Cooper Discoverer AT3 tires LT275/70R18 D1 I purchased these tires on 11/08/2019. My truck had 166,736 miles it now has around 202,000. I experienced a blow out where the total tread separated from the rear driver side side walls. The tread separated piece was in one piece. As if a re-tread tire. It caused extensive damage to …
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Cooper Discoverer AT3 tires LT275/70R18 D1 I purchased these tires on 11/08/2019. My truck had 166,736 miles it now has around 202,000. I experienced a blow out where the total tread separated from the rear driver side side walls. The tread separated piece was in one piece. As if a re-tread tire. It caused extensive damage to my rear quarter panel among a list of other damaged parts. The tread was on the tires were still in excellent shape.
NHTSA ODI #11673254
Mileage unknown · Oct 9, 2024
Tires
TIRE HAD A FULL TREAD SEPERATION WHILE DOING 65 ON [XXX] IN BROWARD COUNTY FL CAUSED DAMAGE TO DRIVER SIDE FRONT FENDER AND ALLOY RIM , WAS ABLE TO GET OFF THE ROAD WITH NO ACCIDENT TIRE SIZE WAS LT275 / 70 R18 AND HAD LESS THAN 12000 MILES I CHECKED THE OTHER 3 TIRES AND A COUPLE HAVE UNUSUAL WEAR WHICH MAY BE STARTING TO HAVE…
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TIRE HAD A FULL TREAD SEPERATION WHILE DOING 65 ON [XXX] IN BROWARD COUNTY FL CAUSED DAMAGE TO DRIVER SIDE FRONT FENDER AND ALLOY RIM , WAS ABLE TO GET OFF THE ROAD WITH NO ACCIDENT TIRE SIZE WAS LT275 / 70 R18 AND HAD LESS THAN 12000 MILES I CHECKED THE OTHER 3 TIRES AND A COUPLE HAVE UNUSUAL WEAR WHICH MAY BE STARTING TO HAVE THE TREAD SEPERATE AS YOU CAN A CRACK FORMING WHERE THE FAILED TIRE SEPERATED. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA ODI #11618970
Mileage unknown · Jul 3, 2023
Tires
295/65R20 Had 3 out of 4 tires separate with about 1400 miles on them at highway speeds. Purchase in 11/22 first on failed 4/23 the other 2 5/23. 1st one had belts break at hwy speeds the 2nd had a large chunk of trade come off and 3rd had belts separate. 70mph was average speed when the issue occurred.
NHTSA ODI #11530161
Mileage unknown · Sep 17, 2015
Tires
CPSC: I1590170A. 2008 FORD F-250. CONSUMER STATED THAT ON TWO DIFFERENT OCCASIONS THE TIRES FAILED. *LN THE CONSUMER STATED THE PASSENGER SIDE REAR TIRE TREAD SEPARATED AS A PORTION OF THE TREAD BEGAN PEELING OFF WHILE DRIVING. THE NEXT MONTH, THE DRIVER'S SIDE REAR TIRE FAILED WHILE DRIVING ON THE INTERSTATE AND CAUSED NEARLY …
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CPSC: I1590170A. 2008 FORD F-250. CONSUMER STATED THAT ON TWO DIFFERENT OCCASIONS THE TIRES FAILED. *LN THE CONSUMER STATED THE PASSENGER SIDE REAR TIRE TREAD SEPARATED AS A PORTION OF THE TREAD BEGAN PEELING OFF WHILE DRIVING. THE NEXT MONTH, THE DRIVER'S SIDE REAR TIRE FAILED WHILE DRIVING ON THE INTERSTATE AND CAUSED NEARLY $3,00 IN DAMAGE TO THE TRUCK. *JB
NHTSA ODI #10765687
78,655 miles · Jul 12, 2015
TiresCrashInjury
DRIVING TEXAS HIGHWAY 183 NEAR BERTRAM TX, RF DRIVERS SIDE BF GOODRICH BAJA CHAMPION TRUCK TIRE EXPLODED CAUSING VEHICLE TO SERVE INTO ONCOMING TRAFFIC, I RECOVERED. TIRE EXPLODED WITH GREAT FORCE CAUSING THE OUTER TREAD TO DISLODGE CAUSING 4000 DOLLARS DAMAGE TO F250. THE TIRE SPILT INTO TWO EXPOSING THE WIRE STEEL BELTS. T…
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DRIVING TEXAS HIGHWAY 183 NEAR BERTRAM TX, RF DRIVERS SIDE BF GOODRICH BAJA CHAMPION TRUCK TIRE EXPLODED CAUSING VEHICLE TO SERVE INTO ONCOMING TRAFFIC, I RECOVERED. TIRE EXPLODED WITH GREAT FORCE CAUSING THE OUTER TREAD TO DISLODGE CAUSING 4000 DOLLARS DAMAGE TO F250. THE TIRE SPILT INTO TWO EXPOSING THE WIRE STEEL BELTS. THE BELTS LOOK AS OF THEY WERE RIPPED APART SIMILAR TO IED EXPLOSIONS EXPERIENCED IN PERSIAN GULF. IT WAS COOL THAT SATURDAY IN THE MID TO UPPER 80'S. ALMOST KILLED ME AS THE VEHICLE FELL TO THE RIM IMMEDIATELY AFTER CATASTROPHIC FAILURE.
