IllustrationTHIS VEHICLE HAS NO AFTERMARKET ALTERATIONS AND THE FRONT END PARTS ARE IN SATISFACTORY CONDITION BUT AT CERTAIN SPEEDS WHEN HITTING A BUMP THE VEHICLE SHAKES UNCONTROLLABLY AS IF IT IS GOING TO EXPLODE! IT ONLY HAPPENS ON THE HIGHWAY.
2008 Ford F-250
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2008 Ford F-250 do not stand out strongly from the model-year median of 119.
About this comparison →How this year compares
Owner complaints by model year
Compare all F-250 years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
200–25K
4025–50K
2250–75K
1675–100K
34100–150K
28150K+
160 reports with mileage · 35 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Steering. Review the 80 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Suspension. Review the 35 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Engine. Review the 18 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
10 crash reports4 fire reports3 injury reports
Suspension complaints
35 reportsWHILE DRIVING AT SPEEDS 55 MPH OR MORE WHEN DRIVING ON TO A BRIDGE OR CHANGE IN HIGHWAY,OR HITTING A POTHOLE IN THE ROAD THE FRONT END OF MY TRUCK STARTS SHAKING VIOLENTLY IT ONLY STOP THIS BY SLOWING DOWN TO ABOUT 20 MPH.THE SHAKING IS SO VIOLENT YOU ALMOST LOSE CONTROL.IT HAPPENS WHENEVER I HIT A ROUGH SPOT IN THE ROAD.
TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING OVER A BUMP AT 60 MPH, THE VEHICLE JERKED AND WOBBLED OUT OF CONTROL. THE FAILURE WAS EXPERIENCED NUMEROUS TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN REPLACED THE TRACK BAR, THE FRONT STEERING DAMPER, THE CENTER LINK, AND THE FRONT SUSPENSION; HOW…
Read full complaint
TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING OVER A BUMP AT 60 MPH, THE VEHICLE JERKED AND WOBBLED OUT OF CONTROL. THE FAILURE WAS EXPERIENCED NUMEROUS TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN REPLACED THE TRACK BAR, THE FRONT STEERING DAMPER, THE CENTER LINK, AND THE FRONT SUSPENSION; HOWEVER, THE FAILURE WAS NOT CORRECTED. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 159,000. MA 09/03/15
VIOLENT FRONT END SHAKING WHEN I RUN OVER A POT HOLE OR BAD SPOT ON THE INTERSTATE..
I TOOK MY 2008 FORD F-250 TO THE FORD DEALER TO HAVE AN ALIGNMENT AND OIL CHANGE. I HAD THE VEHICLE ALIGNED APPROXIMATELY EIGHT MONTHS AGO BUT THE ALIGNMENT HAS STEADILY DETERIORATED. THE VEHICLE HAS A LITTLE OVER 77,000 MILES. I PURCHASED THIS VEHICLE BRAND NEW AND HAVE BEEN THE ONLY OWNER. I HAVE NEVER BEEN "OFF-ROADING" O…
Read full complaint
I TOOK MY 2008 FORD F-250 TO THE FORD DEALER TO HAVE AN ALIGNMENT AND OIL CHANGE. I HAD THE VEHICLE ALIGNED APPROXIMATELY EIGHT MONTHS AGO BUT THE ALIGNMENT HAS STEADILY DETERIORATED. THE VEHICLE HAS A LITTLE OVER 77,000 MILES. I PURCHASED THIS VEHICLE BRAND NEW AND HAVE BEEN THE ONLY OWNER. I HAVE NEVER BEEN "OFF-ROADING" OR "MUDDING" IN THE VEHICLE. ALL MILES ARE HIGHWAY/CITY MILES. LITTLE TOWING HAS BEEN DONE WITH THE VEHICLE. ALL RECOMMENDED SERVICES HAVE BEEN PROVIDED BY FORD DEALERSHIPS. THERE HAVE BEEN NO MODIFICATIONS TO THE VEHICLE NOR HAVE THERE BEEN ANY ACCIDENTS THAT WOULD EFFECT THE STEERING OF THE VEHICLE. THE DEALERSHIP CALLED AND STATED THAT MY STEERING GEAR BOX IS ABOUT TO GO OUT. THE FIX FOR THIS WOULD BE OVER $1100.00 WHICH I AM UNABLE TO AFFORD AT THIS TIME. IT SEEMS THE GEAR BOX IN THE "SUPER DUTY" WOULD LAST LONGER UNDER THESE REASONABLE CONDITIONS. *TR
ON MY DAILY COMMUTE TO WORK I EXPERIENCED WHAT I HAVE LATER RESEARCHED TO FIND OUT IS CALLED THE "DEATH WOBBLE". THE FIRST OCCURRENCE HAPPENED WHILE MAINTAINING A SPEED OF APPROXIMATELY 55 MPH WHICH WAS THE SUGGESTED ROAD SPEED LIMIT, AFTER RIDING OVER A SMALL BUMP IN THE ROAD MY FRONT LEFT END INITIATED INTO A VIOLENT SHAKING S…
