NHTSA owner reports · September 18, 2026 snapshot.
Service Brakes complaints
17 reportsClear category filter91,000 miles · May 1, 2024
Service BrakesService Brakes, Hydraulic
The contact owns a 2008 Lincoln MKX. The contact stated that while driving at unknown speeds, the brake pedal was firm when depressed, and the vehicle was slow to respond. There was an abnormal hissing noise detected from the dashboard. There were no warning lights illuminated. The contact called the local dealer, but the vehicl…
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The contact owns a 2008 Lincoln MKX. The contact stated that while driving at unknown speeds, the brake pedal was firm when depressed, and the vehicle was slow to respond. There was an abnormal hissing noise detected from the dashboard. There were no warning lights illuminated. The contact called the local dealer, but the vehicle was not diagnosed or repaired. The contact called another local dealer, Cavalier Ford Greenbrier (1515 S Military Hwy, Chesapeake, VA 23320), who informed the contact that there were no recalls on the VIN and to schedule an appointment. The vehicle was not diagnosed or repaired. The contact stated that the failure was related to NHTSA Campaign Number: 20V469000 (Service Brakes, Service Brakes, Hydraulic) but the VIN was not included. The manufacturer was contacted, but no assistance was provided. The failure mileage was approximately 91,000.
NHTSA ODI #11586390
160,000 miles · Aug 27, 2020
EngineService BrakesSuspension
I HAVE HAD NUMEROUS ALIGNMENTS AND TIRES SINCE GOT THIS VEHICLE LAST YEAR AND NOW IT'S SHACKING, RIDES LIKES I HAVE A FLAT OR WEAVING UP AND DOWN AND STARTING TO PULL/ STOP WORKING WHILE DRIVING AND CAN'T FIND ANYTHING WRONG STILL HAS ALL ORIGINAL PARTS! LIGHTS GO THRU BULBS AND CAN'T SEE
NHTSA ODI #11351655
150,000 miles · Jul 27, 2020
Service Brakes
TL* THE CONTACT OWNS A 2008 LINCOLN MKX. THE CONTACT STATED THAT THE POWER BRAKE BOOSTER FAILED WHILE HIS DAUGHTER WAS DRIVING AT AN UNDISCLOSED SPEED. THE CONTACT STATED THAT ADDITIONAL FORCE WAS APPLIED ON THE BRAKE PEDAL TO BRING THE VEHICLE TO A STOP. THE CONTACT STATED THAT HE WAS NOT AWARE OF ANY WARNING LIGHTS BEING ILLUM…
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TL* THE CONTACT OWNS A 2008 LINCOLN MKX. THE CONTACT STATED THAT THE POWER BRAKE BOOSTER FAILED WHILE HIS DAUGHTER WAS DRIVING AT AN UNDISCLOSED SPEED. THE CONTACT STATED THAT ADDITIONAL FORCE WAS APPLIED ON THE BRAKE PEDAL TO BRING THE VEHICLE TO A STOP. THE CONTACT STATED THAT HE WAS NOT AWARE OF ANY WARNING LIGHTS BEING ILLUMINATED. THE CONTACT CALLED BRONDES FORD LINCOLN MAUMEE (1475 ARROWHEAD RD, MAUMEE, OH 43537), AND INFORMED THE DEALER OF THE FAILURE. THE CONTACT WAS INFORMED THAT THE VEHICLE WAS NOT SUBJECTED TO A RECALL. THE VEHICLE WAS NOT TAKEN TO A DEALER. THE CONTACT MADE AN APPOINTMENT WITH AN INDEPENDENT MECHANIC TO HAVE THE VEHICLE REPAIRED WHICH WAS STILL PENDING. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 150,000.
