2008 FORD F450 6.4L TURBO DIESEL PROBLEMS MY WIFE TRUCK BROKE DOWN ON HER WITH 137000 MILES ON IT COMING BACK FROM SOUTH CAROLINA IN JULY 2016. MECHANICS FOUND METAL SHAVING IN THE OIL FILTER HOUSING. LONG STORY SHORT, HAD TO HAVE THE LONG BLOCK REPLACED ON THE TRUCK. 15,000 DOLLARS TO FIX THIS ISSUE. APPEARS WE ARE NOT…
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2008 FORD F450 6.4L TURBO DIESEL PROBLEMS MY WIFE TRUCK BROKE DOWN ON HER WITH 137000 MILES ON IT COMING BACK FROM SOUTH CAROLINA IN JULY 2016. MECHANICS FOUND METAL SHAVING IN THE OIL FILTER HOUSING. LONG STORY SHORT, HAD TO HAVE THE LONG BLOCK REPLACED ON THE TRUCK. 15,000 DOLLARS TO FIX THIS ISSUE. APPEARS WE ARE NOT THE ONLY ONES WHO ARE HAVING THIS ISSUE. THREE MORE PEOPLE WE KNOW WHO JUST BOUGHT 2008 FORD F450 SD 6.4L TRUCKS HAVE HAD THE SAME ISSUE. ONE FAMILIES TRUCK BROKE DOWN ON THEM THREE WEEKS AFTER BUYING IT ON THERE WAY HOME FROM A HORSE SHOW. SAME THING HAPPEN TO THE OTHER FAMILY. COMMON FACTOR IN ALL THREE STORIES...METAL SHAVINGS IN OIL FILTER HOUSING. NONE OF THE TRUCKS WERE LOW ON FLUID. APPEARS 6.4L ENGINES HAVING THE SAME ISSUES AS 6.0L ENGINES. INVESTIGATION NEEDS TO BE DONE ON 6.4L ISSUES AND HOLD FORD ACCOUNTABLE TO REPAIR THESE ENGINES OR REFUND THE MONEY THAT WAS SPENT TO FIX THESE ENGINES IF REPAIR HAS ALREADY BEEN DONE. *TR
NHTSA ODI #10916771
37,062 miles · Jan 27, 2016
EngineFuel/propulsion SystemVehicle Speed Control
I WAS TRAVELING DOWN A TWO LANE ROAD IN MY 2008 F250 PICKUP (DIESEL) ON 26 JAN 2016 ABOUT 35 MPH, AND CAME UPON A STOP SIGN. I RELEASED THE GAS PEDAL AND STARTED BRAKING. THE ENGINE STARTED ACCELERATING, EVEN THOUGH I WAS APPLYING THE BRAKES. THE VEHICLE WAS IN FOUR WHEEL DRIVE (HIGH), SO ALL FOUR TIRES WERE SPINNING FAST, AND K…
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I WAS TRAVELING DOWN A TWO LANE ROAD IN MY 2008 F250 PICKUP (DIESEL) ON 26 JAN 2016 ABOUT 35 MPH, AND CAME UPON A STOP SIGN. I RELEASED THE GAS PEDAL AND STARTED BRAKING. THE ENGINE STARTED ACCELERATING, EVEN THOUGH I WAS APPLYING THE BRAKES. THE VEHICLE WAS IN FOUR WHEEL DRIVE (HIGH), SO ALL FOUR TIRES WERE SPINNING FAST, AND KEPT THE VEHICLE MOVING FORWARD. I STOOD ON THE BRAKE PEDAL WITH BOTH FEET, AND AFTER GOING SEVERAL FEET INTO THE INTERSECTION, IT FINALLY STOPPED. I QUICKLY SHIFTED INTO NEUTRAL, AND A FEW SECONDS LATER THE PROBLEM STOPPED. I THEN CONTINUED ON MY WAY. THE VEHICLE HAD 37,062 MILES.
