NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
77 reportsClear category filter87,351 miles · Feb 10, 2012
Engine And Engine CoolingPower Train
THE NUMBER 3 SPARK PLUG WAS BLOWN OUT OF THE CYLINDER HEAD. THIS IS THE SECOND OCCURRENCE OF THE SAME SPARK PLUG. THE FIRST INCIDENT OCCURRED ON 10/21/2011 AT 82781 MILES. THE FIRST REPAIR WAS COMPLETED BY MIKE NAUGHTON FORD IN AURORA CO. THE MECHANIC INSTALLED A SLEEVE INTO THE CYLINDER HEAD TO REINSTALL A NEW SPARK PLUG. THE M…
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THE NUMBER 3 SPARK PLUG WAS BLOWN OUT OF THE CYLINDER HEAD. THIS IS THE SECOND OCCURRENCE OF THE SAME SPARK PLUG. THE FIRST INCIDENT OCCURRED ON 10/21/2011 AT 82781 MILES. THE FIRST REPAIR WAS COMPLETED BY MIKE NAUGHTON FORD IN AURORA CO. THE MECHANIC INSTALLED A SLEEVE INTO THE CYLINDER HEAD TO REINSTALL A NEW SPARK PLUG. THE MECHANIC EXPLAINED THAT THIS IS A KNOWN PROBLEM BECAUSE THE CYLINDER HEAD ONLY HAS 3-4 THREADS FOR THE SPARK PLUG TO SCREW INTO. *TR
NHTSA ODI #10447411
128,183 miles · Dec 1, 2011
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD F150. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 30 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED TO THE DEALER WHERE THE DEALER PERFORMED A DIAGNOSTIC AND LOCATED THE FAILURE AS THE ENGINE LOCKING DUE TO DEFECTIVE PARTS. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MA…
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TL* THE CONTACT OWNS A 2006 FORD F150. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 30 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED TO THE DEALER WHERE THE DEALER PERFORMED A DIAGNOSTIC AND LOCATED THE FAILURE AS THE ENGINE LOCKING DUE TO DEFECTIVE PARTS. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE AND THE CURRENT MILEAGE WAS 128,183.
NHTSA ODI #10437986
52,000 miles · Nov 28, 2011
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD F-150. THE CONTACT STATED THAT WHILE HAVING ROUTINE MAINTENANCE PERFORMED ON THE VEHICLE, THE DEALER ADVISED HIM THAT THE SPARK PLUGS NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE. THE VEHICLE WAS REPAIRED. THE FAILURE AND THE CURRENT MILEA…
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TL* THE CONTACT OWNS A 2006 FORD F-150. THE CONTACT STATED THAT WHILE HAVING ROUTINE MAINTENANCE PERFORMED ON THE VEHICLE, THE DEALER ADVISED HIM THAT THE SPARK PLUGS NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE. THE VEHICLE WAS REPAIRED. THE FAILURE AND THE CURRENT MILEAGE WAS 52,000.
NHTSA ODI #10437505
66,000 miles · Nov 10, 2011
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD F-150. THE CONTACT STATED WHILE DRIVING 55 MPH THERE WAS A KNOCKING AND BANGING NOISE IN THE ENGINE WHICH CAUSED THE VEHICLE TO MALFUNCTION. THE VEHICLE WAS THEN DRIVEN HOME. THE DEALER WAS NOT NOTIFIED OF THE FAILURE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND OFFERED NO ASSISTANCE. THE FA…
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TL* THE CONTACT OWNS A 2006 FORD F-150. THE CONTACT STATED WHILE DRIVING 55 MPH THERE WAS A KNOCKING AND BANGING NOISE IN THE ENGINE WHICH CAUSED THE VEHICLE TO MALFUNCTION. THE VEHICLE WAS THEN DRIVEN HOME. THE DEALER WAS NOT NOTIFIED OF THE FAILURE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 66,000. RVK
NHTSA ODI #10435139
30,000 miles · Oct 6, 2011
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD F-150. WHILE DRIVING HIGHWAY SPEEDS, THE WRENCH WARNING LIGHT ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE THEN DECELERATED, LOST POWER AND STALLED. THE DEALER AND THE MANUFACTURER WERE CONTACTED BUT DENIED ANY ASSISTANCE WITH REPAIRS. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS …
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TL* THE CONTACT OWNS A 2006 FORD F-150. WHILE DRIVING HIGHWAY SPEEDS, THE WRENCH WARNING LIGHT ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE THEN DECELERATED, LOST POWER AND STALLED. THE DEALER AND THE MANUFACTURER WERE CONTACTED BUT DENIED ANY ASSISTANCE WITH REPAIRS. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 30,000 AND THE CURRENT MILEAGE WAS 52,000.
