NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
111 reportsClear category filter98,000 miles · Jun 28, 2010
Engine And Engine CoolingFuel System, Other
NOTIFIED TODAY THAT THERE IS AN ISSUE WITH REMOVING AND REPLACING SPARK PLUGS FOR THE FORD 5.3 TRITON V8 3 VALVE ENGINE. FORD HAS ISSUED A TECHNICAL SERVICE BULLETIN TSB 08-7-6 AND IT IS NOT AVAILABLE ON YOUR WEBSITE. WHY? IF THIS IS INDEED A MANUFACTURERS DEFECT SHOULD IT NOT BE COVERED BY THEIR ORIGINAL WARRANTY OR THE MAGNUSE…
Read full complaint
NOTIFIED TODAY THAT THERE IS AN ISSUE WITH REMOVING AND REPLACING SPARK PLUGS FOR THE FORD 5.3 TRITON V8 3 VALVE ENGINE. FORD HAS ISSUED A TECHNICAL SERVICE BULLETIN TSB 08-7-6 AND IT IS NOT AVAILABLE ON YOUR WEBSITE. WHY? IF THIS IS INDEED A MANUFACTURERS DEFECT SHOULD IT NOT BE COVERED BY THEIR ORIGINAL WARRANTY OR THE MAGNUSEN-MOSS WARRANTY ACT AND OR THE UCC, ARTICLE 2. THIS PROCEDURE CAN BE BOTH TIMELY AND COSTLY FOR A CONSUMER. I HAVE RECEIVED QUOTES RANGING FROM 250 TO 1600 DOLLARS. SHOULD THE CONSUMER BE EXPECTED TO SHOULDER THE BURDEN OF THIS ISSUE? *TR
NHTSA ODI #10340380
67,000 miles · Jun 22, 2010
Engine And Engine Cooling
APPROXIMATELY 2 YEARS AGO I PURCHASED A 2005 FORD F-150 EXTENDED CAB TRUCK. I HAVE HAD NO PROBLEMS WITH THE TRUCK UP UNTIL THIS POINT AND MY TRUCK CURRENTLY HAS APPROXIMATELY 67,000 MILES ON IT. HOWEVER, APPROXIMATELY THREE (3) WEEKS AGO I NOTICED MY TRUCK "SPUTTERING" AND "MISSING" AND HAVING SOME DIFFICULTY STARTING. I TOOK…
Read full complaint
APPROXIMATELY 2 YEARS AGO I PURCHASED A 2005 FORD F-150 EXTENDED CAB TRUCK. I HAVE HAD NO PROBLEMS WITH THE TRUCK UP UNTIL THIS POINT AND MY TRUCK CURRENTLY HAS APPROXIMATELY 67,000 MILES ON IT. HOWEVER, APPROXIMATELY THREE (3) WEEKS AGO I NOTICED MY TRUCK "SPUTTERING" AND "MISSING" AND HAVING SOME DIFFICULTY STARTING. I TOOK IT TO THE DEALERSHIP (KAMAAINA MOTOR'S) THAT I PURCHASED IT FROM. THE MECHANICS ARE NOW TELLING ME THAT THE SPARK PLUGS BROKE OFF AND FELL INTO THE ENGINE "HEAD". THEY HAVE ATTEMPTED TO RETRIEVE THE PIECES OF THE SPARK PLUGS (TWO AS THEY ARE CURRENTLY REPORTING) BUT THEY FEEL THAT THE IMPACT OF THE SPARK PLUGS FALLING INTO THE HEAD MAY HAVE NOW CAUSED MY MOTOR TO FREEZE UP. AT THIS POINT THEY ARE RECOMMENDING COMPLETE ENGINE REPLACEMENT FOR MY TRUCK WHICH WILL COST THOUSANDS OF DOLLARS. I AM DEVASTATED. THIS IS MY ONLY VEHICLE AND I STILL OWE MONEY TO THE BANK TO PAY IT OFF. I DON'T HAVE THOUSANDS OF DOLLARS TO REPLACE THE MOTOR AND I