NHTSA owner reports · September 18, 2026 snapshot.
Power Train complaints
14 reportsClear category filter48,048 miles · Apr 6, 2021
Power TrainSteering
TL* THE CONTACT OWNS A 2008 FORD F-250. THE CONTACT STATED WHILE DRIVING 20-25 MPH, THE VEHICLE STARTED SHAKING. NO WARNING LIGHTS WERE ILLUMINATED. THE VEHICLE WAS TAKEN TO SPITZER FORD (543 W MAPLE ST, HARTVILLE, OH 44632) AND INFORMED THAT THE TRACK BAR, BALL JOINTS, TIE ROD JOINTS AND POSSIBLE STEERING GEAR ASSEMBLY NEEDED T…
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TL* THE CONTACT OWNS A 2008 FORD F-250. THE CONTACT STATED WHILE DRIVING 20-25 MPH, THE VEHICLE STARTED SHAKING. NO WARNING LIGHTS WERE ILLUMINATED. THE VEHICLE WAS TAKEN TO SPITZER FORD (543 W MAPLE ST, HARTVILLE, OH 44632) AND INFORMED THAT THE TRACK BAR, BALL JOINTS, TIE ROD JOINTS AND POSSIBLE STEERING GEAR ASSEMBLY NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND OPENED A CASE. THE MANUFACTURER ALSO INFORMED THE CONTACT THAT HE WOULD BE NOTIFIED IN THE EVENT THERE WAS A RECALL ASSOCIATED WITH THE VIN FOR THE FAILURE EXPERIENCED. IT WAS SUGGESTED THAT AN EXTRA HEAVY DUTY STEERING DAMPER BE INSTALLED ON THE VEHICLE. THE FAILURE MILEAGE WAS 48,048.*DT
NHTSA ODI #11406671
15,000 miles · Jan 8, 2020
Power Train
TL* THE CONTACT OWNS A 2008 FORD F-250. THE CONTACT STATED THAT AFTER THE VEHICLE WAS PARKED FOR AN UNSTATED AMOUNT OF TIME, THE VEHICLE WAS RESTARTED AND THE GEAR SHIFT LEVER CEASED IN THE PARK POSITION. THERE WAS NO WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TOWED TO REPUBLIC FORD LINCOLN LOCATED AT 1740 US-60, REPUBLIC, MO 6…
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TL* THE CONTACT OWNS A 2008 FORD F-250. THE CONTACT STATED THAT AFTER THE VEHICLE WAS PARKED FOR AN UNSTATED AMOUNT OF TIME, THE VEHICLE WAS RESTARTED AND THE GEAR SHIFT LEVER CEASED IN THE PARK POSITION. THERE WAS NO WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TOWED TO REPUBLIC FORD LINCOLN LOCATED AT 1740 US-60, REPUBLIC, MO 65738, (417)732-2626, BUT WAS NOT DIAGNOSED NOR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 15,000.
NHTSA ODI #11297897
251,314 miles · Sep 1, 2019
Power Train
WHEN I WAS DRIVING I LOST POWER I PUT ON THE SCANNER GOT A CODE P0701 WHICH IS THE TORQUE CONVERTER SOLENOID I LOST ALL GEARS I RESET THE LIGHT GOT 3 AND 4 WAS ABLE TO MAKE IT HOME BUT NOW HAVE NO GEARS WHAT SO EVER
NHTSA ODI #11252687
200,000 miles · Jan 22, 2019
Power Train
TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING APPROXIMATELY 65 MPH, A POPPING NOISE SUDDENLY OCCURRED. THE VEHICLE BEGAN TO LOSE POWER AND WOULD NOT ACCELERATE PAST 30 MPH. THE VEHICLE WAS TOWED TO RED MCCOMBS FORD (8333 I10, SAN ANTONIO, TX) WHERE IT WAS DIAGNOSED THAT THE PARTICULATE FILTER WAS FAULTY AND NEEDED TO BE …
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TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING APPROXIMATELY 65 MPH, A POPPING NOISE SUDDENLY OCCURRED. THE VEHICLE BEGAN TO LOSE POWER AND WOULD NOT ACCELERATE PAST 30 MPH. THE VEHICLE WAS TOWED TO RED MCCOMBS FORD (8333 I10, SAN ANTONIO, TX) WHERE IT WAS DIAGNOSED THAT THE PARTICULATE FILTER WAS FAULTY AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED, BUT NO ASSISTANCE WAS OFFERED. THE CONTACT WAS INFORMED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 07V139000 (POWER TRAIN). THE FAILURE MILEAGE WAS 200,000. *TT*JB
NHTSA ODI #11171431
14,200 miles · Dec 8, 2018
Power Train
THE TRUCK WILL NOT SHIFT OUT OF PARK, EVEN WHEN THE DRIVERS FOOT IS FIRMLY PLACED ON THE BRAKE. THIS IS AN INTERMITTENT ISSUE. VEHICLE CAN BE PARKED ANYWHERE...I.E. IN THE GARAGE, DRIVEWAY OR PARKING LOT. ALL FLAT SURFACES, (SO NO HEAVY TENSION ON THE TRANSMISSION LIKE YOU MIGHT HAVE IF PARKED ON A HILL AND THE PARKING BRAKE …
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THE TRUCK WILL NOT SHIFT OUT OF PARK, EVEN WHEN THE DRIVERS FOOT IS FIRMLY PLACED ON THE BRAKE. THIS IS AN INTERMITTENT ISSUE. VEHICLE CAN BE PARKED ANYWHERE...I.E. IN THE GARAGE, DRIVEWAY OR PARKING LOT. ALL FLAT SURFACES, (SO NO HEAVY TENSION ON THE TRANSMISSION LIKE YOU MIGHT HAVE IF PARKED ON A HILL AND THE PARKING BRAKE NOT ENGAGED).
