NHTSA owner reports · September 18, 2026 snapshot.
Service Brakes complaints
9 reportsClear category filter33,692 miles · Jan 19, 2020
Service Brakes
CRUSE CONTROL SWITCH ON THE BRAKE MASTER CYLINDER DISINTEGRATED, CAUSING IMMEDIATE LOSS OF BRAKE FLUID AND BRAKING. SWITCH BODY APPEARED RUSTY, WHILE THE SWITCH NEXT TO IT ON THE MASTER CYLINDER DID NOT. VEHICLE IN MOTION, DESCENDING DRIVEWAY WHEN BRAKE PEDAL WENT TO THE FLOOR AND ALL BRAKING ACTION WAS LOST. VEHICLE STOPPED VIA…
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CRUSE CONTROL SWITCH ON THE BRAKE MASTER CYLINDER DISINTEGRATED, CAUSING IMMEDIATE LOSS OF BRAKE FLUID AND BRAKING. SWITCH BODY APPEARED RUSTY, WHILE THE SWITCH NEXT TO IT ON THE MASTER CYLINDER DID NOT. VEHICLE IN MOTION, DESCENDING DRIVEWAY WHEN BRAKE PEDAL WENT TO THE FLOOR AND ALL BRAKING ACTION WAS LOST. VEHICLE STOPPED VIA EMERGENCY BRAKE.
NHTSA ODI #11300300
130,000 miles · Jun 13, 2019
Service Brakes
I WAS IN MY DRIVEWAY AND STEPPED ON THE BRAKE PEDAL TO PUT THE TRUCK IN REVERSE AND I HEARD A LOUD 'POP' WHICH FELT LIKE THE BRAKE PEDAL BROKE AND THEN IT SANK TO THE FLOOR, I POPPED THE HOOD AND SAW BRAKE FLUID DRIPPING FROM THE BOTTOM OF THE BRAKE MASTER CYLINDER. THIS PART---"SWITCH ASSY - FORD PART-SW6349 (9F924)" HAD BLOW…
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I WAS IN MY DRIVEWAY AND STEPPED ON THE BRAKE PEDAL TO PUT THE TRUCK IN REVERSE AND I HEARD A LOUD 'POP' WHICH FELT LIKE THE BRAKE PEDAL BROKE AND THEN IT SANK TO THE FLOOR, I POPPED THE HOOD AND SAW BRAKE FLUID DRIPPING FROM THE BOTTOM OF THE BRAKE MASTER CYLINDER. THIS PART---"SWITCH ASSY - FORD PART-SW6349 (9F924)" HAD BLOWN OUT THE PLASTIC CONNECTOR WHILE THE METAL CASING WAS STILL ATTACHED TO THE BOTTOM OF THE MASTER CYLINDER. THIS WILL LEAVE YOU WITH NO BRAKES. IF IT HAPPENED ON THE ROAD IN TRAFFIC IT COULD BE DEADLY.
NHTSA ODI #11219774
104,000 miles · Apr 16, 2018
Service BrakesSteering
TL* THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING 65 MPH AND ATTEMPTED TO EXIT THE HIGHWAY, THE STEERING WHEEL SEIZED AND THE BRAKE PEDAL WAS DEPRESSED, BUT THE BRAKES FAILED TO ENGAGE. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE DEALER WAS NOT CALLED FOR DIAGNOSTIC TESTING OR REPAIRS. THE CONTACT STATED THAT THE FAILU…
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TL* THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING 65 MPH AND ATTEMPTED TO EXIT THE HIGHWAY, THE STEERING WHEEL SEIZED AND THE BRAKE PEDAL WAS DEPRESSED, BUT THE BRAKES FAILED TO ENGAGE. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE DEALER WAS NOT CALLED FOR DIAGNOSTIC TESTING OR REPAIRS. THE CONTACT STATED THAT THE FAILURE RECURRED. THE CONTACT CALLED THE MANUFACTURER, BUT THERE WAS NO RESPONSE. THE FAILURE MILEAGE WAS APPROXIMATELY 104,000.
NHTSA ODI #11088363
118,000 miles · Jan 5, 2017
Service BrakesSteering
TL* THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING APPROXIMATELY 55 MPH, THE STEERING WHEEL AND BRAKING ABILITY SEIZED AND BECAME DIFFICULT TO MANEUVER WITHOUT WARNING. THE FAILURE RECURRED SEVERAL TIMES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEA…
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TL* THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING APPROXIMATELY 55 MPH, THE STEERING WHEEL AND BRAKING ABILITY SEIZED AND BECAME DIFFICULT TO MANEUVER WITHOUT WARNING. THE FAILURE RECURRED SEVERAL TIMES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 118,000.
NHTSA ODI #10939920
35,000 miles · Sep 21, 2015
Service BrakesFire
TL* THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING APPROXIMATELY 50 MPH, THE VEHICLE VEERED TO THE RIGHT CAUSING THE CONTACT TO ALMOST CRASH INTO A GUARD RAIL. THE CONTACT DISCOVERED SMOKE ENTERING FROM A PASSENGER SIDE WHEEL. THE CONTACT STATED THAT THE PASSENGER BRAKE DISC WAS RED FROM THE HEAT AND EMITTED SMOKE. THE CONTAC…
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TL* THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING APPROXIMATELY 50 MPH, THE VEHICLE VEERED TO THE RIGHT CAUSING THE CONTACT TO ALMOST CRASH INTO A GUARD RAIL. THE CONTACT DISCOVERED SMOKE ENTERING FROM A PASSENGER SIDE WHEEL. THE CONTACT STATED THAT THE PASSENGER BRAKE DISC WAS RED FROM THE HEAT AND EMITTED SMOKE. THE CONTACT ALSO STATED THAT THE SAME FAILURE OCCURRED SIX TIMES ON DIFFERENT WHEELS. THE CONTACT HAD TO WAIT FOR THE WHEELS TO COOL DOWN IN ORDER FOR THE VEHICLE TO RETURN TO NORMAL. THE VEHICLE WAS DRIVEN TO THE DEALER SIX TIMES AND THEY WERE NOT ABLE TO DUPLICATE THE FAILURE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE CONTACT MENTIONED THAT THE BRAKE SYSTEM WAS REPAIRED FOUR TIMES. THE APPROXIMATE FAILURE MILEAGE WAS 35,000.
