Air Bags. Review the 330 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Power Train. Review the 193 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Fuel/propulsion System. Review the 105 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

16 crash reports22 fire reports13 injury reports

Power Train complaints

193 reports

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57,267 miles · Feb 6, 2015

Power Train

PTU UNIT KEEPS LEAKING. HAD UNIT REPLACED IN 2012 AND NOW JUST HAD TO HAVE IT DONE AGAIN IN 2015. *JS

NHTSA ODI #10681688

87,500 miles · Feb 3, 2015

Electrical SystemPower Train

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I HAVE A 2007 FORD EDGE WITH VERY LOW MILEAGE TO DATE. THIS IS USUALLY MY FAMILY CAR, DRIVEN BY MY WIFE. WE LIVE IN GUATEMALA AND DROVE TO A HOUSE ON THE BEACH, THAT IS ABOUT 100 MILES AWAY. ON JANUARY FIRST WHEN WE WERE RETURNING I STARTED THE CAR AND NOTICED A SHAKE AND SPUTTER, AND I THOUGHT THAT IT WAS PROBABLY A DEFECTIVE SPARK PLUG. I MANAGED TO DRIVE OUT OF WHERE WE WERE AND AS SOON AS WE GOT TO THE MAIN HIGHWAY I HAD TO STOP AND CALL FOR A TOW. THE SHAKING AND SPUTTERING WERE FRIGHTENING. THE SHOP I TOOK IT TO SAYS THAT AT LEAST 3 IGNITION COILS NEED TO BE REPLACED AND ARE NOT SURE IF THE PCM ALSO HAS TO BE REPLACED. UNFORTUNATELY, SINCE THERE ARE PARTS STOCK PROBLEM HERE, I HAD TO WAIT ALMOST A MONTH TO GET THE PARTS AND NOW THAT I HAVE THEM (THE COILS) I STILL HAVE TO WAIT TO SEE WHAT THE REAL PROBLEM IS. I HAVE CONTACTED THE DEALER IN THE REGION TO SEE WHAT CAN BE DONE. I HAD TO REPORT THIS AS IT IS NOT A UNIQUE PROBLEM TOBUYERS IN THE US, ALSO ABROAD. *TR

NHTSA ODI #10680995

167,000 miles · Jan 26, 2015

Power Train

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ON OR AROUND 11/29/2014 I WAS DRIVING MY FAMILY IN OUR 2007 FORD EDGE ON THE FREEWAY, TRAVELING APPROX. 70 MPH, WHEN THE SYSTEM DISPLAY READ SOMETHING REFERRING TO O/D TRANSMISSION MESSAGE OF SOME SORT. I LOST DRIVE TRAIN POWER AND COASTED TO AN EXIT RAMP WHILE THE VEHICLE STRUGGLE TO MAINTAIN DRIVE. A SHORT TIME LATER I WAS ABLE TO PARK IN A PARKING LOT, AND WHEN I SHIFTED THE LEVER INTO PARK IT PASSED BY REVERSE AND SHIFTED VIOLENTLY. I TRIED TO SHIFT TO DRIVE WITH THE SAME RESULT. I CONTACTED AVIS FORD WHERE WE PURCHASED THE VEHICLE, TOLD THEM WHAT HAPPENED, AND THEY INFORMED ME THAT THEIR SERVICE CENTER WAS BACKED UP ON TRANSMISSION REPAIRS FOR A RECALL TILL FEBRUARY 2015! I FOUND ATRANSMISSION SHOP WHO, RAN A DIAGNOSTIC CHECK, AND DROVE MY VEHICLE WITH ME IN IT, AND SAID THERE WASN'T ANYTHING HE COULD SEE. I CALLED MY SALESMAN, HE TRIED TO SEE WHAT HE COULD DO. HE LATER INFORMED ME IF I COULD SOMEHOW GET THE VEHICLE HOME, TO UNHOOK THE BATTERY, WAIT FOR AN HOUR, AND HOOK IT BACK UP THAT THIS WOULD RESET THE PCM MODULE, AND MAYBE CORRECT THE ISSUE. IT APPEARED TO REMEDY THE SYMPTOM, UNTIL TODAY WHEN MY WIFE ARRIVED AT HER OFFICE, AND AS SHE WAS PULLING IN TO PARK THE SAME MESSAGE APPEARED, WITH THE SAME SYMPTOMS. UNFORTUNATELY THIS IS OUR ONLY VEHICLE, AND I'LL HAVE TO WAIT AND SEE WHAT TO DO NEXT. I HAVE CONTACTED MY DEALER. I ALSO CALLE FORD MOTOR CO.'S CUSTOMER SERVICE TODAY TO SEE IF THERE WERE ANY RECALLS FOR THESE SYMPTOMS, AND THE REPRESENTATIVE STATED THAT THERE WERE NONE FOR THAT. BUT DID GIVE ME A RECALL ON GAS TANK STRAPS, AND A CASE #[XXX]. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).' *TR

