NHTSA owner reports · September 18, 2026 snapshot.
Electrical System complaints
73 reportsClear category filter98,778 miles · Jul 11, 2017
Electrical SystemFuel/propulsion System
TL* THE CONTACT OWNS A 2005 FORD F-150. WHILE DRIVING, THE VEHICLE IDLED WITHOUT WARNING. THE CONTACT HAD TO PULL THE VEHICLE OVER TO RESTART IT, BUT IT CONTINUED TO IDLE. THE MAINTENANCE WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL INJECTION CONTROL MODULE NEEDED TO…
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TL* THE CONTACT OWNS A 2005 FORD F-150. WHILE DRIVING, THE VEHICLE IDLED WITHOUT WARNING. THE CONTACT HAD TO PULL THE VEHICLE OVER TO RESTART IT, BUT IT CONTINUED TO IDLE. THE MAINTENANCE WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL INJECTION CONTROL MODULE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED, BUT THE FAILURE RECURRED. THE DEALER WAS NOT NOTIFIED. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBER: 05V270000 (ELECTRICAL SYSTEM). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND STATED THAT THERE WAS NO RECALL ASSOCIATED WITH THE VIN. THE APPROXIMATE FAILURE MILEAGE WAS 98,778.
NHTSA ODI #11004662
148,000 miles · Jun 6, 2017
Electrical SystemEngineStructure
VEHICLE WENT INTO "FAILSAFE" MODE ON TWO SEPARATE OCCASIONS WITHIN THE LAST YEAR! AND MOST RECENTLY, TWO WEEKS AGO! BOTH AT HIGHWAY SPEED ON TWO DIFFERENT INTERSTATES IN FLORIDA! VERY DANGEROUS, AND HARD TO CONTROL VEHICLE TO "LIMP" TO A SAFE PLACE TO STOP! MANY POSSIBLE CAUSES FROM ELECTRICAL, FUEL, OR ENGINE ISSUES THAT ARE W…
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VEHICLE WENT INTO "FAILSAFE" MODE ON TWO SEPARATE OCCASIONS WITHIN THE LAST YEAR! AND MOST RECENTLY, TWO WEEKS AGO! BOTH AT HIGHWAY SPEED ON TWO DIFFERENT INTERSTATES IN FLORIDA! VERY DANGEROUS, AND HARD TO CONTROL VEHICLE TO "LIMP" TO A SAFE PLACE TO STOP! MANY POSSIBLE CAUSES FROM ELECTRICAL, FUEL, OR ENGINE ISSUES THAT ARE WELL DOCUMENTED ON MANY INTERNET SITES AND F150 FORUMS! ALSO RUST ISSUES ON ROOF OF VEHICLE IN RAIN CHANNELS! VERY COMMON,AND VERY POOR DESIGN!
NHTSA ODI #10993552
108,000 miles · Dec 7, 2016
Electrical SystemEngine
TL* THE CONTACT OWNS A 2005 FORD F-150. THE CONTACT STATED THAT WHILE DRIVING THE VEHICLE AT 65 MPH, THE VEHICLE BEGAN STALLING INTIMITTENTLY THEN THE ENGINE AND MAINTANENENCE WARNING LIGHT ILLUMINATED. THE CONTACT TOOK THE VEHICLE TO A MECHANIC WHERE IT WAS DIAGNOSED THAT THE AIR FILTER WAS OUTDATED AND NEEDED TO BE REPLACED. T…
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TL* THE CONTACT OWNS A 2005 FORD F-150. THE CONTACT STATED THAT WHILE DRIVING THE VEHICLE AT 65 MPH, THE VEHICLE BEGAN STALLING INTIMITTENTLY THEN THE ENGINE AND MAINTANENENCE WARNING LIGHT ILLUMINATED. THE CONTACT TOOK THE VEHICLE TO A MECHANIC WHERE IT WAS DIAGNOSED THAT THE AIR FILTER WAS OUTDATED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 108,000.
NHTSA ODI #10930354
190,000 miles · May 6, 2016
Air BagsElectrical System
TL* THE CONTACT OWNS A 2005 FORD F-150. WHILE DRIVING 40 MPH, THE DRIVER SIDE AIR BAG LIGHT REMAINED ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 190,000.
NHTSA ODI #10863675
114,000 miles · Apr 26, 2016
Electrical SystemService BrakesUnknown Or OtherFire
FUSE 14 CONTROLLING ABS MODULE, DTR SENSOR, REVERSE LIGHTS, PCV HEATER, AIR CONDITIONER COMPRESSOR, CRUISE CONTROL DEACTIVATOR SWITCH AND DAYTIME HEADLIGHTS WAS REPEATEDLY BLOWING. TRUCK WAS SERVICED BY DEALER ON 3-23-16, REPLACING THE A/C COMPRESSOR. REPLACING THE A/C COMPRESSOR DID NOT RESOLVE ANY ISSUES. THE TRUCK WAS RETURNE…
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FUSE 14 CONTROLLING ABS MODULE, DTR SENSOR, REVERSE LIGHTS, PCV HEATER, AIR CONDITIONER COMPRESSOR, CRUISE CONTROL DEACTIVATOR SWITCH AND DAYTIME HEADLIGHTS WAS REPEATEDLY BLOWING. TRUCK WAS SERVICED BY DEALER ON 3-23-16, REPLACING THE A/C COMPRESSOR. REPLACING THE A/C COMPRESSOR DID NOT RESOLVE ANY ISSUES. THE TRUCK WAS RETURNED TO THE DEALER ON 4-6-16 FOR THE SAME ISSUE WITH THE SAME FUSE. THE DEALERSHIP REPLACED THE FUSE AND PERFORMED DIAGNOSTIC TESTS ON THE TRUCK, THEN INFORMING ME THAT THEY COULD NOT DIAGNOSE OR LOCATE THE SHORT. THE DEALERSHIP INFORMED ME THAT I WOULD HAVE TO DRIVE THE TRUCK UNTIL THE FUSE STARTED BLOWING MORE FREQUENTLY. THE FIRST TIME THE TRUCK WAS DRIVEN AFTER WORK WAS PERFORMED THE CRUISE CONTROL WAS NOT FUNCTIONING PROPERLY. THE TRUCK ENGINE WOULD SURGE AS THE TRUCK WENT DOWN THE ROAD WITH THE CRUISE CONTROL ON. THE ISSUE WITH THE CRUISE CONTROL HAPPENED ON 4-9-16. ON THE MORNING OF 4-10-16 THE TRUCK WAS DRIVEN APPROXIMATELY 4 MILES AND PARKED IN THE DRIVE OF MY HOME. AFTER ENTERING THE HOUSE THE ALARM WAS HEARD SOUNDING ON THE VEHICLE, AT WHICH TIME I STEPPED OUTSIDE TO FIND THE TRUCK ON FIRE. THE FIRE SEEMED TO HAVE STARTED ON THE INSIDE OF THE TRUCK.
