IllustrationWHEN I TURNED OFF THE HIGHWAY THE STEERING WAS ALMOST STUCK- AS IF THE TRUCK HAD BEEN TURNED OFF. I MADE IT TO THE SIDE OF THE ROAD, TURNED IT OFF AND BACK ON AND THEN IT STEERED OK. THIS HAS HAPPENED TWICE BEFORE. *TR
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
What owners actually said
195 reportsSLOWING DOWN EXITING TO THE LEFT OFF HI-WAY AFTER ABOUT A HALF AN HOUR AT 70MPH. BRAKE PEDAL FELT LIKE IT KICKED BACK, BOTH BRAKES AND STEERING LOCKED UP, SLID UNTO SHOULDER, THEN EVERYTHING RELEASED LIKE NORMAL. BROUGHT TO DEALER, THEY REPLACED HYRO-BOOSTER SYSTEM AND FLUIDS. ISSUE SEEMED CORRECTED, EXITING RIGHT ON HWY NO I…
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SLOWING DOWN EXITING TO THE LEFT OFF HI-WAY AFTER ABOUT A HALF AN HOUR AT 70MPH. BRAKE PEDAL FELT LIKE IT KICKED BACK, BOTH BRAKES AND STEERING LOCKED UP, SLID UNTO SHOULDER, THEN EVERYTHING RELEASED LIKE NORMAL. BROUGHT TO DEALER, THEY REPLACED HYRO-BOOSTER SYSTEM AND FLUIDS. ISSUE SEEMED CORRECTED, EXITING RIGHT ON HWY NO ISSUE, HOWEVER EVERYTHING LOCKED UP AGAIN FIRST TIME EXITING LEFT. AFTER 10 DAYS RESEARCHING ISSUE, DEALER ASSURED REPLACING DAMPER ASSEMBLY(?) AND ALL FOUR TIRES WOULD RESOLVE. ISSUE HAPPENED AGAIN SAME DAY AS PICKUP. BEING TOWED BACK TO DEALER FOR THIRD ATTEMPT TO CORRECT. *TR
TL* THE CONTACT OWNS A 2008 FORD F-250. THE CONTACT STATED THAT WHILE DRIVING AT AN UNKNOWN SPEED, THE LOW ENGINE POWER WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE RADIATOR SEAL FRACTURED AND THE HOSES WERE LEAKING. THE RADIATOR WAS REPLACED. THE MANUFACTURER WAS MADE AWARE O…
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TL* THE CONTACT OWNS A 2008 FORD F-250. THE CONTACT STATED THAT WHILE DRIVING AT AN UNKNOWN SPEED, THE LOW ENGINE POWER WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE RADIATOR SEAL FRACTURED AND THE HOSES WERE LEAKING. THE RADIATOR WAS REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 68,000.
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
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.
TL* THE CONTACT OWNS A 2008 FORD F-250. THE CONTACT STATED THAT THE EXHAUST MANIFOLD BOLTS WERE RUSTED AND FRACTURED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE EXHAUST MANIFOLD WAS FRACTURED AND LEAKING. THE TECHNICIAN REPLACED BOTH EXHAUST MANIFOLDS, 20 STUDS, FOUR NUTS, AND TWO GASKETS. THE MANUFACTUR…
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TL* THE CONTACT OWNS A 2008 FORD F-250. THE CONTACT STATED THAT THE EXHAUST MANIFOLD BOLTS WERE RUSTED AND FRACTURED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE EXHAUST MANIFOLD WAS FRACTURED AND LEAKING. THE TECHNICIAN REPLACED BOTH EXHAUST MANIFOLDS, 20 STUDS, FOUR NUTS, AND TWO GASKETS. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 110,851.
TL* THE CONTACT OWNS A 2008 FORD F-250. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 45 MPH, THE STEERING WHEEL BECAME LOOSE WHICH CAUSED THE CONTACT TO LOSE CONTROL OF VEHICLE AND SWERVED OFF OF THE ROAD. THE VEHICLE WAS TOWED TO A DEALER FOR DIAGNOSTIC TESTING WHERE THE STEERING GEAR BOX WAS REPLACED. THE FAILURE RECURRED. T…
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TL* THE CONTACT OWNS A 2008 FORD F-250. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 45 MPH, THE STEERING WHEEL BECAME LOOSE WHICH CAUSED THE CONTACT TO LOSE CONTROL OF VEHICLE AND SWERVED OFF OF THE ROAD. THE VEHICLE WAS TOWED TO A DEALER FOR DIAGNOSTIC TESTING WHERE THE STEERING GEAR BOX WAS REPLACED. THE FAILURE RECURRED. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS UNAVAILABLE. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 44,000.
TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING APPROXIMATELY 62 MPH, THE STEERING WHEEL AND BOTH FRONT TIRES BEGAN SHAKING WITHOUT WARNING. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN DIAGNOSED THAT THE STEERING GEAR BOX NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT NOTIFIE…
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TL* THE CONTACT OWNS A 2008 FORD F-250. WHILE DRIVING APPROXIMATELY 62 MPH, THE STEERING WHEEL AND BOTH FRONT TIRES BEGAN SHAKING WITHOUT WARNING. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN DIAGNOSED THAT THE STEERING GEAR BOX NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 77,600.
INTERMITTENT POWER STEERING FAILURE WHILE DRIVING THE VEHICLE, THIS HAS HAPPENED MANY TIMES. THE POWER STEERING WILL STOP WORKING WHILE DRIVING DURING TURNS, THE STEERING BECOME VERY HARD LIKE (MANUAL). THE FAILURE LASTS ABOUT 4 SECONDS. NOT SURE HOW TO PROCEED, AFRAID TO DRIVE. *TR
THE WIRES SUPPLYING POWER TO THE HIGH PRESSURE OIL PUMP FRAYED. THIS WAS CAUSED BY THE WIRES NOT BEING PROPERLY PROTECTED BY FORD (ACCORDING TO THE FORD DEALERSHIP). ONCE THE SHORT IN THE WIRE OCCURRED, MY TRUCK IMMEDIATELY SHUT OFF IN THE MIDDLE OF THE HIGHWAY. I WAS GOING 65 MPH AND LUCKILY NO ONE WAS BEHIND ME. OTHERWISE …
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THE WIRES SUPPLYING POWER TO THE HIGH PRESSURE OIL PUMP FRAYED. THIS WAS CAUSED BY THE WIRES NOT BEING PROPERLY PROTECTED BY FORD (ACCORDING TO THE FORD DEALERSHIP). ONCE THE SHORT IN THE WIRE OCCURRED, MY TRUCK IMMEDIATELY SHUT OFF IN THE MIDDLE OF THE HIGHWAY. I WAS GOING 65 MPH AND LUCKILY NO ONE WAS BEHIND ME. OTHERWISE I WOULD HAVE BEEN IN A SERIOUS ACCIDENT SINCE MY TRUCK WAS SHUT DOWN IN THE MIDDLE OF THE ROAD. *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