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2005 Ford Escape

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2005 Ford Escape do not stand out strongly from the model-year median of 996.

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When problems were reported

Mileage at the reported incident

1,211 reports with mileage · 183 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Suspension. Review the 459 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Structure. Review the 434 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 153 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

40 crash reports20 fire reports20 injury reports

Suspension complaints

459 reports
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120,000 miles · Feb 10, 2014
Suspension

THIS IS FOR A FORD 2005 ESCAPE. THE SUV'S PASSENGER REAR SHOCK WHERE ATTACHED TO THE WHEEL WELL IS RUSTED. THE WHEEL WELL IS RUSTED OUT AROUND THE THE AREA THAT THE SHOCK ATTACHES TO. IN READING THE FORD FORUM, THERE ARE A LOT OF COMPLAINTS ON THIS YEAR FORD ESCAPE. I HAVE ALSO CONTACTED FORD ON THIS AND THEY DO NOT SEE ANY ISSU…

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THIS IS FOR A FORD 2005 ESCAPE. THE SUV'S PASSENGER REAR SHOCK WHERE ATTACHED TO THE WHEEL WELL IS RUSTED. THE WHEEL WELL IS RUSTED OUT AROUND THE THE AREA THAT THE SHOCK ATTACHES TO. IN READING THE FORD FORUM, THERE ARE A LOT OF COMPLAINTS ON THIS YEAR FORD ESCAPE. I HAVE ALSO CONTACTED FORD ON THIS AND THEY DO NOT SEE ANY ISSUES. *TR

NHTSA ODI #10563743

160,000 miles · Feb 8, 2014
StructureSuspension

I HAD BEEN HEARING RATTLING FROM THE REAR PASSENGER SIDE FOR ABOUT 3 WEEKS. ON AROUND JANUARY 28TH I WAS DRIVING HOME FROM WORK AND HEARD A LOUD NOISE. I LATER DISCOVERED A LARGE CRACK AND HOLE ON THE INSIDE PASSENGER PANEL. AFTER FURTHER INSPECTION I DISCOVERED THE PASSENGER SIDE REAR WHEEL WELL HAD A WHOLE SECTION MISSING AND …

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I HAD BEEN HEARING RATTLING FROM THE REAR PASSENGER SIDE FOR ABOUT 3 WEEKS. ON AROUND JANUARY 28TH I WAS DRIVING HOME FROM WORK AND HEARD A LOUD NOISE. I LATER DISCOVERED A LARGE CRACK AND HOLE ON THE INSIDE PASSENGER PANEL. AFTER FURTHER INSPECTION I DISCOVERED THE PASSENGER SIDE REAR WHEEL WELL HAD A WHOLE SECTION MISSING AND THE SHOCK I CAN MOVE WITH MY HAND. AFTER DOING SOME RESEARCH ONLINE I HAVE DISCOVERED THAT SEVERAL 2004/2005 ESCAPES HAVE HAD THE SAME ISSUE. THIS IS CLEARLY A DEFECT. IT NEEDS TO BE ADDRESSED AND A RECALL NEEDS TO BE DONE. *TR

NHTSA ODI #10563469

160,000 miles · Feb 7, 2014
Suspension

THE PASSENGER SIDE REAR PANEL WHEN THE SHOCK ATTACHES TO THE UNDER PART HAS COMPLETELY RUSHED AWAY. WE WERE TOLD THAT THERE IS OVER THOUSANDS OF VEHICLE THAT HAVE BEEN AFFECTED. WE TOOK THE VEHICLE TO THE FORD COLLISION SHOP AND WAS TOLD THAT THEY HAVE NOT EVEN STARTED TO DO ANYTHING ABOUT THIS, HE STARTED THAT HE HAS SEEN SEVE…