KNOW CAN'T JUST GET ANOTHER LOAN FOR ANOTHER CAR. I HAVE BEEN READING ONLINE ABOUT THIS REPEATED FAILURE ON FORD'S FAULT OF DEFECTIVE SPARK PLUGS AND THAT THIS IS COMMON AND OF NO FAULT OF THE OWNERS OF THE VEHICLES. AT THIS POINT MY TRUCK IS STILL SITTING AT THE MECHANICS AND IS NOT MOVING AND I AM WITHOUT A CAR. IS THERE NOT ANYTHING THAT THE FORD COMPANY CAN DO TO BE RESPONSIBLE FOR THEIR DEFECTIVE PRODUCTIONS?? I DEVASTATED BY THIS AND HAVE NO IDEA WHAT I AM GOING TO DO TO GET BACK INTO A RUNNING VEHICLE SO I CAN GET TO WORK AND TAKE MY KIDS TO AND FROM SCHOOL. PLEASE HELP????? *TR
NHTSA ODI #10339518
80,000 miles · May 25, 2010
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2005 FORD F-150. WHILE DRIVING AT 55 MPH, THE SPARK PLUGS DISBURSED FROM THE ENGINE AND THE VEHICLE LOST POWER AND STALLED. THE DEALER WAS CONTACTED AND THE CONTACT WAS INFORMED THAT THE REPAIRS WOULD BE AT HER EXPENSE. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 80,000.
NHTSA ODI #10332232
74,000 miles · Apr 6, 2010
Engine And Engine CoolingPower Train
FORD MOTOR COMPANY-THERE WAS A SERVICE BULLETIN PUT OUT SHOW THERE WAS A PROBLEM WITH THE CAM PHASERS AND CAM CHAIN TENSIONER CAUSING THE ENGINE TO MAKE NOISES AND THEN ENGINE FAILURE THERE HAS BEEN LOTS OF COMPLAINTSTO FORD WITH NOTHING BEING DONE IF YOU WHERE DRIVING ONTHE ROAD AND THE ENGINE BLEW COULDCAUSE A ACCIDENT I CONTA…
Read full complaint
FORD MOTOR COMPANY-THERE WAS A SERVICE BULLETIN PUT OUT SHOW THERE WAS A PROBLEM WITH THE CAM PHASERS AND CAM CHAIN TENSIONER CAUSING THE ENGINE TO MAKE NOISES AND THEN ENGINE FAILURE THERE HAS BEEN LOTS OF COMPLAINTSTO FORD WITH NOTHING BEING DONE IF YOU WHERE DRIVING ONTHE ROAD AND THE ENGINE BLEW COULDCAUSE A ACCIDENT I CONTACT FORD AND THEY HAVE ALL MOST ADMITTED TO IT THAT THEY NEW THERE WAS A PROBLEM I HAVE FOUND THAT THERE HAS BEEN 1092 COMPLAINTS OVER THIS PROBLEM AND NOTHING DONE. I CONTACTED FORD AND THAT'S HOW I FOUND OUT ABOUT YOU THEY KEEP SAYING THERE SENDING THE COMPLAINT TO ANOTHER DEPT..BUT THIS IS APROBLEM THAT COULD HAVE BEEN CORRECT BEFORE THE ENGINE WAS RUINED. *TR
NHTSA ODI #10324113
80,000 miles · Apr 3, 2010
Engine And Engine Cooling
2005 FORD F-150 5.4L TRITON HAD 2 BLOWN SPARK PLUGS. FIRST ONE HAPPENED AT 80,000 MILES, SECOND AT 130,000. THE FIRST TIME IT DESTROYED THE EXHAUST MANIFOLD AND COST $3000 TO REPAIR. THE SECOND TIME THIS HAPPENED IT BLEW THE LEFT SIDE EXHAUST AND THE COIL PACK. THIS COST ABOUT $1500 TO REPAIR.