NHTSA ODI #11341631
115,575 miles · Oct 28, 2019
EngineService BrakesSteering
TL* THE CONTACT CALLED ON BEHALF OF THE OWNER OF A 2008 LINCOLN MKX. WHILE DRIVING 65 MPH, THE VEHICLE STALLED WITHOUT WARNING. ALSO, THE VEHICLE FAILED TO SLOW DOWN WHEN THE BRAKE PEDAL WAS DEPRESSED AND THE POWER STEERING BECAME INOPERABLE. THE VEHICLE WAS PULLED OVER TO THE SIDE OF THE ROAD AND TAKEN TO AN INDEPENDENT MECHANI…
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TL* THE CONTACT CALLED ON BEHALF OF THE OWNER OF A 2008 LINCOLN MKX. WHILE DRIVING 65 MPH, THE VEHICLE STALLED WITHOUT WARNING. ALSO, THE VEHICLE FAILED TO SLOW DOWN WHEN THE BRAKE PEDAL WAS DEPRESSED AND THE POWER STEERING BECAME INOPERABLE. THE VEHICLE WAS PULLED OVER TO THE SIDE OF THE ROAD AND TAKEN TO AN INDEPENDENT MECHANIC TO BE DIAGNOSED. THE CONTACT WAS INFORMED THAT THE THROTTLE BODY POSITION SENSOR NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED; HOWEVER, THE FAILURE RECURRED. A LOCAL DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS INFORMED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 115,575.
NHTSA ODI #11271626
110,000 miles · Oct 29, 2018
Service Brakes
TOOK CAR IN FOR SERVICE BECAUSE ABS LIGHT CAME ON AND BRAKES WOULD SCRUB WHEN STOPPING. DEALER REPLACED WHEEL SENSOR AND TOLD US THAT BRAKE BOOSTER WAS BAD, SO WE AGREED TO REPLACEMENT. AFTER REPAIRS, WITH NEW BRAKE BOOSTER THE BRAKES SOMETIMES ARE REAL HARD TO PUSH AND DO NOT STOP THE CAR CORRECTLY. VERY UNSAFE CONDITION. IT SE…
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TOOK CAR IN FOR SERVICE BECAUSE ABS LIGHT CAME ON AND BRAKES WOULD SCRUB WHEN STOPPING. DEALER REPLACED WHEEL SENSOR AND TOLD US THAT BRAKE BOOSTER WAS BAD, SO WE AGREED TO REPLACEMENT. AFTER REPAIRS, WITH NEW BRAKE BOOSTER THE BRAKES SOMETIMES ARE REAL HARD TO PUSH AND DO NOT STOP THE CAR CORRECTLY. VERY UNSAFE CONDITION. IT SEEMS TO BE RE-OCCURRING AND SHORT-LIVED WHEN IT HAPPENS, BUT WHO KNOWS WHEN IT WILL HAPPEN AT THE WRONG TIME. DEALER ALSO SUGGESTED NEW PADS WHICH HAD JUST BEEN REPLACED???
NHTSA ODI #11143600
141,000 miles · Oct 15, 2018
Service Brakes
ABOUT A MONTH AGO, WHILE DRIVING ON THE INTERSTATE MY ABS AND TRACTION CONTROL PANEL LIGHTS LIT UP WITH SEEMINGLY NO INSTIGATOR, THEY STAYED ON UNTIL I GOT OFF THE INTERSTATE THEN WENT AWAY. FROM THEN ON THEY WOULD INTERMITTENTLY POP ON WHICH I EVENTUALLY DISCOVERED WAS MOSTLY ONCE THE VEHICLE WAS GOING OVER 60MPH. ABOUT A WEEK…
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ABOUT A MONTH AGO, WHILE DRIVING ON THE INTERSTATE MY ABS AND TRACTION CONTROL PANEL LIGHTS LIT UP WITH SEEMINGLY NO INSTIGATOR, THEY STAYED ON UNTIL I GOT OFF THE INTERSTATE THEN WENT AWAY. FROM THEN ON THEY WOULD INTERMITTENTLY POP ON WHICH I EVENTUALLY DISCOVERED WAS MOSTLY ONCE THE VEHICLE WAS GOING OVER 60MPH. ABOUT A WEEK AFTER THE LIGHTS STARTED COMING ON, I NOTICED OCCASIONALLY WHEN I WOULD TRY TO STOP MY VEHICLE THE BRAKES WOULD LOCK UP AS IF I WAS DRIVING ON ICE. I WOULD HAVE TO PUMP MY BRAKES MULTIPLE TIMES TO GET THEM TO ENGAGE WHICH IS VERY NERVE WRECKING. THAT PARTICULAR ISSUE HAS HAPPENED A 2-3 TIMES A WEEK SINCE THEN. I HAVE TAKEN MY VEHICLE IN AND HAD THE SEAL REPLACED WHICH DIDN'T FIX THE ISSUE AND NOW I'M BEING TOLD THAT THIS IS SUCH A COMMON ISSUE AMONG LINCOLN MKX'S, FORD EDGES, AND FORD FUSIONS THAT THEY HAVE "UPDATED" AXLES THAT REMEDY THE PROBLEM. I AM GETTING THESE NEW AXLES TO HOPEFULLY FIX THIS ISSUE BUT THIS HAS BEEN A HUGE SAFETY CONCERN THAT HAS MADE ME NERVOUS TO EVEN PUT MY SON IN THE CAR.