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THE PASSENGER SIDE REAR PANEL WHEN THE SHOCK ATTACHES TO THE UNDER PART HAS COMPLETELY RUSHED AWAY. WE WERE TOLD THAT THERE IS OVER THOUSANDS OF VEHICLE THAT HAVE BEEN AFFECTED. WE TOOK THE VEHICLE TO THE FORD COLLISION SHOP AND WAS TOLD THAT THEY HAVE NOT EVEN STARTED TO DO ANYTHING ABOUT THIS, HE STARTED THAT HE HAS SEEN SEVERAL VEHICLE COME INTO THE SHOP THAT ARE FORD ESCAPE THAT THE WHOLE BACK UNDER SUSPENSION HAS COMPLETELY RUSHED OUT. *TR

NHTSA ODI #10563441

77,000 miles · Feb 7, 2014
Suspension

TL* THE CONTACT OWNS A 2005 FORD ESCAPE. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 35 MPH, A SUDDEN BANGING NOISE WAS HEARD FROM THE REAR OF THE VEHICLE. THE CONTACT DISCOVERED THAT THE REAR PASSENGER'S SIDE WHEEL HOUSING PANEL WAS RUSTED AND CAUSED THE SHOCK ABSORBER TO BECOME DETACHED FROM THE VEHICLE. THE CONTACT IN…

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TL* THE CONTACT OWNS A 2005 FORD ESCAPE. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 35 MPH, A SUDDEN BANGING NOISE WAS HEARD FROM THE REAR OF THE VEHICLE. THE CONTACT DISCOVERED THAT THE REAR PASSENGER'S SIDE WHEEL HOUSING PANEL WAS RUSTED AND CAUSED THE SHOCK ABSORBER TO BECOME DETACHED FROM THE VEHICLE. THE CONTACT INDICATED THAT THE VEHICLE WAS DIAGNOSED BY THE DEALER BUT NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED AND NO SOLUTION WAS OFFERED. THE FAILURE MILEAGE WAS 77,000. UUPDATED 07/08/14 MA

NHTSA ODI #10563431

115,000 miles · Feb 7, 2014
Suspension

LIKE MANY OTHERS, THE REAR PASSENGER WHEEL WELL IS RUSTED OUT SO SIGNIFICANTLY THAT THE STRUT MOUNT IS ALMOST COMPLETELY DETACHED. THIS IS VERY UNSAFE AND DIFFICULT TO DETECT UNTIL IT'S TOO LATE. IT'S OBVIOUS FROM SPEAKING WITH BODY SHOPS AND FORD REPS THAT THIS IS A WELL KNOWN ISSUE. I CAN'T REITERATE ENOUGH THAT THIS IS DANGER…

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LIKE MANY OTHERS, THE REAR PASSENGER WHEEL WELL IS RUSTED OUT SO SIGNIFICANTLY THAT THE STRUT MOUNT IS ALMOST COMPLETELY DETACHED. THIS IS VERY UNSAFE AND DIFFICULT TO DETECT UNTIL IT'S TOO LATE. IT'S OBVIOUS FROM SPEAKING WITH BODY SHOPS AND FORD REPS THAT THIS IS A WELL KNOWN ISSUE. I CAN'T REITERATE ENOUGH THAT THIS IS DANGEROUS BECAUSE OF 1) THE SUSPENSION CAN COLLAPSE ONTO THE TIRE AND 2) IT'S DIFFICULT TO IDENTIFY UNTIL THE STRUT MOUNT COLLAPSES. *TR

NHTSA ODI #10563392

128,000 miles · Feb 6, 2014
StructureSuspension

THIS IS A 2005 FORD ESCAPE WITH THE SAME PROBLEM REPORTED BY HUNDREDS OF OTHER PEOPLE ON FACEBOOK, FORD FORUMS, THIS AGENCIES OWN WEBSITE ETC. THE REAR RIGHT INNER WHEEL WELL HAS TOTALLY DISINTEGRATED LEAVING THE TOP OF THE SHOCK ABSORBER UNCONNECTED TO ANYTHING. FORD HAVE NOT CARRIED OUT A RECALL FOR THIS DANGEROUS SITUATION TH…