NHTSA ODI #10323634
35,742 miles · Mar 3, 2010
Engine And Engine CoolingFuel System, Gasoline
TL*THE CONTACT OWNS A 2005 FORD F150. WHILE DRIVING AT SPEEDS OVER 20 MPH, THE VEHICLE WOULD SHAKE AND VIBRATE VIOLENTLY. HE ALSO OBSERVED BLACK SMOKE EMITTING FROM THE EXHAUST PIPE AND A STRONG GASOLINE FUEL ODOR FROM THE VEHICLE INTERIOR. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THEY REPLACED THE FUEL INJECTORS (PERFORMED UND…
Read full complaint
TL*THE CONTACT OWNS A 2005 FORD F150. WHILE DRIVING AT SPEEDS OVER 20 MPH, THE VEHICLE WOULD SHAKE AND VIBRATE VIOLENTLY. HE ALSO OBSERVED BLACK SMOKE EMITTING FROM THE EXHAUST PIPE AND A STRONG GASOLINE FUEL ODOR FROM THE VEHICLE INTERIOR. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THEY REPLACED THE FUEL INJECTORS (PERFORMED UNDER FORD CUSTOMER SATISFACTION PROGRAM 07M08, NHTSA SERVICE BULLETIN NUMBER : 07M08, FUEL SYSTEM, GASOLINE:FUEL INJECTION SYSTEM:INJECTORS) AND MADE REPAIRS TO THE BRAKE BOOSTER (PERFORMED UNDER NHTSA CAMPAIGN ID NUMBER: 08V208000: COMPONENT: SERVICE BRAKES, HYDRAULIC:POWER ASSIST:VACUUM:HOSES, LINES/PIPING, AND FITTINGS). IMMEDIATELY AFTER THE REPAIRS, WHEN PUTTING THE VEHICLE INTO THE DRIVE POSITION, THERE WAS A RATTLING NOISE UNDER THE VEHICLE. THE VEHICLE WAS TAKEN BACK TO THE DEALER WHO STATED THAT THE CATALYTIC CONVERTER WAS DAMAGED DUE TO THE FUEL INJECTOR FAILURE. THE DEALER WAS ADVISED BY THE MANUFACTURER THAT THE CATALYTIC CONVERTER WOULD NOT BE COVERED AND THEY WOULD TAKE NO LIABILITY FOR THE FAILURE. THERE WERE NO REPAIRS MADE TO THE CATALYTIC CONVERTER, TO DATE. THE CONTACT HAS ALL SERVICE RECORDS, IF NEEDED. THE FAILURE MILEAGE WAS 35,742 AND THE CURRENT APPROXIMATE MILEAGE WAS 84,000.
NHTSA ODI #10316300
64,000 miles · Feb 27, 2010
Engine And Engine Cooling
2005 FORD F150 V8 4.6L DRIVING DOWN THE ROAD, SPARK PLUG POPPED OUT OF THE HEAD. 65,000 MILES, ORIGINAL PLUGS. *TR
NHTSA ODI #10314888
59,000 miles · Feb 26, 2010
Engine And Engine Cooling
AT JUST OVER 59K MILES ON MY 2005 F-150 5.4L TRITON V8 DRIVING AT 30 MPH I NOTICED A TICKING SOUND THAT INCREASED/DECREASED WITH RPMS. TRAVELING ABOUT 2 MILES FURTHER THE NOISE INCREASED IN VOLUME SO I PULLED OVER AND RAISED THE HOOD. THE NOISE WAS COMING FORM THE PASSENGER SIDE OF THE MOTOR AND THE MOTOR WAS SHAKING AS IF MIS…
Read full complaint