NHTSA ODI #10861613
140,000 miles · Dec 30, 2015
Electrical System
TL* THE CONTACT OWNS A 2005 FORD F-150. WHILE DRIVING AND MAKING A RIGHT TURN, THE VEHICLE LOST POWER AND STALLED. THE CONTACT HEARD A BEEP SOUND PRIOR TO THE FAILURE. THE FAILURE RECURRED TWICE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO WAS UNABLE TO DUPLICATE THE FAILURE OR RETRIEVE A FAULT CODE. THE VEHICLE WAS NOT…
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TL* THE CONTACT OWNS A 2005 FORD F-150. WHILE DRIVING AND MAKING A RIGHT TURN, THE VEHICLE LOST POWER AND STALLED. THE CONTACT HEARD A BEEP SOUND PRIOR TO THE FAILURE. THE FAILURE RECURRED TWICE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO WAS UNABLE TO DUPLICATE THE FAILURE OR RETRIEVE A FAULT CODE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS UNAVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 140,000.
NHTSA ODI #10816962
120,000 miles · Jul 4, 2015
Electrical System
A NUMBER OF WIRES LEADING FROM THE BODY INTO THE DRIVER'S SIDE DOOR HAVE BEEN CUT/WORN POSSIBLY DUE TO CONTACT WITH THE INSIDE OF THE DOOR. THE RUBBER AND PLASTIC PARTS MEANT TO PROTECT THE WIRES WERE ALSO CUT/WORN. THIS HAS LED TO COMPLETE FAILURE OF ALL ELECTRONICS IN THE DOOR INCLUDING POWER LOCK, POWER WINDOWS, AUTOMATIC …
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A NUMBER OF WIRES LEADING FROM THE BODY INTO THE DRIVER'S SIDE DOOR HAVE BEEN CUT/WORN POSSIBLY DUE TO CONTACT WITH THE INSIDE OF THE DOOR. THE RUBBER AND PLASTIC PARTS MEANT TO PROTECT THE WIRES WERE ALSO CUT/WORN. THIS HAS LED TO COMPLETE FAILURE OF ALL ELECTRONICS IN THE DOOR INCLUDING POWER LOCK, POWER WINDOWS, AUTOMATIC SHUTOFF OF RADIO, DOOR CHIME, KEYPAD, AND MIRRORS. DISCUSSION WITH FORD DEALER INDICATED THAT THEY HAVE SEEN THIS PROBLEM IN THE PAST.
NHTSA ODI #10731953
175,000 miles · Jun 2, 2015
Electrical SystemPower TrainUnknown Or OtherFire
ON THE MORNING OF MARCH 5TH 2015 I STARTED MY TRUCK TO WARM THE INSIDE AND ALSO MELT THE SNOW OFF MY WINDSHIELD. I GOT IN THE TRUCK AND BACKED OUT AWAY FROM HOUSE. DUE TO HAVING SNOW ON THE DRIVEWAY I TURNED ON THE 4 WHEEL DRIVE IN HIGH. MY FOUR WHEEL DRIVE WOULD NOT WORK SO I TRIED TO SWICTH TO 2 WHEEL DRIVE BACK TO FOUR WHEEL…
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ON THE MORNING OF MARCH 5TH 2015 I STARTED MY TRUCK TO WARM THE INSIDE AND ALSO MELT THE SNOW OFF MY WINDSHIELD. I GOT IN THE TRUCK AND BACKED OUT AWAY FROM HOUSE. DUE TO HAVING SNOW ON THE DRIVEWAY I TURNED ON THE 4 WHEEL DRIVE IN HIGH. MY FOUR WHEEL DRIVE WOULD NOT WORK SO I TRIED TO SWICTH TO 2 WHEEL DRIVE BACK TO FOUR WHEEL DRIVE BUT THE 4 WHEEL DRIVE WOULD NOT TURN ON. I GRABBED THE GEAR SHIFT TO PUT THE TRUCK BACK IN PARK WHEN I NOTICED MY GEAR SHIFT COULD FLOAT TO PARK TO 1ST GEAR FREELY AND WOULD NOT SHIFT. AT THIS TIME I NOTICED SMOKE STARTING TO COME INSIDE CAB FROM UNDER DASH AND THRU THE VENTS. I JUMPED OUT AND OPENED THE HOOD. A 1 FOOT SECTION OF A WIRING HARNES MOUNTED TO THE FIREWALL HAD CAUGHT FIRE. I MADE ATTEMPTS TO PUT OUT THE FIRE BUT WITHIN A FEW SECONDS THE ENGINE COMPARTMENT WAS ENGULFED. IN 2 TO 3 MINUTES THE ENTIRE INSIDE OF THE CAB WAS ALSO COMPLETELY ON FIRE. MY WIFE WHO WAS WATCHING ME IMMEDIATLY CALLED 911 TO GET THE FIRE DEPARTMENT. AFTER 3 MINUTES THE TRUCK WAS ALREADY A TOTAL LOSE. DUE TO THE TRUCK BEING ONLY 60' FROM MY HOUSE AND BURNING SO HOT I WAS CONCERNED ABOUT MY HOUSE CATCHING FIRE. TWO GENTLEMAN FROM THE RESCUE SQUAD ARRIVED BUT IT WAS TOO LATE FOR ANYTHING TO BE DONE. I WAS ABLE TO GET A BACKHOE AND PUT THE FIRE OUT WITH SNOW. UNFORTUNATELY I HAD LIABILITY INSURANCE ONLY WHICH MEANT A TOTAL LOSE. I NEVER DREAMED THAT THE TRUCK WOULD BURN UP SITTING IN MY DRIVEWAY!!!! I KNOW THERE HAVE BEEN SOME RECALLS FOR F150 DUE TO FIRE HAZARDS WITH THE CRUISE CONTROL FOR OTHER YEAR MODEL CLOSE TO 2005. A VEHICLE CATCHING FIRE WHILE ITS SITTING IN A DRIVEWAY RUNNING IS TOTALLY UNACCEPTABLE. THE TRUCK WAS IN EXCELLENT SHAPE AND HAD NO AFTER MARKET PARTS OR WORK PERFORMED. I HAVE NO IDEAL WHY THE WIRING HARNESS CAUGHT FIRE.
