NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
131 reports80,200 miles · Jun 25, 2019
Visibility/wiper
DRIVING DOWN THE ROAD AT 65 MPH, ON OPEN HIGHWAY GOING STRAIGHT, AND ON CRUISE CONTROL, MY SUN ROOF EXPLODED. IF I HAD NOT HAD THE SUN SHADE PULLED CLOSED, WE WOULD HAVE BEEN SHOWERED IN GLASS! I HAD A TRUCK CAMPER ON THE TRUCK AT THE TIME, HOWEVER, I'VE DRIVEN TENS OF THOUSANDS OF MILES WITH THIS CAMPER, SO IT SHOULDN'T BE TH…
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DRIVING DOWN THE ROAD AT 65 MPH, ON OPEN HIGHWAY GOING STRAIGHT, AND ON CRUISE CONTROL, MY SUN ROOF EXPLODED. IF I HAD NOT HAD THE SUN SHADE PULLED CLOSED, WE WOULD HAVE BEEN SHOWERED IN GLASS! I HAD A TRUCK CAMPER ON THE TRUCK AT THE TIME, HOWEVER, I'VE DRIVEN TENS OF THOUSANDS OF MILES WITH THIS CAMPER, SO IT SHOULDN'T BE THAT - AND THE GLASS OUGHT TO BE STRONG ENOUGH FOR THIS USAGE ANYWAY. THIS SHOULD NOT HAVE HAPPENED, AND THE TYPE OF GLASS THAT IS USED SHOULD NOT ALLOW GLASS TO SHATTER INTO FLYING PIECES LIKE THAT! THIS IS COSTING ME A BUNDLE OF MONEY TO REPAIR, BUT MORE IMPORTANTLY, HAD THE SUN SHADE NOT BEEN CLOSED, I COULD HAVE HAD AN ACCIDENT WITH 6+ TONS OF TRUCK AND CAMPER.
NHTSA ODI #11222414
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
48,000 miles · May 20, 2019
StructureSuspension
TL* THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING OVER A BUMP IN THE ROAD, THE VEHICLE SHOOK, BOUNCED, AND MADE A SQUEAKING NOISE. THE CONTACT CALLED SCHULTZ FORD LINCOLN (LOCATED AT 80 NU-304, NANUET, NY 10954, (877) 724-8589) AND WAS INFORMED TO CONTACT THE MANUFACTURER TO SEE IF THE VEHICLE WAS COVERED UNDER WARRANTY OR R…
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TL* THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING OVER A BUMP IN THE ROAD, THE VEHICLE SHOOK, BOUNCED, AND MADE A SQUEAKING NOISE. THE CONTACT CALLED SCHULTZ FORD LINCOLN (LOCATED AT 80 NU-304, NANUET, NY 10954, (877) 724-8589) AND WAS INFORMED TO CONTACT THE MANUFACTURER TO SEE IF THE VEHICLE WAS COVERED UNDER WARRANTY OR RECALLS. IN ADDITION, WHEN THE CONTACT CHECK UNDER THE VEHICLE, HE NOTICED THAT THE RUBBER BUSHING DISINTEGRATED FROM THE CAB AND CHASSIS. THE VEHICLE WAS NOT TAKEN TO A DEALER AND WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURES. THE CONTACT WAS INFORMED THAT THE VEHICLE WAS OUT OF WARRANTY AND THERE WERE NO RECALLS ASSOCIATED WITH THE VIN. THE APPROXIMATE FAILURE MILEAGE WAS 48,000.
NHTSA ODI #11208610
75,430 miles · Feb 17, 2019
Electrical SystemStructureFire
HAD JUST BACK THE VEHICLE IN CUT IT OFF, HALF AN HOUR LATER IT WAS IN FLAMES, BURNT EVERYTHING IN THE MOTOR AND FRONT OF TRUCK UP. *DT*JB *DT*JB *DT*JB *TR
NHTSA ODI #11180629
160,000 miles · Jan 7, 2019
Engine
FORD SHOULD BE HELD ACCOUNTABLE FOR THE 6.4 DIESEL AS MUCH AS THESE TRUCKS COST HARD WORKING AMERICANS, PAY CLOSE TO 30 THOUSAND DOLLARS FOR A PICKUP TRUCK THEN HAVE TO PAY ANOTHER 15 THOUSAND TO FIX THE MOTOR DUE TO IT NOT BEING BUILT CORRECTLY, JUNK RODS, HEAD BOLTS, HEADS, TURBOS, OIL LEVEL BEING RAISED BY 2 TO 3 GALLONS P…
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FORD SHOULD BE HELD ACCOUNTABLE FOR THE 6.4 DIESEL AS MUCH AS THESE TRUCKS COST HARD WORKING AMERICANS, PAY CLOSE TO 30 THOUSAND DOLLARS FOR A PICKUP TRUCK THEN HAVE TO PAY ANOTHER 15 THOUSAND TO FIX THE MOTOR DUE TO IT NOT BEING BUILT CORRECTLY, JUNK RODS, HEAD BOLTS, HEADS, TURBOS, OIL LEVEL BEING RAISED BY 2 TO 3 GALLONS PER OIL CHANGE, DUE TO FUEL BEING PUMPED BACK INTO THE ENGINE, CAUSING SEVERE INTERNAL ENGINE PROBLEMS, IT'S NOT IF IT WILL BLOW BUT WHEN IT WILL, AS PER FORD MASTER MECHANIC. THIS IS A DANGEROUS SITUATION, TO KNOW AT ANY GIVING MINUTE WHILE DRIVING YOU'RE MOTOR COULD BLOW CAUSING LOSS OF CONTROL OF THE VEHICLE.