NHTSA ODI #11140325
150,000 miles · Jul 11, 2018
Air BagsFuel/propulsion SystemService Brakes
I HAVE BEEN EXPERIENCING BRAKING ISSUES. I HAVE BROUGHT MY MKX TO A DEALER AND WAS INFORMED THAT I NEED A NEW BRAKE BOOSTER. THEY HAVE INFORMED ME THAT FORD IS AWARE OF THIS DESIGN ISSUE. IS THIS COVERED UNDER ANY TYPE OF RECALL SINCE THEY ARE AWARE OF THE ISSUE?
NHTSA ODI #11110749
92,341 miles · Aug 9, 2017
Service Brakes
DRIVING DOWN THE ROAD AND WENT TO PUT ON THE BRAKES AND THE PEDAL WAS REAL HARD HAD TO PUMP AND PUSH HARD. WAS TOLD IT COULD BE MASTER CYLINDER . WAS TOLD BY A LOCAL MECHANIC HE THOUGH IT WAS UNDER WARRENTY AS A RECALL. DEALER SHIP HAD NO RECORD OF SUCH.
NHTSA ODI #11013953
95,000 miles · Jul 31, 2017
Service Brakes
95000 MILES. WENT OVER A SMALL POTHOLE WHILE TAKING A RIGHT HAND TURN. BRAKE PEDAL WENT TO THE FLOOR. 4TH TIME THIS HAS HAPPENED IN THE LAST 2 YEARS. USUALLY FIXED ITSELF AFTER A COUPLE HOURS OF DRIVING. THIS TIME IT DID NOT. DROVE OVER 200 MILES WITH THE PEDAL GOING TO THE FLOOR TO STOP. READ ON A FORUM THAT IT IS A BAD AND HYD…
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95000 MILES. WENT OVER A SMALL POTHOLE WHILE TAKING A RIGHT HAND TURN. BRAKE PEDAL WENT TO THE FLOOR. 4TH TIME THIS HAS HAPPENED IN THE LAST 2 YEARS. USUALLY FIXED ITSELF AFTER A COUPLE HOURS OF DRIVING. THIS TIME IT DID NOT. DROVE OVER 200 MILES WITH THE PEDAL GOING TO THE FLOOR TO STOP. READ ON A FORUM THAT IT IS A BAD AND HYDRAULIC C UNIT AND THAT A TEMP FIX WOULD BE TO DO SEVERAL ABS STOPS ON A LOOSE GRAVEL ROAD. TRIED THAT AND IT WORKED. AFRAID THAT THIS IS GOING TO HAPPEN AGAIN AND WON'T STOP IN TIME. THIS IS VERY DANGEROUS. NEED A RECALL. THIS IS HAPPENING IN 2008 FORDS AND LINCOLNS. SAW AT LEAST 200 INSTANCES ON FORUMS. I HAVE A EXTENDED WARRANTY BUT UNLESS IT'S DOING IT WHEN I BRING IT IN THEY WON'T FIX IT
NHTSA ODI #11011666
Mileage unknown · May 14, 2017
Service BrakesSuspensionVehicle Speed Control
VEHICLE VEHICLE FREQUENTLY HAS TO STARTED TWICE BECAUSE THE FIRST TIME THE VEHICLE IS STARTED IF I GO OVER 40MPH THE ENGINE AND SUSPENSION START PULLING AND JERKING AND THE SPEEDOMETER WILL KEEP INCREASING EVEN THOUGH THE CAR SUSPENSION IS ONLY ALLLOWING 30MPH
NHTSA ODI #10985567
Official recalls
6Mar 10, 2021
Ford Motor Company (Ford) is recalling certain 2007-2011 Ranger, 2006-2012 Fusion, Lincoln Zephyr, Lincoln MKZ, 2006-2011 Mercury Milan, 2007-2010 Ford Edge, and Lincoln MKX vehicles. The driver's side air bag inflator may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.
Consequence & remedy
Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.
