AT APPROXIMATELY 3 PM ON SATURDAY, JUNE 2, 2018, MY 2008 F-250 SD 4WD TRUCK EXPERIENCED AN ABRUPT CATASTROPHIC FAILURE OF THE TRANSFER CASE. THE INCIDENT OCCURRED ON A BUSY INTERSTATE CORRIDOR WHILE I WAS TRAVELING AT APPROXIMATELY 70 MPH WHILE IN 2WD MODE. IMMEDIATELY PRIOR TO THE INCIDENT, A DULL RUMBLE COULD BE HEARD, WHICH R…
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AT APPROXIMATELY 3 PM ON SATURDAY, JUNE 2, 2018, MY 2008 F-250 SD 4WD TRUCK EXPERIENCED AN ABRUPT CATASTROPHIC FAILURE OF THE TRANSFER CASE. THE INCIDENT OCCURRED ON A BUSY INTERSTATE CORRIDOR WHILE I WAS TRAVELING AT APPROXIMATELY 70 MPH WHILE IN 2WD MODE. IMMEDIATELY PRIOR TO THE INCIDENT, A DULL RUMBLE COULD BE HEARD, WHICH RAPIDLY AMPLIFIED TO A LOUD ROAR. I REMOVED MY FOOT FROM THE ACCELERATOR PEDAL AND WAS ALMOST IMMEDIATELY JOLTED BY A THUNDEROUS EXPLOSION THAT EMANATED FROM UNDERNEATH THE VEHICLE. THE ENTIRE TRUCK SHOOK VIOLENTLY AS I PULLED OVER ONTO THE HIGHWAY SHOULDER. AS THE TRUCK LURCHED FORWARD HESITANTLY, A CLOUD OF THICK SMOKE BILLOWED OUT FROM BELOW THE TRUCK NEAR THE FRONT DOORS. UPON EXITING THE VEHICLE, I NOTICED THAT TRANSMISSION FLUID WAS POURING OUT THE TRANSFER CASE, WHOSE EXTERIOR WALL HAD LITERALLY BEEN RIPPED APART. LARGE GEAR COMPONENTS FROM THE TRANSFER CASE WERE STREWN ALONG THE HIGHWAY SHOULDER. THE EXPLOSION WITHIN THE TRANSFER CASE CAUSED SEVERAL INTERNAL PARTS TO BE EJECTED WITH SIGNIFICANT FORCE AND VELOCITY. THE SIZABLE INDENTATIONS AND LARGE SCRAPES INFLICTED UPON THE EXHAUST SYSTEM AND THE PASSENGER FLOOR PAN, RESPECTIVELY, ARE A CONSPICUOUS TESTAMENT TO THE FORCEFUL DISCHARGE OF THESE VARIOUS COMPONENTS PARTS FROM INSIDE THE TRANSFER CASE. THE SUBSTANTIAL ENERGY CONTAINED IN THIS EXPLOSION NECESSARILY IMPLIES THAT TREMENDOUS PRESSURE WAS BUILDING UP INSIDE THE TRANSFER CASE. FURTHERMORE, THE THICK, ACRID SMOKE RELEASED FOLLOWING THE EXPLOSION IS ALSO INDICATIVE THAT THE TRANSFER CASE WAS SUBJECT TO APPRECIABLE HEAT GENERATION. FORTUNATELY, AND RATHER INCREDIBLY, NO INJURIES NOR CRASHES WERE SUSTAINED WHEN THE TRANSFER CASE PRECIPITOUSLY BURST. DESPITE THE ABSENCE OF COLLATERAL DAMAGE OR CASUALTIES, THE SEVERITY AND MAGNITUDE OF THIS INEXPLICABLE EQUIPMENT FAILURE WARRANT DOCUMENTATION AS THIS IS A CRITICAL PART MALFUNCTION.