NHTSA ODI #10723002
20,000 miles · May 5, 2015
Electrical SystemVisibility
I STARTED THE TRUCK AND THEN TURNED ON THE REAR DEFROST, WHICH I RARELY USE. IT WAS ABOUT 55 DEGREES OUTSIDE. AFTER ABOUT 2 MINUTES I HEARD A HISSING NOISE THAT LASTED FOR ABOUT 5 SECONDS AND THEN A HEARD LOUD POP AND THEN THE WINDSHIELD SHATTERED. MANY OTHER ARTICLES ON THE WEB INDICATE THAT THIS IS A KNOWN DEFECT WITH THE REAR…
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I STARTED THE TRUCK AND THEN TURNED ON THE REAR DEFROST, WHICH I RARELY USE. IT WAS ABOUT 55 DEGREES OUTSIDE. AFTER ABOUT 2 MINUTES I HEARD A HISSING NOISE THAT LASTED FOR ABOUT 5 SECONDS AND THEN A HEARD LOUD POP AND THEN THE WINDSHIELD SHATTERED. MANY OTHER ARTICLES ON THE WEB INDICATE THAT THIS IS A KNOWN DEFECT WITH THE REAR DEFROST. I CALLED FORD AND THEY WILL NOT OFFER AND COMPENSATION TO HAVE IT FIXED EVEN THOUGH IT IS A KNOWN ISSUE. MY DAUGHTER WAS IN THE BACK SEAT AND GOT GLASS IN HER HAIR. *TR
NHTSA ODI #10714694
170,000 miles · Feb 10, 2015
Electrical SystemEngine
WE HAVE HAD OUR 2005 F-150 KING RANCH FOR ABOUT 10 YEARS NOW. TODAY (FEB 10,2015), MY WIFE AND OUR ONE YEAR BABE WERE HEADING TO THE POST OFFICE THE TRUCK DISPLAYED A MESSAGE READING "ENGINE FAILSAFE MODE". THE TRUCK LOST ALL POWER, NO STEERING, AND IT STALL ON THE HIGHWAY GOING ABOUT 65 MPH. LUCKILY, SHE SAID THERE WERE VEHIC…
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WE HAVE HAD OUR 2005 F-150 KING RANCH FOR ABOUT 10 YEARS NOW. TODAY (FEB 10,2015), MY WIFE AND OUR ONE YEAR BABE WERE HEADING TO THE POST OFFICE THE TRUCK DISPLAYED A MESSAGE READING "ENGINE FAILSAFE MODE". THE TRUCK LOST ALL POWER, NO STEERING, AND IT STALL ON THE HIGHWAY GOING ABOUT 65 MPH. LUCKILY, SHE SAID THERE WERE VEHICLES BEHIND HER AND SHE PULLED IT OVER WITH NO STEERING AND THE ENGINE DEAD. MY WIFE THEN SAT ON THE HIGHWAY FOR ABOUT 10 MINUTES AND TRIED TO START THE VEHICLE, WHICH STARTED AND THERE WERE NO "ENGINE FAILSAFE MODE" ON DISPLAY ANYMORE. KNOW WITH-IN THE LAST YEAR OUR TRUCK HAS HAD THE CHECK ENGINE LIGHT AND THE ABS LIGHT HAS COME ON AND OFF EVERY OTHER MONTH. I HAVE CHECKED THE FUSES AND HAD REPLACE A FEW BUT AT TIME IT IS NOT THE FUSE. I'VE HAD THE INTERIOR DIM IN AND OUT AND AT TIMES IT DOES NOT WORK AT ALL. BY READING THE F150.NET FORUM FOUND OUT THE A WIRE THAT SPLITS INTO TWO WIRES WAS CORRODED ON THE PASSENGER SIDE FLOOR BOARD, IT SEEMS THAT CONDENSATION OR WATER COME IN AND STAYS IN THAT POCKET WERE THAT WIRING HARNESS GOES THRU. I AM NOW TERRIFIED THAT TRUCK WILL SHUT OFF ON THE HIGHWAY AGAIN WITH MY FAMILY AND I IN IT. THIS SEEMS TO BE A LIFE THREATENING PROBLEM. I HAVE READ THRU SOME FORUMS AND IT SEEMS THAT PEOPLE HAVE CALLED THE FORD DEALERSHIP AND THE SERVICE DEPARTMENT CLAIMED THEY HAVE NEVER HEARD OF THIS PROBLEM, BUT CAN WORK ON IT IF THEY BRING IT IN. BUT THAT FORD CLAIM THAT THEY FIX THE PROBLEM AND THE PEOPLE SAYS THAT THE PROBLEM STILL EXIST. HOPE SOME ONE CAN HELP OR ASSIST US IN FIXING THIS ISSUE NOT JUST FOR OUR FAMILY BUT FOR OTHERS TOO. SINCERELY [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #10682659
NHTSA investigations
3EA10001 · Inadvertent Airbag Deployment
Opened Jan 13, 2010 · Closed Apr 25, 2011
Status: closed (inferred from source dates) · Air Bags; Air Bags:frontal; Air Bags:frontal:driver Side:inflator Module; Air Bags:frontal:sensor/control MODULE-INACTIVE
ODI opened this investigation based on reports of inadvertent airbag deployment.Data provided by Ford indicated that the airbag clockspring jumper wire, which is situated inside the steering wheel assembly, was installed in a manner that would allow it to rub (abrade) against a sharp metal edge on the nearby horn plate.Because the horn plate is electrically grounded the abrasion of an airbag wire on the sharp edge could cause a short circuit condition.As a result the airbag light may illuminate and/or the airbag may inadvertently deploy.Inadvertent deployments are most likely to occur during the airbag system's self-diagnostic test that initiates when the ignition switch is turned on.Ford modified the vehicle design in late January 2006 adding a protective tape over the sharp metal edge of the horn plate.Ford made additional design changes on MY 2007 vehicles to the horn plate, the clockspring jumper, and the connector layouts to further address this issue.ODI identified 318 deployment incidents with 121 alleged injury reports from subject vehicles.All but one of the incident and injury reports occurred in vehicles built before the January 2006 modification.In addition, there was one incident and alleged injury reported in the MY 2006 Mark LT vehicles that share the same design. In letters dated February 21 and April 11, 2011, Ford announced a recall of all of the approximately 1.3 million MY 2004-2006 F-150 vehicles built prior to January 24, 2006, the date the initial vehicle modification was made.In addition, approximately 14,000 MY 2006 Mark LT vehicles built prior to January 24, 2006 will also be recalled.Vehicles built after that date, which contain the modification, are not within the recall scope.Accordingly the investigation is closed.
