NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
131 reports50,200 miles · Jun 11, 2015
Steering
I WAS MAKING A LEFT HAND TURN WHEN THE STEERING STARTED TO WOBBLE, SHIMMING. I WAS TRAVELING AT APPROX. 45 MPH AND HAD TO SLOW TO 20 BEFORE IT STOPPED. THIS PICK UP HAS HAD SMALL SHIMMING BEFORE BUT NOTHING THIS BAD. I JUST REPLACED THE SHOCKS AND HAD IT ALIGNED. IT SEEMS TO BE EVEN WORSE AND YES I HAVE THE TIRE PRESSURE AT T…
Read full complaint
I WAS MAKING A LEFT HAND TURN WHEN THE STEERING STARTED TO WOBBLE, SHIMMING. I WAS TRAVELING AT APPROX. 45 MPH AND HAD TO SLOW TO 20 BEFORE IT STOPPED. THIS PICK UP HAS HAD SMALL SHIMMING BEFORE BUT NOTHING THIS BAD. I JUST REPLACED THE SHOCKS AND HAD IT ALIGNED. IT SEEMS TO BE EVEN WORSE AND YES I HAVE THE TIRE PRESSURE AT THE RECOMMENDED 80 PSI. IT IS DANGEREOUS. FORD SENT A LETTER APRIL 2009 09L02. THEY PRETTY MUCH SAID THE NHTSA WAS LOOKING INTO IT AND LIVE WITH IT. PLEASE HELP!
NHTSA ODI #10724808
79,000 miles · Jun 2, 2015
Steering
TL* THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING APPROXIMATELY 45 MPH, THE POWER STEERING FAILED. THE FAILURE RECURRED SEVERAL TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO PROVIDED AN UNKNOWN DIAGNOSTIC FOR THE FAILURE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 79…
Read full complaint
TL* THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING APPROXIMATELY 45 MPH, THE POWER STEERING FAILED. THE FAILURE RECURRED SEVERAL TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO PROVIDED AN UNKNOWN DIAGNOSTIC FOR THE FAILURE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 79,000. THE VIN WAS NOT AVAILABLE.
NHTSA ODI #10722894
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
126,600 miles · May 22, 2015
Fuel/propulsion System
GETTING ON FREEWAY AND TRYING TO REACH AND MAINTAIN POSTED SPEED LIMIT. VEHICLE STARTED SPUTTERING THEN CHECK ENGINE LIGHT CAME ON. I COULD NOT SAFELY MAINTAIN MY SPEED SO I HAD TO PUT FLASHER ON AND PULL OFF THE ROAD. I QUICKLY FOUND OUT THAT THE VEHICLE WENT INTO TO LIMP HOME MODE SO WITH MY FLASHERS ON I PROCEEDED TO HEAD HOM…
Read full complaint
GETTING ON FREEWAY AND TRYING TO REACH AND MAINTAIN POSTED SPEED LIMIT. VEHICLE STARTED SPUTTERING THEN CHECK ENGINE LIGHT CAME ON. I COULD NOT SAFELY MAINTAIN MY SPEED SO I HAD TO PUT FLASHER ON AND PULL OFF THE ROAD. I QUICKLY FOUND OUT THAT THE VEHICLE WENT INTO TO LIMP HOME MODE SO WITH MY FLASHERS ON I PROCEEDED TO HEAD HOME WHICH WAS 40 MILES AWAY. I INDEED LIMPED MY VEHICLE HOME AS I COULD NOT MAINTAIN ANY POSTED SPEED LIMIT AND CREATED WHAT I THOUGHT WAS AN UNSAFE CONDITION FOR OTHER DRIVERS AS THEY WERE TRYING TO PASS AND GET AROUND ME. AFTER MAKING IT HOME I FOUND OUT THAT THERE IS A KNOWN MANUFACTURE DEFECT WITH A PUBLICATION DATE OF APRIL 27, 2011 TSB 11-4-22 6.4L LACKS POWER-DTC P0088. I PULLED MY ENGINE CODES AND I INDEED