NHTSA ODI #10678902

130,000 miles · Jan 18, 2015

Power Train

I HAVE A 2007 FORD EDGE. MY WIFE WAS DRIVE AND WITH NO WARNING OR NOTIFICATION THE CAR STARTED SHAKING, SPUTTERING, AND LOST ALL POWER. THE SHOP I TOOK IT TO SAYS THE PCM AND 3 IGNITION COILS NEED TO BE REPLACED. I HAVE FOUND ONLINE HUNDREDS OF PEOPLE WITH THE SAME PROBLEM ON THE SAME CAR. I CONTACTED FORD ABOUT A RECALL AND WAS…

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NHTSA ODI #10676315

93,000 miles · Dec 21, 2014

Power Train

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THE 2007 FORD EDGE AWD 93,000 MILES DEVELOPED A SLIGHT HUMMING IN THE FRONT END, IT ACTUALLY SOUNDED LIKE A CUPPED TIRE OR A WHEEL BEARING. WE IMMEDIATELY CALLED OUR MECHANIC AND HAD IT INSPECTED. UPON INSPECTION HE INFORMED US THAT THE PTU WAS RUINED, WE HAVE HAD THIS VEHICLE FROM NEW AND SERVICED IT AS REQUIRED AND ONLY DRIVE IT ON THE HIGHWAY APPROX 45 MILES PER DAY. IT TURNS OUT THAT THE PTU (TRANSFER CASE) OVERALL HAS A ISSUE WITH THE SEALS THAT HOLD THE FLUID (OUTER SEAL=GEAR OIL, INNER SEAL= TRANNY FLUID) INSIDE THE UNIT, THE MECHANIC SAID THAT HE'S DONE SO MANY OF THE SEAL REPLACEMENTS THAT AT ONE POINT THAT WAS ALL HE WAS DOING IN A DAY AT THE DEALERSHIP. THE REAL ISSUE IS THAT WHEN THE SEAL GOES YOU CAN'T TELL BECAUSE IT LEAKS DIRECTLY ONTO THE EXHAUST AND BURNS OFF AS YOUR DRIVING. IF WE WERE INFORMED OF THE LEAKY SEAL WE COULD HAVE HAD THE SEALS REPLACED FOR ABOUT $200, BUT UNFORTUNATELY WE FOUND OUT THE HARD (EXPENSIVE) WAY $2000. IM A PERSON THAT TAKES CAR MAINTENANCE VERY SERIOUSLY, WE HAVE A CONSTRUCTION COMPANY AND HAVE HAD ABOUT 14 DIFFERENT FORD MODELS OVER THE YEARS, AND ITS BECOMING MORE APPARENT ANY FORD BUILT AFTER 2004 IS FILLED WITH ISSUES (TO ME FACTORY DEFECTS) THAT THEY AREN'T TAKING RESPONSIBILITY FOR. I WISH I WAS NOTIFIED OF THE ISSUE WITH THE SEAL AS I WOULD HAVE ABOUT $ 1800 DOLLARS MORE IN MY BANK ACCOUNT. *TR

NHTSA ODI #10667479

129,000 miles · Nov 24, 2014

Power Train

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I HAVE HAD AN ONGOING PROBLEM WITH THE WRENCH LOOKING LIGHT COMING ON THEN THE VEHICLE LOSES POWER. WHEN I PUSH THE GAS YOU HAVE TO PUSH THE GAS PEDAL ALL THE WAY DOWN TO GET IT TO CREEP TO GO TO THE SIDE OF THE ROAD. I HAVE TO PULL OVER AND SHUT THE VEHICLE OFF WHEN IT RESTARTS THEN THE VEHICLE WILL GO. THIS LAST TIME THE VEHICLE GOT ME STRANDED ON THE SIDE OF THE ROAD FOR 2.5 HOURS UNTIL THE TOW TRUCK GOT THERE AND TOWED IT TO THE DEALERSHIP. THE DEALER STARTED IT TWO DAYS LATE AND EVERYTHING WAS FINE. I HAD IT TO THE SHOP PREVIOUSLY TO TRY AND GET THIS DIAGNOSED AND THEY COULD NOT FIND THE PROBLEM. I HAVE READ HUNDREDS OF COMPLAINTS INVOLVING THE SAME THING. FORD SHOULD LOOK AT WHAT IS CAUSING THIS PROBLEM AND OPEN A CLAIM TO TAKE CARE OF THESE ISSUES. *TR