NHTSA ODI #10822683
65,477 miles · Jul 2, 2015
Electrical SystemEngine
DURING THE COURSE OF DRIVING DOWN THE ROAD THE ENGINE SHUT OFF AND THE TRUCK LOST ALL POWER. REQUIRED STEERING OFF THE HIGHWAY AND STOPPING WITH THE LOSS OF ALL POWER STEERING AND BRAKE ASSIST. IN TRAFFIC. TRUCK WOULD NOT RESTART ONCE WAS PULLED OFF ONTO SIDE OF HIGHWAY. IF TRUCK HAD BEEN TOWING DOWN A STEEP GRADE IT WOULD HA…
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DURING THE COURSE OF DRIVING DOWN THE ROAD THE ENGINE SHUT OFF AND THE TRUCK LOST ALL POWER. REQUIRED STEERING OFF THE HIGHWAY AND STOPPING WITH THE LOSS OF ALL POWER STEERING AND BRAKE ASSIST. IN TRAFFIC. TRUCK WOULD NOT RESTART ONCE WAS PULLED OFF ONTO SIDE OF HIGHWAY. IF TRUCK HAD BEEN TOWING DOWN A STEEP GRADE IT WOULD HAVE BEEN IMPOSSIBLE TO STOP. UPON HAVING TRUCK REPAIRED IT WAS DIAGNOSED AS A BAD EXHAUST GAS TEMPERATURE SENSOR.
NHTSA ODI #10731783
79,000 miles · Mar 12, 2015
EngineFuel/propulsion System
MY TRUCK BEGAN CUTTING OFF ON ME WHILE I WAS DRIVING EVERY NOW AND THEN. NOW IT IS DOING IT MORE AND MORE. I HAD NO IDEA WHAT IT WAS, SO A COUPLE OF TIMES I THOUGHT IT MIGHT HAVE BEEN BAD GAS SO I CHANGED GAS AND STARTING USING AMOCO GAS AND PUT FUEL INJECTOR CLEANER IN MY GAS TANK. THAT DID NOT FIX THE PROBLEM. NOW I AM LOSING…
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MY TRUCK BEGAN CUTTING OFF ON ME WHILE I WAS DRIVING EVERY NOW AND THEN. NOW IT IS DOING IT MORE AND MORE. I HAD NO IDEA WHAT IT WAS, SO A COUPLE OF TIMES I THOUGHT IT MIGHT HAVE BEEN BAD GAS SO I CHANGED GAS AND STARTING USING AMOCO GAS AND PUT FUEL INJECTOR CLEANER IN MY GAS TANK. THAT DID NOT FIX THE PROBLEM. NOW I AM LOSING PRESSURE WHILE I AM DRIVING. I CALLED FORD MOTORS AND THEY TOLD ME THAT MY VEHICLE IS NOT A PART OF THE RECALL, BUT MY VEHICLE IS DOING THE SAME THING THAT IS IN THE RECALL. I CALLED THE FORD DEALERSHIP WHERE I PURCHASED THE VEHICLE AND WAS TOLD THAT MY VEHICLE WAS NOT A PART OF THE RECALL AND FOR $130.00 I COULD BRING IT IN AND GET A DIAGNOSTIC. THERE HAS BEEN A MALFUNCTION INDICATOR LIGHT ON AND THE VEHICLE STILL STOPS ON ME ON OCCASION. PLEASE HELP BEFORE SOMETHING TRAGIC HAPPENS. *TR
NHTSA ODI #10694003
30,567 miles · Feb 10, 2015
EnginePower Train
THROTTLE STUCK IN EXCEL MODE AND EXCESSIVE WHITE SMOKE FROM TAIL PIPE. FORD STATED TO LOOK DEEPER INTO ENGINE AND STATED THEY CAN NOT FINE PROBLEM TO VEHICLE. INSTRUCTED TO BUY NEW ENGINE. THIS DIESEL ENGINE SHOULD NOT HAD GONE BAD WITH 30, 000 MILES ON IT. WAS TOLD THIS HAPPENS THAT 1% OF THE TIME ALTHOUGH BY THE REVIEWS THIS F…
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THROTTLE STUCK IN EXCEL MODE AND EXCESSIVE WHITE SMOKE FROM TAIL PIPE. FORD STATED TO LOOK DEEPER INTO ENGINE AND STATED THEY CAN NOT FINE PROBLEM TO VEHICLE. INSTRUCTED TO BUY NEW ENGINE. THIS DIESEL ENGINE SHOULD NOT HAD GONE BAD WITH 30, 000 MILES ON IT. WAS TOLD THIS HAPPENS THAT 1% OF THE TIME ALTHOUGH BY THE REVIEWS THIS FREQUENTLY HAPPENS WITH THIS MOTOR. THIS VEHICLE NEEDS TO BE RECALLED ! *TR