NHTSA ODI #10428949
116,000 miles · Sep 22, 2011
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD F150. THE CONTACT STATED THAT THE ENGINE EXHIBITED AN ABNORMAL NOISE WHILE DRIVING AT ANY SPEED OVER 30 MPH. THE VEHICLE WAS TAKEN TO THE LOCAL MECHANIC WHO PERFORMED A DIAGNOSTIC THAT LOCATED THE FAILURE AT THE NUMBER SEVEN AND EIGHT SPARK-PLUGS. THE MECHANIC ADVISED THAT THE SPARK PLUGS HAD SEP…
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TL* THE CONTACT OWNS A 2006 FORD F150. THE CONTACT STATED THAT THE ENGINE EXHIBITED AN ABNORMAL NOISE WHILE DRIVING AT ANY SPEED OVER 30 MPH. THE VEHICLE WAS TAKEN TO THE LOCAL MECHANIC WHO PERFORMED A DIAGNOSTIC THAT LOCATED THE FAILURE AT THE NUMBER SEVEN AND EIGHT SPARK-PLUGS. THE MECHANIC ADVISED THAT THE SPARK PLUGS HAD SEPARATED FROM THE HOLDER AND CAUSED A PIECE OF THE SPARK PLUG TO PENETRATE THE ENGINE. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT AVAILABLE. THE FAILURE AND THE CURRENT MILEAGE WAS 116,000. UPDATED 10/27/11*LJ UPDATED 12/06/2011 *LN
NHTSA ODI #10426727
83,000 miles · Sep 1, 2011
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD F-150. THE CONTACT WAS DRIVING 70 MPH WHEN THE VEHICLE EXHIBITED A LOUD, ABNORMAL NOISE FROM UNDER THE HOOD FOLLOWED BY THE VEHICLE STALLING. THE CHECK ENGINE LIGHT WAS ILLUMINATED. THE VEHICLE WAS TOWED TO THE DEALER WHO PERFORMED A DIAGNOSTIC THAT LOCATED THE FAILURE AS THE NUMBER SEVEN SPARK P…
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TL* THE CONTACT OWNS A 2006 FORD F-150. THE CONTACT WAS DRIVING 70 MPH WHEN THE VEHICLE EXHIBITED A LOUD, ABNORMAL NOISE FROM UNDER THE HOOD FOLLOWED BY THE VEHICLE STALLING. THE CHECK ENGINE LIGHT WAS ILLUMINATED. THE VEHICLE WAS TOWED TO THE DEALER WHO PERFORMED A DIAGNOSTIC THAT LOCATED THE FAILURE AS THE NUMBER SEVEN SPARK PLUG HAVING RELEASED FROM THE COIL HEAD CAUSING THE COIL ASSEMBLY TO FAIL. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND THE CURRENT MILEAGE WAS 83,000.
NHTSA ODI #10422906
111,000 miles · Jul 26, 2011
Engine And Engine Cooling
TRUCK RAN ROUGH WITH HAVE SMOKE FROM EXHAUST. TOOK TRUCK IN AT 41,000 TO FIX A BAD COIL ASSEMBLY, THEN AT 99,000 TO FIX A BAD COIL ASSEMBLY, INJECTOR AND O2 SENSOR. AT 111,000 MILES TWO MORE INJECTORS WENT BAD CAUSING TWO RODS TO BE BENT ALONG WITH ANOTHER BAD O2 SENSOR. SAME PROBLEM AS THE 2005 FORD THAT HAD A RECALL, BUT NOT T…
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TRUCK RAN ROUGH WITH HAVE SMOKE FROM EXHAUST. TOOK TRUCK IN AT 41,000 TO FIX A BAD COIL ASSEMBLY, THEN AT 99,000 TO FIX A BAD COIL ASSEMBLY, INJECTOR AND O2 SENSOR. AT 111,000 MILES TWO MORE INJECTORS WENT BAD CAUSING TWO RODS TO BE BENT ALONG WITH ANOTHER BAD O2 SENSOR. SAME PROBLEM AS THE 2005 FORD THAT HAD A RECALL, BUT NOT THE 2006. TOTAL ESTIMATE TO FIX TRUCK $7500 PLUS TAX! FORD KNOWS ABOUT PROBLEM BUT WONT RECALL. *TR
NHTSA ODI #10415277
70,000 miles · Jul 20, 2011
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD F150. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 20-55 MPH, THERE WAS EXCESSIVE HESITATION WITH AN INTERMITTENT ILLUMINATION OF THE CHECK ENGINE WARNING LIGHT. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHO STATED A SPARK PLUG FRACTURED WITHIN THE ENGINE AND IT WOULD NEED A TUNE-UP. THE VE…
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TL* THE CONTACT OWNS A 2006 FORD F150. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 20-55 MPH, THERE WAS EXCESSIVE HESITATION WITH AN INTERMITTENT ILLUMINATION OF THE CHECK ENGINE WARNING LIGHT. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHO STATED A SPARK PLUG FRACTURED WITHIN THE ENGINE AND IT WOULD NEED A TUNE-UP. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 70,000.