Remedy: Ford will notify owners, and dealers will replace the driver-side airbag inflator or module with an alternate one, free of charge. Owner notification letters were mailed on April 9, 2021 for the passenger side, and November 14, 2022 for the driver side. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S12.
Feb 16, 2021
Ford Motor Company (Ford) is recalling certain 2005-2014 Mustang, 2004-2011 Ranger, 2009-2011 Mercury Milan, 2006 Ford GT, 2008-2012 Fusion, 2007-2010 Edge and Lincoln MKX, and 2009-2010 Lincoln MKZ vehicles. These vehicles may be equipped with a driver or passenger frontal air bag inflator used as a replacement service part, that may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.
Consequence & remedy
Consequence: In the event of a crash necessitating deployment of the frontal air bag, an inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Ford will notify owners, and dealers will inspect the driver and passenger air bag module, and replace either the module or the inflator, if necessary, free of charge. The recall began March 17, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S05.
Additional source detail variants (3)
Air Bags:frontal:passenger Side:inflator Module
Ford Motor Company (Ford) is recalling certain 2005-2014 Mustang, 2004-2011 Ranger, 2009-2011 Mercury Milan, 2006 Ford GT, 2008-2012 Fusion, 2007-2010 Edge and Lincoln MKX, and 2009-2010 Lincoln MKZ vehicles. These vehicles may be equipped with a driver or passenger frontal air bag inflator used as a replacement service part, that may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.
Consequence: In the event of a crash necessitating deployment of the frontal air bag, an inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Ford will notify owners, and dealers will inspect the driver and passenger air bag module, and replace either the module or the inflator, if necessary, free of charge. The recall began March 17, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S05.
Air Bags:frontal:driver Side:inflator Module
Ford Motor Company (Ford) is recalling certain 2005-2014 Mustang, 2004-2011 Ranger, 2009-2011 Mercury Milan, 2006 Ford GT, 2008-2012 Fusion, 2007-2010 Edge and Lincoln MKX, and 2009-2010 Lincoln MKZ vehicles. These vehicles may be equipped with a driver or passenger frontal air bag inflator used as a replacement service part, that may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.
Consequence: In the event of a crash necessitating deployment of the frontal air bag, an inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Ford will notify owners, and dealers will inspect the driver and passenger air bag module, and replace either the module or the inflator, if necessary, free of charge. The recall began March 17, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S05.
Air Bags:frontal
Ford Motor Company (Ford) is recalling certain 2005-2014 Mustang, 2004-2011 Ranger, 2009-2011 Mercury Milan, 2006 Ford GT, 2008-2012 Fusion, 2007-2010 Edge and Lincoln MKX, and 2009-2010 Lincoln MKZ vehicles. These vehicles may be equipped with a driver or passenger frontal air bag inflator used as a replacement service part, that may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.