AT JUST OVER 59K MILES ON MY 2005 F-150 5.4L TRITON V8 DRIVING AT 30 MPH I NOTICED A TICKING SOUND THAT INCREASED/DECREASED WITH RPMS. TRAVELING ABOUT 2 MILES FURTHER THE NOISE INCREASED IN VOLUME SO I PULLED OVER AND RAISED THE HOOD. THE NOISE WAS COMING FORM THE PASSENGER SIDE OF THE MOTOR AND THE MOTOR WAS SHAKING AS IF MISS FIRING OR RUNNING IRATICLY. I HAD NO ENGINE WARNING LIGHT OR ANY OTHER NOTIFICATIONS ON THE DASH PRIOR. I WENT DIRECTLY TO MY MECHANIC. WHEN MY MECHANIC CAME OUT TO SEE WHAT WAS HAPPENING HE KNEW RIGHT AWAY WHAT WAS GOING ON. HE HAS REPAIRED THIS PROBLEM SEVERAL TIMES BEFORE. HE SAID THAT I HAD BLOWNOUT A LEAST ONE SPARK PLUG. THIS IS A KNOWN FLAW WITH THE TRITON V8 MOTORS OR RATHER THE SPARK PLUG DESIGN THAT WAS PUT IN THE ENGINE FROM THE FACTORY. THE SPARK PLUG IS A THREE PIECE DESIGN THE IS CRIMPED TOGETHER AND ULTIMATELY CRACKS AND SEPARATES OVER A PERIOD OF TIME LEADING TO LITERALLY BLOWING UP. IN SOME CASES THE THREADS IN THE MOTOR WHERE THE SPARK PLUG SCREWS IN CAN BE TORN OUT. THIS REQUIRES RE-TAPPING NEW THREADS OR A HELIOCOIL PACK. THIS ISSUE WAS NOT POINTED OUT TO ME BY FORD PRIOR SO I COULD PREVENT POSSIBLE DAMAGE AND VERY EXPENSIVE REPAIR COSTS AS I KNOW THEY ARE AWARE OF THIS PROBLEM AND THAT IS VERY WRONG. THE MANUAL PROVIDED BY FORD WITH THE TRUCK SAYS THE SPARK PLUGS DON'T NEED TO BE CHANGED UNTIL 100K. AFTER FURTHER INVESTIGATION ONLINE I FOUND HUNDREDS OF OTHERS EXPERIENCING THE SAME PROBLEM PRIOR TO 100K. I WILL BE SENDING THE BILL TO REPAIR MY TRUCK TO FORD THROUGH MY ATTORNEY AS THIS IS NEGLIGENT BEHAVIOR AND A FAULTY DESIGN FLAW THAT I COULD NOT HAVE PREVENTED. FORD IS SENDING OWNERS OF THIS MOTOR DOWN A PATH OF GUARANTEED FINANCIAL AND POTENTIAL PHYSICAL HARM. FORD NEEDS TO STAND UP AND OWN THIS MISTAKE. *TR
NHTSA ODI #10314550
49,500 miles · Feb 16, 2010
Engine And Engine CoolingFuel System, Gasoline
WHILE AT ~45MPH, I EASED OFF THE ACCELERATOR TO GO INTO A LEFT HAND TURN. MY F150 THEN LOST ALL POWER AND SHUT OFF (NO POWER STEERING, ETC), AND THERE WERE 2 TRACKER TRAILERS COMING IN THE OPPOSITE DIRECTION FROM ME. I WAS BARELY ABLE TO COMPLETE THE TURN WITH THE MOMENTUM THAT I HAD BEFORE THE TRUCK DIED. THE TRUCK RE-STARTE…
Read full complaint
WHILE AT ~45MPH, I EASED OFF THE ACCELERATOR TO GO INTO A LEFT HAND TURN. MY F150 THEN LOST ALL POWER AND SHUT OFF (NO POWER STEERING, ETC), AND THERE WERE 2 TRACKER TRAILERS COMING IN THE OPPOSITE DIRECTION FROM ME. I WAS BARELY ABLE TO COMPLETE THE TURN WITH THE MOMENTUM THAT I HAD BEFORE THE TRUCK DIED. THE TRUCK RE-STARTED WITHOUT ANY ISSUE. THIS HAD HAPPENED BEFORE 2 OTHER TIMES WITH LARGE GAPS OF TIME IN BETWEEN (ONCE IN NOVEMBER 09 AND THE OTHER TIME A WEEK BEFORE THIS LATEST INCIDENT). THE OTHER 2 OCCURRENCES WERE SIMILAR (HIGHWAY SPEEDS OF 60MPH), AND