NHTSA owner reports · September 18, 2026 snapshot.
Service Brakes complaints
87 reportsClear category filter82,000 miles · Aug 31, 2015
Service Brakes
TL* THE CONTACT OWNS A 2007 FORD EDGE. WHILE DRIVING AT AN UNKNOWN SPEED AND ATTEMPTING TO ENGAGE THE BRAKES, THE BRAKES FAILED TO RESPOND. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE POWER BRAKE BOOSTER NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THERE WAS A MANUFACTURERS RECALL RELATED TO THE FAILU…
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TL* THE CONTACT OWNS A 2007 FORD EDGE. WHILE DRIVING AT AN UNKNOWN SPEED AND ATTEMPTING TO ENGAGE THE BRAKES, THE BRAKES FAILED TO RESPOND. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE POWER BRAKE BOOSTER NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THERE WAS A MANUFACTURERS RECALL RELATED TO THE FAILURE HOWEVER THE VIN WAS NOT INCLUDED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 82,000. MA 10/19/2015 *CN
NHTSA ODI #10760446
90,000 miles · Aug 28, 2015
EngineService BrakesFire
TL* THE CONTACT OWNS A 2007 FORD EDGE. WHILE DRIVING AT AN UNKNOWN SPEED, THE BRAKE PEDAL WAS DEPRESSED AND THE VEHICLE FAILED TO STOP. THE CONTACT HAD TO APPLY FORCE TO THE BRAKE PEDAL MULTIPLE TIMES IN ORDER TO STOP THE VEHICLE. IN ADDITION, THE CONTACT STATED THAT THERE WAS AN INCREASE IN TEMPERATURE DISPLAYED ON THE TEMPERAT…
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TL* THE CONTACT OWNS A 2007 FORD EDGE. WHILE DRIVING AT AN UNKNOWN SPEED, THE BRAKE PEDAL WAS DEPRESSED AND THE VEHICLE FAILED TO STOP. THE CONTACT HAD TO APPLY FORCE TO THE BRAKE PEDAL MULTIPLE TIMES IN ORDER TO STOP THE VEHICLE. IN ADDITION, THE CONTACT STATED THAT THERE WAS AN INCREASE IN TEMPERATURE DISPLAYED ON THE TEMPERATURE GAUGE AS WELL AS SMOKE COMING FROM THE ENGINE COMPARTMENT OF THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE VEHICLE OVERHEATED AND STATED THAT THE BRAKE BOOSTER AND FAN NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 90,000.
NHTSA ODI #10760051
102,000 miles · Aug 10, 2015
Service Brakes
WHILE DRIVING WITH MY CHILDREN I PRESSED THE BREAK TO STOP IN TRAFFIC AND ALMOST RAN INTO THE VEHICLE IN FRONT OF ME BECAUSE MY BRAKES BECAME VERY HARD AND I HAD TO PRESS THEM DOWN TO THE GROUND PRACTICALLY TO STOP. TOOK VEHICLE TO A LOCAL SHOP AND WAS TOLD MY BRAKE BOOSTER NEEDED TO BE REPLACED. WAS TOLD THERE HAVE BEEN ISSUES …
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WHILE DRIVING WITH MY CHILDREN I PRESSED THE BREAK TO STOP IN TRAFFIC AND ALMOST RAN INTO THE VEHICLE IN FRONT OF ME BECAUSE MY BRAKES BECAME VERY HARD AND I HAD TO PRESS THEM DOWN TO THE GROUND PRACTICALLY TO STOP. TOOK VEHICLE TO A LOCAL SHOP AND WAS TOLD MY BRAKE BOOSTER NEEDED TO BE REPLACED. WAS TOLD THERE HAVE BEEN ISSUES LIKE THIS WITH FORD MODELS IN THE PAST. AFTER BASIC INTERNET RESEARCH FOUND THERE WAS A RECALL FOR NEWER MODELS BUT NOT MY MODEL. CONTACTED FORD MOTOR COMPANY DIRECTLY AND WAS TOLD THERE IS NOTHING THEY CAN DO FOR ME BECAUSE THERE ISN'T A RECALL ON MY YEAR, MAKE, MODEL EVEN THOUGH THERE ARE A NUMBER OF COMPLAINTS THAT THIS HAS HAPPENED TO OTHER 2007 FORD EDGES NOT ONCE, BUT EVEN AFTER HAVING BOOSTER REPLACED. I AM VERY DISAPPOINTED THAT FORD IS NOT WILLING TO STEP UP AND MAKE RECALL FOR 2007 FORD EDGES WHEN IT IS CLEAR THERE ARE MULTIPLE PEOPLE ALL OVER THE COUNTRY THAT HAVE BEEN AFFECTED BY THIS. I AM THANKFUL I DID NOT GET INTO AN ACCIDENT WITH MY CHILDREN IN THE VEHICLE WITH ME AND AM GOING TO FIX MY VEHICLE BUT THINK IT IS FORD WHO SHOULD BE RECTIFYING THIS SITUATION, NOT MY OWN POCKET!