NHTSA ODI #10733496
Mileage unknown · Jan 7, 2015
TiresCrash
TL* THE CONTACT OWNS A 2008 FORD F-250 EQUIPPED WITH FEDERAL TIRES, TIRE LINE: COURAGIA A/T, AND TIRE SIZE: LT245/75R16 120/116Q. THE CONTACT STATED THAT WHILE DRIVING 65 MPH, THE FRONT DRIVER'S SIDE TIRE TREAD SEPARATED. AS A RESULT, THE CONTACT CRASHED INTO A CONCRETE MEDIAN. THE FRONT DRIVER'S SIDE TIRE WAS NOT THE ORIGINAL.…
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TL* THE CONTACT OWNS A 2008 FORD F-250 EQUIPPED WITH FEDERAL TIRES, TIRE LINE: COURAGIA A/T, AND TIRE SIZE: LT245/75R16 120/116Q. THE CONTACT STATED THAT WHILE DRIVING 65 MPH, THE FRONT DRIVER'S SIDE TIRE TREAD SEPARATED. AS A RESULT, THE CONTACT CRASHED INTO A CONCRETE MEDIAN. THE FRONT DRIVER'S SIDE TIRE WAS NOT THE ORIGINAL. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE DOT NUMBER WAS UNAVAILABLE. THE FAILURE TIRE MILEAGE WAS 14,000 AND THE VEHICLE FAILURE MILEAGE WAS UNKNOWN.
NHTSA ODI #10670788
79,000 miles · Mar 5, 2014
Tires
TODAY I REPLACED THE SECOND TIRE FROM A SET OF FOUR LT275/70R18E1 BFG COMMERCIAL T/A A/S TIRES PURCHASED ON NOVEMBER 23, 2010. BOTH TIRES WERE REPLACED WITH LESS THAN 30,000 MILES OF WEAR BECAUSE OF TREAD SEPARATION. FORTUNATELY, IN BOTH CASES THE ISSUE WAS DISCOVERED BEFORE CATASTROPHIC FAILURE. THE SEPARATION EVENTS HAPPENE…
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TODAY I REPLACED THE SECOND TIRE FROM A SET OF FOUR LT275/70R18E1 BFG COMMERCIAL T/A A/S TIRES PURCHASED ON NOVEMBER 23, 2010. BOTH TIRES WERE REPLACED WITH LESS THAN 30,000 MILES OF WEAR BECAUSE OF TREAD SEPARATION. FORTUNATELY, IN BOTH CASES THE ISSUE WAS DISCOVERED BEFORE CATASTROPHIC FAILURE. THE SEPARATION EVENTS HAPPENED ABOUT 3,000 MILES APART. BECAUSE OF THE DANGERS OF TREAD SEPARATION, I WENT AHEAD AND REPLACED THE OTHER TWO TIRES ON THE VEHICLE. BECAUSE THOSE TWO TIRES WERE NOT CURRENTLY EXHIBITING SIGNS OF SEPARATION, THE TIRE SERVICE COMPANY WAS NOT ABLE TO OBTAIN ANY WARRANTY PRORATION. I COMPLAINED IN WRITING TO THE MANUFACTURER AND ASKED FOR A FULL REPLACEMENT SET. I RECEIVED A REPLY THAT BASICALLY SAID FOR ME TO WORK WITH THE TIRE SERVICE COMPANY AND THAT THE ONLY THING THEY WOULD AGREE TO WOULD BE A PRORATION. THIS RESPONSE IS TOTALLY UNACCEPTABLE AS IT IS MY UNDERSTANDING THAT TREAD SEPARATION IS THE RESULT OF A MANUFACTURING DEFECT, AND SINCE TWO OUT OF THE FOUR TIRES FROM THE SAME SET EXHIBITED THIS DEFECT IT IS HIGHLY PROBABLE THAT IT WAS MERELY A MATTER OF TIME BEFORE THE OTHER TWO EXHIBITED THE DEFECT AS WELL. I ALSO FOUND THE RESPONSE TO BE TOTALLY UNACCEPTABLE BECAUSE THIS COMPANY HAS A RECALL IN PLACE FOR SIMILAR TIRES AND THEREFORE SHOULD BE FULLY AWARE OF THE SAFETY IMPLICATIONS. *TR
NHTSA ODI #10567445
Mileage unknown · Jun 17, 2013
Tires
