NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
101 reports110,000 miles · Jul 15, 2016
Steering
TL* THE CONTACT OWNS A 2008 FORD F-350 SD. WHILE DRIVING VARIOUS SPEEDS, THE BRAKE PEDAL WAS DEPRESSED AND THE POWER STEERING LOST POWER AND BECAME DIFFICULT TO OPERATE. THE VEHICLE WAS DIAGNOSED BY AN INDEPENDENT MECHANIC WHO STATED THAT A BOLT IN THE POWER STEERING MECHANISM FRACTURED AND NEEDED TO BE REPAIRED. THE VEHICLE WAS…
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TL* THE CONTACT OWNS A 2008 FORD F-350 SD. WHILE DRIVING VARIOUS SPEEDS, THE BRAKE PEDAL WAS DEPRESSED AND THE POWER STEERING LOST POWER AND BECAME DIFFICULT TO OPERATE. THE VEHICLE WAS DIAGNOSED BY AN INDEPENDENT MECHANIC WHO STATED THAT A BOLT IN THE POWER STEERING MECHANISM FRACTURED AND NEEDED TO BE REPAIRED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 110,000. UPDATED 09/06/16*LJ UPDATED 09/08/16.*JB
NHTSA ODI #10885140
100,000 miles · May 11, 2016
EngineFuel/propulsion System
SHORTLY AFTER THE TRUCK IS UP TO OPERATING TEMPERATURE A CONSTANT PLUME OF WHITE SMOKE CONTINUOUSLY EMITS FROM THE EXHAUST. FUEL ECONOMY HAS HAD A SUBSTANTIAL LOSS. DURING LOWER LEVELS (1/4 OR LOWER LEVELS OF DIESEL) OF FUEL CAPACITY THE ENGINE WILL STALL AND DIE UPON TAKE OFF. ATTEMPTING TO RESTART AFTERWARDS WAS VERY DIFFIC…
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SHORTLY AFTER THE TRUCK IS UP TO OPERATING TEMPERATURE A CONSTANT PLUME OF WHITE SMOKE CONTINUOUSLY EMITS FROM THE EXHAUST. FUEL ECONOMY HAS HAD A SUBSTANTIAL LOSS. DURING LOWER LEVELS (1/4 OR LOWER LEVELS OF DIESEL) OF FUEL CAPACITY THE ENGINE WILL STALL AND DIE UPON TAKE OFF. ATTEMPTING TO RESTART AFTERWARDS WAS VERY DIFFICULT. DURING THIS PROCESS A "WRENCH" APPEARS ON THE DASH AND THAT'S ABOUT IT. I HAVE NOT CHECKED "CODES" YET AND THE CHECK ENGINE LITE IN ON.
NHTSA ODI #10864355
115,000 miles · Apr 19, 2016
Air BagsSteering
TL* THE CONTACT OWNS A 2008 FORD F-350 SD. WHILE THE VEHICLE WAS PARKED, THE STEERING WHEEL BECAME STUCK FOR TWO MINUTES AND THEN FAILED TO MOVE. THE AIR BAG WARNING LIGHT ILLUMINATED. THE CONTACT ATTEMPTED TO DRIVE THE VEHICLE AND THE STEERING WHEEL FAILED TO TURN. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE MANUFACTURER WA…
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TL* THE CONTACT OWNS A 2008 FORD F-350 SD. WHILE THE VEHICLE WAS PARKED, THE STEERING WHEEL BECAME STUCK FOR TWO MINUTES AND THEN FAILED TO MOVE. THE AIR BAG WARNING LIGHT ILLUMINATED. THE CONTACT ATTEMPTED TO DRIVE THE VEHICLE AND THE STEERING WHEEL FAILED TO TURN. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 115,000.