NHTSA ODI #10747348
180,000 miles · Aug 5, 2015
Service Brakes
THE BRAKE PEDAL WAS TOO HARD TO DEPRESS TO BRAKE SAFELY AND EFFECTIVELY. HAD CAR CHECK OUT AND THE MASTER CYLINDER AND BOOSTER NEED REPLACED. CAR IS OUT OF COMMISSION. QUOTED $1000 FOR FIX.
NHTSA ODI #10746310
90,000 miles · Jul 21, 2015
Electronic Stability Control (esc)Service Brakes
A WHEEL SPEED SENSOR FAILED (PER MY MECHANIC), CAUSING THE ABS AND TRACTION CONTROL SYSTEMS TO MALFUNCTION. IT BECAME EXTREMELY DIFFICULT TO STOP THE CAR, WITH THE BRAKE PEDAL PULSING AND TRAVELING NEARLY TO THE FLOORBOARD. I WAS FINALLY ABLE TO STOP THE CAR JUST BEFORE RUNNING A RED LIGHT BY STANDING ON THE BRAKE PEDAL. THE BRA…
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A WHEEL SPEED SENSOR FAILED (PER MY MECHANIC), CAUSING THE ABS AND TRACTION CONTROL SYSTEMS TO MALFUNCTION. IT BECAME EXTREMELY DIFFICULT TO STOP THE CAR, WITH THE BRAKE PEDAL PULSING AND TRAVELING NEARLY TO THE FLOORBOARD. I WAS FINALLY ABLE TO STOP THE CAR JUST BEFORE RUNNING A RED LIGHT BY STANDING ON THE BRAKE PEDAL. THE BRAKE PADS WERE AT ~50% PER A RECENT STATE INSPECTION. THIS HAPPENED AGAIN IN FEBRUARY 2015 WHEN ANOTHER WHEEL SPEED SENSOR FAILED WITH MY WIFE AND CHILDREN IN THE CAR WITH ME. I WAS ABLE TO TEMPORARILY RESOLVE THE ISSUE BY PULLING THE ABS FUSE TO DISABLE THE ABS SYSTEM. FORD'S R&M ENGINEERS MUST HAVE FORGOTTEN TO PERFORM A FAILURE MODE ANALYSIS ON THE EDGE'S ABS SYSTEM.