NHTSA ODI #10413686
109,000 miles · Jul 10, 2011
Engine And Engine Cooling
TO START OUT, IT SHOULD NOT COST $1249.00 TO CHANGE ONE SPARK PLUG... DUE TO FORD'S DESIGN FLAW ON THEIR MOTOR CRAFT SPARK PLUGS WHICH CAUSES TH EM TO BREAK EXTREMELY EASY, I AM BEING CHARGED TO TEAR DOWN MY ENTIRE ENGINE TO RETREIVE ONE SPARK PLUG!!! THIS IS FORD'S FAULT AND I FEEL THEY SHOULD BE HELD LIABLE FOR THE COST OF …
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TO START OUT, IT SHOULD NOT COST $1249.00 TO CHANGE ONE SPARK PLUG... DUE TO FORD'S DESIGN FLAW ON THEIR MOTOR CRAFT SPARK PLUGS WHICH CAUSES TH EM TO BREAK EXTREMELY EASY, I AM BEING CHARGED TO TEAR DOWN MY ENTIRE ENGINE TO RETREIVE ONE SPARK PLUG!!! THIS IS FORD'S FAULT AND I FEEL THEY SHOULD BE HELD LIABLE FOR THE COST OF REPAIR. I HAVE BEEN TOLD BY SEVERAL MECHANICS THAT FORD DESIGNED THEIR MOTOR CRAFT PLUGS TO BREAK!! FORD IS ALSO THE ONLY ONE WHO CAN FIX THE PROBLEM. IT WAS NOT UNTIL I PAID OVER $400.00 TO CHANGE 2 COIL PACKS THAT I WAS HIT WITH THIS PRICE. THIS F-150 WOULONLY DO 30-35 MPH ON THE INTERSTATE HIGHWAY...I COULD HAVE BEEN KILLED IF I WAS HIT FROM BEHIND!! THESE SPARK PLUGS SHOULD BE RECALLED AND I SHOULD BE REIMBURSED! MY TRUCK IS STILL AT THE FORD DEALERSHIP AFTER A WEEK...I ALREADY PAID $126.00 FOR MY MOTOR CRAFT PARTS BY CASH EVEN BEFORE TAKING MY TRUCK TO THEM. THIS IS NOT RIGHT ON THE PART OF FORD TO DESIGN A VEHICLE LIKE THAT. PLEASE INVESTIGATE THIS DEFECT PROBLEM SO OTHERS ARE NOT CHARGED LIKE I AM BEING CHARGED. PLEASE RECALL THESE SPARK PLUGS !!!! *TR
NHTSA ODI #10411649
Official recalls
4Feb 23, 2011
FORD IS RECALLING CERTAIN MODEL YEAR 2004-2006 F-150 PICK UP TRUCKS AS WELL AS CERTAIN MODEL YEAR 2006 LINCOLN MARK LT VEHICLES. IF THE CLOCKSPRING JUMPER WIRE COMES IN CONTACT WITH THE DRIVER SIDE FRONTAL AIR BAG LOWER HORN PLATE, THE WIRE INSULATION MAY BECOME CHAFED, CREATING A POTENTIAL FOR A SHORT CIRCUIT. IF THIS OCCURS THE AIR BAG WARNING LAMP MAY ILLUMINATE INDICATING THAT SERVICE IS REQUIRED.
