from impact related torsional overloading of the sector shaft for the subject vehicles and the prior generation Ford Super Duty trucks investigated in EA01-009.Figure 3 shows an example of a failed sector shaft investigated in EA01-009 and comparisons of fracture surfaces of sector shafts failing from fatigue loading and from torsional overload.Ford provided field return part analysis of failed steering gears from MY 2005 through 2009 Super Duty trucks found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload (Figure 4).Laboratory analysis found no evidence of fatigue or material property defects in any of the fractures.Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns (Figure 5).Analysis of failures by time in service indicates a random failure pattern/distribution, consistent with incidents of impact induced overload (Figure 6). The complaint rate for the subject vehicles after approximately 5 to 6 years, 7.1 incidents per 100,000 vehicles, is lower than the rate observed in EA01-009. Furthermore, similar to the condition investigated in EA01-009, a number of incident records include evidence of impact loads (e.g., curb strikes) and several alleged crashes include incidents in which information suggests that the steering gear failure was most likely a result of crash forces, rather than the cause of the crash.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at ww
Steering:gear Box (other Than Rack And Pinion)
The Office of DefectsInvestigation (ODI) opened PE13-014 after identifying five complaints alleging steering gear failure in model year (MY) 2008 Ford F-250 and F-350 Super Duty pick-up trucks and to evaluate the relationship between the design history of the steering gear assembly and the alleged defect.As background, ODI investigated steering gear sector shaft fractures in approximately 1.3 million MY 1999 - 2001 Ford Super Duty pick-up trucks and MY 2000 - 2001 Ford Excursion sport utility vehicles in Engineering Analysis EA01-009.The investigation determined that the sector shaft failures were the result of extraordinary, possibly multiple, impacts and not the result of fatigue.No defect in design, manufacturing or materials was identified in the sector shaft.EA01-009 was closed August 19, 2003 with 169 complaints, resulting in a rate of 12.9 incidents per 100,000 vehicles after approximately one year of service.Ford increased the diameter of the sector shaft from 1.375 inches to 1.625 inches at the start of MY 2005 production, increasing the resistance of the steering gear assembly to torsional overload by approximately 48% and changing the failure mode from sector shaft fracture to cracked or broken sector shaft gear teeth.The redesigned steering gear assembly was used in approximately 1.1 million MY 2005 through 2009 Ford Super Duty pick-up trucks, including the subject vehicles.Figure 1 shows the basic steering system design used in Ford Super Duty trucks investigated in EA01-009 and PE13-014. Figure 2 shows the locations of failures resulting from impact related torsional overloading of the sector shaft for the subject vehicles and the prior generation Ford Super Duty trucks investigated in EA01-009.Figure 3 shows an example of a failed sector shaft investigated in EA01-009 and comparisons of fracture surfaces of sector shafts failing from fatigue loading and from torsional overload.Ford provided field return part analysis of failed steering gears from MY 2005 through 2009 Super Duty trucks found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload (Figure 4).Laboratory analysis found no evidence of fatigue or material property defects in any of the fractures.Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns (Figure 5).Analysis of failures by time in service indicates a random failure pattern/distribution, consistent with incidents of impact induced overload (Figure 6). The complaint rate for the subject vehicles after approximately 5 to 6 years, 7.1 incidents per 100,000 vehicles, is lower than the rate observed in EA01-009. Furthermore, similar to the condition investigated in EA01-009, a number of incident records include evidence of impact loads (e.g., curb strikes) and several alleged crashes include incidents in which information suggests that the steering gear failure was most likely a result of crash forces, rather than the cause of the crash.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at ww
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