Read full complaint
ON MY DAILY COMMUTE TO WORK I EXPERIENCED WHAT I HAVE LATER RESEARCHED TO FIND OUT IS CALLED THE "DEATH WOBBLE". THE FIRST OCCURRENCE HAPPENED WHILE MAINTAINING A SPEED OF APPROXIMATELY 55 MPH WHICH WAS THE SUGGESTED ROAD SPEED LIMIT, AFTER RIDING OVER A SMALL BUMP IN THE ROAD MY FRONT LEFT END INITIATED INTO A VIOLENT SHAKING SENSATION THAT FELT AS THOUGH I HAD JUST BLOWN A TIRE. AFTER REDUCING MY SPEED ABRUPTLY AND NEARLY BEING REAR ENDED THE FRONT END REGAINED ITS CONTROL AND I CONTINUED AND ARRIVED SAFELY TO WORK AFTER REDUCING MY SPEED TO 45 MPH. I LOOKED IN THE WHEEL HUB AND UNDERNEATH BUT DID NOT SEE ANYTHING OUT OF THE ORDINARY FROM PLANE SIGHT. I EXPERIENCED THE VIOLENT SHAKING ON MULTIPLE OCCASIONS, DIFFERENT LOCATIONS AND FOUND MYSELF EXPERIENCING IT MORE AND MORE AT LOWER SPEEDS AND ON SMALLER ROAD BUMPS/POT HOLES. AFTER DAY 2 I SCHEDULED AN APPOINTMENT FOR 6/30/14 WITH FORD SERVICE TO HAVE THE REPAIR & DIAGNOSES. THE NEXT DAY 6/27/14 WE HAD TO EVACUATE OUR JOB SITE IN LOUISIANA DUE TO EXTREME WEATHER CONDITIONS AND POSSIBLE TORNADOS, ON MY COMMUTE HOME, THE SO CALLED DEATH WOBBLE OCCURRED AGAIN AND THIS TIME RESULTED IN LOOSING CONTROL AND CRASHING INTO A SMALL TREE BECAUSE OF THE VIOLENT SHAKING AND NECESSARY BRAKING TO REGAIN CONTROL. I WAS ABLE TO ESCAPE WITH MINOR DAMAGES TO MY FRONT BUMPER. FORD IS HAVING TO REPLACE MY BALL JOINTS, BEARINGS AND TIE BAR THAT WILL COST WELL OVER $600 IN REPAIRS EXCLUDING A NEW FRONT BUMPER THAT I CANNOT AFFORD TO FIX. I'M AFRAID THIS COULD RESULT IN A SERIOUS INJURY/FATALITY IF NOT RECALLED AND FIXED. HAD I GONE INTO INCOMING TRAFFIC IT COULD HAVE BEEN MY LIFE OR THEIRS AND I WOULD THINK FORD WOULD BE FULLY RESPONSIBLE. THERE ARE HUNDREDS OF SIMILAR CASES FROM OLDER MODELS AND EVEN NEWER UP TO 2013, MINE IS A F-250 2008. HTTP://WWW.TOPIX.COM/FORUM/AUTOS/FORD-F-250-SUPER-DUTY/TOHP1M75VBFBFT9IL/P5. *TR
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…
Read full complaint
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
BEGAN IN 2010...DEATH WOBBLE....HITTING A BUMP,,STEERING WHEEL SHAKES VIOLENTLY.....LOSS OF CONFIDENCE IN THE ABILITY OF THE VEHICLE TO PROVIDE SAFE TRANSPORTATION.....DEALERSHIP VISIT WAS NOT HELPFUL...SAID IT WAS TIRE PRESSURE...ADDED A DIFFERENT TRAC BAR IN 2012...HELPED SOME BUT TIL PRODUCES THE WOBBLE AT LOWER SPEEDS. *TR
2008 F250 6,4 POWERSTROKE 4X4 DRIVE ABOVE 55 AND HIT ROLLING BUMP AND THE FRONT END STARTS SHAKING VIOLENTLY STEERING WHEEL ALSO SHAKES. I HAVE HAD EVERYTHING INSPECTED AND EVERYTHING IS TIGHT AS A VEHICLE WITH ONLY 59,000 MILE SHOULD BE. THE MORE I DRIVE IT THE WORSE IT GETS ITS STARTING TO JUST SHAKE RANDOMLY WITHOUT HITTING A…
Read full complaint
2008 F250 6,4 POWERSTROKE 4X4 DRIVE ABOVE 55 AND HIT ROLLING BUMP AND THE FRONT END STARTS SHAKING VIOLENTLY STEERING WHEEL ALSO SHAKES. I HAVE HAD EVERYTHING INSPECTED AND EVERYTHING IS TIGHT AS A VEHICLE WITH ONLY 59,000 MILE SHOULD BE. THE MORE I DRIVE IT THE WORSE IT GETS ITS STARTING TO JUST SHAKE RANDOMLY WITHOUT HITTING A BUMP. *TR
THE FRONT END OF THE TRUCK WILL JUST START SHAKING UNCONTROLLABLY. *TR
Official recalls
508V191000 · Fuel System, Gasoline:delivery
Apr 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.
08V096000 · Seats
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.
07V541000 · Air Bags:frontal:driver Side:inflator Module
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.
07V139000 · Power Train:automatic Transmission:control Module (tcm/pcm/tecm)
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.
07V140000 · Electrical SYSTEM:12V/24V/48V Battery
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