NHTSA owner reports · September 18, 2026 snapshot.
Service Brakes complaints
77 reportsClear category filter52,741 miles · Jan 12, 2015
Electrical SystemService Brakes
TOOK MY VEHICLE IN EARLY FOR SERVICE AT SUNRISE BECAUSE WAS CONCERNED ABOUT LOUD SCREECHING NOISE ON BRAKES AND ERRATIC BEHAVIOR OF VEHICLE -SURGING. WHEN DRIVING. WHEN THE SERVICE TECH (TROY) OPENED THE HOOD HE ASKED EM TO GET OUT OF THE VEHICLE AND STAND BACK, AS THE TOP OF THE BATTERY WAS SPATTERED WITH BLACK OIL LOOKING MA…
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TOOK MY VEHICLE IN EARLY FOR SERVICE AT SUNRISE BECAUSE WAS CONCERNED ABOUT LOUD SCREECHING NOISE ON BRAKES AND ERRATIC BEHAVIOR OF VEHICLE -SURGING. WHEN DRIVING. WHEN THE SERVICE TECH (TROY) OPENED THE HOOD HE ASKED EM TO GET OUT OF THE VEHICLE AND STAND BACK, AS THE TOP OF THE BATTERY WAS SPATTERED WITH BLACK OIL LOOKING MATERIAL AND APPARENTLY HE AND ANOTHER TECHNICIAN WERE CONCERNED IT MIGHT RUPTURE OR EXPLODE. THEY ASKED EM TO GET OUT OF THE VEHICLE, GIVE THEM THE KEYS AND THAT THEY WOULD CHECK THE VEHICLE AND ASKED ME TO WAIT. ABOUT 90 MINUTES LATER THEY CAME OUT AND SAID ALL WAS FINE, NOTHING WRONG WITH BATTERY OR BRAKES. I LEFT AND DROVE VEHICLE HOME AND SAME PROBLEMS WERE OCCURRING, I RETURNED AND AFTER CALLING AND SAYING SAME THINGS WERE OCCURRING. I HAD HPED TO SPEAK TO [XXX], WHO WAS AN AMAZING SERVICE SUPERVISOR, BUT HE WAS NOT THERE AND ANOTHER MAN WHO WAS RUDE CLAIMED THE BATTERY WAS STILL UNDER WARRANTY BUT THAT IT WAS NORMAL TO HAVE OILY SLUDGE ON THE BATTERY . HE SAID IT WAS "NORMAL, BECAUSE IT WAS JUST SWEATING". HE REFUSED TO DO ANYTHING..SAID THE BRAKES NEEDED TO BE AT 3 BEFORE FORD WOULD REPLACE THEM. I ASKED THAT HE CONTACT FORD CORPORATE AND INQUIRE. HE SAID, "NO HE WOULD NOT" THE BATTERY I SHOULD ADD SINCE I HAVE OWNED THE VEHICLE HAS BEEN REPEATEDLY REPLACED. I HAVE LIMITED DRIVING THE VEHICLE, EXCEPT FOR SHORT LOCAL TRIPS, AND TONIGHT THE VEHICLE WOULD NOT START AND AAA CLAIMED THE BATTERY WAS DEFECTIVE AND CLEARLY DEAD. IT IS MOST DISTURBING WHEN FORD MISREPRESENTS THEIR WARRANTY AND REFUSED TO ACKNOWLEDGE DEFECTS THAT HAVE BEEN PUBLISHED IN THEIR WON ALERTS. SERIOUSLY DANGEROUS! THERE ARE NUMEROUS POSTINGS OF OTHER FORD EDGE OWNERS HAVING THESE PROBLEMS. PLEASE INVESTIGATE THEIR QUESTIONABLE PROTOCOLS ON DANGERS THAT ARE KNOWN WITH THEIR VEHICLES. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #10671713
105,000 miles · Dec 29, 2014
Service Brakes
I WAS DRIVING AND THE BRAKES ARE STIFF AND I COULD NOT STOP. I HAVE NEARLY WRECKED 3 TIMES NOW APPARENTLY DUE TO A FAULTY BRAKE BOOSTER. THIS SEEMS TO BE A KNOWN PROBLEM BUT I DON'T KNOW WHY ONLY THE 2010 TO 2013 MODELS HAVE THE EXTENDED WARRANTY FOR THE BRAKE BOOSTERS. THIS IS RIDICULOUS TO NOT HAVE ANY WARNING MY BRAKES ARE OU…