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THIS IS A 2005 FORD ESCAPE WITH THE SAME PROBLEM REPORTED BY HUNDREDS OF OTHER PEOPLE ON FACEBOOK, FORD FORUMS, THIS AGENCIES OWN WEBSITE ETC. THE REAR RIGHT INNER WHEEL WELL HAS TOTALLY DISINTEGRATED LEAVING THE TOP OF THE SHOCK ABSORBER UNCONNECTED TO ANYTHING. FORD HAVE NOT CARRIED OUT A RECALL FOR THIS DANGEROUS SITUATION THOUGH APPARENTLY THE PARTS INVOLVED WERE MODIFIED ON NEWER VEHICLES TO PREVENT THIS HAPPENING. THE PROBLEM APPEARS WORSE IN NORTHERN STATES WITH BAD WINTERS WHERE SALTY WATER BECOMES TRAPPED INSIDE THE WATERPROOFING SEALANT AND THE WHEEL WELL ACCELERATING THE RUSTING PROCESS. UPDATED 04/16/14

NHTSA ODI #10563223

158,000 miles · Feb 3, 2014
StructureSuspension

I AM HERE TO WRITE AN INCIDENT ABOUT MY MY RIGHT REAR SUSPENSION BREAKING AWAY FROM THE STRUT TOWER SUPPORT BRACKET. IT WAS ALL RUSTED OUT. THE LEFT SIDE OF THE CAR IS FINE. I HAVE SEEN QUITE A LOT OF THESE SAME PROBLEMS ON THE INTERNET. WHEN WE TOOK OUR CAR IN TO THE FORD DEALERSHIP THEY CALLED IT A CATASTROPHIC FAILURE. CAR W…

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I AM HERE TO WRITE AN INCIDENT ABOUT MY MY RIGHT REAR SUSPENSION BREAKING AWAY FROM THE STRUT TOWER SUPPORT BRACKET. IT WAS ALL RUSTED OUT. THE LEFT SIDE OF THE CAR IS FINE. I HAVE SEEN QUITE A LOT OF THESE SAME PROBLEMS ON THE INTERNET. WHEN WE TOOK OUR CAR IN TO THE FORD DEALERSHIP THEY CALLED IT A CATASTROPHIC FAILURE. CAR WAS UNSAFE TOO DRIVE. WE FEEL THIS IS A SAFETY CONCERN FOR OWNERS OF THIS VEHICLE AND, THE PUBLIC. *TR

NHTSA ODI #10562770

132,000 miles · Feb 3, 2014
SuspensionWheels

TL* THE CONTACT OWNS A 2005 FORD ESCAPE. THE CONTACT STATED THAT WHILE DRIVING 35 MPH, A LOUD NOISE EMITTED FROM THE REAR OF THE VEHICLE. THE VEHICLE WAS TAKEN TO A LOCAL MECHANIC, WHO ADVISED THAT THE REAR PASSENGER SIDE WHEEL WAS CORRODED. AS A RESULT, THE HOUSING AND REAR SHOCKS WERE CORRODED AND SEPARATED FROM THE WHEEL. THE…

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TL* THE CONTACT OWNS A 2005 FORD ESCAPE. THE CONTACT STATED THAT WHILE DRIVING 35 MPH, A LOUD NOISE EMITTED FROM THE REAR OF THE VEHICLE. THE VEHICLE WAS TAKEN TO A LOCAL MECHANIC, WHO ADVISED THAT THE REAR PASSENGER SIDE WHEEL WAS CORRODED. AS A RESULT, THE HOUSING AND REAR SHOCKS WERE CORRODED AND SEPARATED FROM THE WHEEL. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE AND CURRENT MILEAGE WAS 132,000.