HAD THE P0088 CODE WHICH IS FUEL RAIL PRESSURE TOO HIGH. I CALLED MY LOCAL FORD DEALERSHIP TO FIND OUT IF THERE WAS A RECALL FOR THE KNOWN MANUFACTURE DEFECT. THE GENTLEMAN PUT MY VIN# IN AND TOLD ME THERE WAS NO RECALL FOR THAT KNOWN DEFECT FROM FORD. I'VE DONE MY RESEARCH AND THERE ARE MANY PEOPLE OUT THERE WITH THIS SAME PROBLEM. FORD HAS ADMITTED TO THE KNOWN MANUFACTURE DEFECT BY CREATING THE TSB WITH THE PUBLICATION DATE OF APRIL 27, 2011
NHTSA ODI #10721001
68,000 miles · Feb 25, 2015
Electrical SystemStructure
THE MOON ROOF TRACK ON MY FORD F-350 (2008) FAILED AFTER ABOUT 5 YEARS. I HAD IT REPLACED AT JIM CLICK FORD IN TUCSON AT THE BEGINNING OF 2013 AT A COST OF $2400.00. AT THE BEGINNING OF 2015 IT FAILED AGAIN. NEITHER THE DEALER NOR FORD HAVE AN ANSWER FOR THE FAILURE(S) AND BOTH SAID I NEED TO DO THE REPAIR AGAIN AT MY EXPENSE. …
Read full complaint
THE MOON ROOF TRACK ON MY FORD F-350 (2008) FAILED AFTER ABOUT 5 YEARS. I HAD IT REPLACED AT JIM CLICK FORD IN TUCSON AT THE BEGINNING OF 2013 AT A COST OF $2400.00. AT THE BEGINNING OF 2015 IT FAILED AGAIN. NEITHER THE DEALER NOR FORD HAVE AN ANSWER FOR THE FAILURE(S) AND BOTH SAID I NEED TO DO THE REPAIR AGAIN AT MY EXPENSE. I FEEL THAT THE MOON ROOF APPARATUS SHOULD BE STURDY ENOUGH TO LAST THE LIFESPAN OF THE VEHICLE. MY CONTENTION IS THAT THIS ISSUE IS A DEFECT AND COULD BE A SAFETY ISSUE IS THE MOON ROOF IS BLOWN OFF OR CANNOT BE SEALED. FROM THE BEGINNING WITH THIS TRUCK WHEN I WOULD DRIVE IT FORWARD IN HIGH WINDS THE MOON ROOF WOULD LIFT AND CHATTER. THE FRAME IS PLASTIC AND NOT VERY STURDY. I'M SURE FORD USES THIS SAME PLASTIC FRAME ON MANY OF THEIR VEHICLES AND I THINK THAT RESEARCHING REPAIR RECORDS OF THOSE VEHICLES USING THIS FRAME MIGHT BE OF USE IN SEEING IF FAILURES ARE FREQUENT AND A POSSIBLE SAFETY ISSUE. *JS
NHTSA ODI #10690623
80,000 miles · Feb 19, 2015
Air BagsCrash
TL* THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING APPROXIMATELY 25 MPH, THE VEHICLE SLID ON ICE AND CRASHED INTO A PARKED TRAILER. THE AIR BAGS FAILED TO DEPLOY. A POLICE REPORT WAS FILED. THE VEHICLE WAS TOWED TO A BODY SHOP WHERE IT WAS REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE M…
Read full complaint
TL* THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING APPROXIMATELY 25 MPH, THE VEHICLE SLID ON ICE AND CRASHED INTO A PARKED TRAILER. THE AIR BAGS FAILED TO DEPLOY. A POLICE REPORT WAS FILED. THE VEHICLE WAS TOWED TO A BODY SHOP WHERE IT WAS REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE FOR THIS CRASH WAS 80,000. IN ADDITION, WHILE DRIVING APPROXIMATELY 50 MPH, THE CONTACT STRUCK A DEER. THE AIR BAGS FAILED TO DEPLOY. A POLICE REPORT WAS FILED. THE VEHICLE WAS DRIVEN TO THE BODY SHOP WHERE IT WAS REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THERE WERE NO INJURIES IN EITHER CRASH. THE APPROXIMATE FAILURE MILEAGE WAS 105,000.