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I WAS DRIVING AND THE BRAKES ARE STIFF AND I COULD NOT STOP. I HAVE NEARLY WRECKED 3 TIMES NOW APPARENTLY DUE TO A FAULTY BRAKE BOOSTER. THIS SEEMS TO BE A KNOWN PROBLEM BUT I DON'T KNOW WHY ONLY THE 2010 TO 2013 MODELS HAVE THE EXTENDED WARRANTY FOR THE BRAKE BOOSTERS. THIS IS RIDICULOUS TO NOT HAVE ANY WARNING MY BRAKES ARE OUT. ESPECIALLY SINCE FORD IS AWARE OF THE ISSUE. *TR
NHTSA ODI #10668822
105,000 miles · Nov 20, 2014
Service Brakes
POWER BOOSTER LEAKING. SEEMS TO BEA PROBLEM WITH THIS MODEL. *TR
NHTSA ODI #10659900
100,000 miles · Aug 30, 2014
Electrical SystemPower TrainService Brakes
THIS HAS NOW HAPPENED TO ME TWICE WITH BOTH MY SMALL CHILDREN IN THE CAR WHILE ON THE HIGHWAY, AT HIGHWAY SPEEDS. T HE SPEEDOMETER WENT TO 0, THE MAINTENANCE WRENCH DISPLAY LIT UP, ALONG WITH THE ERROR MESSAGE "TIRE PRESSURE MONITOR FAULT" (OR SOMETHING TO THAT EFFECT) AND I WAS UNABLE AFTER STOPPING AT A STOP LIGHT TO ACCELE…
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THIS HAS NOW HAPPENED TO ME TWICE WITH BOTH MY SMALL CHILDREN IN THE CAR WHILE ON THE HIGHWAY, AT HIGHWAY SPEEDS. T HE SPEEDOMETER WENT TO 0, THE MAINTENANCE WRENCH DISPLAY LIT UP, ALONG WITH THE ERROR MESSAGE "TIRE PRESSURE MONITOR FAULT" (OR SOMETHING TO THAT EFFECT) AND I WAS UNABLE AFTER STOPPING AT A STOP LIGHT TO ACCELERATE ALMOST CAUSING THE PERSON BEHIND ME TO REAR END ME. ONCE GETTING TO MY HOME WHEN PUTTING THE CAR INTO PARK IT MAKES A LOUD CLUNKING NOISE THEN PROCEEDS TO JERK THE ENTIRE VEHICLE. AFTER LETTING THE CAR SIT FOR AN HOUR I TRIED TO TURN IT ONE ONCE AGAIN AND TEST DRIVING A FEW FEET FORWARD, IT ONLY MOVED AT A SLOW PACE WHEN GAS PEDAL APPLIED. *TR
NHTSA ODI #10629650
93,000 miles · Aug 7, 2014
Service Brakes
THE BRAKE BOOSTER FAILED MAKING THE VEHICLE VERY SLOW TO RESPOND TO STOPPING. HAD THE NEED FOR A EMERGENCY STOP OCCURRED THERE WOULD HAVE BEEN AN ACCIDENT. I AM TOLD BY THE MECHANIC THAT REPAIRED THE VEHICLE THAT THIS PART RARELY FAILS AND NOT IN A VEHICLE WITH SO FEW MILES RELATIVE TO THE PART. *TR
NHTSA ODI #10620660
75,000 miles · Jul 17, 2014
Service Brakes
TL* THE CONTACT OWNS A 2008 FORD EDGE. THE CONTACT STATED THAT WHILE REVERSING, THE BRAKES FAILED TO ENGAGE AND THE EMERGENCY BRAKE HAD TO BE ENGAGED TO STOP THE VEHICLE. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE BRAKE POWER BOOSTER NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS…
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TL* THE CONTACT OWNS A 2008 FORD EDGE. THE CONTACT STATED THAT WHILE REVERSING, THE BRAKES FAILED TO ENGAGE AND THE EMERGENCY BRAKE HAD TO BE ENGAGED TO STOP THE VEHICLE. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE BRAKE POWER BOOSTER NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE AND CURRENT MILEAGE WAS 75,000.