NHTSA ODI #10562742

87,000 miles · Jan 30, 2014
StructureSuspension

I OWN A 2005 FORD ESCAPE 87,00 MILES, GARAGE KEPT. I BOUGHT IT NEW FROM THE FORD DEALER. SO I HEAR A LOUD BANGING NOISE AND TAKE IT INTO A SHOP TO GET CHECKED OUT. SHOP CALLS ME IN AWE? HE SAID THAT RIGHT SIDE INTER FENDER WHEEL WELL AND SHOCK TOWER HAS COMPLETELY RUSTED AWAY AND IS NO LONGER CONNECTED TO THE VEHICLE?HE ALSO S…

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I OWN A 2005 FORD ESCAPE 87,00 MILES, GARAGE KEPT. I BOUGHT IT NEW FROM THE FORD DEALER. SO I HEAR A LOUD BANGING NOISE AND TAKE IT INTO A SHOP TO GET CHECKED OUT. SHOP CALLS ME IN AWE? HE SAID THAT RIGHT SIDE INTER FENDER WHEEL WELL AND SHOCK TOWER HAS COMPLETELY RUSTED AWAY AND IS NO LONGER CONNECTED TO THE VEHICLE?HE ALSO SAID YOU CAN SEE TO THE INSIDE OF THE VEHICLE. HE SAID IN ALL HIS YEARS, HES NEVER SEEN ANYTHING LIKE IT. HE SAID THAT A 1990 CAR SHOULD NOT HAVE THIS DAMAGE. SO I START TO GOOGLE AND LOW AND BEHOLD HUNDREDS OF COMPLAINTS OF THE SAME THING. IT SEEMS TO BE A MAJOR ISSUE WITH 2004, 2005 AND SOME 2006 FORD ESCAPE MODELS AND FORD WILL NOT RECALL OR MAKE GOOD ON THEIR POOR CRAFTSMANSHIP. I CONTACTED THE DEALER WHERE I BOUGHT MY VEHICLE AND SPOKE TO A REPAIR MANAGER WHO SAID HE WILL CALL ME BACK?SO AFTER A FEW HOURS (HE GOOGLED HIMSELF), HE CALLS AND SAYS TOUGH LUCK?HAVE A NICE DAY. THERE ARE ALL KINDS OF PICTURES ON THE NET THAT LOOK LIKE MY CAR?.I TOOK MY OWN PICTURES BUT THIS IS APPALLING AND FORD NEEDS TO BE HELP ACCOUNTABLE. THIS IS A STRUCTURE PROBLEM AND VERY DANGEROUS. I WILL PROBABLY HAVE A HARD TIME FINDING SOMEONE TO EVEN ATTEMPT TO REPAIR THIS AS THE DON'T WANT THE LIABILITY (ESPECIALLY SEEING I HAVE 2 CAR SEATS IN MY VEHICLE.) *TR

NHTSA ODI #10562158

115,000 miles · Jan 29, 2014
Suspension

TL* THE CONTACT OWNS A 2005 FORD ESCAPE. THE CONTACT STATED THE REAR FENDER WHEEL WELL EXHIBITED EXCESSIVE RUST. THE CONTACT TOOK THE VEHICLE TO LOCAL MECHANIC, WHO STATED THAT THE VEHICLE WAS NOT SAFE TO DRIVE DUE TO THE REAR WHEEL NOT BEING SECURED AND COULD BECOME DETACHED FROM THE VEHICLE WHILE DRIVING. THE FAILURE MILEAGE W…

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TL* THE CONTACT OWNS A 2005 FORD ESCAPE. THE CONTACT STATED THE REAR FENDER WHEEL WELL EXHIBITED EXCESSIVE RUST. THE CONTACT TOOK THE VEHICLE TO LOCAL MECHANIC, WHO STATED THAT THE VEHICLE WAS NOT SAFE TO DRIVE DUE TO THE REAR WHEEL NOT BEING SECURED AND COULD BECOME DETACHED FROM THE VEHICLE WHILE DRIVING. THE FAILURE MILEAGE WAS 115,000.