NHTSA ODI #10735638
101,991 miles · Apr 30, 2015
Service BrakesSuspension
I KEPT HEARING A STRANGE NOISE WHEN I APPLIED MY BRAKES. WHEN I TOOK THE VEHICLE IN THEIR DIAGNOSIS WAS THAT A PIN WAS BREAKING ON THE FRONT CALIPER ON THE FRONT RIGHT TIRE. THEY REPLACED THE PIN, RIGHT FRONT WHEEL BEARING ASSEMBLY, AND HUB. THEY REPLACED THE FRONT BRAKE PADS AND INSPECTED THE BRAKE SYSTEM. HUB ASSEMBLY WAS "WOB…
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I KEPT HEARING A STRANGE NOISE WHEN I APPLIED MY BRAKES. WHEN I TOOK THE VEHICLE IN THEIR DIAGNOSIS WAS THAT A PIN WAS BREAKING ON THE FRONT CALIPER ON THE FRONT RIGHT TIRE. THEY REPLACED THE PIN, RIGHT FRONT WHEEL BEARING ASSEMBLY, AND HUB. THEY REPLACED THE FRONT BRAKE PADS AND INSPECTED THE BRAKE SYSTEM. HUB ASSEMBLY WAS "WOBBLING" CAUSING THE PINS TO BREAK AND CAUSED MY BRAKE PADS TO RUIN. *TR
NHTSA ODI #10713888
75,000 miles · Mar 17, 2015
Service BrakesSteering
START THE CAR PUSH ON BRAKE AND TRY TO MOVE THE SHIFTER AND NOTHING HAPPENS. AS SOON AS I DO THAT TRACTION LIGHT COMESSAGE ON. STILL WILL NOT COME OUT OF PARK. *TR
NHTSA ODI #10694768
51,000 miles · Sep 5, 2014
Service Brakes
THE BRAKE BOOSTER FAILED AND CAUSED THE VEHICLE TO STOP IN THE MIDDLE OF A BUSY INTERSECTION. I HAD THE BRAKE BOOSTER REPLACED AT 51K MILES. I NOW HAVE 85K MILES ON THE VEHICLE AND AS OF 9/5/14, THE BRAKE BOOSTER HAS FAILED AGAIN. I HAVE CONTACTED FORD AND THEY SAY THEY CANNOT DO ANYTHING ABOUT IT. *TR
NHTSA ODI #10631001
146,000 miles · Sep 4, 2014
Service Brakes
I WAS DRIVING ON A LOCAL HIGHWAY WITH CRUISE CONTROL ON AND A MERGING TRUCK FORCED ME TO TAKE THE CAR OF CRUISE AND THE PEDAL WAS SO HARD I COULDN'T AT FIRST AND IM A 250 LB GUY WAS GLAD MY WIFE WAS NOT DRIVING. SINCE THEN IT HAS BECOME MUCH WORSE AND APPEARS THE BRAKE BOOSTER HAS FAILED. WITH VERY LITTLE RESEARCH THIS LOOKS …
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I WAS DRIVING ON A LOCAL HIGHWAY WITH CRUISE CONTROL ON AND A MERGING TRUCK FORCED ME TO TAKE THE CAR OF CRUISE AND THE PEDAL WAS SO HARD I COULDN'T AT FIRST AND IM A 250 LB GUY WAS GLAD MY WIFE WAS NOT DRIVING. SINCE THEN IT HAS BECOME MUCH WORSE AND APPEARS THE BRAKE BOOSTER HAS FAILED. WITH VERY LITTLE RESEARCH THIS LOOKS LIKE AN ISSUE WITH THIS MODEL YEAR AND SEVERAL OTHERS. I TRAVEL HIGHWAY A LOT SO MY MILEAGE IS HIGHER THAN MOST OF THIS AGE AND MAY ALSO BE WHY IT DIDN'T SHOW EARLIER. THE BOOSTER LOSES PRESSURE FAST ENOUGH TO BE A REAL HAZARD TO DRIVE YOU HAVE TO STAND ON THE PEDAL TO GET YOUR BRAKES TO WORK. I HAVE TAKEN THE CAR OFF THE ROAD TILL I CAN FIX IT CANT AFFORD FORDS REPAIR COSTS 580+ BUT SOME MAY TRY TO DRIVE IT AND THEY WILL GET IN AN ACCIDENT. *TR
NHTSA ODI #10630687
33,920 miles · Sep 2, 2014
Service Brakes
TL* THE CONTACT OWNS A 2007 FORD EDGE. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 40 MPH, THE BRAKE PEDAL WAS DEPRESSED AND THE VEHICLE HESITATED TO STOP. THE CONTACT ALSO STATED THAT THE BRAKE PEDAL REQUIRED EXCESSIVE FORCE IN ORDER TO STOP THE VEHICLE. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE…
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TL* THE CONTACT OWNS A 2007 FORD EDGE. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 40 MPH, THE BRAKE PEDAL WAS DEPRESSED AND THE VEHICLE HESITATED TO STOP. THE CONTACT ALSO STATED THAT THE BRAKE PEDAL REQUIRED EXCESSIVE FORCE IN ORDER TO STOP THE VEHICLE. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE BRAKE BOOSTER NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 33,920.
NHTSA ODI #10630124
Official recalls
5Mar 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.
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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