NHTSA ODI #11100533
14,545 miles · Nov 30, 2012
Power Train
TL*THE CONTACT OWNS A 2008 FORD F-250 SD. THE CONTACT STATED THAT HE RECEIVED NOTIFICATION OF A MANUFACTURER'S RECALL AND TOOK THE VEHICLE TO THE DEALER FOR RECALIBRATION. AFTER THE RECALL SERVICE, THE CONTACT WAS DRIVING APPROXIMATELY 50-60 MPH WHEN THE TRANSMISSION STARTED TO SLIP. THE VEHICLE WAS TAKEN BACK TO THE DEALER WHE…
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TL*THE CONTACT OWNS A 2008 FORD F-250 SD. THE CONTACT STATED THAT HE RECEIVED NOTIFICATION OF A MANUFACTURER'S RECALL AND TOOK THE VEHICLE TO THE DEALER FOR RECALIBRATION. AFTER THE RECALL SERVICE, THE CONTACT WAS DRIVING APPROXIMATELY 50-60 MPH WHEN THE TRANSMISSION STARTED TO SLIP. THE VEHICLE WAS TAKEN BACK TO THE DEALER WHERE THEY ADVISED THE CONTACT THAT HE WOULD HAVE TO DRIVE THE VEHICLE AROUND FOR A WHILE UNTIL IT FUNCTIONED NORMALLY. THE MANUFACTURER WAS CONTACTED AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 14,545. THE CURRENT MILEAGE WAS APPROXIMATELY 17,344. THE CONSUMER STATED WHILE DRIVING AT AN ESTIMATED SPEED OF 50-60 MPH AND ATTEMPTING A FORCED DOWN SHIFT, THE TRANSMISSION SHIFTED INTO 3RD GEAR INSTEAD OF 4TH GEAR CAUSING RAPID REAR WHEEL DECELERATION AND HIGH ENGINE RPM TO OCCUR. IT OCCURRED IMMEDIATELY FOLLOWING SERVICING OF THE PCM PER THE MANUFACTURER'S RECALL. THE DEALER ADVISED THE CONSUMER TO DRIVE THE VEHICLE UP TO 500 MILES WHILE THE TRANSMISSION RE-LEARN ITS SHIFT TO POINTS. AFTER COMPLYING WITH THE DEALERS REQUEST, THE CONSUMER CONTINUED TO EXPERIENCE THE PROBLEM. THE DEALER INFORMED THE CONSUMER THERE WAS NOTHING WRONG WITH THE TRANSMISSION AND IT WAS PERFORMING AS DESIGNED. UPDATED 12/19/12.. UPDATED 12/31/12 *BF UPDATED 1/3/2013 *JS
NHTSA ODI #10486552
70,000 miles · Sep 18, 2012
Engine And Engine CoolingPower TrainFire
TL* THE CONTACT OWNS A 2008 FORD F-250 SD. WHILE DRIVING APPROXIMATELY 50 MPH, THE TURBO ENGINE STALLED WITH AN ILLUMINATION OF A WARNING INDICATOR. THE VEHICLE BEGAN TO PERFORM ROUGHLY WITH SMOKE AND FLAMES EMITTING FROM THE EXHAUST. WHEN THE ENGINE WAS TURNED OFF THE FLAMES WERE NO LONGER VISIBLE. THE VEHICLE WAS TOWED TO AN A…
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TL* THE CONTACT OWNS A 2008 FORD F-250 SD. WHILE DRIVING APPROXIMATELY 50 MPH, THE TURBO ENGINE STALLED WITH AN ILLUMINATION OF A WARNING INDICATOR. THE VEHICLE BEGAN TO PERFORM ROUGHLY WITH SMOKE AND FLAMES EMITTING FROM THE EXHAUST. WHEN THE ENGINE WAS TURNED OFF THE FLAMES WERE NO LONGER VISIBLE. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER WHO STATED THE TURBO CHARGER WOULD NEED TO BE REPLACED AND INCLUDING OTHER DEFECTIVE PARTS. THE FAILURE WAS RELATED TO THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER 07V139000 (POWER TRAIN: AUTOMATIC TRANSMISSION: CONTROL MODULE (TCM, PCM)). THE CONTACT EXPERIENCED THE IDENTICAL DEFECT AS STATED IN THE RECALL. THE MANUFACTURER WAS NOTIFIED AND THEY INFORMED THE CONTACT THAT THE VIN WAS NOT INCLUDED IN THE RECALL. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 70,000. UPDATED 11/01/12*LJ
NHTSA ODI #10475851
30,000 miles · Sep 28, 2010
Power Train
MY FORD F-250 SD ENGAGES INTO 4X4 HIGH AND LOW WHILE AT HIGHWAY SPEEDS ALL ON ITS OWN. *TR
NHTSA ODI #10358056
10,000 miles · Jun 8, 2010
Power Train
FRONT END SHAKES A LOT. *TR
NHTSA ODI #10335240
Mileage unknown · Feb 16, 2008
Power Train
HARD VIBRATION IN TRANSMISSION WHEN DOWNSHIFTING, ESPECIALLY UPHILL WHILE TOWING. VIBRATION STOPS WHEN LETTING UP ON ACCELERATOR. THIS HAPPENS WHILE IN CRUISE OR MANUAL. DEALER STATES CANNOT FIND THE PROBLEM AFTER THREE VISITS. MECHANIC AT ANOTHER DEALERSHIP IN HAMPTON, VA HAD SIMILAR EXPERIENCE. BOUGHT VEHICLE ON 07/28/2007…