NHTSA ODI #10682669
60,000 miles · Mar 11, 2014
Electrical SystemEngineService Brakes
THIS TRUCK HAS BEEN AN ISSUE FROM THE TIME WE BOUGHT IT. WE HAVE CONTACTED FORD MULTIPLE TIMES AND THEIR RESPONSE IS "KEEP YOUR RECEIPTS JUST IN CASE." WE HAVE REPLACED THE TURBOS BOTH HIGH AND LOW END TWICE AND THEY ARE STARTING TO ACT UP AGAIN. TRAVELING 60 MPH DOWN THE ROAD YOU LOSE ALL TURBO PRESSURE CAUSING YOU TO LOSE POWE…
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THIS TRUCK HAS BEEN AN ISSUE FROM THE TIME WE BOUGHT IT. WE HAVE CONTACTED FORD MULTIPLE TIMES AND THEIR RESPONSE IS "KEEP YOUR RECEIPTS JUST IN CASE." WE HAVE REPLACED THE TURBOS BOTH HIGH AND LOW END TWICE AND THEY ARE STARTING TO ACT UP AGAIN. TRAVELING 60 MPH DOWN THE ROAD YOU LOSE ALL TURBO PRESSURE CAUSING YOU TO LOSE POWER. YOU HAVE TO PULL OVER SHUT THE TRUCK OFF AND RE-CRANK IT. THE TRUCK SHUTS OFF WHILE DRIVING WITHOUT THROWING A CHECK ENGINE LIGHT. THE BELT TENSIONER HAS SEPARATED COMING DOWN THE HIGHWAY SHUTTING OFF COMPLETE POWER AT 60 MPH. ABOUT EVERY 3RD TIME OF FILLING UP WITH DIESEL FUEL WE HAVE TO DRAIN THE WATER SEPARATOR. WHEN THE REGEN SYSTEM KICKS IN TREMENDOUS AMOUNT OF DIESEL FUMES COME IN TO THE TRUCK CAUSING HEADACHES WITH EXTREME LOSE OF POWER. WHITE SMOKE COMING OUT OF THE TAIL PIPE. THE STOCK RIM SPLIT ON THE DRIVER FRONT TIRE AND THE DEALERSHIP WANTED $1300.00 FOR ONE RIM WHEN A WHOLE SET OF AFTERMARKET RIMS ARE HUNDREDS OF DOLLARS CHEAPER. BOTH FRONT CALIPERS HAVE LOCKED UP AT DIFFERENT OCCASIONS TOWING 1,000 LB TRAILER AND ONE JUST DRIVING DOWN THE ROAD.ALL SEALS ARE LEAKING. RADIATOR IS LEAKING. ROCKER ARMS ARE TAPPING AND COST $1700 TO REPLACE COMING FROM A CERTIFIED FORD MECHANIC. WE HAVE HAD 3 DEALERSHIPS TELL US THEY DON'T WANT THE TRUCK AND REFUSE TO GO LOOK AT IT BECAUSE OF THE MOTOR. ITS ASHAME THE TRUCK WAS A $55,000 TRUCK BRAND NEW. 2 YEARS OLD IT VALUED AT $40,000 AND 2 YEARS AFTER ITS AT $17,000 RESALE. STEERING IS ALL OVER THE PLACE WHEN HITTING SEEMS OR RUTS IN THE ROAD MAKING THE TRUCK HARD TO CONTROL AND VERY UNSAFE. THIS IS BY FAR THE WORST VEHICLE WE HAVE EVER OWNED. FORD SHOULD BE ASHAMED OF PUTTING SUCH A UNSAFE VEHICLE ON THE ROAD AND NOT DOING ANYTHING TO HELP THE CUSTOMERS THAT HAVE WASTED $55,000. WOULD YOU TRUST YOUR KIDS IN THIS VEHICLE? THERE HAS BEEN 5 FORD DEALERS TELL US THEY DON'T EVEN WANT IT. 6.4L=JUNK. *TR
NHTSA ODI #10568648
88,000 miles · Oct 17, 2013
Engine
I WAS PULLING A HORSE TRAILER UPHILL, AND ENGINE BEGAN TO OVERHEAT. A FEW DAYS LATER WHEN IN MY MECHANICS SHOP, I DISCOVERED THAT THE RADIATOR HAD CRACKED, AND SUBSEQUENT REPAIR FOR NEW COMPONENTS WAS APPX. $2K. WITHIN TWO WEEKS I BEGAN HAVING ISSUES AGAIN WITH OVERHEATING, AND UPON FURTHER RESEARCH BY MY MECHANIC, WE DISCOVER…