NHTSA ODI #10660460

93,000 miles · Nov 20, 2014

Electrical SystemEnginePower Train

AT A STOP, THE CAR WOULD NOT ACCELERATE,LOUD CLUNKING SOUND, AIRBAG LIGHT TURNED ON. WOULD NOT MOVE, HAD TO COMPLETELY TURN OFF CAR FOR A FEW SECONDS, ONLY MOVED A FEW FEET BEFORE IT DID AGAIN. NEXT DAY SAME PROBLEM. *TR

NHTSA ODI #10659605

89,000 miles · Nov 11, 2014

Power Train

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CAR SAT UN-DRIVEN IN GARAGE FOR 9 DAYS. WHEN CAR WAS TAKEN OUT AND DRIVEN, THE CAR WOULD NOT MOVE FORWARD. SPEED SHOWN CAR GOING 55 MILES AND HOUR BUT IT WAS NOT MOVING. PUT CAR IN REVERSE AND IT WOULD MOVE. PUT CAR IN DRIVE AND LOW GEARS AND CAR WOULD MOVE FORWARD VERY SLOWLY. CAR HAD TO BE TOWED TO THE DEALERSHIP. DEALERSHIP STATED ONLY FIX WAS TO REPLACE THE TRANSMISSION. MEANING A LOT OF MONEY HAD TO BE SPENT TO FIX THE CAR. THIS IS A VERY CLEAN CAR AND TAKEN IN FOR REGULAR TURN-UPS, WITH LOW MILES FOR THE AGE OF THE CAR. THERE WAS NO INDICATION OF ANYTHING BEING WRONG WITH THE TRANSMISSION PRIOR TO THIS INCIDENT. ACCORDING TO REPORTS, FORD HAS HAD MANY ISSUES WITH THE TRANSMISSIONS. FORD NEEDS TO TAKE THE STAND AND TAKE CARE OF THIS PROBLEM, BEFORE THERE AREA ANY FATALITIES. *TR

NHTSA ODI #10654262

143,612 miles · Nov 7, 2014

Power Train

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2007 EDGE SEL, ON THE INSTRUMENT PANEL AN "ODO DATA ERROR" APPEARED. THE "WRENCH AND AIRBAG" LIGHTS WERE LIT UP AS WELL. HARD CLUNK SHIFTING INTO DRIVE, CAR HAD NO POWER RAN RPM HIGHER STARTED TO SLOWLY ROLL. TURNED OFF CAR, UNCONNECTED BATTERY CABLE, CONNECTED BACK AND STARTED UP INSTRUMENT PANEL READ OUT WAS NOW CORRECT AND PUT INTO DRIVE AND IT DID A FEW HARD SHIFTS AS WE DROVE OUT, BUT RAN FINE ALL THE WAY HOME. I SEE MANY OTHERS STATING THIS SAME THING! I WILL TAKE THIS IN AGAIN AS I HAD ALREADY TAKEN FOR HARD SHIFTS, BUT THEY FOUND NOTHING. THIS TIME LOOKS LIKE OSS AND TSS FROM ALL THE READING I HAVE DONE ON THIS ISSUE. *TR

NHTSA ODI #10653543

71,000 miles · Oct 24, 2014

Power Train

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TO WHOM IT MAY CONCERN, I HAVE NOTICED NUMEROUS 2007 FORD EDGE OWNERS WITH THE SAME ISSUE I HAD RECENTLY, LEAKING TRANSFER CASE PTU UNIT. I ALSO NOTICED THIS SAME ISSUE IS HAPPENING WITH LINCOLN'S AND MAZDA'S OF SAME MODEL TYPE. I BELIEVE MAZDA HAS OFFERED OWNERS SOME SORT OF COMPENSATION/RECALL/EXTENDED WARRANTY FOR THIS MANUFACTURED DEFECT. MY QUESTION IS WHAT IS FORD GOING TO DO ABOUT THIS VERY EXPENSIVE REPAIR THAT OWNERS HAVE TO PAY FOR THAT IS A MANUFACTURER DEFECT? I DID HAVE IT REPLACED FOR A PRETTY PENNY AND NOW I HEAR A CLANKING NOISE WHEN I TURN THAT WAS NOT THERE BEFORE THE REPAIR. SINCERELY, VERY CONCERNED AND FRUSTRATED LOYAL CUSTOMER *TR

NHTSA ODI #10649822

Official recalls

21V158000 · Air Bags:frontal:driver Side:inflator Module

Mar 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.

21V081000 · Air Bags:frontal; Air Bags:frontal:driver Side:inflator Module; Air Bags:frontal:passenger Side:inflator Module

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

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

Air Bags:frontal

17V024000 · Air Bags:frontal:passenger Side:inflator Module

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.

16V384000 · Air Bags:frontal:passenger Side:inflator Module

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.

14V682000 · Fuel System, Gasoline:storage:tank Assembly

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.

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

PE09031 · 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