NHTSA ODI #10689403
22,000 miles · Feb 2, 2015
Suspension
TL* THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING 65 MPH OVER A POTHOLE, THE VEHICLE BEGAN TO VIBRATE VIOLENTLY. THE FAILURE RECURRED ON SEVERAL OCCASIONS. THE VEHICLE WAS TAKEN TO A DEALER, WHERE THE TRACK BAR BALL JOINT WAS REPLACED. THE FAILURE PERSISTED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILU…
Read full complaint
TL* THE CONTACT OWNS A 2008 FORD F-350. WHILE DRIVING 65 MPH OVER A POTHOLE, THE VEHICLE BEGAN TO VIBRATE VIOLENTLY. THE FAILURE RECURRED ON SEVERAL OCCASIONS. THE VEHICLE WAS TAKEN TO A DEALER, WHERE THE TRACK BAR BALL JOINT WAS REPLACED. THE FAILURE PERSISTED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 22,000. UPDATED 03/24/15*LJ UPDATED 9/20/2017*CN
NHTSA ODI #10680495
81,000 miles · Jan 16, 2015
Electrical SystemFire
TL* THE CONTACT OWNS A 2008 FORD F-350. THE CONTACT STATED THAT THE BATTERY WARNING LIGHT ILLUMINATED AND THE CONTACT DISCOVERED SMOKE COMING FROM UNDER THE HOOD. THE CONTACT ALSO MENTIONED THAT ONCE THE HOOD WAS OPENED, THE ALTERNATOR CAUGHT ON FIRE. THE CONTACT EXTINGUISHED THE FIRE. THE POLICE REPORT WAS NOT FILED. THE VEHICL…
Read full complaint
TL* THE CONTACT OWNS A 2008 FORD F-350. THE CONTACT STATED THAT THE BATTERY WARNING LIGHT ILLUMINATED AND THE CONTACT DISCOVERED SMOKE COMING FROM UNDER THE HOOD. THE CONTACT ALSO MENTIONED THAT ONCE THE HOOD WAS OPENED, THE ALTERNATOR CAUGHT ON FIRE. THE CONTACT EXTINGUISHED THE FIRE. THE POLICE REPORT WAS NOT FILED. THE VEHICLE WAS TAKEN TO THE DEALER, WHO DIAGNOSED THAT THE ALTERNATOR WAS CYCLING MORE THAN DESIGNED BECAUSE THE BATTERY WAS NOT FUNCTIONING PROPERLY CAUSING THE FIRE. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 81,000.
NHTSA ODI #10672945
83,000 miles · Dec 2, 2014
Steering
TL* THE CONTACT OWNS A 2008 FORD F-350. THE CONTACT STATED THAT WHILE DRIVING 25 MPH, THE STEERING WHEEL SEIZED ABD AS A RESULT, EXCESSIVE FORCE WAS REQUIRED IN ORDER TO MANEUVER THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 83,000.
NHTSA ODI #10661832
65,000 miles · Oct 16, 2014
Wheels
TL* THE CONTACT OWNS A 2008 FORD F-350. THE CONTACT STATED THAT THE RIMS ON THE VEHICLE WERE CRACKING. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC WHERE THE FAILURE WAS UNABLE TO BE DETERMINED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 65,000. ..UPDATED 12/11/…
Read full complaint
TL* THE CONTACT OWNS A 2008 FORD F-350. THE CONTACT STATED THAT THE RIMS ON THE VEHICLE WERE CRACKING. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC WHERE THE FAILURE WAS UNABLE TO BE DETERMINED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 65,000. ..UPDATED 12/11/14 *BF UPDATED 06/2/2015 *JS
NHTSA ODI #10648239
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
Illustration