NHTSA ODI #10860415
130,000 miles · Mar 30, 2015
EngineVehicle Speed Control
SUDDEN VEHICLE ACCELERATION DURING SLOWING/BRAKING. REGISTERED OVER 4000 RPM AT APPROXIMATELY 10 MPH WITH BRAKES FULLY DEPRESSED AND WAS EXTREMELY DIFFICULT TO STOP WHICH ALMOST LED TO A REAR END COLLISION. AFTER COMING TO A COMPLETE STOP, VEHICLE WAS PUT INTO PARK AND ENGINE SLOWLY DECREASED FROM RACING AND WENT TO NORMAL RPM O…
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SUDDEN VEHICLE ACCELERATION DURING SLOWING/BRAKING. REGISTERED OVER 4000 RPM AT APPROXIMATELY 10 MPH WITH BRAKES FULLY DEPRESSED AND WAS EXTREMELY DIFFICULT TO STOP WHICH ALMOST LED TO A REAR END COLLISION. AFTER COMING TO A COMPLETE STOP, VEHICLE WAS PUT INTO PARK AND ENGINE SLOWLY DECREASED FROM RACING AND WENT TO NORMAL RPM OPERATING RANGE AT IDLE WITHIN SECONDS. *TR
NHTSA ODI #10702677
31,000 miles · Feb 2, 2015
Tires
I PURCHASED A 2008 FORD F-350 P/U TRUCK WITH THE ORIGINAL CONTINENTAL/CONTITRAC TIRES (LT275/70R18 125/122S). THEY ONLY HAVE APPROX. 31K MILES ON THEM AND THE TREAD SHOWING SIGNS OF SEPARATION AS OUTLINED IN A RECALL DATED MARCH 11, 2011. THERE HAVE BEEN NO ACCIDENTS, AND THAT IS WHAT I AM TRYING TO AVOID. I HAVE CONTACTED T…
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I PURCHASED A 2008 FORD F-350 P/U TRUCK WITH THE ORIGINAL CONTINENTAL/CONTITRAC TIRES (LT275/70R18 125/122S). THEY ONLY HAVE APPROX. 31K MILES ON THEM AND THE TREAD SHOWING SIGNS OF SEPARATION AS OUTLINED IN A RECALL DATED MARCH 11, 2011. THERE HAVE BEEN NO ACCIDENTS, AND THAT IS WHAT I AM TRYING TO AVOID. I HAVE CONTACTED THE MANUFACTURER AND IT DOES NOT APPEAR THAT THEY WILL BE HELPFUL IN RESOLVING THIS MATTER. PLEASE HELP! *TR
NHTSA ODI #10680494
Mileage unknown · Jan 31, 2015
Tires
DURING ROUTINE SERVICE I NOTICED THAT ALL FOUR OF MY MICHELIN LTX AT2 LT275-70R18 TIRES ARE CRACKING BETWEEN THE TREAD AND THE CENTER OF THE SIDE WALL, TIRES HAVE LESS THAN 20,000 MILES ON THEM AND THEY ARE LESS THAN THREE YEARS OLD. CONTACTED MICHELIN DIRECT, AND THEY ADVISED THERE WAS NOTHING THEY COULD DO FOR ME. THERE WEB SI…
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DURING ROUTINE SERVICE I NOTICED THAT ALL FOUR OF MY MICHELIN LTX AT2 LT275-70R18 TIRES ARE CRACKING BETWEEN THE TREAD AND THE CENTER OF THE SIDE WALL, TIRES HAVE LESS THAN 20,000 MILES ON THEM AND THEY ARE LESS THAN THREE YEARS OLD. CONTACTED MICHELIN DIRECT, AND THEY ADVISED THERE WAS NOTHING THEY COULD DO FOR ME. THERE WEB SITE STATES THE TIRES HAVE A 6 YEAR WARRANTY AND A TREAD WARRANTY UP TO 2/32. TIRES HAVE 7/32 OF TREAD LEFT. I HAVE SEEN SEVERAL OTHER COMPLAINTS ABOUT CRACKING SIDE WALLS ON THE SAME MICHELIN TIRE IN DIFFERENT SIZES. MICHELIN HAS A PROBLEM, THEY ARE JUST LOOKING THE OTHER WAY. *TR
NHTSA ODI #10680166
98,500 miles · Nov 25, 2014
Steering
WHILE TURNING SHARP LEFT AT A TRAFFIC SIGNAL, THE TRUCK DID NOT WANT TO CORRECT BACK STRAIGHT. I FORCED IT BACK TO STRAIGHT AND CONTINUED ON. WHILE CONTINUING TO DRIVE, THE TRUCK WOULD TRACK LEFT AND THEN TRACK RIGHT. I TURNED THE STEERING WHEEL QUICKLY AND IT STRAIGHTENED BACK UP. THE TRUCK IS AT A PRIVATE REPAIR SHOP WITH THE …