RESTARTING WITHOUT ANY ISSUE OR ERROR CODES. AN ERROR CODE WAS GENERATED (FINALLY) WITH THE INCIDENT DESCRIBED AT THE TOP OF THIS COMPLAINT, AND I BROUGHT THE TRUCK TO THE DEALERSHIP. THEY DIAGNOSED A FAULTY THROTTLE SENSOR WHICH WAS REPLACED. AT LESS THAN 50,000 MILES I DID NOT EXPECT TO SEE AN ISSUE WITH THIS SENSOR, AND CERTAINLY I WOULD EXPECT THE TRUCK TO DEFAULT INTO THE "LIMP HOME MODE" DESCRIBED IN THE MANUAL, WHICH IT DID NOT. THERE WERE SEVERAL OTHER SIMILAR COMPLAINTS FOR THIS ON SOME FORUMS AND I FELT IT MIGHT NEED SOME ATTENTION. *TR
NHTSA ODI #10311146
59,000 miles · Feb 12, 2010
Engine And Engine Cooling
2005 FORD F150, 5.4 V-8 ENGINE, 59,000 MILES INCIDENT 1) 02/7/10 - UPON ACCELERATING AWAY FROM A STOP LIGHT WHILE TURNING LEFT, THE TRUCK ACCELERATOR PEDAL BECAME INACTIVE. TRUCK WAS MOVING AT 25-30 MPH. ADDITIONAL PRESSURE APPLIED TO THE PEDAL CAUSED NO ACCELERATION. LIGHT TRAFFIC ALLOWED ME TO COAST TO SHOULDER WHERE I WAS …
Read full complaint
2005 FORD F150, 5.4 V-8 ENGINE, 59,000 MILES INCIDENT 1) 02/7/10 - UPON ACCELERATING AWAY FROM A STOP LIGHT WHILE TURNING LEFT, THE TRUCK ACCELERATOR PEDAL BECAME INACTIVE. TRUCK WAS MOVING AT 25-30 MPH. ADDITIONAL PRESSURE APPLIED TO THE PEDAL CAUSED NO ACCELERATION. LIGHT TRAFFIC ALLOWED ME TO COAST TO SHOULDER WHERE I WAS ABLE TO PUT THE TRUCK IN PARK. TRUCK FAULTED INTO 'LIMP MODE' THAT LIMITS THE ACCELERATOR PEDAL OPERATION (PER MANUAL), THIS WAS INDICATED BY THE 'WRENCH' LIGHT ON THE DASH, NO CHECK ENGINE LIGHT APPEARED. TURNED THE IGNITION OFF, WAITED A ~15 SECONDS AND RESTARTED. UPON RESTART 'WRENCH' LIGHT CLEARED AND ACCELERATOR FUNCTIONED AS PRIOR, AGAIN NO CHECK ENGINE LIGHT APPEARED. INCIDENT 2) 02/12/10 - WHILE DRIVING ON A FEDERAL HIGHWAY AT 55 MPH IN RIGHT LANE THE SAME SEQUENCE AS INCIDENT ONE ABOVE OCCURRED ? THE TRUCK ACCELERATOR PEDAL BECAME INACTIVE. BEING IN THE RIGHT-MOST LANE I WAS ABLE TO COAST ON TO THE SHOULDER AND AVOID A REAR-END COLLISION. SAME ?WRENCH? LIGHT WAS INDICATED ON DASH, SAME SEQUENCE WAS USED TO RESTART AND DRIVE OFF. THIS OBVIOUSLY COULD HAVE BEEN MUCH WORSE HAD THE SITUATION BEEN DIFFERENT, I.E. IN HIGH-SPEED LANE OR HEAVIER TRAFFIC PATTERNS. THIS IS CERTAINLY A SAFETY CONCERN FOR DRIVING PUBLIC, BOTH THOSE IN THE F150 AND ON THE ROAD AROUND THEM. ALMOST IDENTICAL INSTANCES CAN BE SEEN ON NHTSA SITE FOR EXACT MAKE/MODEL/YEAR TRUCK. ADMINISTRATION SHOULD INVESTIGATE AND CONSIDER A SAFETY RECALL TO AVOID FUTURE DAMAGE. *TR
NHTSA ODI #10310032
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.
Illustration