NHTSA ODI #10562119

Official recalls

4

15V606000 · Power Train:automatic Transmission:gear Position Indication (prndl); Power Train:automatic Transmission:lever And Linkage:floor Shift

Sep 29, 2015

Ford Motor Company (Ford) is recalling certain model year 2001-2008 Ford Escape and Mercury Mariner vehicles manufactured March 31, 2001, to September 1, 2009. The affected vehicles are equipped with either a 2.3L or 3.0L engine and have had their CD4E transmission replaced with remanufactured one that was rebuilt between June 11, 2015 through July 15, 2015. These service repair part transmissions have a shift lever bolt that may not be properly tightened. As a result, the shift control lever could disengage from the transmission without warning.

Consequence & remedy

Consequence: If the shift lever disengages from the transmission, a driver may be unable to shift gear positions and the indicated shift position may not represent the gear position the vehicle is in. Should a disengagement occur while the vehicle is being driven, when the driver goes to stop and park the vehicle, the gear selection indicator may show that the transmission is in the "PARK" position, but the vehicle transmission may not actually be in the "PARK" gear position. If the vehicle is not in the "PARK" position there is a risk the vehicle will roll away as the driver and other occupants exit the vehicle or anytime thereafter. A vehicle rollaway increases the risk of injury to exiting occupants and bystanders.

Remedy: Ford will notify owners, and dealers will inspect the transmissions and either tighten the manual shift lever bolt or replace the manual shift lever assembly. These repairs will be performed free of charge. The recall began on October 23, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S28.

Additional source detail variants (2)

Power Train:automatic Transmission:lever And Linkage:floor Shift

Ford Motor Company (Ford) is recalling certain model year 2001-2008 Ford Escape and Mercury Mariner vehicles manufactured March 31, 2001, to September 1, 2009. The affected vehicles are equipped with either a 2.3L or 3.0L engine and have had their CD4E transmission replaced with remanufactured one that was rebuilt between June 11, 2015 through July 15, 2015. These service repair part transmissions have a shift lever bolt that may not be properly tightened. As a result, the shift control lever could disengage from the transmission without warning.

Consequence: If the shift lever disengages from the transmission, a driver may be unable to shift gear positions and the indicated shift position may not represent the gear position the vehicle is in. Should a disengagement occur while the vehicle is being driven, when the driver goes to stop and park the vehicle, the gear selection indicator may show that the transmission is in the "PARK" position, but the vehicle transmission may not actually be in the "PARK" gear position. If the vehicle is not in the "PARK" position there is a risk the vehicle will roll away as the driver and other occupants exit the vehicle or anytime thereafter. A vehicle rollaway increases the risk of injury to exiting occupants and bystanders.

Remedy: Ford will notify owners, and dealers will inspect the transmissions and either tighten the manual shift lever bolt or replace the manual shift lever assembly. These repairs will be performed free of charge. The recall began on October 23, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S28.

Power Train:automatic Transmission:gear Position Indication (prndl)

Ford Motor Company (Ford) is recalling certain model year 2001-2008 Ford Escape and Mercury Mariner vehicles manufactured March 31, 2001, to September 1, 2009. The affected vehicles are equipped with either a 2.3L or 3.0L engine and have had their CD4E transmission replaced with remanufactured one that was rebuilt between June 11, 2015 through July 15, 2015. These service repair part transmissions have a shift lever bolt that may not be properly tightened. As a result, the shift control lever could disengage from the transmission without warning.

Consequence: If the shift lever disengages from the transmission, a driver may be unable to shift gear positions and the indicated shift position may not represent the gear position the vehicle is in. Should a disengagement occur while the vehicle is being driven, when the driver goes to stop and park the vehicle, the gear selection indicator may show that the transmission is in the "PARK" position, but the vehicle transmission may not actually be in the "PARK" gear position. If the vehicle is not in the "PARK" position there is a risk the vehicle will roll away as the driver and other occupants exit the vehicle or anytime thereafter. A vehicle rollaway increases the risk of injury to exiting occupants and bystanders.