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HARD VIBRATION IN TRANSMISSION WHEN DOWNSHIFTING, ESPECIALLY UPHILL WHILE TOWING. VIBRATION STOPS WHEN LETTING UP ON ACCELERATOR. THIS HAPPENS WHILE IN CRUISE OR MANUAL. DEALER STATES CANNOT FIND THE PROBLEM AFTER THREE VISITS. MECHANIC AT ANOTHER DEALERSHIP IN HAMPTON, VA HAD SIMILAR EXPERIENCE. BOUGHT VEHICLE ON 07/28/2007. CURRENTLY 28,000 MILES AND AM CONCERNED ABOUT THE EXPIRATION OF WARRANTY BEFORE PROBLEM IS RESOLVED. NO HELP FROM ORIGINAL DEALER. *TR
NHTSA ODI #10218177
6,930 miles · Dec 18, 2007
Power TrainCrash
TL*THE CONTACT OWNS A 2008 FORD F-250 SD. THE CONTACT STATED THAT THE GEAR SHIFT HAS RELEASED OUT OF PARK ON TWO OCCASIONS. SHE CANNOT EXIT THE VEHICLE WHEN THE FAILURE OCCURS. THE FAILURE IS INTERMITTENT. THE DEALER WOULD NOT OFFER ANY ASSISTANCE DUE TO LIABILITY. AS A RESULT, HER HUSBAND WAS INVOLVED IN A CRASH. THE VEHI…
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TL*THE CONTACT OWNS A 2008 FORD F-250 SD. THE CONTACT STATED THAT THE GEAR SHIFT HAS RELEASED OUT OF PARK ON TWO OCCASIONS. SHE CANNOT EXIT THE VEHICLE WHEN THE FAILURE OCCURS. THE FAILURE IS INTERMITTENT. THE DEALER WOULD NOT OFFER ANY ASSISTANCE DUE TO LIABILITY. AS A RESULT, HER HUSBAND WAS INVOLVED IN A CRASH. THE VEHICLE WAS PLACED INTO PARK, BUT ROLLED FORWARD WHILE IN PARK AND STRUCK TWO VEHICLES. A POLICE REPORT WAS FILED. THERE WERE NO INJURIES. THE SPEED WAS UNKNOWN. THE FAILURE AND CURRENT MILEAGES WERE 6,930. UPDATED 01-30-08. *KB THE CONSUMER STATED WILL NOT BE ACCESSED INSURANCE POINTS AND PAID A $500 DEDUCTIBLE TO REPAIR VEHICLE. UPDATED 01/30/08 *TR
NHTSA ODI #10212258
Official recalls
0
No recalls in this snapshot.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
1
PE13014 · Alleged Loss Of Steering
Opened May 7, 2013 · Closed Jan 31, 2014
Status: closed (inferred from source dates) · Steering; Steering:gear Box (other Than Rack And Pinion)
The Office of DefectsInvestigation (ODI) opened PE13-014 after identifying five complaints alleging steering gear failure in model year (MY) 2008 Ford F-250 and F-350 Super Duty pick-up trucks and to evaluate the relationship between the design history of the steering gear assembly and the alleged defect.As background, ODI investigated steering gear sector shaft fractures in approximately 1.3 million MY 1999 - 2001 Ford Super Duty pick-up trucks and MY 2000 - 2001 Ford Excursion sport utility vehicles in Engineering Analysis EA01-009.The investigation determined that the sector shaft failures were the result of extraordinary, possibly multiple, impacts and not the result of fatigue.No defect in design, manufacturing or materials was identified in the sector shaft.EA01-009 was closed August 19, 2003 with 169 complaints, resulting in a rate of 12.9 incidents per 100,000 vehicles after approximately one year of service.Ford increased the diameter of the sector shaft from 1.375 inches to 1.625 inches at the start of MY 2005 production, increasing the resistance of the steering gear assembly to torsional overload by approximately 48% and changing the failure mode from sector shaft fracture to cracked or broken sector shaft gear teeth.The redesigned steering gear assembly was used in approximately 1.1 million MY 2005 through 2009 Ford Super Duty pick-up trucks, including the subject vehicles.Figure 1 shows the basic steering system design used in Ford Super Duty trucks investigated in EA01-009 and PE13-014. Figure 2 shows the locations of failures resulting from impact related torsional overloading of the sector shaft for the subject vehicles and the prior generation Ford Super Duty trucks investigated in EA01-009.Figure 3 shows an example of a failed sector shaft investigated in EA01-009 and comparisons of fracture surfaces of sector shafts failing from fatigue loading and from torsional overload.Ford provided field return part analysis of failed steering gears from MY 2005 through 2009 Super Duty trucks found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload (Figure 4).Laboratory analysis found no evidence of fatigue or material property defects in any of the fractures.Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns (Figure 5).Analysis of failures by time in service indicates a random failure pattern/distribution, consistent with incidents of impact induced overload (Figure 6). The complaint rate for the subject vehicles after approximately 5 to 6 years, 7.1 incidents per 100,000 vehicles, is lower than the rate observed in EA01-009. Furthermore, similar to the condition investigated in EA01-009, a number of incident records include evidence of impact loads (e.g., curb strikes) and several alleged crashes include incidents in which information suggests that the steering gear failure was most likely a result of crash forces, rather than the cause of the crash.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at ww
Additional source detail variants (2)
Steering
The Office of DefectsInvestigation (ODI) opened PE13-014 after identifying five complaints alleging steering gear failure in model year (MY) 2008 Ford F-250 and F-350 Super Duty pick-up trucks and to evaluate the relationship between the design history of the steering gear assembly and the alleged defect.As background, ODI investigated steering gear sector shaft fractures in approximately 1.3 million MY 1999 - 2001 Ford Super Duty pick-up trucks and MY 2000 - 2001 Ford Excursion sport utility vehicles in Engineering Analysis EA01-009.The investigation determined that the sector shaft failures were the result of extraordinary, possibly multiple, impacts and not the result of fatigue.No defect in design, manufacturing or materials was identified in the sector shaft.EA01-009 was closed August 19, 2003 with 169 complaints, resulting in a rate of 12.9 incidents per 100,000 vehicles after approximately one year of service.Ford increased the diameter of the sector shaft from 1.375 inches to 1.625 inches at the start of MY 2005 production, increasing the resistance of the steering gear assembly to torsional overload by approximately 48% and changing the failure mode from sector shaft fracture to cracked or broken sector shaft gear teeth.The redesigned steering gear assembly was used in approximately 1.1 million MY 2005 through 2009 Ford Super Duty pick-up trucks, including the subject vehicles.Figure 1 shows the basic steering system design used in Ford Super Duty trucks investigated in EA01-009 and PE13-014. Figure 2 shows the locations of failures resulting from impact related torsional overloading of the sector shaft for the subject vehicles and the prior generation Ford Super Duty trucks investigated in EA01-009.Figure 3 shows an example of a failed sector shaft investigated in EA01-009 and comparisons of fracture surfaces of sector shafts failing from fatigue loading and from torsional overload.Ford provided field return part analysis of failed steering gears from MY 2005 through 2009 Super Duty trucks found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload (Figure 4).Laboratory analysis found no evidence of fatigue or material property defects in any of the fractures.Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns (Figure 5).Analysis of failures by time in service indicates a random failure pattern/distribution, consistent with incidents of impact induced overload (Figure 6). The complaint rate for the subject vehicles after approximately 5 to 6 years, 7.1 incidents per 100,000 vehicles, is lower than the rate observed in EA01-009. Furthermore, similar to the condition investigated in EA01-009, a number of incident records include evidence of impact loads (e.g., curb strikes) and several alleged crashes include incidents in which information suggests that the steering gear failure was most likely a result of crash forces, rather than the cause of the crash.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at ww
Steering:gear Box (other Than Rack And Pinion)
The Office of DefectsInvestigation (ODI) opened PE13-014 after identifying five complaints alleging steering gear failure in model year (MY) 2008 Ford F-250 and F-350 Super Duty pick-up trucks and to evaluate the relationship between the design history of the steering gear assembly and the alleged defect.As background, ODI investigated steering gear sector shaft fractures in approximately 1.3 million MY 1999 - 2001 Ford Super Duty pick-up trucks and MY 2000 - 2001 Ford Excursion sport utility vehicles in Engineering Analysis EA01-009.The investigation determined that the sector shaft failures were the result of extraordinary, possibly multiple, impacts and not the result of fatigue.No defect in design, manufacturing or materials was identified in the sector shaft.EA01-009 was closed August 19, 2003 with 169 complaints, resulting in a rate of 12.9 incidents per 100,000 vehicles after approximately one year of service.Ford increased the diameter of the sector shaft from 1.375 inches to 1.625 inches at the start of MY 2005 production, increasing the resistance of the steering gear assembly to torsional overload by approximately 48% and changing the failure mode from sector shaft fracture to cracked or broken sector shaft gear teeth.The redesigned steering gear assembly was used in approximately 1.1 million MY 2005 through 2009 Ford Super Duty pick-up trucks, including the subject vehicles.Figure 1 shows the basic steering system design used in Ford Super Duty trucks investigated in EA01-009 and PE13-014. Figure 2 shows the locations of failures resulting from impact related torsional overloading of the sector shaft for the subject vehicles and the prior generation Ford Super Duty trucks investigated in EA01-009.Figure 3 shows an example of a failed sector shaft investigated in EA01-009 and comparisons of fracture surfaces of sector shafts failing from fatigue loading and from torsional overload.Ford provided field return part analysis of failed steering gears from MY 2005 through 2009 Super Duty trucks found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload (Figure 4).Laboratory analysis found no evidence of fatigue or material property defects in any of the fractures.Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns (Figure 5).Analysis of failures by time in service indicates a random failure pattern/distribution, consistent with incidents of impact induced overload (Figure 6). The complaint rate for the subject vehicles after approximately 5 to 6 years, 7.1 incidents per 100,000 vehicles, is lower than the rate observed in EA01-009. Furthermore, similar to the condition investigated in EA01-009, a number of incident records include evidence of impact loads (e.g., curb strikes) and several alleged crashes include incidents in which information suggests that the steering gear failure was most likely a result of crash forces, rather than the cause of the crash.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at ww
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