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I WAS PULLING A HORSE TRAILER UPHILL, AND ENGINE BEGAN TO OVERHEAT. A FEW DAYS LATER WHEN IN MY MECHANICS SHOP, I DISCOVERED THAT THE RADIATOR HAD CRACKED, AND SUBSEQUENT REPAIR FOR NEW COMPONENTS WAS APPX. $2K. WITHIN TWO WEEKS I BEGAN HAVING ISSUES AGAIN WITH OVERHEATING, AND UPON FURTHER RESEARCH BY MY MECHANIC, WE DISCOVERED THAT THE OIL COOLER, AND TWO EGR COOLERS WERE DEFECTIVE, AND THIS IN FACT HAD CAUSED THE ORIGINAL PROBLEM. MY VEHICLE WAS A COUPLE OF MONTHS OUT OF WARRANTY, AND FORD REFUSED TO CONSIDER A WARRANTY REPAIR FOR THIS ISSUE. THIS REPAIR WAS AN ADDITIONAL $5K. AFTER SPEAKING WITH SEVERAL MECHANICS, INCLUDING ONE THAT WORKS FOR A FORD DEALER, WE DISCOVERED THAT THIS IS NOT AN UNKNOWN ISSUE FOR FORD. THERE WERE PREVIOUS ISSUES WITH THE 6.0 ENGINE, WHICH DID RECEIVE A RECALL. THEY ARE NOW HAVING THE SAME ISSUES WITH THE 6.4 ENGINE, BUT AT THIS POINT HAVE BEEN UNWILLING TO ISSUE A RECALL NOTICE. MY BELIEF IS THAT FORD IS BEING UNRESPONSIVE TO AN ISSUE THEY ARE AWARE OF, AND WHICH COULD CAUSE A POTENTIAL SAFETY ISSUE EVENTUALLY WITH BREAKDOWNS ALONG ROADS AND FREEWAYS. *LN
NHTSA ODI #10548326
79,300 miles · Oct 27, 2012
Engine
THE RADIATOR IS LEAKING WERE THE SIDE TANKS ARE ATTACHED TO THE CORE AND BOTH THE UPPER AND LOWER RADIATOR HOSES ARE LEAKING. WHEN I HAD THE PICKUP IN THE DEALERSHIP FOR SERVICE I WAS ADVISED THAT THERE WAS UPGRADED RADIATOR HOSES AVAILABLE. THE DEALERSHIP RECOMMENDED I REPLACE THEM TO PREVENT HOSE FAILURE. THIS WOULD BE AT MY …
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THE RADIATOR IS LEAKING WERE THE SIDE TANKS ARE ATTACHED TO THE CORE AND BOTH THE UPPER AND LOWER RADIATOR HOSES ARE LEAKING. WHEN I HAD THE PICKUP IN THE DEALERSHIP FOR SERVICE I WAS ADVISED THAT THERE WAS UPGRADED RADIATOR HOSES AVAILABLE. THE DEALERSHIP RECOMMENDED I REPLACE THEM TO PREVENT HOSE FAILURE. THIS WOULD BE AT MY COST, BUT CLEARLY ARE FACTORY DEFECTS. WHEN I HAD SEVERAL DIFFERENT LOCAL MECHANICS GIVE ME ESTIMATES AND ASKED WHAT THE PROBLEM WAS, AND TOLD THEM WHAT YEAR AND MODEL FORD I HAD THEY ALL DESCRIBED THE SAME LEAKS IN THE RADIATORS AND HOSES. SO THERE APPEARS TO BE A DEFECT WITH THE HOSES AND RADIATORS OF THESE YEAR AND MODELS OF FORDS. I CALLED MY LOCAL DEALERSHIP AND THEY SAID THESE PROBLEMS WOULD NOT BE CORRECTED BY FORD AT THIS TIME. THE ESTIMATE FOR THE REPAIRS IS $1116.46. I CONTACTED FORDS CUSTOMER SERVICE AND BROUGHT THESE PROBLEMS TO THEIR ATTENTION BUT WAS TOLD THAT FORD DID NOT HAVE ANY WARRANTY OR PROGRAMS TO RESOLVE THESE DEFECTIVE ITEMS. IT IS MY OPINION THAT IF ANY COMPANY OR BUSINESS PROVIDES DEFECTIVE WORKMANSHIP THAT IT SHOULD BE RESOLVED BY THEM. APPARENTLY THE AUTO REPAIR SHOPS AND THE DEALERSHIPS ARE AWARE OF THE PROBLEMS.[XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #10482410
Official recalls
0
No recalls in this snapshot.