Additional source detail variants (4)
Air Bags
ODI opened this investigation based on reports of inadvertent airbag deployment.Data provided by Ford indicated that the airbag clockspring jumper wire, which is situated inside the steering wheel assembly, was installed in a manner that would allow it to rub (abrade) against a sharp metal edge on the nearby horn plate.Because the horn plate is electrically grounded the abrasion of an airbag wire on the sharp edge could cause a short circuit condition.As a result the airbag light may illuminate and/or the airbag may inadvertently deploy.Inadvertent deployments are most likely to occur during the airbag system's self-diagnostic test that initiates when the ignition switch is turned on.Ford modified the vehicle design in late January 2006 adding a protective tape over the sharp metal edge of the horn plate.Ford made additional design changes on MY 2007 vehicles to the horn plate, the clockspring jumper, and the connector layouts to further address this issue.ODI identified 318 deployment incidents with 121 alleged injury reports from subject vehicles.All but one of the incident and injury reports occurred in vehicles built before the January 2006 modification.In addition, there was one incident and alleged injury reported in the MY 2006 Mark LT vehicles that share the same design. In letters dated February 21 and April 11, 2011, Ford announced a recall of all of the approximately 1.3 million MY 2004-2006 F-150 vehicles built prior to January 24, 2006, the date the initial vehicle modification was made.In addition, approximately 14,000 MY 2006 Mark LT vehicles built prior to January 24, 2006 will also be recalled.Vehicles built after that date, which contain the modification, are not within the recall scope.Accordingly the investigation is closed.
Air Bags:frontal:driver Side:inflator Module
ODI opened this investigation based on reports of inadvertent airbag deployment.Data provided by Ford indicated that the airbag clockspring jumper wire, which is situated inside the steering wheel assembly, was installed in a manner that would allow it to rub (abrade) against a sharp metal edge on the nearby horn plate.Because the horn plate is electrically grounded the abrasion of an airbag wire on the sharp edge could cause a short circuit condition.As a result the airbag light may illuminate and/or the airbag may inadvertently deploy.Inadvertent deployments are most likely to occur during the airbag system's self-diagnostic test that initiates when the ignition switch is turned on.Ford modified the vehicle design in late January 2006 adding a protective tape over the sharp metal edge of the horn plate.Ford made additional design changes on MY 2007 vehicles to the horn plate, the clockspring jumper, and the connector layouts to further address this issue.ODI identified 318 deployment incidents with 121 alleged injury reports from subject vehicles.All but one of the incident and injury reports occurred in vehicles built before the January 2006 modification.In addition, there was one incident and alleged injury reported in the MY 2006 Mark LT vehicles that share the same design. In letters dated February 21 and April 11, 2011, Ford announced a recall of all of the approximately 1.3 million MY 2004-2006 F-150 vehicles built prior to January 24, 2006, the date the initial vehicle modification was made.In addition, approximately 14,000 MY 2006 Mark LT vehicles built prior to January 24, 2006 will also be recalled.Vehicles built after that date, which contain the modification, are not within the recall scope.Accordingly the investigation is closed.
Air Bags:frontal
ODI opened this investigation based on reports of inadvertent airbag deployment.Data provided by Ford indicated that the airbag clockspring jumper wire, which is situated inside the steering wheel assembly, was installed in a manner that would allow it to rub (abrade) against a sharp metal edge on the nearby horn plate.Because the horn plate is electrically grounded the abrasion of an airbag wire on the sharp edge could cause a short circuit condition.As a result the airbag light may illuminate and/or the airbag may inadvertently deploy.Inadvertent deployments are most likely to occur during the airbag system's self-diagnostic test that initiates when the ignition switch is turned on.Ford modified the vehicle design in late January 2006 adding a protective tape over the sharp metal edge of the horn plate.Ford made additional design changes on MY 2007 vehicles to the horn plate, the clockspring jumper, and the connector layouts to further address this issue.ODI identified 318 deployment incidents with 121 alleged injury reports from subject vehicles.All but one of the incident and injury reports occurred in vehicles built before the January 2006 modification.In addition, there was one incident and alleged injury reported in the MY 2006 Mark LT vehicles that share the same design. In letters dated February 21 and April 11, 2011, Ford announced a recall of all of the approximately 1.3 million MY 2004-2006 F-150 vehicles built prior to January 24, 2006, the date the initial vehicle modification was made.In addition, approximately 14,000 MY 2006 Mark LT vehicles built prior to January 24, 2006 will also be recalled.Vehicles built after that date, which contain the modification, are not within the recall scope.Accordingly the investigation is closed.
Air Bags:frontal:sensor/control MODULE-INACTIVE
ODI opened this investigation based on reports of inadvertent airbag deployment.Data provided by Ford indicated that the airbag clockspring jumper wire, which is situated inside the steering wheel assembly, was installed in a manner that would allow it to rub (abrade) against a sharp metal edge on the nearby horn plate.Because the horn plate is electrically grounded the abrasion of an airbag wire on the sharp edge could cause a short circuit condition.As a result the airbag light may illuminate and/or the airbag may inadvertently deploy.Inadvertent deployments are most likely to occur during the airbag system's self-diagnostic test that initiates when the ignition switch is turned on.Ford modified the vehicle design in late January 2006 adding a protective tape over the sharp metal edge of the horn plate.Ford made additional design changes on MY 2007 vehicles to the horn plate, the clockspring jumper, and the connector layouts to further address this issue.ODI identified 318 deployment incidents with 121 alleged injury reports from subject vehicles.All but one of the incident and injury reports occurred in vehicles built before the January 2006 modification.In addition, there was one incident and alleged injury reported in the MY 2006 Mark LT vehicles that share the same design. In letters dated February 21 and April 11, 2011, Ford announced a recall of all of the approximately 1.3 million MY 2004-2006 F-150 vehicles built prior to January 24, 2006, the date the initial vehicle modification was made.In addition, approximately 14,000 MY 2006 Mark LT vehicles built prior to January 24, 2006 will also be recalled.Vehicles built after that date, which contain the modification, are not within the recall scope.Accordingly the investigation is closed.