Consequence: In the event of a crash necessitating deployment of the frontal air bag, an inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Ford will notify owners, and dealers will inspect the driver and passenger air bag module, and replace either the module or the inflator, if necessary, free of charge. The recall began March 17, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S05.
Jan 10, 2017
Ford Motor Company (Ford) is recalling certain 2012 Ford Fusion and Mustang and Lincoln Zephyr and MKZ vehicles originally sold, or ever registered, in Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands, or "Zone A." Additionally, unless included in "Zone A" above, Ford is recalling certain 2009 Ford Ranger, Edge, Fusion and Mustang, Lincoln MKX, MKZ and Zephyr and Mercury Milan vehicles originally sold, or ever registered, in Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia and West Virginia, or "Zone B." Additionally, unless included in "Zone A" or "Zone B" above, Ford is recalling certain 2007-2008 Ford Ranger, Edge and Lincoln MKX, 2006-2008 Ford Fusion, Mercury Milan, Lincoln Zephyr and MKZ, 2005-2008 Ford Mustang and 2005-2006 Ford GT vehicles originally sold, or ever registered, in the states of Alaska, Colorado, Connecticut, Idaho, Iowa, Maine, Massachusetts, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, Oregon, Rhode Island, South Dakota, Utah, Vermont, Washington, Wisconsin and Wyoming. These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the passenger frontal air bag, these inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.
Consequence & remedy
Consequence: An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.
Remedy: Owners are advised not to drive their vehicles until the repair has been performed. Ford will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. Interim letters informing owners of the recall and that parts are not yet available began mailing March 1, 2017. Owners will receive a second notice when remedy parts become available. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S01.
May 31, 2016
Ford Motor Company (Ford) is recalling certain model year 2007-2011 Ford Ranger vehicles, 2006-2011 Ford Fusion, Mercury Milan and Lincoln Zephyr/MKZ vehicles, 2007-2010 Ford Edge, Lincoln MKX vehicles, 2005-2006 Ford GT vehicles, and 2005-2011 Ford Mustang vehicles originally sold, or ever registered, in Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands, or "Zone A." Additionally, unless included in "Zone A" above, Ford is recalling certain model year 2007-2008 Ford Ranger, Edge and Lincoln MKX vehicles, 2006-2008 Ford Fusion, Mercury Milan and Lincoln Zephyr/MKZ vehicles, 2005-2006 Ford GT vehicles and 2005-2008 Ford Mustang vehicles originally sold, or ever registered, in Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia, or "Zone B." Any vehicle not included in "Zone A", or "Zone B" is not included in the safety recall. These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules, and used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the front air bags, these inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.
Consequence & remedy
Consequence: An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.
Remedy: Owners are advised not to drive their vehicles until the repair has been performed. Ford will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. Ford mailed interim letters informing owners that parts are not yet available on July 15, 2016. Owners will receive a second notice when remedy parts become available. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S01.
Oct 29, 2014
Ford Motor Company (Ford) is recalling certain model year 2007-2008 Lincoln MKX, and Ford Edge vehicles, manufactured June 15, 2006, to September 22, 2008, and originally sold, or currently registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin and the District of Columbia. Due to corrosion from salt water exposure such as from road salt use, the affected vehicles may leak fuel from the fuel tank seam weld under the tank mounting reinforcement brackets.
Consequence & remedy
Consequence: A fuel leak in the presence of an ignition source increases the risk of a fire.
Remedy: Interim notices were mailed to owners on December 12, 2014. The recall began on October 6, 2015. Dealers will inspect the vehicles and either clean and treat the fuel tank with a corrosion preventative or replace the tank, free of charge. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 14S22.
