NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
18 reportsClear category filterMileage unknown · Jan 17, 2026
EngineStructureUnknown Or OtherFireInjury
Items in my bed and liner caught on fire. Engine regeneration for emissions got so hot melted all of the bed liner and caught a new large tv on fire. Ford has a glue on heat shield under bed which fell off. Exhaust gets so hot it caught on fire. They should have put a metal fixed plate or something fixed no a cheap glue on piece…
Read full complaint
Items in my bed and liner caught on fire. Engine regeneration for emissions got so hot melted all of the bed liner and caught a new large tv on fire. Ford has a glue on heat shield under bed which fell off. Exhaust gets so hot it caught on fire. They should have put a metal fixed plate or something fixed no a cheap glue on piece of foil. I inspected other trucks all missing!
NHTSA ODI #11711591
Mileage unknown · Jan 13, 2026
Engine
I have had multiple incidents of my truck shutting off completely while driving. The latest incident resulted in a "catastrophic engine failure". In the latest incident occurring in April 2025, I was driving on [XXX] . [XXX] is a two-lane highway with no divider, navigating through mountainous terrain. I was driving up a hi…
Read full complaint
I have had multiple incidents of my truck shutting off completely while driving. The latest incident resulted in a "catastrophic engine failure". In the latest incident occurring in April 2025, I was driving on [XXX] . [XXX] is a two-lane highway with no divider, navigating through mountainous terrain. I was driving up a hilly area when my truck shut off, and I lost all power steering. There is no shoulder on this part of the freeway, with an approximate 40-foot embankment. I was able to navigate the vehicle to the side of the road and position it just before the beginning of a guard rail beginning allowing me some grace. Due to no shoulder space, I was effectively parked on the white containment line of the road. I had my [XXX] daughter and wife in the car. I had to wait for a break in traffic to be able to open the driver's door due to the proximity to the active highway. I was safely get the truck towed to the nearest FORD dealership, where it was determined the engine was in "catastrophic failure" due to oil engine overfill. I informed FORD that my last oil change was with the FORD dealership and within the recommended time frame. I was informed by a technician that there is an ongoing issue with this engine make (6.4-liter, diesel). The technician stated that FORD is aware of the issue. The technician stated that fuel gets mixed with the oil and causes an "engine oil overfill". None of these issues stems from negligence but rather an unakknowledged issue by FORD. There was a check engine light that appeared at the time of failure. The check engine light had come on, at which point I contacted a mechanic to schedule an appointment. When I arrived for my appointment, the check engine light had disappeared, and I was told that no codes would alert if the actual check engine light was not on during the inspection. That same scenario occurred on approximately 3 occasions. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA ODI #11710743
Mileage unknown · May 14, 2025
EngineFuel/propulsion System
Vehicle died while driving on the freeway. Towed to the local Ford who did a diagnostic and test they found that the engine is completely done with as there was an engine oil overfill, and it filled the CAC system and melted cylinder eight piston. they’re saying that they will need to replace the entire engine and HP fuel pump i…
Read full complaint
Vehicle died while driving on the freeway. Towed to the local Ford who did a diagnostic and test they found that the engine is completely done with as there was an engine oil overfill, and it filled the CAC system and melted cylinder eight piston. they’re saying that they will need to replace the entire engine and HP fuel pump in order to repair and I see many others have experienced this same problem.