NHTSA ODI #11164876
57,000 miles · Nov 18, 2018
Steering
JUST GOT ON THE ON RAMP TO GET ON THE FREEWAY WHEN LOST TOTAL CONTROL OF THE TRUCKS POWERSTEERING. I WAS GOING MAYBE 35-45MPH BUT HAD TO SLOW DOWN. TOOK TO THE FORD DEALER THE REPLACED THE GEARBOX WITH A REMANUFACTURED GEARBOX AND DID THE SAME THING ON MY SECOND TRIP. NOT SURE WHAT TO DO AS THIS IS A BIG SAFETY CONCERN
NHTSA ODI #11152248
144,975 miles · Oct 29, 2018
Steering
THE STEERING IS HARD TO TURN I HAVE TO WRESTLE WITH IT VERY OFTEN..
NHTSA ODI #11143961
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
125,000 miles · Feb 13, 2018
SteeringCrashInjury
TL* THE CONTACT OWNED A 2008 FORD F-350. WHILE DRIVING 25 MPH, THE STEERING ABILITY FAILED ON THE VEHICLE. THE CONTACT LOST CONTROL OF THE VEHICLE AND CRASHED INTO THE WALL OF A BRIDGE. THE CRASH OCCURRED ON JANUARY 11, 2018. A POLICE REPORT WAS FILED. THE CONTACT WAS INJURED AND REQUIRED MEDICAL ATTENTION. THERE WERE NO WARNING…
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TL* THE CONTACT OWNED A 2008 FORD F-350. WHILE DRIVING 25 MPH, THE STEERING ABILITY FAILED ON THE VEHICLE. THE CONTACT LOST CONTROL OF THE VEHICLE AND CRASHED INTO THE WALL OF A BRIDGE. THE CRASH OCCURRED ON JANUARY 11, 2018. A POLICE REPORT WAS FILED. THE CONTACT WAS INJURED AND REQUIRED MEDICAL ATTENTION. THERE WERE NO WARNINGS INDICATORS ILLUMINATED BEFORE THE FAILURE. THE VEHICLE WAS NOT TAKEN TO A DEALER OR INDEPENDENT MECHANIC. THE VEHICLE WAS DESTROYED AND TOWED. THE CONTACT RECEIVED AN UNKNOWN RECALL NOTICE FROM FORD MOTOR COMPANY A WEEK AFTER THE CRASH. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VIN WAS INVALID. THE FAILURE MILEAGE WAS 125,000.
NHTSA ODI #11072480
150,000 miles · Feb 11, 2018
Suspension
WHILE DRIVING OVER 40 MPH IF A BUMP OR POTHOLE IS HIT THE TRUCK BOUNCES OR SHAKES VIOLENTLY AT THE FRONT. THE TRUCK HAD PREVIOUSLY DONE IT ONE OTHER TIME. THIS TIME THE TRUCK WAS TRAVEING ABOUT 55 MPH ON A 2 LANE HIGHWAY WHEN I HIT A DIP IN THE ROAD AND THE TRUCK STARTED VIOLENTLY BOUNCING AND WENT ACROSS THE OPPOSITE DIRECTIO…
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WHILE DRIVING OVER 40 MPH IF A BUMP OR POTHOLE IS HIT THE TRUCK BOUNCES OR SHAKES VIOLENTLY AT THE FRONT. THE TRUCK HAD PREVIOUSLY DONE IT ONE OTHER TIME. THIS TIME THE TRUCK WAS TRAVEING ABOUT 55 MPH ON A 2 LANE HIGHWAY WHEN I HIT A DIP IN THE ROAD AND THE TRUCK STARTED VIOLENTLY BOUNCING AND WENT ACROSS THE OPPOSITE DIRECTION SIDE OF THE HIGHWAY. LUCKILY NO OTHER CAR WAS COMING BUT DAMAGE WAS DONE TO THE FRONT OF THE TRUCK WHEN IT WENT TO THE OPPOSITE SIDE OF THE ROADWAY. I HAVE SINCE PARKED THE VEHICLE UNTIL IT CAN BE FOUND WHAT CAUSED THE PROBLEM. I WILL HAVE TO CONTACT THE INSURANCE CO ABOUT THE FRONT END REPAIR BUT NOT UNTIL IT IS SAFE TO DRIVE.
NHTSA ODI #11072152
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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