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WHILE TURNING SHARP LEFT AT A TRAFFIC SIGNAL, THE TRUCK DID NOT WANT TO CORRECT BACK STRAIGHT. I FORCED IT BACK TO STRAIGHT AND CONTINUED ON. WHILE CONTINUING TO DRIVE, THE TRUCK WOULD TRACK LEFT AND THEN TRACK RIGHT. I TURNED THE STEERING WHEEL QUICKLY AND IT STRAIGHTENED BACK UP. THE TRUCK IS AT A PRIVATE REPAIR SHOP WITH THE TECHNICIAN UNABLE TO FIND ANYTHING BROKEN. HE SUGGESTED THAT IT MAY BE THE POWER STEERING BOX. *TR
NHTSA ODI #10660879
41,000 miles · Nov 6, 2014
Electrical System
EXHAUST GAS TEMP SENSOR ISSUE: DRIVING AT HIGHWAY SPEED, THANK GOD I WASN'T TOWING MY 5TH WHEEL. GOT THE MESSAGE ON THE DASH "STOP SAFELY NOW" AND 10 SECONDS LATER THE TRUCK SHUT ITSELF OFF. THIS IS A SERIOUS SAFETY HAZARD. IF I HAD BEEN TOWING THE TRAILER ON A HILL I DREAD TO THINK WHAT WOULD HAVE HAPPENED. TOWED THE VEHIC…
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EXHAUST GAS TEMP SENSOR ISSUE: DRIVING AT HIGHWAY SPEED, THANK GOD I WASN'T TOWING MY 5TH WHEEL. GOT THE MESSAGE ON THE DASH "STOP SAFELY NOW" AND 10 SECONDS LATER THE TRUCK SHUT ITSELF OFF. THIS IS A SERIOUS SAFETY HAZARD. IF I HAD BEEN TOWING THE TRAILER ON A HILL I DREAD TO THINK WHAT WOULD HAVE HAPPENED. TOWED THE VEHICLE TO ONE FORD DEALER, THEY COULDN'T DIAGNOSE EVEN THOUGH I FOUND THE PROBLEM ONLINE ( MANY F350 OWNERS HAVE HAD THE EXACT SAME EXPERIENCE) AND THEY TOLD ME TO PICK IT UP THE NEXT DAY. I DID THAT, AND ABOUT A HALF HOUR DOWN THE ROAD IT HAPPENED AGAIN. TOWED TO A DIFFERENT DEALERSHIP, THEY REPLACED ONE OF THE 4 EXHAUST GAS TEMP SENSORS AND AFTER AN ABSURD $500 REPAIR BILL FOR AN $89 PART I WAS ON MY WAY. FORD HAS OBVIOUSLY KNOWN THIS IS A PROBLEM AS THEY HAVE CHANGED THEIR PART NUMBER ON THESE SENSORS - THEY DID SOME SORT OF A REDESIGN REQUIRING A NEW PART NUMBER. I NOW CARRY A SPARE SENSOR WITH ME AT ALL TIMES AS WELL AS THE CORRECT SIZE WRENCH TO REPLACE IT. THIS SHOULD ABSOLUTELY BE A RECALL ISSUE SINCE IT IS BOTH A SERIOUS SAFETY ISSUE AS WELL AS SOMETHING THAT MANY OF US HAVE HAD. A SIMPLE ONLINE SEARCH FINDS MANY PEOPLE WITH THE SAME STORY. I DID CALL FORD CUSTOMER SERVICE, ABSOLUTELY NO ACTION ON THEIR PART. THE OLD ADAGE OF FORD = FOUND ON ROADSIDE DEAD OR FIX OR REPAIR DAILY WAS DEFINITELY TRUE FOR ME. I DO HAVE THE FORD CUSTOMER CARE CASE NUMBER SOMEWHERE IF YOU NEED THAT... *TR
NHTSA ODI #10653018
44,000 miles · Oct 15, 2014
Engine
I HAVE SUBMITTED MY REQUEST FOR A RECALL TO BE ISSUED ON ALL 2008 FORD F350SD FOR THE EXHAUST TEMPERATURE SENSOR FAILURE CAUSING THE VEHICLE TO SHUTDOWN. LOOKS AS THOUGH A RECALL WAS ISSUED FOR 2012 FORD 6.7L AMBULANCE PACKAGES: F-350 ENGINE RECALL NUMBER: 13V535000 RECALL DATE: 10/30/2013 PROBLEM SUMMARY: FORD MOTOR COM…
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I HAVE SUBMITTED MY REQUEST FOR A RECALL TO BE ISSUED ON ALL 2008 FORD F350SD FOR THE EXHAUST TEMPERATURE SENSOR FAILURE CAUSING THE VEHICLE TO SHUTDOWN. LOOKS AS THOUGH A RECALL WAS ISSUED FOR 2012 FORD 6.7L AMBULANCE PACKAGES: F-350 ENGINE RECALL NUMBER: 13V535000 RECALL DATE: 10/30/2013 PROBLEM SUMMARY: FORD MOTOR COMPANY (FORD) IS RECALLING CERTAIN MODEL YEAR 2011-2012 F-350/450/550 AMBULANCE PACKAGE VEHICLES MANUFACTURED FEBRUARY 22, 2010, THROUGH OCTOBER 19, 2012 AND