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
1
PE13014 · Alleged Loss Of Steering
Opened May 7, 2013 · Closed Jan 31, 2014
Status: closed (inferred from source dates) · Steering; Steering:gear Box (other Than Rack And Pinion)
The Office of DefectsInvestigation (ODI) opened PE13-014 after identifying five complaints alleging steering gear failure in model year (MY) 2008 Ford F-250 and F-350 Super Duty pick-up trucks and to evaluate the relationship between the design history of the steering gear assembly and the alleged defect.As background, ODI investigated steering gear sector shaft fractures in approximately 1.3 million MY 1999 - 2001 Ford Super Duty pick-up trucks and MY 2000 - 2001 Ford Excursion sport utility vehicles in Engineering Analysis EA01-009.The investigation determined that the sector shaft failures were the result of extraordinary, possibly multiple, impacts and not the result of fatigue.No defect in design, manufacturing or materials was identified in the sector shaft.EA01-009 was closed August 19, 2003 with 169 complaints, resulting in a rate of 12.9 incidents per 100,000 vehicles after approximately one year of service.Ford increased the diameter of the sector shaft from 1.375 inches to 1.625 inches at the start of MY 2005 production, increasing the resistance of the steering gear assembly to torsional overload by approximately 48% and changing the failure mode from sector shaft fracture to cracked or broken sector shaft gear teeth.The redesigned steering gear assembly was used in approximately 1.1 million MY 2005 through 2009 Ford Super Duty pick-up trucks, including the subject vehicles.Figure 1 shows the basic steering system design used in Ford Super Duty trucks investigated in EA01-009 and PE13-014. Figure 2 shows the locations of failures resulting from impact related torsional overloading of the sector shaft for the subject vehicles and the prior generation Ford Super Duty trucks investigated in EA01-009.Figure 3 shows an example of a failed sector shaft investigated in EA01-009 and comparisons of fracture surfaces of sector shafts failing from fatigue loading and from torsional overload.Ford provided field return part analysis of failed steering gears from MY 2005 through 2009 Super Duty trucks found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload (Figure 4).Laboratory analysis found no evidence of fatigue or material property defects in any of the fractures.Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns (Figure 5).Analysis of failures by time in service indicates a random failure pattern/distribution, consistent with incidents of impact induced overload (Figure 6). The complaint rate for the subject vehicles after approximately 5 to 6 years, 7.1 incidents per 100,000 vehicles, is lower than the rate observed in EA01-009. Furthermore, similar to the condition investigated in EA01-009, a number of incident records include evidence of impact loads (e.g., curb strikes) and several alleged crashes include incidents in which information suggests that the steering gear failure was most likely a result of crash forces, rather than the cause of the crash.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.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 monitor this issue and reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at ww
Additional source detail variants (2)
Steering
The Office of DefectsInvestigation (ODI) opened PE13-014 after identifying five complaints alleging steering gear failure in model year (MY) 2008 Ford F-250 and F-350 Super Duty pick-up trucks and to evaluate the relationship between the design history of the steering gear assembly and the alleged defect.As background, ODI investigated steering gear sector shaft fractures in approximately 1.3 million MY 1999 - 2001 Ford Super Duty pick-up trucks and MY 2000 - 2001 Ford Excursion sport utility vehicles in Engineering Analysis EA01-009.The investigation determined that the sector shaft failures were the result of extraordinary, possibly multiple, impacts and not the result of fatigue.No defect in design, manufacturing or materials was identified in the sector shaft.EA01-009 was closed August 19, 2003 with 169 complaints, resulting in a rate of 12.9 incidents per 100,000 vehicles after approximately one year of service.Ford increased the diameter of the sector shaft from 1.375 inches to 1.625 inches at the start of MY 2005 production, increasing the resistance of the steering gear assembly to torsional overload by approximately 48% and changing the failure mode from sector shaft fracture to cracked or broken sector shaft gear teeth.The redesigned steering gear assembly was used in approximately 1.1 million MY 2005 through 2009 Ford Super Duty pick-up trucks, including the subject vehicles.Figure 1 shows the basic steering system design used in