Jul 3, 2008
FORD IS RECALLING 142 MY 2008 EDGE AND LINCOLN MKK ALL WHEEL DRIVE VEHICLES. THE FUEL TANK WELD FIXTURE MAY HAVE BEEN EXPOSED TO A CONTAMINANT DURING PRODUCTION WHICH COULD CAUSE A DIMPLE IN THE BOTTOM OF THE FUEL TANK AT A SPOT WELD.
Consequence & remedy
Consequence: THIS DIMPLE COULD RESULT IN A FUEL LEAK OR A FUEL DRIP FROM THE TANK. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE FUEL TANK FREE OF CHARGE. THE RECALL BEGAN ON JULY 11, 2008. OWNERS MAY CONTACT FORD AT 1-866-437-7332.
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
2PE09031 · Front Suspension Lower Ball Joint
Opened Jul 13, 2009 · Closed Nov 19, 2009
Status: closed (inferred from source dates) · Suspension:front:control Arm:lower Ball Joint
ON JULY 13, 2009, THE OFFICE OF DEFECTS INVESTIGATIONS (ODI) OPENED PRELIMINARY EVALUATION PE09-031 TO INVESTIGATE ALLEGATIONS OF FRONT LOWER BALL JOINT SEPARATION IN MODEL YEAR (MY) 2007 AND 2008 FORD EDGE AND LINCOLN MKX VEHICLES.THE INVESTIGATION WAS BASED ON THREE OWNER COMPLAINTS ALLEGING THAT THE FRONT LOWER BALL JOINT SEPARATED AND CAUSED THE FRONT SUSPENSION TO COLLAPSE WHILE DRIVING.ODI ALSO IDENTIFIED INFORMATION RELATED TO THE ALLEGED DEFECT IN EARLY WARNING DATA SUBMITTED BY FORD.PRELIMINARY ANALYSIS INDICATED THAT THE FAILURES WERE RELATED TO THE PINCH BOLT USED TO SECURE THE FRONT LOWER BALL JOINT STUD TO THE STEERING KNUCKLE.ONE COMPLAINT ALLEGED THAT A CRASH OCCURRED WHICH RESULTED IN A MINOR INJURY.HOWEVER, NO ADDITIONAL INFORMATION COULD BE OBTAINED TO SUPPORT THIS CLAIM.INFORMATION PROVIDED BY FORD IN RESPONSE TO ODI'S INFORMATION REQUEST LETTER FOR PE09-031 INDICATE THAT IN EARLY MY 2007 PRODUCTION THERE WERE SOME ISSUES WITH THE FRONT LOWER CONTROL ARM BALL JOINT ASSEMBLY PROCESS.THE PINCH BOLTS USED WERE HAND STARTED AND HAD THE POTENTIAL TO CROSS THREAD AND NOT ACHIEVE PROPER CLAMP LOAD, POTENTIALLY RESULTING IN A LOOSE JOINT.IN NOVEMBER 2007, CHANGES WERE IMPLEMENTED TO CHASE AND CLEAN THE FIRST SIX THREADS OF THE BOLT TO PROVIDE EASIER HAND STARTING OF THE NUT AND ENSURE GOOD THREAD ENGAGEMENT BEFORE TIGHTENING. FORD ALSO IDENTIFIED ONGOING CONCERNS WITH THE POWER TRANSMISSION UNIT (PTU) SEALS AND FRONT SUSPENSION HYDRO-BUSHINGS ON THE SUBJECT VEHICLES, WHICH BOTH REQUIRE DISASSEMBLY OF THE FRONT LOWER BALL JOINT TO REPAIR.IF THE BALL JOINT IS NOT PROPERLY REASSEMBLED FOLLOWING SUCH SERVICE, THE JOINT MAY SEPARATE IN LATER SERVICE.FORD HAS PROVIDED ADDITIONAL INSTRUCTIONS AND NEW PINCH BOLTS TO THE PTU REPAIR