PE09046 · Inadvertent Airbag Deployment
Opened Sep 24, 2009 · Closed Jan 19, 2010
Status: closed (inferred from source dates) · Air Bags; Air Bags:frontal; Air Bags:frontal:driver Side:inflator Module; Air Bags:frontal:sensor/control MODULE-INACTIVE
FORD REPORTS THAT THE INADVERTENT AIRBAG DEPLOYMENTS ARE MOST LIKELY CAUSED BY THE AIRBAG HORN MOUNTING PLATE'S SHARP METAL EDGE THAT EVENTUALLY CAN CHAFE/CUT THE AIRBAG CLOCKSPRING JUMPER WIRE LEADING TO A SHORT-TO-GROUND CONDITION.ONE HUNDRED EIGHTY TWO (182) OF THE 230 REPORTS WERE FOR AIRBAG DEPLOYMENTS RESULTING IN 56 INJURIES WITH REMAINING 48 REPORTS FOR AN AIRBAG LIGHT ILLUMINATION CONDITION.INJURIES INCLUDE ABRASION, CONTUSION AND CUTS TO THE ARM/HAND/FACE AND/OR UPPER BODY REGIONS.ONE OWNER REPORTED A BROKEN TOOTH AND TWO OWNERS REPORTED BEING KNOCKED UNCONSCIOUS AS A RESULT OF THE AIRBAG DEPLOYMENT.IN ADDITION, MY2004 AND MY2006 F-150 VEHICLES ALSO CONTAIN THE SAME DESIGN THAT RESULTED IN AN ADDITIONAL 89 REPORTS WITH 37 AIRBAG DEPLOYMENTS AND NINE INJURIES. FORD MADE AN INTERIM DESIGN CHANGE TO THE HORN MOUNTING PLATE IN JANUARY 2006 AND THEN MAJOR CHANGES TO THE HORN MOUNTING PLATE, AIRBAG MODULE AND CLOCKSPRING JUMPER WIRE DESIGNS IN JUNE 2006 FOR THE MY2007 VEHICLES.THIS PRELIMINARY EVALUATION IS UPGRADED TO AN ENGINEERING ANALYSIS (EA10-001) TO INCLUDE MY2004-2006 F-150 VEHICLES AND TO FURTHER EVALUATE THE CONDITION.
Additional source detail variants (4)
Air Bags
FORD REPORTS THAT THE INADVERTENT AIRBAG DEPLOYMENTS ARE MOST LIKELY CAUSED BY THE AIRBAG HORN MOUNTING PLATE'S SHARP METAL EDGE THAT EVENTUALLY CAN CHAFE/CUT THE AIRBAG CLOCKSPRING JUMPER WIRE LEADING TO A SHORT-TO-GROUND CONDITION.ONE HUNDRED EIGHTY TWO (182) OF THE 230 REPORTS WERE FOR AIRBAG DEPLOYMENTS RESULTING IN 56 INJURIES WITH REMAINING 48 REPORTS FOR AN AIRBAG LIGHT ILLUMINATION CONDITION.INJURIES INCLUDE ABRASION, CONTUSION AND CUTS TO THE ARM/HAND/FACE AND/OR UPPER BODY REGIONS.ONE OWNER REPORTED A BROKEN TOOTH AND TWO OWNERS REPORTED BEING KNOCKED UNCONSCIOUS AS A RESULT OF THE AIRBAG DEPLOYMENT.IN ADDITION, MY2004 AND MY2006 F-150 VEHICLES ALSO CONTAIN THE SAME DESIGN THAT RESULTED IN AN ADDITIONAL 89 REPORTS WITH 37 AIRBAG DEPLOYMENTS AND NINE INJURIES. FORD MADE AN INTERIM DESIGN CHANGE TO THE HORN MOUNTING PLATE IN JANUARY 2006 AND THEN MAJOR CHANGES TO THE HORN MOUNTING PLATE, AIRBAG MODULE AND CLOCKSPRING JUMPER WIRE DESIGNS IN JUNE 2006 FOR THE MY2007 VEHICLES.THIS PRELIMINARY EVALUATION IS UPGRADED TO AN ENGINEERING ANALYSIS (EA10-001) TO INCLUDE MY2004-2006 F-150 VEHICLES AND TO FURTHER EVALUATE THE CONDITION.
Air Bags:frontal:driver Side:inflator Module
FORD REPORTS THAT THE INADVERTENT AIRBAG DEPLOYMENTS ARE MOST LIKELY CAUSED BY THE AIRBAG HORN MOUNTING PLATE'S SHARP METAL EDGE THAT EVENTUALLY CAN CHAFE/CUT THE AIRBAG CLOCKSPRING JUMPER WIRE LEADING TO A SHORT-TO-GROUND CONDITION.ONE HUNDRED EIGHTY TWO (182) OF THE 230 REPORTS WERE FOR AIRBAG DEPLOYMENTS RESULTING IN 56 INJURIES WITH REMAINING 48 REPORTS FOR AN AIRBAG LIGHT ILLUMINATION CONDITION.INJURIES INCLUDE ABRASION, CONTUSION AND CUTS TO THE ARM/HAND/FACE AND/OR UPPER BODY REGIONS.ONE OWNER REPORTED A BROKEN TOOTH AND TWO OWNERS REPORTED BEING KNOCKED UNCONSCIOUS AS A RESULT OF THE AIRBAG DEPLOYMENT.IN ADDITION, MY2004 AND MY2006 F-150 VEHICLES ALSO CONTAIN THE SAME DESIGN THAT RESULTED IN AN ADDITIONAL 89 REPORTS WITH 37 AIRBAG DEPLOYMENTS AND NINE INJURIES. FORD MADE AN INTERIM DESIGN CHANGE TO THE HORN MOUNTING PLATE IN JANUARY 2006 AND THEN MAJOR CHANGES TO THE HORN MOUNTING PLATE, AIRBAG MODULE AND CLOCKSPRING JUMPER WIRE DESIGNS IN JUNE 2006 FOR THE MY2007 VEHICLES.THIS PRELIMINARY EVALUATION IS UPGRADED TO AN ENGINEERING ANALYSIS (EA10-001) TO INCLUDE MY2004-2006 F-150 VEHICLES AND TO FURTHER EVALUATE THE CONDITION.