NHTSA ODI #11156999
70,000 miles · Aug 24, 2018
Engine And Engine CoolingPower TrainFire
TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING 35 MPH, WHITE SMOKE CAME OUT OF THE EXHAUST. THE CONTACT STATED THAT THE VEHICLE EXHIBITED THE SAME SYMPTOMS AS LISTED IN NHTSA CAMPAIGN NUMBER: 07V139000 (POWER TRAIN). THE VEHICLE WAS TAKEN TO COLLEY FORD (1945 AUTO CENTRE DR, GLENDORA, CA 91740, 909-592-4131) WHERE IT WAS …
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TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING 35 MPH, WHITE SMOKE CAME OUT OF THE EXHAUST. THE CONTACT STATED THAT THE VEHICLE EXHIBITED THE SAME SYMPTOMS AS LISTED IN NHTSA CAMPAIGN NUMBER: 07V139000 (POWER TRAIN). THE VEHICLE WAS TAKEN TO COLLEY FORD (1945 AUTO CENTRE DR, GLENDORA, CA 91740, 909-592-4131) WHERE IT WAS DIAGNOSED, BUT THE FAILURE COULD NOT BE DUPLICATED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 70,000.
NHTSA ODI #11122212
75,000 miles · Jun 4, 2018
Power Train
TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING VARIOUS SPEEDS, THE STEERING WHEEL WOULD TURN ALL THE WAY TO THE LEFT OR RIGHT WITHOUT WARNING. THE CONTACT CALLED FAIRWAY FORD LINCOLN MERCURY AT 888-281-7109 (472 EAST MAIN ST, BRADFORD, PA 16701) AND A NEW STEERING BOX WAS ORDERED. THE MANUFACTURER WAS NOT MADE AWARE OF TH…
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TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING VARIOUS SPEEDS, THE STEERING WHEEL WOULD TURN ALL THE WAY TO THE LEFT OR RIGHT WITHOUT WARNING. THE CONTACT CALLED FAIRWAY FORD LINCOLN MERCURY AT 888-281-7109 (472 EAST MAIN ST, BRADFORD, PA 16701) AND A NEW STEERING BOX WAS ORDERED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 75,000. *TT THE CONSUMER STATED A FROZEN U-JOINT WAS THE CAUSE OF THE FAILURE. *JS
NHTSA ODI #11099579
60,150 miles · Feb 12, 2015
EnginePower TrainFire
VEHICLE HAD BEEN DRIVING IT BUT IT WAS PARKED FOR ABOUT 25 MINUTES, WITH NOTHING RUNNING OR KEYS IN THE IGNITION. CAME OUT SIDE TO THE SMELL OF SMOKE AND THE ENGINE COMPARTMENT BUST INTO FLAMES. FIRE INVESTIGATOR SAID THAT THE FIRE WAS ELECTRICAL THAT STARTED ON THE PASSENGER SIDE OF THE ENGINE. TRUCK WAS A TOTAL LOSS AS FIRE…
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VEHICLE HAD BEEN DRIVING IT BUT IT WAS PARKED FOR ABOUT 25 MINUTES, WITH NOTHING RUNNING OR KEYS IN THE IGNITION. CAME OUT SIDE TO THE SMELL OF SMOKE AND THE ENGINE COMPARTMENT BUST INTO FLAMES. FIRE INVESTIGATOR SAID THAT THE FIRE WAS ELECTRICAL THAT STARTED ON THE PASSENGER SIDE OF THE ENGINE. TRUCK WAS A TOTAL LOSS AS FIRE SPREAD ALONG DRIVETRAIN TO GAS TANK. FIRE DEPARTMENT WAS ABLE TO KEEP GAS TANK FROM EXPLODING. *TR
NHTSA ODI #10683017
40,300 miles · Aug 12, 2014
Power TrainVehicle Speed Control
WHEN I BOUGHT MY FORD F250 BACK IN 2008 I HAVE HAD CONSTANT PROBLEMS WITH THE TRUCK AS I WOULD BE GOING DOWN THE HIGHWAY THE TRUCK WOULD LOSE POWER AND I WOULD PRESS THE GAS PEDAL AND THE TRUCK WOULD ONLY DO AROUND 40MPH. A FEW WEEKS AGO I DROVE FROM CHICAGO UP TO GREEN BAY WI AND THEN BACK GOING THERE ABOUT HALF WAY THE TRUCK W…