KIT TO IMPROVE THE JOINT REASSEMBLY PROCESS. ODI'S ANALYSIS OF FAILURE DATA IDENTIFIED 31 INCIDENTS OF JOINT SEPARATION (WITH 12 SPECIFICALLY STATING THAT THEY OCCURRED WHILE DRIVING).REPAIR RECORDS FOR THESE 31 VEHICLES SHOWS THAT 28 INVOLVE SEPARATION OF THE JOINT ON THE PASSENGER (RIGHT) SIDE, WHICH IS THE SIDE THAT MUST BE DISASSEMBLED FOR PTU SERVICE.TWENTY-THREE OF THESE WERE FOUND TO HAVE BEEN PREVIOUSLY DISASSEMBLED FOR CONTROL ARM BUSHING SERVICE, PTU SERVICE OR OTHER TRANSMISSION REPAIR. THE EIGHT CLAIMS THAT DID NOT INVOLVE PRIOR SERVICE REPAIRS REQUIRING JOINT DISASSEMBLY ALL OCCURRED VERY EARLY IN VEHICLE LIFE, INDICATING THAT IT IS UNLIKELY THAT ANY JOINTS MANUFACTURED WITH LOOSE PINCH BOLTS ARE STILL IN SERVICE.ALL OF THESE JOINTS FAILED WITHIN 6 MONTHS IN SERVICE AND 10,000 MILES (THE MAXIMUM FAILURE MILEAGE IS 8,097 MILES).THERE HAVEN'T BEEN ANY SUCH FAILURES (I.E., NOT INVOLVING PRIOR SERVICE/DISASSEMBLY) SINCE DECEMBER 2008.THE RATE FOR INCIDENTS THAT DID NOT OCCUR FOLLOWING SERVICE AND, THUS, MAY BE RELATED TO THE MANUFACTURING PROCESS ISSUES IDENTIFIED BY FORD IS VERY LOW (2.5 PER 100,000 VEHICLES) AND THESE INCIDENTS OCCURRED VERY EARLY IN THE LIFE OF THE VEHICLES AND ARE NOT SHOWING A CONTINUING FAILURE TREND.ACCORDINGLY, THIS INVESTIGATION HAS BEEN CLOSED. THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.
PE08060 · Tire Valve Cracking
Opened Oct 14, 2008 · Closed Apr 9, 2009
Status: closed (inferred from source dates) · Tires:valve
ON OCTOBER 14, 2008, ODI OPENED PE08-060 TO INVESTIGATE ALLEGATIONS OF CRACKED AND LEAKING SNAP-IN TIRE VALVES IN MODEL YEAR (MY) 2007 VEHICLES MANUFACTURED BY FORD MOTOR COMPANY.THE VALVES WERE SUPPLIED TO FORD BY TOPSEAL AUTO-PARTS, A SUBSIDIARY OF THE SHANGHAI BAOLONG AUTOMOTIVE CORPORATION IN CHINA.VALVES MADE BY TOPSEAL FOR AFTERMARKET SALE WERE THE SUBJECT OF TWO RECENT SAFETY RECALLS BY TECH INTERNATIONAL (08T-018) AND DILL AIR CONTROLS (08T-028), THE LATTER OF WHICH WAS INVESTIGATED BY ODI IN PE08-036 AND EA08-022.THE DEFECT CONDITIONS ADDRESSED BY THE AFTERMARKET TIRE VALVE RECALLS BOTH INVOLVED INADEQUATE RESISTANCE TO OZONE CRACKING DUE TO ISSUES WITH THE SUPPLY OF ANTI-OZONANT CHEMICALS TO TOPSEAL FOR A PERIOD FROM JULY TO MID-NOVEMBER 2006.THE AFTERMARKET VALVES WERE COMPOUNDED WITH A BLEND OF EPDM AND NATURAL RUBBER, USING A RELATIVELY LOW PERCENTAGE OF EPDM (EPDM PROVIDES INHERENT RESISTANCE TO OZONE CRACKING).HENCE, THE NEED FOR ANTI-OZONANT CHEMICALS AND THE PROBLEMS WITH CRACKING WHEN