Air Bags:frontal
FORD REPORTS THAT THE INADVERTENT AIRBAG DEPLOYMENTS ARE MOST LIKELY CAUSED BY THE AIRBAG HORN MOUNTING PLATE'S SHARP METAL EDGE THAT EVENTUALLY CAN CHAFE/CUT THE AIRBAG CLOCKSPRING JUMPER WIRE LEADING TO A SHORT-TO-GROUND CONDITION.ONE HUNDRED EIGHTY TWO (182) OF THE 230 REPORTS WERE FOR AIRBAG DEPLOYMENTS RESULTING IN 56 INJURIES WITH REMAINING 48 REPORTS FOR AN AIRBAG LIGHT ILLUMINATION CONDITION.INJURIES INCLUDE ABRASION, CONTUSION AND CUTS TO THE ARM/HAND/FACE AND/OR UPPER BODY REGIONS.ONE OWNER REPORTED A BROKEN TOOTH AND TWO OWNERS REPORTED BEING KNOCKED UNCONSCIOUS AS A RESULT OF THE AIRBAG DEPLOYMENT.IN ADDITION, MY2004 AND MY2006 F-150 VEHICLES ALSO CONTAIN THE SAME DESIGN THAT RESULTED IN AN ADDITIONAL 89 REPORTS WITH 37 AIRBAG DEPLOYMENTS AND NINE INJURIES. FORD MADE AN INTERIM DESIGN CHANGE TO THE HORN MOUNTING PLATE IN JANUARY 2006 AND THEN MAJOR CHANGES TO THE HORN MOUNTING PLATE, AIRBAG MODULE AND CLOCKSPRING JUMPER WIRE DESIGNS IN JUNE 2006 FOR THE MY2007 VEHICLES.THIS PRELIMINARY EVALUATION IS UPGRADED TO AN ENGINEERING ANALYSIS (EA10-001) TO INCLUDE MY2004-2006 F-150 VEHICLES AND TO FURTHER EVALUATE THE CONDITION.
Air Bags:frontal:sensor/control MODULE-INACTIVE
FORD REPORTS THAT THE INADVERTENT AIRBAG DEPLOYMENTS ARE MOST LIKELY CAUSED BY THE AIRBAG HORN MOUNTING PLATE'S SHARP METAL EDGE THAT EVENTUALLY CAN CHAFE/CUT THE AIRBAG CLOCKSPRING JUMPER WIRE LEADING TO A SHORT-TO-GROUND CONDITION.ONE HUNDRED EIGHTY TWO (182) OF THE 230 REPORTS WERE FOR AIRBAG DEPLOYMENTS RESULTING IN 56 INJURIES WITH REMAINING 48 REPORTS FOR AN AIRBAG LIGHT ILLUMINATION CONDITION.INJURIES INCLUDE ABRASION, CONTUSION AND CUTS TO THE ARM/HAND/FACE AND/OR UPPER BODY REGIONS.ONE OWNER REPORTED A BROKEN TOOTH AND TWO OWNERS REPORTED BEING KNOCKED UNCONSCIOUS AS A RESULT OF THE AIRBAG DEPLOYMENT.IN ADDITION, MY2004 AND MY2006 F-150 VEHICLES ALSO CONTAIN THE SAME DESIGN THAT RESULTED IN AN ADDITIONAL 89 REPORTS WITH 37 AIRBAG DEPLOYMENTS AND NINE INJURIES. FORD MADE AN INTERIM DESIGN CHANGE TO THE HORN MOUNTING PLATE IN JANUARY 2006 AND THEN MAJOR CHANGES TO THE HORN MOUNTING PLATE, AIRBAG MODULE AND CLOCKSPRING JUMPER WIRE DESIGNS IN JUNE 2006 FOR THE MY2007 VEHICLES.THIS PRELIMINARY EVALUATION IS UPGRADED TO AN ENGINEERING ANALYSIS (EA10-001) TO INCLUDE MY2004-2006 F-150 VEHICLES AND TO FURTHER EVALUATE THE CONDITION.
PE08001 · Loss Of Brake POWER-ASSIST
Opened Jan 8, 2008 · Closed May 9, 2008
Status: closed (inferred from source dates) · Service Brakes, Hydraulic:power Assist; Service Brakes, Hydraulic:power Assist:vacuum; Service Brakes, Hydraulic:power Assist:vacuum:hoses, Lines/piping, And Fittings
BY LETTER DATED MAY 5, 2008, FORD MOTOR COMPANY (FORD) NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA RECALL NUMBER 08V-208) TO ADDRESS A MANUFACTURING DEFECT IN APPROXIMATELY 605,684 MODEL YEAR (MY) 2005 AND 2006 FORD F-150 AND LINCOLN MARK LT VEHICLES ORIGINALLY EQUIPPED WITH THE 5.4L DISPLACEMENT, 3-VALVE PER CYLINDER, V-8 ENGINE.THE RECALLED VEHICLES WERE BUILT FROM JULY 18, 2004 THROUGH MAY 31, 2006 AT THE DEARBORN TRUCK PLANT; FROM MAY 4, 2004 THROUGH MAY 31, 2006 AT THE KANSAS CITY ASSEMBLY PLANT; AND FROM APRIL 19, 2004 THROUGH MAY 31, 2006 AT THE NORFOLK TRUCK PLANT.THE VEHICLES WERE MANUFACTURED WITH THE SAME DEFECTIVE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY UNIQUE TO THE 5.4L V-8 ENGINE.FORD F-150 VEHICLES EQUIPPED WITH OPTIONALLY AVAILABLE 4.2L V6 AND 4.6L V-8 ENGINES ARE NOT INCLUDED IN THIS RECALL ACTION BECAUSE THEY UTILIZE A DIFFERENT, ONE-PIECE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY THAT DOES NOT EXHIBIT AN APPARENT DEFECT TREND. THE RECALLED VEHICLES UTILIZE A TWO-PIECE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY COMPRISED OF A STANDPIPE ASSEMBLY AND VACUUM HOSE.THE STANDPIPE ASSEMBLY ATTACHES TO A FITTING ON THE ENGINE AIR INTAKE MANIFOLD UTILIZING A FLEXIBLE RUBBER HOSE AND PLASTIC ELBOW.THE VACUUM HOSE ATTACHES TO THE OPPOSITE END OF THE STANDPIPE ASSEMBLY AND CONNECTS TO A CHECK VALVE FITTING AT THE BRAKE BOOSTER ASSEMBLY.ACCORDING TO FORD, THE PORTION OF THE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY ATTACHED TO THE INTAKE MANIFOLD MAY SWELL OVER TIME AND LOSE RETENTION FORCE, WHICH MAY ALLOW THE HOSE TO BECOME DETACHED FROM THE INTAKE MANIFOLD.SHOULD THE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY BE DISRUPTED, APPLICATION OF THE BRAKE PEDAL MAY DEPLETE THE VACUUM RESERVE AND CONSEQUENTLY RESULT IN LOSS OF BRAKE POWER-ASSIST. TO CORRECT THE SAFETY DEFECT, FORD WILL INSTALL AN IMPROVED DESIGN BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY THAT UTILIZES A HOSE CLAMP AT THE INTAKE MANIFOLD ATTACHMENT. THIS REMEDY WILL BE PROVIDED FREE OF CHARGE FOR ALL RECALLED VEHICLES.LATER PRODUCTION FORD F-150 AND LINCOLN MARK LT VEHICLES BUILT AFTER MAY 2006 WERE MANUFACTURED WITH A HOSE CLAMP AT THE BRAKE BOOSTER VACUUM SUPPLY HOSE/INTAKE MANIFOLD ATTACHMENT AND ARE NOT AFFECTED. TO DATE, THE OFFICE OF DEFECTS INVESTIGATION (ODI) IS AWARE OF 324 NON-DUPLICATIVE COMPLAINTS AND 14 NON-INJURY CRASHES RELATED TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF 4,465 SUBJECT VEHICLES THAT EXPERIENCED ONE OR MORE WARRANTY CLAIMS TO REPAIR OR REPLACE THE SUBJECT BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY. THE ACTION TAKEN BY FORD IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Additional source detail variants (3)
Service Brakes, Hydraulic:power Assist
BY LETTER DATED MAY 5, 2008, FORD MOTOR COMPANY (FORD) NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA RECALL NUMBER 08V-208) TO ADDRESS A MANUFACTURING DEFECT IN APPROXIMATELY 605,684 MODEL YEAR (MY) 2005 AND 2006 FORD F-150 AND LINCOLN MARK LT VEHICLES ORIGINALLY EQUIPPED WITH THE 5.4L DISPLACEMENT, 3-VALVE PER CYLINDER, V-8 ENGINE.THE RECALLED VEHICLES WERE BUILT FROM JULY 18, 2004 THROUGH MAY 31, 2006 AT THE DEARBORN TRUCK PLANT; FROM MAY 4, 2004 THROUGH MAY 31, 2006 AT THE KANSAS CITY ASSEMBLY PLANT; AND FROM APRIL 19, 2004 THROUGH MAY 31, 2006 AT THE NORFOLK TRUCK PLANT.THE VEHICLES WERE MANUFACTURED WITH THE SAME DEFECTIVE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY UNIQUE TO THE 5.4L V-8 ENGINE.FORD F-150 VEHICLES EQUIPPED WITH OPTIONALLY AVAILABLE 4.2L V6 AND 4.6L V-8 ENGINES ARE NOT INCLUDED IN THIS RECALL ACTION BECAUSE THEY UTILIZE A DIFFERENT, ONE-PIECE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY THAT DOES NOT EXHIBIT AN APPARENT DEFECT TREND. THE RECALLED VEHICLES UTILIZE A TWO-PIECE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY COMPRISED OF A STANDPIPE ASSEMBLY AND VACUUM HOSE.THE STANDPIPE ASSEMBLY ATTACHES TO A FITTING ON THE ENGINE AIR INTAKE MANIFOLD UTILIZING A FLEXIBLE RUBBER HOSE AND PLASTIC ELBOW.THE VACUUM HOSE ATTACHES TO THE OPPOSITE END OF THE STANDPIPE ASSEMBLY AND CONNECTS TO A CHECK VALVE FITTING AT THE BRAKE BOOSTER ASSEMBLY.ACCORDING TO FORD, THE PORTION OF THE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY ATTACHED TO THE INTAKE MANIFOLD MAY SWELL OVER TIME AND LOSE RETENTION FORCE, WHICH MAY ALLOW THE HOSE TO BECOME DETACHED FROM THE INTAKE MANIFOLD.SHOULD THE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY BE DISRUPTED, APPLICATION OF THE BRAKE PEDAL MAY DEPLETE THE VACUUM RESERVE AND CONSEQUENTLY RESULT IN LOSS OF BRAKE POWER-ASSIST. TO CORRECT THE SAFETY DEFECT, FORD WILL INSTALL AN IMPROVED DESIGN BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY THAT UTILIZES A HOSE CLAMP AT THE INTAKE MANIFOLD ATTACHMENT. THIS REMEDY WILL BE PROVIDED FREE OF CHARGE FOR ALL RECALLED VEHICLES.LATER PRODUCTION FORD F-150 AND LINCOLN MARK LT VEHICLES BUILT AFTER MAY 2006 WERE MANUFACTURED WITH A HOSE CLAMP AT THE BRAKE BOOSTER VACUUM SUPPLY HOSE/INTAKE MANIFOLD ATTACHMENT AND ARE NOT AFFECTED. TO DATE, THE OFFICE OF DEFECTS INVESTIGATION (ODI) IS AWARE OF 324 NON-DUPLICATIVE COMPLAINTS AND 14 NON-INJURY CRASHES RELATED TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF 4,465 SUBJECT VEHICLES THAT EXPERIENCED ONE OR MORE WARRANTY CLAIMS TO REPAIR OR REPLACE THE SUBJECT BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY. THE ACTION TAKEN BY FORD IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Service Brakes, Hydraulic:power Assist:vacuum
BY LETTER DATED MAY 5, 2008, FORD MOTOR COMPANY (FORD) NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA RECALL NUMBER 08V-208) TO ADDRESS A MANUFACTURING DEFECT IN APPROXIMATELY 605,684 MODEL YEAR (MY) 2005 AND 2006 FORD F-150 AND LINCOLN MARK LT VEHICLES ORIGINALLY EQUIPPED WITH THE 5.4L DISPLACEMENT, 3-VALVE PER CYLINDER, V-8 ENGINE.THE RECALLED VEHICLES WERE BUILT FROM JULY 18, 2004 THROUGH MAY 31, 2006 AT THE DEARBORN TRUCK PLANT; FROM MAY 4, 2004 THROUGH MAY 31, 2006 AT THE KANSAS CITY ASSEMBLY PLANT; AND FROM APRIL 19, 2004 THROUGH MAY 31, 2006 AT THE NORFOLK TRUCK PLANT.THE VEHICLES WERE MANUFACTURED WITH THE SAME DEFECTIVE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY UNIQUE TO THE 5.4L V-8 ENGINE.FORD F-150 VEHICLES EQUIPPED WITH OPTIONALLY AVAILABLE 4.2L V6 AND 4.6L V-8 ENGINES ARE NOT INCLUDED IN THIS RECALL ACTION BECAUSE THEY UTILIZE A DIFFERENT, ONE-PIECE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY THAT DOES NOT EXHIBIT AN APPARENT