Remedy: Ford will notify owners, and dealers will inspect the transmissions and either tighten the manual shift lever bolt or replace the manual shift lever assembly. These repairs will be performed free of charge. The recall began on October 23, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S28.

14V526000 · Hybrid Propulsion System

Sep 3, 2014

Ford Motor Company (Ford) is recalling certain model year 2005-2008 Ford Escape hybrid electric vehicles manufactured October 13, 2003, to June 20, 2008, and 2006-2008 Mercury Mariner hybrid electric vehicles manufactured June 10, 2005, to June 20, 2008. The coolant pump for the hybrid system may fail resulting in the hybrid electronics overheating.

Consequence & remedy

Consequence: If the hybrid electronics system overheats, it may shut down the powertrain, resulting in a stall-like condition, increasing the risk of a crash.

Remedy: Ford will notify owners, and dealers will inspect and replace the original Motor Electronics Coolant (MEC) Pump with an improved brushless pump, free of charge. The recall is expected to begin on October 27, 2014. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 14S19.

06V111000 · Seats:front Assembly:head Restraint

Apr 7, 2006

CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITHOUT SIDE AIR CURTAINS OR MOONROOFS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 201, "OCCUPANT PROTECTION IN INTERIOR IMPACT." DURING TESTING, THE FREE MOTION HEAD FORM REGISTERED A MEASUREMENT ABOVE THE PERMITTED LIMIT AT THE LEFT HAND A-PILLAR TRIM AREA.

Consequence & remedy

Consequence: IN THE EVENT OF A VEHICLE CRASH, PERSONAL INJURY TO OCCUPANTS MAY OCCUR.

Remedy: DEALERS WILL MAKE MODIFICATIONS TO THE ENERGY ABSORBING MATERIAL LOCATED ABOVE THE HEADLINER IN THE AFFECTED AREA FREE OF CHARGE. THE RECALL BEGAN ON MAY 19, 2006. OWNERS MAY CONTACT FORD AT 1-800-392-3673.

04V602000 · Latches/locks/linkages:doors:latch

Dec 20, 2004

CERTAIN 2004-2005 SPORT UTILITY VEHICLES AND CERTAIN 2001-2003 SPORT UTIITY VEHICLE HAVING REAR LIFTGATE COMPONENTS SERVICED WITH 2004 EQUIVALENT COMPONENTS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 206, 'DOOR LOCKS AND DOOR RETENTION COMPONENTS.' THE REAR LIFTGATE LATCHING SYSTEM DOES NOT MEET THE INERTIA LOAD REQUIREMENT IN ONE DIRECTION.

Consequence & remedy

Consequence: IF THE LIFTGATE IS LEFT UNLOCKED, THERE IS THE POTENTIAL THAT IT MAY OPEN DURING A CRASH.

Remedy: DEALERS WILL REPLACE THE REAR LIFTGATE LATCH RELEASE ROD, THE RELEASE ROD ATTACHMENT CLIP AND THE DOOR HANDLE RETURN SPRING. THE RECALL BEGAN ON MARCH 31, 2005. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