NHTSA ODI #11661000
200,000 miles · Apr 6, 2021
EngineFire
WE WERE HAULING A LOAD OF LOGS ABOUT AN HOUR AWAY EVERYTHING WAS FINE WHEN ALL OF THE SUDDEN THE TRUCK DOWN SHIFTED AND WHITE SMOKE STARTED POURING OUT FROM UNDER THE PASSENGER SIDE OF THE HOOD FOLLOWED BY FLAMES. WE HAD TO TRY TO GET OFF THE ROAD WHERE WE WERE THERE WAS NO WHERE TO PULL OFF AND FINALLY COULD SWING INTO A STATE…
Read full complaint
WE WERE HAULING A LOAD OF LOGS ABOUT AN HOUR AWAY EVERYTHING WAS FINE WHEN ALL OF THE SUDDEN THE TRUCK DOWN SHIFTED AND WHITE SMOKE STARTED POURING OUT FROM UNDER THE PASSENGER SIDE OF THE HOOD FOLLOWED BY FLAMES. WE HAD TO TRY TO GET OFF THE ROAD WHERE WE WERE THERE WAS NO WHERE TO PULL OFF AND FINALLY COULD SWING INTO A STATE GAMESLAND AND SOMEONE CALLED THE FIRE DEPT. I AM NOW OUT OF A TRUCK I JUST PURCHASED 2 MONTHS AGO AND MY VIN NUMBER ISN'T EVEN SHOWING UP
NHTSA ODI #11406635
20,000 miles · Jul 2, 2020
EnginePower Train
TL* THE CONTACT OWNS A 2008 FORD F-350. THE CONTACT STATED THAT THE VEHICLE SHOOK VIOLENTLY AFTER GOING OVER A SPEED BUMP. THE VEHICLE WAS TAKEN TO BEACH FORD LOCATED AT (2717 VIRGINIA BEACH BLVD, VIRGINIA BEACH, VA 23452) HOWEVER, THE MECHANIC WAS UNABLE TO DUPLICATE THE FAILURE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC…
Read full complaint
TL* THE CONTACT OWNS A 2008 FORD F-350. THE CONTACT STATED THAT THE VEHICLE SHOOK VIOLENTLY AFTER GOING OVER A SPEED BUMP. THE VEHICLE WAS TAKEN TO BEACH FORD LOCATED AT (2717 VIRGINIA BEACH BLVD, VIRGINIA BEACH, VA 23452) HOWEVER, THE MECHANIC WAS UNABLE TO DUPLICATE THE FAILURE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO INFORMED THE CONTACT THE FAILURE WAS KNOWN AS THE DEATH WOBBLE. AN UNKNOWN REPAIR WAS PERFORMED HOWEVER, THE FAILURE RECURRED. THE VEHICLE WAS TAKEN BACK TO BEACH FORD TO BE DIAGNOSED. THE CONTACT WAS INFORMED THAT THE TURBO CHARGER NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 20,000.
NHTSA ODI #11337125
99,000 miles · Oct 22, 2019
Engine
HAD THE TRUCK OVER HEAT MULTIPLE TIMES. HAD TO CHANGE THE COOLANT AND ALSO THE RADIATOR ON LONG WITH THE OIL COOLANT CONTAINER. HAS A TICKING SOUND AND HAS NOT YET GONE AWAY. HAVE TAKEN IT TO FORD DEALER AND THEY CAN'T FIGURE IT OUT. WOULD LIKE TO KNOW WHAT TO DO SINCE I HAVE SPENT A LOT OF MONEY AND THE PROBLEM HASN'T BEEN FIXE…
Read full complaint
HAD THE TRUCK OVER HEAT MULTIPLE TIMES. HAD TO CHANGE THE COOLANT AND ALSO THE RADIATOR ON LONG WITH THE OIL COOLANT CONTAINER. HAS A TICKING SOUND AND HAS NOT YET GONE AWAY. HAVE TAKEN IT TO FORD DEALER AND THEY CAN'T FIGURE IT OUT. WOULD LIKE TO KNOW WHAT TO DO SINCE I HAVE SPENT A LOT OF MONEY AND THE PROBLEM HASN'T BEEN FIXED AND THE ONLY THING THE FORD DEALER TELLS ME IS TO TRADE IT IN FOR A NEW ONE. HELP1
NHTSA ODI #11270289
160,000 miles · Jan 7, 2019
Engine
FORD SHOULD BE HELD ACCOUNTABLE FOR THE 6.4 DIESEL AS MUCH AS THESE TRUCKS COST HARD WORKING AMERICANS, PAY CLOSE TO 30 THOUSAND DOLLARS FOR A PICKUP TRUCK THEN HAVE TO PAY ANOTHER 15 THOUSAND TO FIX THE MOTOR DUE TO IT NOT BEING BUILT CORRECTLY, JUNK RODS, HEAD BOLTS, HEADS, TURBOS, OIL LEVEL BEING RAISED BY 2 TO 3 GALLONS P…
Read full complaint
FORD SHOULD BE HELD ACCOUNTABLE FOR THE 6.4 DIESEL AS MUCH AS THESE TRUCKS COST HARD WORKING AMERICANS, PAY CLOSE TO 30 THOUSAND DOLLARS FOR A PICKUP TRUCK THEN HAVE TO PAY ANOTHER 15 THOUSAND TO FIX THE MOTOR DUE TO IT NOT BEING BUILT CORRECTLY, JUNK RODS, HEAD BOLTS, HEADS, TURBOS, OIL LEVEL BEING RAISED BY 2 TO 3 GALLONS PER OIL CHANGE, DUE TO FUEL BEING PUMPED BACK INTO THE ENGINE, CAUSING SEVERE INTERNAL ENGINE PROBLEMS, IT'S NOT IF IT WILL BLOW BUT WHEN IT WILL, AS PER FORD MASTER MECHANIC. THIS IS A DANGEROUS SITUATION, TO KNOW AT ANY GIVING MINUTE WHILE DRIVING YOU'RE MOTOR COULD BLOW CAUSING LOSS OF CONTROL OF THE VEHICLE.