DEFECT TREND. THE RECALLED VEHICLES UTILIZE A TWO-PIECE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY COMPRISED OF A STANDPIPE ASSEMBLY AND VACUUM HOSE.THE STANDPIPE ASSEMBLY ATTACHES TO A FITTING ON THE ENGINE AIR INTAKE MANIFOLD UTILIZING A FLEXIBLE RUBBER HOSE AND PLASTIC ELBOW.THE VACUUM HOSE ATTACHES TO THE OPPOSITE END OF THE STANDPIPE ASSEMBLY AND CONNECTS TO A CHECK VALVE FITTING AT THE BRAKE BOOSTER ASSEMBLY.ACCORDING TO FORD, THE PORTION OF THE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY ATTACHED TO THE INTAKE MANIFOLD MAY SWELL OVER TIME AND LOSE RETENTION FORCE, WHICH MAY ALLOW THE HOSE TO BECOME DETACHED FROM THE INTAKE MANIFOLD.SHOULD THE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY BE DISRUPTED, APPLICATION OF THE BRAKE PEDAL MAY DEPLETE THE VACUUM RESERVE AND CONSEQUENTLY RESULT IN LOSS OF BRAKE POWER-ASSIST. TO CORRECT THE SAFETY DEFECT, FORD WILL INSTALL AN IMPROVED DESIGN BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY THAT UTILIZES A HOSE CLAMP AT THE INTAKE MANIFOLD ATTACHMENT. THIS REMEDY WILL BE PROVIDED FREE OF CHARGE FOR ALL RECALLED VEHICLES.LATER PRODUCTION FORD F-150 AND LINCOLN MARK LT VEHICLES BUILT AFTER MAY 2006 WERE MANUFACTURED WITH A HOSE CLAMP AT THE BRAKE BOOSTER VACUUM SUPPLY HOSE/INTAKE MANIFOLD ATTACHMENT AND ARE NOT AFFECTED. TO DATE, THE OFFICE OF DEFECTS INVESTIGATION (ODI) IS AWARE OF 324 NON-DUPLICATIVE COMPLAINTS AND 14 NON-INJURY CRASHES RELATED TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF 4,465 SUBJECT VEHICLES THAT EXPERIENCED ONE OR MORE WARRANTY CLAIMS TO REPAIR OR REPLACE THE SUBJECT BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY. THE ACTION TAKEN BY FORD IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Service Brakes, Hydraulic:power Assist:vacuum:hoses, Lines/piping, And Fittings
BY LETTER DATED MAY 5, 2008, FORD MOTOR COMPANY (FORD) NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA RECALL NUMBER 08V-208) TO ADDRESS A MANUFACTURING DEFECT IN APPROXIMATELY 605,684 MODEL YEAR (MY) 2005 AND 2006 FORD F-150 AND LINCOLN MARK LT VEHICLES ORIGINALLY EQUIPPED WITH THE 5.4L DISPLACEMENT, 3-VALVE PER CYLINDER, V-8 ENGINE.THE RECALLED VEHICLES WERE BUILT FROM JULY 18, 2004 THROUGH MAY 31, 2006 AT THE DEARBORN TRUCK PLANT; FROM MAY 4, 2004 THROUGH MAY 31, 2006 AT THE KANSAS CITY ASSEMBLY PLANT; AND FROM APRIL 19, 2004 THROUGH MAY 31, 2006 AT THE NORFOLK TRUCK PLANT.THE VEHICLES WERE MANUFACTURED WITH THE SAME DEFECTIVE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY UNIQUE TO THE 5.4L V-8 ENGINE.FORD F-150 VEHICLES EQUIPPED WITH OPTIONALLY AVAILABLE 4.2L V6 AND 4.6L V-8 ENGINES ARE NOT INCLUDED IN THIS RECALL ACTION BECAUSE THEY UTILIZE A DIFFERENT, ONE-PIECE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY THAT DOES NOT EXHIBIT AN APPARENT DEFECT TREND. THE RECALLED VEHICLES UTILIZE A TWO-PIECE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY COMPRISED OF A STANDPIPE ASSEMBLY AND VACUUM HOSE.THE STANDPIPE ASSEMBLY ATTACHES TO A FITTING ON THE ENGINE AIR INTAKE MANIFOLD UTILIZING A FLEXIBLE RUBBER HOSE AND PLASTIC ELBOW.THE VACUUM HOSE ATTACHES TO THE OPPOSITE END OF THE STANDPIPE ASSEMBLY AND CONNECTS TO A CHECK VALVE FITTING AT THE BRAKE BOOSTER ASSEMBLY.ACCORDING TO FORD, THE PORTION OF THE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY ATTACHED TO THE INTAKE MANIFOLD MAY SWELL OVER TIME AND LOSE RETENTION FORCE, WHICH MAY ALLOW THE HOSE TO BECOME DETACHED FROM THE INTAKE MANIFOLD.SHOULD THE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY BE DISRUPTED, APPLICATION OF THE BRAKE PEDAL MAY DEPLETE THE VACUUM RESERVE AND CONSEQUENTLY RESULT IN LOSS OF BRAKE POWER-ASSIST. TO CORRECT THE SAFETY DEFECT, FORD WILL INSTALL AN IMPROVED DESIGN BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY THAT UTILIZES A HOSE CLAMP AT THE INTAKE MANIFOLD ATTACHMENT. THIS REMEDY WILL BE PROVIDED FREE OF CHARGE FOR ALL RECALLED VEHICLES.LATER PRODUCTION FORD F-150 AND LINCOLN MARK LT VEHICLES BUILT AFTER MAY 2006 WERE MANUFACTURED WITH A HOSE CLAMP AT THE BRAKE BOOSTER VACUUM SUPPLY HOSE/INTAKE MANIFOLD ATTACHMENT AND ARE NOT AFFECTED. TO DATE, THE OFFICE OF DEFECTS INVESTIGATION (ODI) IS AWARE OF 324 NON-DUPLICATIVE COMPLAINTS AND 14 NON-INJURY CRASHES RELATED TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF 4,465 SUBJECT VEHICLES THAT EXPERIENCED ONE OR MORE WARRANTY CLAIMS TO REPAIR OR REPLACE THE SUBJECT BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY. THE ACTION TAKEN BY FORD IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
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