THOSE CHEMICALS WERE MISSING OR OUT OF SPECIFICATION IN SOME LOTS OF VALVES.BOTH RECALL CAMPAIGNS INVOLVED INSPECTION PROGRAMS TO IDENTIFY AND REPLACE VALVES WITH VISIBLE SURFACE CRACKING.ALTHOUGH THE TOPSEAL VALVES SUPPLIED TO FORD ALSO APPEAR TO HAVE BEEN AFFECTED BY THE ANTI-OZONANT SUPPLY ISSUES IN MID TO LATE-2006, FORD INDICATED THAT ITS VALVES WERE MADE AT A DIFFERENT TOPSEAL PRODUCTION LINE AND WERE COMPOUNDED WITH A HIGHER PERCENTAGE OF EPDM RUBBER TO MEET MORE STRINGENT SPECIFICATIONS FROM FORD.ODI'S ANALYSIS OF COMPLAINT AND WARRANTY DATA PROVIDED BY FORD SHOWED THAT PROBLEMS WITH CRACKED TIRE VALVES WERE SIGNIFICANTLY HIGHER FOR MY 2007 VEHICLES PRODUCED FROM DECEMBER 2006 THROUGH MARCH 2007.FORD RESPONDED BY IMPLEMENTING CHANGES IN ITS MATERIAL SPECIFICATIONS FOR SNAP-IN RUBBER TIRE VALVES AND ALSO INCREASING THE QUALITY AND ACCEPTANCE STANDARDS FOR VALVES IMPORTED FOR USE IN ITS VEHICLES.WHILE THE COMPLAINT AND WARRANTY CLAIM RATES ARE ELEVATED FOR SUBJECT VEHICLES PRODUCED FROM DECEMBER 2006 THROUGH MARCH 2007, THE RATES OF LEAKING VALVES ARE WELL BELOW ONE PERCENT OF PRODUCTION FOR EACH OF THE PEAK MONTHS FOR ALL OF THE AFFECTED MODELS.A SUBSTANTIAL MAJORITY OF THE SUBJECT VEHICLES ARE EQUIPPED WITH TIRE PRESSURE MONITORING SYSTEMS (TPMS) WHICH WARN THE DRIVER WHEN ANY TIRE PRESSURES DROPS BELOW 25 PERCENT OF RECOMMENDED INFLATION PRESSURE. AS OUTLINED IN A LETTER TO ODI DATED APRIL 6, 2009, FORD HAS AGREED TO SEND LETTERS TO OWNERS OF CERTAIN MY 2007 AND 2008 FORD, LINCOLN AND MERCURY VEHICLES TO PROVIDE INFORMATION ABOUT THE CRACKING CONCERN. LETTERS WILL BE SENT TO OWNERS OF VEHICLES BUILT FROM NOVEMBER 2006 THROUGH MAY 2007.OWNERS CAN OPT FOR A FREE DEALER INSPECTION.VALVES EXHIBITING SURFACE CRACKS OR AIR LEAKAGE RELATED TO OZONE ATTACK WILL BE REPLACED BY FORD UNDER ITS NORMAL WARRANTY TERMS.FORD EXPECTS TO SEND THE LETTER BY APPROXIMATELY MID-MAY 2009. BASED ON THE USE OF TPMS IN THE MAJORITY OF SUBJECT VEHICLES AND THE RELATIVELY LOW RATES OF REPAIRS ASSOCIATED WITH LEAKING VALVES AND RESULTANT TIRE DAMAGE, ODI BELIEVES THAT THE ACTIONS FORD HAS AGREED TO TAKE WILL PROVIDE EFFECTIVE AND EXPEDITIOUS RESOLUTION FOR VEHICLES THAT WERE BUILT DURING THE PERIOD WHEN VALVES WITH INADEQUATE RESISTANCE TO OZONE CRACKING WERE MOST LIKELY TO HAVE BEEN USED IN VEHICLE PRODUCTION.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.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 CONTINUE TO
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