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WHEN I BOUGHT MY FORD F250 BACK IN 2008 I HAVE HAD CONSTANT PROBLEMS WITH THE TRUCK AS I WOULD BE GOING DOWN THE HIGHWAY THE TRUCK WOULD LOSE POWER AND I WOULD PRESS THE GAS PEDAL AND THE TRUCK WOULD ONLY DO AROUND 40MPH. A FEW WEEKS AGO I DROVE FROM CHICAGO UP TO GREEN BAY WI AND THEN BACK GOING THERE ABOUT HALF WAY THE TRUCK WAS OK THE OTHER HALF WAY UP THERE AND BACK THE CHICAGO THE TRUCK WAS NOT SHIFTING IT FELT LIKE IT WAS TOWING A TRAILER WHEN IT WAS NOT MY FOOT WAS ON THE FLOOR ALL THE WAY AND I WAS ONLY DOING 40MPH ON A 60+MPH HIGHWAY WHICH I HAD TRUCKERS ALMOST COMING IN CONTACT WITH MY TRUCK. MY TRUCK HAS BEEN IN THE SHOP OVER A DOZEN TIMES AND FORD DOES NOT HAVE A CLUE WHAT IS WRONG WITH THE TRUCK BECAUSE THERE COMPUTERS SHOW NOTHING WRONG WHEN THERE SERVICE TECH DROVE THE TRUCK AND SAID THERE IS A PROBLEM WITH IT BUT THEY OUR UNSURE. THE LAST TIME MY FORD DEALER STATED THAT IT MIGHT BE A CATALYTIC CONVERTER. I HAVE CONTACTED FORD MOTOR COMPANY ABOUT THIS ISSUE AND THEY DID NOT WANT TO WORK WITH ME ON FIXING THE TRUCK ONLY OFFERING 20% OFF OF THE COST TO FIX THE CATALYTIC CONVERTER AND THEY ARE NOT SURE THAT THIS WILL FIX THE ISSUES I HAVE BEEN HAVING I AM NOT THE ONLY PERSON HAVING THIS PROBLEM WITH MY TRUCK I TALKED TO A FEW OTHER FORD TRUCK OWNERS AND THEY HAVE THE SAME PROBLEM. *TR
NHTSA ODI #10621710
79,000 miles · May 27, 2014
Electrical SystemPower TrainSuspension
A WEEK AFTER I BOUGHT THE TRUCK THE TRANSMISSION WENT OUT THEN ITS HAD COUNTLESS ELECTRICAL PROBLEMS ITS BEEN TO 2 FORD DEALERS IT WAS AT ONE FOR 7 MONTHS AND THE OTHER FOR 3 AND A CHEVY DEALER NOONE CAN FIX MY TRUCK ITS HAD 3 TRANSMISSIONS PUT IN IT 1000S OF DOLLARS LATER AND I HAVEN'T BEEN ABLE TO DRIVE MY TRUCK IN 2 AND A HAL…
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A WEEK AFTER I BOUGHT THE TRUCK THE TRANSMISSION WENT OUT THEN ITS HAD COUNTLESS ELECTRICAL PROBLEMS ITS BEEN TO 2 FORD DEALERS IT WAS AT ONE FOR 7 MONTHS AND THE OTHER FOR 3 AND A CHEVY DEALER NOONE CAN FIX MY TRUCK ITS HAD 3 TRANSMISSIONS PUT IN IT 1000S OF DOLLARS LATER AND I HAVEN'T BEEN ABLE TO DRIVE MY TRUCK IN 2 AND A HALF YEARS FORD IS UNWILLING TO DO ANYTHING WITH IT. THEY CANT FIND THE PROBLEM AND GIVE UP AND TELL ME TO COME GET THE TRUCK I STILL OWE15 000 ON THE TRUCK. *TR
NHTSA ODI #10594167
Official recalls
5Apr 25, 2008
FORD IS RECALLING 64,754 MY 2008 F-250 AND F-350 SINGLE REAR WHEEL, 4X4, 156 INCH WHEEL BASE PICK UP TRUCKS EQUIPPED WITH A TWO PIECE DRIVE SHAFT FOR FAILING TO CONFORM TO THE FUEL SPILLAGE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 301, "FUEL SYSTEM INTEGRITY." DURING A 30 MPH FRONTAL IMPACT INTO A RIGID BARRIER, THE FUEL TANK CAN MOVE FORWARD AND CONTACT A FRAME CROSS MEMBER, POTENTIALLY CAUSING DAMAGE TO THE FUEL DELIVERY MODULE WHICH CAN RESULT IN FUEL SPILLAGE.