NHTSA ODI #10766337
129,000 miles · May 26, 2015
Service BrakesSteering
TL* THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING APPROXIMATELY 60 MPH, THE STEERING AND BRAKING ABILITY SEIZED WITHOUT WARNING. THE VEHICLE WAS NOT DIAGNOSED BY THE DEALER OR AN INDEPENDENT MECHANIC. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS UNKNOWN. THE APPROXIMATE FAILURE MILEAGE WAS 129,000.
NHTSA ODI #10721406
102,000 miles · Oct 1, 2014
Service BrakesSteeringWheels
I WAS DRIVING ON INTERSTATE 75 WHEN THE TRUCK AND STEERING WHEEL STARTED VIBRATING VIOLENTLY, AS I APPLIED THE BRAKES TO SLOW THE VEHICLE IT PULLED SHARP TO THE LEFT TAKING THE VEHICLE ONTO THE MEDIAN. ONCE THE VEHICLE STOPPED, FACING IN THE OPPOSITE DIRECTION I GOT OUT AND CHECKED THE LEFT FRONT WHEEL, IT WAS TOO HOT TO TOUCH.…
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I WAS DRIVING ON INTERSTATE 75 WHEN THE TRUCK AND STEERING WHEEL STARTED VIBRATING VIOLENTLY, AS I APPLIED THE BRAKES TO SLOW THE VEHICLE IT PULLED SHARP TO THE LEFT TAKING THE VEHICLE ONTO THE MEDIAN. ONCE THE VEHICLE STOPPED, FACING IN THE OPPOSITE DIRECTION I GOT OUT AND CHECKED THE LEFT FRONT WHEEL, IT WAS TOO HOT TO TOUCH. I LET IT COOL AND THEN PROCEEDED TO THE NEAREST EXIT. I HAD THE LEFT FRONT WHEEL INSPECTED, BUT NO PROBLEM WAS DISCOVERED. I CONTINUED ON MY TRIP FROM TENNESSEE TO FLORIDA. ON THE RETURN TRIP THE PROBLEM HAPPENED THREE TIMES, EACH TIME I STOPPED AND LET THE WHEEL COOL BEFORE CONTINUING. I RESEARCHED THIS PROBLEM ON THE INTERNET AND FOUND THAT SEVERAL OTHER INDIVIDUALS HAVE EXPERIENCED THE SAME PROBLEM. I BELIEVE THE NTSB SHOULD REQUIRE FORD MOTOR COMPANY TO RECALL THESE VEHICLES AND CORRECT THE PROBLEM BEFORE SOMEONE IS INJURED OR KILLED. THERE IS SUFFICIENT DOCUMENTATION ON THE INTERNET TO JUSTIFY THE NTSB TAKING ACTION. *TR
NHTSA ODI #10640673
26,000 miles · May 21, 2014
Service BrakesSteering
I WAS DRIVING AT 20 MPH WHEN THE POWER STEERING DID NOT WORK, I WENT TO BRAKE AND IT DIDN'T BRAKE FOR AT LEAST 20 FT. GOOD THING NO ONE WAS IN FRONT OF ME. I TOOK IT HOME AND NOW IS NOT DRIVABLE , I CALLED FORD SEVERAL TIMES AND THEY SAID THEY CAN NOT DO ANYTHING FOR ME.I HAVE A $48,000.00 LEMON ROTTING IN MY DRIVEWAY. *TR
NHTSA ODI #10593264
53,000 miles · Jun 4, 2013
Service BrakesSteering
I WAS SLOWING DOWN TO MAKE A LEFT HAND TURN AND I COMPLETELY LOST THE ABILITY TO STEER. I COULD NOT BUDGE THE WHEEL AT ALL. MY BRAKES STILL WORKED, BUT IT DIDN'T FEEL 100%. IT HAS HAPPENED AT LEAST 10-15 TIMES IN THE LAST YEAR. WHEN IT HAPPENS, I CAN SHIFT THE TRUCK INTO NEUTRAL AND REV THE ENGINE AND I'LL GET MY STEERING BACK. …
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I WAS SLOWING DOWN TO MAKE A LEFT HAND TURN AND I COMPLETELY LOST THE ABILITY TO STEER. I COULD NOT BUDGE THE WHEEL AT ALL. MY BRAKES STILL WORKED, BUT IT DIDN'T FEEL 100%. IT HAS HAPPENED AT LEAST 10-15 TIMES IN THE LAST YEAR. WHEN IT HAPPENS, I CAN SHIFT THE TRUCK INTO NEUTRAL AND REV THE ENGINE AND I'LL GET MY STEERING BACK. ALSO, IF I SHIFT INTO NEUTRAL AND TURN THE TRUCK OFF AND BACK ON AGAIN, THE STEERING WILL WORK. THE ONLY TIME IT HAPPENS IS WHEN I'M SLOWING DOWN FROM HIGHWAY SPEEDS, 55+ MPH. IT HAS HAPPENED WHEN TOWING ALSO. THIS IS MY FATHER TRUCK, BUT I USE IT FOR THE FAMILY BUSINESS. *TR
NHTSA ODI #10515101
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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