2

DP12006 · Electronic Throttle Body Malfunction

Opened Oct 2, 2012 · Closed Feb 21, 2013

Status: closed (inferred from source dates) · Engine

In a letter dated August 30, 2012, The North Carolina Consumers Council (NCCC) petitioned the National Highway Traffic Safety Administration (NHTSA) to initiate a defect investigation of alleged electronic throttle body failures resulting in engine stall or surge while driving in model year (MY) 2005 through 2012 Ford Escape vehicles. On October 2, 2012 the Office of Defects Investigation (ODI) opened a Defect Petition DP12-006 to evaluate whether to grant or deny the petition. The petition is hereby granted on certain model years. The NCCC letter cites two complaints of stall while driving in MY 2009 Ford Escape vehicles that were diagnosed as failed throttle bodies with diagnostic trouble codes (DTC) P2111, Throttle Body Stuck Open, and P2112, Throttle Body Stuck Closed. The petitioner indicates that the owners of both vehicles reported experiencing repeated incidents of stalling and engine surging. According to Ford, Escape non-hybrid vehicles are equipped with Electronic Throttle Body (ETB) assemblies beginning with MY 2009. Vehicles manufactured between June 22, 2009 and October 15, 2009 may contain contaminated printed circuit boards (PCB) with plating variations. Plating variations could lead to a lack of continuity in the throttle position sensor circuit where P2111 and/or other DTCs would be generated and stored. Ford and its electronic throttle body supplier, Delphi, modified the PCB manufacturing process and issued a technical service bulletin (TSB) 09-23-5. Vehicles produced after October 15, 2009 incorporated ETBs manufactured with a PCB process that resolved this condition. ODI's analysis identified a total of 123 unique reports indicating allegations of reduced motive power or vehicle stall. Depending on the condition of throttle control system malfunction, a driver may experience varying levels of reduced engine performance associated with three limp home modes. In two limp modes, reduced engine performance may maintain vehicle speeds above 20mph while the third is a limited limp home mode with engine speeds limited to approximately 900 RPM. Allegations of stall appear to be related to the limited limp home mode. Vehicles are not likely to unexpectedly stall as a result of this condition, but drivers may characterize the reduced functionality as a stall, even though their vehicle may still has motive capability. Allegations of vehicle surge appear to be related to limp home mode operation. Complaints alleging surge are most likely related to engine RPM fluctuations at low vehicle speeds or idle as the control system engages to prevent engine stall. In limited limp mode, rough-idle conditions may exist while the control system attempts to modulate engine RPMs once the vehicle reaches a reduced speed to maintain approximately 900 RPM. Separately, ODI received 59 complaints alleging incidents of engine stall while driving in model year (MY) 2010-2011 Ford Fusion vehicles. Approximately 60 percent (36) of the incidents occurred at speeds of 40 miles per hour or more. Eighty percent of complaints (47) were received beginning March 2012 and 14 complaints reported that the throttle body was replaced or DTCs associated with limp home modes. Additionally, Ford issued TSB 10-21-6 addressing DTCs associated with idle speed drops and limited limp home mode. The petition is granted on certain model years.Preliminary Evaluation PE13-003 has been opened to assess the scope, frequency and potential safety consequences associated with the alleged defect.See full copy of the closing resume for this defect petition for list of the VOQs associated with the defect petition analysis.

AQ10001 · Fleet Vehicle Recall Completion Audit

Opened Nov 18, 2010 · Closed Dec 28, 2015

Status: closed (inferred from source dates) · Unknown Or Other

On November 18, 2010, NHTSA's Recall Management Division (RMD) opened an audit query (AQ10-001) to investigate recall remedy completion by rental car companies on safety recall campaigns.It was expected to provide the agency an indication of how completely and how quickly rental car fleets perform necessary recall-related remedies on the vehicles owned and then rented/leased for use on the roadways.RMD queried three (3) major motor vehicle manufacturers (Ford, Chrysler, and General Motors) and requested data regarding completion figures for fifteen (15) discreet safety recalls.Analysis of this data demonstrated that rental car recalls completion was neither complete nor consistent.The rental car companies representing the largest market share in the industry were then queried as to their respective policies for the rental, lease, and sale of vehicles with open recalls.The data and responses from the manufacturers and the rental car companies can be found in the document repository by accessing the ?Associated Documents link above.In December 2015, Congress enacted the Fixing America's Surface Transportation (FAST) Act.One section of the Act prohibits rental car companies from renting, leasing, or selling motor vehicles subject to open safety recalls.With the passage of the FAST Act and its prohibition, there is no continuing need for the agency to investigate rental car recall completions.Accordingly, this investigation is closed.The agency reserves the right to open any future investigations, including audits of individual recalls, or groups of recalls, or rental car companies, to examine more closely safety recalls performance and completion issues in this area.

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