Consequence & remedy
Consequence: THE DRIVER SIDE FRONTAL AIR BAG COULD INADVERTENTLY DEPLOY INCREASING THE RISK OF INJURY OR LOSS OF VEHICLE CONTROL IF OCCURRING WHILE IN MOTION.
Remedy: FORD WILL NOTIFY OWNERS AND INSTRUCT THEM TO TAKE THEIR VEHICLES TO A FORD OR LINCOLN/MERCURY DEALER TO HAVE A NEW CLOCKSPRING JUMPER WIRE INSTALLED THAT INCORPORATES A PROTECTIVE MESH COVER. REPAIRS WILL BE PERFORMED FREE OF CHARGE. THIS SAFETY RECALL BEGAN ON SOME VEHICLES IN MARCH 2011. THE RECALL CAMPAIGN ON THE EXPANDED POPULATION IS EXPECTED TO BEGIN ON OR ABOUT MAY 9, 2011. OWNERS MAY CONTACT THE FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.
May 7, 2008
FORD IS RECALLING 605,684 MY 2005-2006 F-150 AND LINCOLN MARK LT VEHICLES EQUIPPED WITH 5.4L 3-VALVE ENGINES. THE BRAKE BOOSTER VACUUM SUPPLY HOSE ATTACHED TO THE INTAKE MANIFOLD FITTING MAY SWELL OVER TIME AND LOSE RETENTION FORCE. THIS CONDITION COULD ALLOW THE HOSE TO BECOME DETACHED FROM THE FITTING DURING AN INTAKE MANIFOLD BACKFIRE. SHOULD THE HOSE DETACH FROM THE INTAKE MANIFOLD, SEVERAL BRAKE APPLICATIONS WITH POWER ASSIST WILL BE AVAILABLE BEFORE THE VACUUM RESERVE IS DEPLETED.
Consequence & remedy
Consequence: ONCE THE BRAKE BOOSTER VACUUM RESERVE IS DEPLETED, THE DRIVER WILL HAVE FOUNDATION BRAKE FUNCTION, BUT WITH INCREASED BRAKE PEDAL EFFORT. REDUCED VEHICLE BRAKING COULD LEAD TO A CRASH.
Remedy: DEALERS WILL REPLACE A RUBBER HOSE ON THE BRAKE BOOSTER VACUUM SUPPLY TUBE ASSEMBLY. THE RECALL BEGAN ON JUNE 27, 2008. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Feb 6, 2006
CERTAIN PICKUP TRUCKS FAIL TO COMPLY WITH EITHER THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD (FMVSS) NO. 105, 'HYDRAULIC AND ELECTRIC BRAKE SYSTEMS' OR FMVSS NO. 135, 'PASSENGER CAR BRAKE SYSTEMS.' THESE VEHICLES WERE BUILT WITH A SOFTWARE ERROR IN THE INSTRUMENT CLUSTER.
Consequence & remedy
Consequence: THIS ERROR COULD PREVENT THE ANTILOCK BRAKE SYSTEM (ABS) WARNING LIGHT FROM ILLUMINATING IF THE ABS MODULE EVER BECAME INOPERATIVE.
Remedy: DEALERS WILL RECALIBRATE THE INSTRUMENT CLUSTER IN THESE VEHICLES. THE RECALL BEGAN ON FEBRUARY 27, 2006. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Nov 9, 2005
ON CERTAIN TRUCKS, PASSENGER CARS AND SPORT UTILITY VEHICLES, THE WINDSHIELD WIPER MOTOR MAY HAVE BEEN PRODUCED WITHOUT GREASE BEING APPLIED TO THE OUTPUT SHAFT GEAR.
Consequence & remedy
Consequence: AFTER A PERIOD OF CONTINUOUS USE ON THE HIGH SPEED SETTING, LACK OF GREASE ON THE OUTPUT SHAFT GEAR MAY CAUSE THE GEAR TO DISTORT OR FRACTURE DURING OPERATION RESULTING IN A LOSS OF WIPER FUNCTION. INOPERATIVE WIPERS UNDER INCLEMENT WEATHER CONDITIONS COULD CAUSE A CRASH DUE TO IMPAIRED VISIBILITY.
Remedy: DEALERS WILL INSPECT THE WIPER MOTOR FOR THE PRESENCE OF GREASE AND GREASE THE WIPER MOTOR GEARS IF NECESSARY. THE RECALL BEGAN ON NOVEMBER 22, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673 OR LINCOLN/MERCURY AT 1-800-521-4140.
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
2EA10001 · 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.
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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