EQUIPPED WITH A 6.7L DIESEL ENGINE. DUE TO AN EXHAUST SENSOR PROBLEM, THE VEHICLES MAY EXPERIENCE LOSS OF POWER FOLLOWED BY AN ENGINE STALL. CONSEQUENCE: AN UNEXPECTED ENGINE STALL INCREASES THE RISK OF A CRASH. ADDITIONALLY, IF THIS WERE TO OCCUR WHEN THE AMBULANCE IS TRANSPORTING A PATIENT, THERE IS AN INCREASED RISK OF INJURY TO THE PATIENT. CORRECTIVE ACTION: FORD WILL NOTIFY OWNERS, AND DEALERS WILL REPLACE THE EXHAUST GAS TEMPERATURE SENSOR, FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN BY THE END OF NOVEMBER 2013. OWNERS MAY CONTACT FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332. FORD'S RECALL CAMPAIGN NUMBER IS 13S10. SURE IF A CRASH CAN RESULT IN THE VEHICLE SHUTTING DOWN ON A 6.7L, IT COULD ALSO OCCUR ON A 6.4L 2008 FORD F350 SUPER DUTY THAT IS NOT AN AMBULANCE PACKAGE. A CRASH IS WHAT ALMOST HAPPEN WHEN MY WIFE'S VEHICLE SHUTDOWN ON HER DUE TO THE SENSOR GOING OUT HEADING DOWN HILL WITH NO POWER STEERING. INVESTIGATE THIS AND HAVE FORD HELD ACCOUNTABLE. I HAVE EMAILED FORD ON SEVERAL OCCASSIONS AND THIS IS THEIR LATEST RESPONSE: OUR RECORDS INDICATE THAT YOU CONTACTED THE FORD CRC ON 9/30/14, AND OUR CUSTOMER CARE REPRESENTATIVE ADVISED YOU THAT WE HAVE DOCUMENTED YOUR COMMENTS WHICH WILL BE FORWARDED TO THE APPROPRIATE DEPARTMENT FOR REVIEW AND CONSIDERATION. WOW "FOR REVIEW AND CONSIDERATION". *TR
NHTSA ODI #10644933
44,000 miles · Oct 15, 2014
Engine
EXHAUST TEMPERATURE SENSOR WILL CAUSE A CRASH THAT MAY END UP KILLING SOMEONE. THIS IS WHAT FAILED ON MY WIFE WHO WAS PULLING A 28' HORSE TRAILER WITH HER SHOW HORSE INSIDE WORTH OVER $30,000 DOLLARS. SHE MERGED TO A ONE LANE ROAD ON INTERSTATE 68 IN MARYLAND HEADING DOWN HILL WHEN THE CHECK ENGINE LIGHT CAME ONE SOON TO FOLLOW …
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EXHAUST TEMPERATURE SENSOR WILL CAUSE A CRASH THAT MAY END UP KILLING SOMEONE. THIS IS WHAT FAILED ON MY WIFE WHO WAS PULLING A 28' HORSE TRAILER WITH HER SHOW HORSE INSIDE WORTH OVER $30,000 DOLLARS. SHE MERGED TO A ONE LANE ROAD ON INTERSTATE 68 IN MARYLAND HEADING DOWN HILL WHEN THE CHECK ENGINE LIGHT CAME ONE SOON TO FOLLOW WITH A MESSAGE OF PULL OVER SAFELY. 20 SECONDS LATER, THE ENGINE SHUTOFF. THIS CAUSED HER TO LOSE POWER STEERING ON A ONE LANE ROAD GOING OVER A BRIDGE DOWN HILL PULLING A HORSE TRAILER WITH A GROSS WEIGHT OF OVER 10,000 POUNDS. SHE HAD NO WHERE TO PULL OVER SAFELY WHEN THE TRUCK SHUTDOWN ON HER. SHE HAD TO GET OUT OF THE TRUCK IN ORDER TO MOVE THE BARRELS BLOCKING THE RIGHT LANE IN ORDER TO TRY AND GET THE TRUCK AND TRAILER OUT OF THE OPEN LANE. SHE HAD TO BLOCK AN EXIT IN ORDER TO MAKE ROOM FOR THE OTHER VEHICLES. THE TRUCK WENT TO THE FORD DEALERSHIP IN CUMBERLAND, MD WHERE IT WAS DIAGNOSED THAT IT WAS THE EXHAUST TEMPERATURE SENSOR. THIS IS A SAFETY ISSUE ON THIS VEHICLE. AT NO TIME SHOULD A VEHICLE SHUTDOWN ON SOMEONE DRIVING IT. BELIEVE IT A VEHICLE GOING INTO A LIMP MODE BUT AT LEAST YOU CAN STILL DRIVE IT SO YOU CAN GET TO A SAFE PLACE. THERE NEEDS TO BE AN INVESTIGATION INTO WHY THIS OCCURS AND ENFORCE FORD TO ISSUE A RECALL TO FIX THIS PROBLEM BEFORE SOMEONE IS INJURED OR KILLED. *TR
NHTSA ODI #10644739
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