TL* THE CONTACT OWNS A 2008 FORD F350. THE CONTACT STATED THAT THE VEHICLE WOULD VIBRATE VIOLENTLY WHEN DRIVING BETWEEN 40-55 MPH OR WHEN TURNING ON ROUGH ROAD SURFACES. THE VEHICLE WAS TAKEN TO THE DEALER NUMEROUS TIMES FOR THE FAILURE. THE DEALER REPLACED THE TRACK LINK AND THE STEERING GEARBOX BUT THE FAILURE WAS NOT CORRECTE…
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TL* THE CONTACT OWNS A 2008 FORD F350. THE CONTACT STATED THAT THE VEHICLE WOULD VIBRATE VIOLENTLY WHEN DRIVING BETWEEN 40-55 MPH OR WHEN TURNING ON ROUGH ROAD SURFACES. THE VEHICLE WAS TAKEN TO THE DEALER NUMEROUS TIMES FOR THE FAILURE. THE DEALER REPLACED THE TRACK LINK AND THE STEERING GEARBOX BUT THE FAILURE WAS NOT CORRECTED AND THE VEHICLE CONTINUED TO VIBRATE EXCESSIVELY. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE BUT THE VEHICLE WAS NOT FURTHER REPAIRED. THE FAILURE MILEAGE WAS 100 AND THE CURRENT MILEAGE WAS 20,000.
NHTSA ODI #10445228
60,000 miles · Dec 2, 2011
SteeringSuspension
VEHICLE SHAKES VIOLENTLY. ONLY WAY TO GET UNDER CONTROL IS TO STOP COMPLETELY. THIS HAS HAPPENED NUMEROUS TIMES. I HAVE READ ON FORUMS THIS IS A MAJOR PROBLEM. FORD NEEDS TO RECOGNIZE THE PROBLEM AND ISSUE A RECALL. THIS IS VERY DANGEROUS. *TR
NHTSA ODI #10438176
33,034 miles · Nov 4, 2010
Steering
I'M THE OWNER OF A 2008 FORD PICKUP TRUCK MODEL F-350. THE TRUCK WAS TAKING SERVO TIMES TO A DEALER TO HAVE THE PROBLEM FIXED. WE ARE HAVING PROBLEMS WITH THE STEERING WHEEL THAT IT LOCKS BY ITSELF YOU WANT TO TURN LEFT AND THE CAR GOES RIGHT OR STRAIGHT AND YOU LOOSE THE CONTROL I ALMOST GOT KILLED .THE DEALER SAD THAT THEY C…
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I'M THE OWNER OF A 2008 FORD PICKUP TRUCK MODEL F-350. THE TRUCK WAS TAKING SERVO TIMES TO A DEALER TO HAVE THE PROBLEM FIXED. WE ARE HAVING PROBLEMS WITH THE STEERING WHEEL THAT IT LOCKS BY ITSELF YOU WANT TO TURN LEFT AND THE CAR GOES RIGHT OR STRAIGHT AND YOU LOOSE THE CONTROL I ALMOST GOT KILLED .THE DEALER SAD THAT THEY CANT SEEN TO FIX THE PROBLEM ONE DEALER SAD THAT HE REPLACED THE GEAR BOX BUT NEVER DID. I'M AFRAID TO DRIVE THIS CAR I HAVE THREE KIDS AND NOBODY WANTS TO HELP ME I EVEN CALLED THE INSURANCE COMPANY AND LET THE NOW THAT IF I HAVE A ACCIDENT IT WILL BE TO THE STEERING PROBLEM WHICH I REPORTED TO THE DEALER BUT THEY CANT FIXED. PLEASE HELP ME WITH THIS I'M RALLY SCARED TO DRIVE THIS CAR. *TR
NHTSA ODI #10364063
86,000 miles · Sep 16, 2010
SteeringSuspension
I HAVE A 2008 FORD F-350 4X4 THAT IS EXPERIENCING A BAD WOBBLE WHEN I HIT A BUMP IN THE ROAD OR TURNING IN A CURVE WITH UNEVEN PAVEMENT. THE PROBLEM OCCURS AROUND 45 OR 50 MPH THIS IS A VERY SCARY SITUATION. I DID SOME RESEARCH ON THE TOPIC AND I SEE ALOT OF FORD OWNERS WITH THE SAME COMPLAINT, BUT FORD WONT DO ANYTHING ABOUT SO…