TL* THE CONTACT OWNS A 2008 FORD F-250 EQUIPPED WITH CONTINENTAL CONTITRAC TIRES, SIZE 275-70-18. THE CONTACT STATED THAT ALL FOUR TIRES DISPLAYED SIGNS OF TREAD SEPARATION. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC WHERE ALL FOUR TIRES WERE REPLACED. THE MANUFACTURER WAS CONTACTED ABOUT THE FAILURE. THE FAILURE MILEAGE WAS 38…
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TL* THE CONTACT OWNS A 2008 FORD F-250 EQUIPPED WITH CONTINENTAL CONTITRAC TIRES, SIZE 275-70-18. THE CONTACT STATED THAT ALL FOUR TIRES DISPLAYED SIGNS OF TREAD SEPARATION. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC WHERE ALL FOUR TIRES WERE REPLACED. THE MANUFACTURER WAS CONTACTED ABOUT THE FAILURE. THE FAILURE MILEAGE WAS 38,000. THE DOT NUMBER WAS NOT AVAILABLE.
NHTSA ODI #10520250
22,000 miles · Jun 6, 2013
Tires
DRIVING ALONG A RURAL ROAD AT 50 MPH, TRUCK BEGAN TO SHAKE, COULD BARELY HOLD IT IN THE ROAD. HAD TIRES CHECKED AT CROSSROADS FORD WHERE TRUCK WAS PURCHASED JUST 5 MONTHS AGO. WAS TOLD THAT CONTINENTAL HAD RECALLED CALLED TIRES ON 2008 F250 TRUCKS BUT TIRES ON THIS TRUCK WERE NOT PART OF THE RECALL. CONTRATRAC P515 46U0 3207. VE…
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DRIVING ALONG A RURAL ROAD AT 50 MPH, TRUCK BEGAN TO SHAKE, COULD BARELY HOLD IT IN THE ROAD. HAD TIRES CHECKED AT CROSSROADS FORD WHERE TRUCK WAS PURCHASED JUST 5 MONTHS AGO. WAS TOLD THAT CONTINENTAL HAD RECALLED CALLED TIRES ON 2008 F250 TRUCKS BUT TIRES ON THIS TRUCK WERE NOT PART OF THE RECALL. CONTRATRAC P515 46U0 3207. VERY DANGEROUS TO DRIVE. CROSSROADS FORD OFFERED TO SELL US MORE TIRES. UNSURE WHAT TO DO. *TR
NHTSA ODI #10515442
23,800 miles · Nov 4, 2011
Tires
TL* THE CONTACT OWNS A 2008 FORD F-250 EQUIPPED WITH CONTINENTAL CONTITRAC TR SIZE LT275/70/R18 TIRES. THE CONTACT STATED THAT THE VEHICLE BEGAN TO SHAKE WHILE DRIVING 70 MPH. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THE CONTACT WAS INFORMED THAT THE TREAD WAS SEPARATING ON THE FRONT DRIVER'S SIDE TIRE. THE VEHICLE WAS …
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TL* THE CONTACT OWNS A 2008 FORD F-250 EQUIPPED WITH CONTINENTAL CONTITRAC TR SIZE LT275/70/R18 TIRES. THE CONTACT STATED THAT THE VEHICLE BEGAN TO SHAKE WHILE DRIVING 70 MPH. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THE CONTACT WAS INFORMED THAT THE TREAD WAS SEPARATING ON THE FRONT DRIVER'S SIDE TIRE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND INFORMED THE CONTACT THAT THE TIRES WERE NOT INCLUDED IN THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER 11T002000 (TIRES:TREAD/BELT). THE MANUFACTURER OFFERED TO REPLACE THE FAILED TIRE, BUT NOT THE REMAINING TIRES. THE FAILURE MILEAGE WAS 23,800.
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.
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.
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.
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.
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
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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