Ford Super Duty trucks investigated in EA01-009 and PE13-014. Figure 2 shows the locations of failures resulting from impact related torsional overloading of the sector shaft for the subject vehicles and the prior generation Ford Super Duty trucks investigated in EA01-009.Figure 3 shows an example of a failed sector shaft investigated in EA01-009 and comparisons of fracture surfaces of sector shafts failing from fatigue loading and from torsional overload.Ford provided field return part analysis of failed steering gears from MY 2005 through 2009 Super Duty trucks found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload (Figure 4).Laboratory analysis found no evidence of fatigue or material property defects in any of the fractures.Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns (Figure 5).Analysis of failures by time in service indicates a random failure pattern/distribution, consistent with incidents of impact induced overload (Figure 6). The complaint rate for the subject vehicles after approximately 5 to 6 years, 7.1 incidents per 100,000 vehicles, is lower than the rate observed in EA01-009. Furthermore, similar to the condition investigated in EA01-009, a number of incident records include evidence of impact loads (e.g., curb strikes) and several alleged crashes include incidents in which information suggests that the steering gear failure was most likely a result of crash forces, rather than the cause of the crash.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.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 monitor this issue and reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at ww
Steering:gear Box (other Than Rack And Pinion)
The Office of DefectsInvestigation (ODI) opened PE13-014 after identifying five complaints alleging steering gear failure in model year (MY) 2008 Ford F-250 and F-350 Super Duty pick-up trucks and to evaluate the relationship between the design history of the steering gear assembly and the alleged defect.As background, ODI investigated steering gear sector shaft fractures in approximately 1.3 million MY 1999 - 2001 Ford Super Duty pick-up trucks and MY 2000 - 2001 Ford Excursion sport utility vehicles in Engineering Analysis EA01-009.The investigation determined that the sector shaft failures were the result of extraordinary, possibly multiple, impacts and not the result of fatigue.No defect in design, manufacturing or materials was identified in the sector shaft.EA01-009 was closed August 19, 2003 with 169 complaints, resulting in a rate of 12.9 incidents per 100,000 vehicles after approximately one year of service.Ford increased the diameter of the sector shaft from 1.375 inches to 1.625 inches at the start of MY 2005 production, increasing the resistance of the steering gear assembly to torsional overload by approximately 48% and changing the failure mode from sector shaft fracture to cracked or broken sector shaft gear teeth.The redesigned steering gear assembly was used in approximately 1.1 million MY 2005 through 2009 Ford Super Duty pick-up trucks, including the subject vehicles.Figure 1 shows the basic steering system design used in Ford Super Duty trucks investigated in EA01-009 and PE13-014. Figure 2 shows the locations of failures resulting from impact related torsional overloading of the sector shaft for the subject vehicles and the prior generation Ford Super Duty trucks investigated in EA01-009.Figure 3 shows an example of a failed sector shaft investigated in EA01-009 and comparisons of fracture surfaces of sector shafts failing from fatigue loading and from torsional overload.Ford provided field return part analysis of failed steering gears from MY 2005 through 2009 Super Duty trucks found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload (Figure 4).Laboratory analysis found no evidence of fatigue or material property defects in any of the fractures.Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns (Figure 5).Analysis of failures by time in service indicates a random failure pattern/distribution, consistent with incidents of impact induced overload (Figure 6). The complaint rate for the subject vehicles after approximately 5 to 6 years, 7.1 incidents per 100,000 vehicles, is lower than the rate observed in EA01-009. Furthermore, similar to the condition investigated in EA01-009, a number of incident records include evidence of impact loads (e.g., curb strikes) and several alleged crashes include incidents in which information suggests that the steering gear failure was most likely a result of crash forces, rather than the cause of the crash.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.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 monitor this issue and reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at ww
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