Consequence & remedy
Consequence: FUEL SPILLAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy: DEALERS WILL INSTALL A BRACKET ON THE AFFECTED VEHICLES FREE OF CHARGE. THE RECALL BEGAN ON MAY 23, 2008. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Feb 28, 2008
FORD IS RECALLING 87,515 MY 2008 F250, F-350, F-450, AND F-550 VEHICLES FOR FAILING TO COMPLY WITH ALL THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 207, "SEATING SYSTEMS." SOME 40% SPLIT AND CAPTAIN'S CHAIR DRIVER'S SEATS, EQUIPPED WITH LUMBAR SUPPORTS, MAY HAVE IMPROPER WELDS AT THE JOINT OF THE SEAT BACK PIVOT BRACKET AND THE SEAT BACK FRAME.
Consequence & remedy
Consequence: IN THE EVENT OF A CRASH, THE SEAT SIDE PIVOT BRACKET MAY CRACK OR BREAK, INCREASING THE RISK OF INJURY TO THE SEAT OCCUPANT.
Remedy: DEALERS WILL ADD A REINFORCEMENT TO THE DRIVER'S SEAT BACK FRAME ON THE 40% SPLIT OR CAPTAIN'S CHAIR SEAT EQUIPPED WITH LUMBAR SUPPORT OR, IF NECESSARY, THE SEAT BACK FRAME WILL BE REPLACED. THE RECALL BEGAN ON MARCH 28, 2008. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Nov 21, 2007
CERTAIN VEHICLES FAIL TO CONFORM TO THE REQUIREMENTS SPECIFIED IN FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 208, 'OCCUPANT CRASH PROTECTION.' THE DRIVER AIR BAG MODULE MAY NOT HAVE BEEN PROPERLY ASSEMBLED.
Consequence & remedy
Consequence: THIS CONDITION MAY PREVENT THE DRIVER AIR BAG FROM PROPERLY DEPLOYING AND REDUCE OCCUPANT PROTECTION IN THE EVENT OF A CRASH.
Remedy: DEALERS WILL REPLACE YOUR DRIVER AIR BAG MODULE FREE OF CHARGE. THE RECALL BEGAN ON NOVEMBER 20, 2007. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Mar 26, 2007
ON CERTAIN TRUCKS EQUIPPED WITH A 6.4L DIESEL ENGINE, EXCESSIVE TEMPERATURES IN THE DIESEL PARTICULATE FILTER IN THE EXHAUST SYSTEM MAY RESULT FROM EXCESS HYDROCARBONS IN THE EXHAUST.
Consequence & remedy
Consequence: LACK OF POWER OR ROUGH OPERATION, UNUSUAL NOISES FROM THE ENGINE OR EXHAUST, WHITE SMOKE FROM THE EXHAUST, AND POTENTIALLY A VISIBLE FLAME OUT THE TAILPIPE CAN OCCUR.
Remedy: DEALERS WILL REPROGRAM THE POWER TRAIN CONTROL MODULE. THE RECALL BEGAN ON APRIL 3, 2007. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Mar 26, 2007
ON CERTAIN TRUCKS EQUIPPED WITH A 6.4L DIESEL ENGINE, INSUFFICIENT CLEARANCE OF THE BATTERY POSITIVE (B+) WIRE TO THE RIGHT HAND SPLASH SHIELD BOLT MAY RESULT IN THE BATTERY B+ WIRE CONTACTING THE SPLASH SHIELD BOLT.
Consequence & remedy
Consequence: LONG TERM CONTACT COULD CAUSE WIRE CHAFE, RESULTING IN COPPER WIRE BEING EXPOSED. IF THIS CONDITION OCCURS, THE BATTERY B+ WIRE COULD SHORT TO GROUND INCREASING THE RISK OF A FIRE.
Remedy: DEALERS WILL INSPECT THE BATTERY B+ WIRE LOCATION AND, IF NECESSARY, REPOSITION THE WIRE. THE RECALL BEGAN ON APRIL 3, 2007. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
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
1PE13014 · 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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