NHTSA ODI #10611259
Mileage unknown · Jun 3, 2014
Electrical SystemExterior LightingService Brakes
I HAVE A 2008 FORD EDGE SEL. WHEN TURNING ON MY LEFT BLINKER IT WAS BLINKING RAPIDLY WHICH I KNEW INDICATED A LIGHT WAS OUT. I FOUND THAT IT WAS MY DRIVER SIDE REAR BLINKER/TAIL LIGHT. I WENT TO THE STORE AND PURCHASED THE BULB. WHEN I GOT HOME TO REPLACE IT I FOUND THAT I COULD NOT REMOVE THE BULB AS THE SOCKET HAS MELTED. I…
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I HAVE A 2008 FORD EDGE SEL. WHEN TURNING ON MY LEFT BLINKER IT WAS BLINKING RAPIDLY WHICH I KNEW INDICATED A LIGHT WAS OUT. I FOUND THAT IT WAS MY DRIVER SIDE REAR BLINKER/TAIL LIGHT. I WENT TO THE STORE AND PURCHASED THE BULB. WHEN I GOT HOME TO REPLACE IT I FOUND THAT I COULD NOT REMOVE THE BULB AS THE SOCKET HAS MELTED. I SEARCHED ONLINE AND FOUND THAT THIS IS COMMON FOR THIS TYPE OF VEHICLE. *TR
NHTSA ODI #10595742
63,998 miles · May 26, 2014
Service Brakes
AFTER NEARLY 6 YEARS I THOUGHT I WOULD CHANGE THE BRAKES.WIFE WAS HEARING A GRINDING NOISE. I THOUGHT WE WERE WE'LL OVERDO ON THEM ANYWAYS. WHEN I WENT TO CHANGE THEM I WAS INSPECTING THEM AND FOUND THE PASSENGER SIDE PADS WERE BARELY WORN THEY LOOKED ALMOST NEW. THE DRIVER SIDE OUTER PAD LOOKED THE SAME PRACTICALLY NEW THE INNE…
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AFTER NEARLY 6 YEARS I THOUGHT I WOULD CHANGE THE BRAKES.WIFE WAS HEARING A GRINDING NOISE. I THOUGHT WE WERE WE'LL OVERDO ON THEM ANYWAYS. WHEN I WENT TO CHANGE THEM I WAS INSPECTING THEM AND FOUND THE PASSENGER SIDE PADS WERE BARELY WORN THEY LOOKED ALMOST NEW. THE DRIVER SIDE OUTER PAD LOOKED THE SAME PRACTICALLY NEW THE INNER PAD ON THE DRIVERS SIDE WAS WORN DOWN TO ABOUT 1/16 TO THE END OF THE PAD I FEEL THIS WARRANTS SOME KIND OF ACTION ON BEHALF OF FORD THANKS. *TR
NHTSA ODI #10594091
130,000 miles · Apr 18, 2014
Exterior LightingService Brakes
THE REAR TAIL LIGHT SOCKETS FOR THE TAIL/BRAKE LIGHT LAMPS ARE BADLY BURNED ON BOTH SIDES. WE NOTICED THE PROBLEM WHEN WE CHANGED THE TAIL LIGHT HOUSING DUE TO WATER VAPOR BUILD UP. ONLY THE RIGHT SIDE HAD THE VISIBLE WATER VAPOR. BOTH SIDES HAD THE BURNED LAMP SOCKETS. THE CAR WAS PURCHASED USED. *TR
NHTSA ODI #10583513
60,000 miles · Mar 20, 2014
Service Brakes
BRAKES FADE, BECOME MUSHY, PEDAL GOES TO THE FLOOR. DOES NOT STOP AT LIGHTS SOMETIMES CAUSING ME TO PUT IN PARK WHILE MOVING. *TR
NHTSA ODI #10573852
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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