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I HAVE A 2008 FORD F-350 4X4 THAT IS EXPERIENCING A BAD WOBBLE WHEN I HIT A BUMP IN THE ROAD OR TURNING IN A CURVE WITH UNEVEN PAVEMENT. THE PROBLEM OCCURS AROUND 45 OR 50 MPH THIS IS A VERY SCARY SITUATION. I DID SOME RESEARCH ON THE TOPIC AND I SEE ALOT OF FORD OWNERS WITH THE SAME COMPLAINT, BUT FORD WONT DO ANYTHING ABOUT SOLVING THE PROBLEM. I DON'T KNOW WHO TO TURN TO. THESE TRUCKS ARE EXPENSIVE AND I EXPECT TO GET WHAT I PAID FOR NOT THIS. HELP ME OUT!!!!! PLEASE! *TR
NHTSA ODI #10356048
35,000 miles · Jul 29, 2009
SteeringSuspension
I HAVE TWO 2008 FORD F-350 SUPERDUTY 4X4 TRUCKS. ONE TRUCK HAS 39000 MILES AND THE OTHER 61000 MILES. AT HIGHWAY SPEEDS, AFTER HITTING UNEVEN ROAD SURFACE OR BUMPS, THEY BEGIN TO SHIMMY AND SHAKE SO BAD THAT I HAVE TO PULL OVER TO GET IT TO QUIT I HAVE HAD THE TRUCKS IN NUMEROUS TIMES TO FIX BUT THE PROBLEM ALWAYS RETURNS. I …
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I HAVE TWO 2008 FORD F-350 SUPERDUTY 4X4 TRUCKS. ONE TRUCK HAS 39000 MILES AND THE OTHER 61000 MILES. AT HIGHWAY SPEEDS, AFTER HITTING UNEVEN ROAD SURFACE OR BUMPS, THEY BEGIN TO SHIMMY AND SHAKE SO BAD THAT I HAVE TO PULL OVER TO GET IT TO QUIT I HAVE HAD THE TRUCKS IN NUMEROUS TIMES TO FIX BUT THE PROBLEM ALWAYS RETURNS. I RECEIVED NOTICE FROM FORD THAT LOW TIRE PRESSURE CAUSES THIS BUT I MAINTAIN CORRECT TIRE PRESSURE IN BOTH OF MY TRUCKS SO I KNOW THIS IS NOT THE PROBLEM. I HAVE BEEN RESEARCHING THIS ONLINE AND THERE IS A COMPANY CALLED WCMOTORSPORTS THAT CLAIMS TO KNOW WHY THESE TRUCKS ARE DOING THIS AND THE SOLUTION. THEIR WEBSITE IS WWW.SUPERDUTYWOBBLE.COM. THEIR PHONE NUMBER IS (508) 668-8638. THEY SEEM VERY KNOWLEDGEABLE ABOUT THIS ISSUE. THE PROBLEM IS THE REPLACEMENT PART TO FIX THIS IS $825. I FEEL THAT THIS SHOULD BE A RECALL ISSUE. AFTER LOOKING ONLINE, MANY PEOPLE HAVE THIS PROBLEM. I HAVE NOT MODIFIED THESE TRUCKS IN ANYWAY AND I FEEL THAT IT IS ONLY A MATTER OF TIME UNTIL THIS CAUSES A FATALITY IF IT HASN'T ALREADY. *TR
NHTSA ODI #10278647
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
125 miles · Aug 1, 2007
Engine And Engine CoolingSteeringSuspension
TWO ISSUES REALLY: A SLOPPILY INSTALLED VALVE COVER GASKET ON THE RIGHT VALVE COVER CAUSING FLUID LEAKAGE. THE SECOND IS A CONSTANT DRIFT TO THE LEFT. 2008 F-350 LARIAT 4X4 CREWCAB LONG BED POWERSTROKE DIESEL. *JB
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.
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.
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.
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.
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.
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
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
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