NHTSA ODI #11164876
180,000 miles · Sep 6, 2017
EngineFuel/propulsion System
TRUCK WAS TAKEN TO FORD DEALER AND DIAGNOSED WITH LOW PRESSURE FUEL PUMP AND HIGH PRESSURE FUEL PUMP OUT.PRIOR TO THIS WHITE SMOKE ROLLED OUT OF EXHAUST WHILE DRIVING ON HIGHWAY AND ENGINE SHUT OFF.TRUCK WAA TOWED TO DEALER WITH ABOVE FINDINGS.FORD DIESEL MECHANIC STATED SEVERAL ISSUES WITH HIGH AND LOW PRESSURE FUEL PUMPS ON TH…
Read full complaint
TRUCK WAS TAKEN TO FORD DEALER AND DIAGNOSED WITH LOW PRESSURE FUEL PUMP AND HIGH PRESSURE FUEL PUMP OUT.PRIOR TO THIS WHITE SMOKE ROLLED OUT OF EXHAUST WHILE DRIVING ON HIGHWAY AND ENGINE SHUT OFF.TRUCK WAA TOWED TO DEALER WITH ABOVE FINDINGS.FORD DIESEL MECHANIC STATED SEVERAL ISSUES WITH HIGH AND LOW PRESSURE FUEL PUMPS ON THESE MODELS.PLEASE LOOK INTO THIS.ESTIMATED COST IS 13,000 DOLLARS TO FIX.
NHTSA ODI #11021669
165,000 miles · Apr 26, 2017
Engine
UPON RETURNING FROM A SHORT DRIVE I NOTICED OIL ON THE GROUND...HAD TRUCK TOWED TO LOCAL FORD DEALER ...WHEN INSPECTED I WAS INFORMED THE SELF CLEANING EXHAUST SYSTEM CAUSED THE RINGS TO WEAR PREMATURELY AND BUILD PRESSURE IN THE CRANKCASE CAUSING OIL TO SPEW OUT ANY OPENING IE THE DIPSTICK TUBE. A DIESEL ENGINE SHOULD HAVE BEEN…
Read full complaint
UPON RETURNING FROM A SHORT DRIVE I NOTICED OIL ON THE GROUND...HAD TRUCK TOWED TO LOCAL FORD DEALER ...WHEN INSPECTED I WAS INFORMED THE SELF CLEANING EXHAUST SYSTEM CAUSED THE RINGS TO WEAR PREMATURELY AND BUILD PRESSURE IN THE CRANKCASE CAUSING OIL TO SPEW OUT ANY OPENING IE THE DIPSTICK TUBE. A DIESEL ENGINE SHOULD HAVE BEEN EXPECTED TO LAST 2-3 TIMES THE 165,000 MILES ON THE TRUCK.
NHTSA ODI #10980960
53,000 miles · Mar 9, 2017
EnginePower TrainUnknown Or Other
EXCESSIVE WHITE SMOKE OUT OF EXHAUST, ESPECIALLY WITH ACCELERATION. SMOKE HAS A FOUL ODOR ALSO. CAN HEAR A KNOCKING SOUND IN ENGINE ON DECELERATION (SIMILAR TO BAD WHEEL BEARING HUMS), ONLY DOES IT IF TURBO IS OVER 150-200 PSI, BUT WILL DO IT EVERY SINGLE TIME. 'DRIVE TO CLEAN EXHAUST' DISPLAYED ON DASH. COMPLETED RECOMMENDED …
Read full complaint
EXCESSIVE WHITE SMOKE OUT OF EXHAUST, ESPECIALLY WITH ACCELERATION. SMOKE HAS A FOUL ODOR ALSO. CAN HEAR A KNOCKING SOUND IN ENGINE ON DECELERATION (SIMILAR TO BAD WHEEL BEARING HUMS), ONLY DOES IT IF TURBO IS OVER 150-200 PSI, BUT WILL DO IT EVERY SINGLE TIME. 'DRIVE TO CLEAN EXHAUST' DISPLAYED ON DASH. COMPLETED RECOMMENDED DRIVE CYCLE (OVER 30MPH FOR AT LEAST 20 MINUTES, I DROVE FOR 45 MINS) AND MESSAGE STILL APPEARS. "WRENCH" SYMBOL DISPLAYED ON DASH. PER OWNER'S GUIDE THE RTT DISPLAYS WHEN ENGINE HAS DEFAULTED TO "LIMP-HOME" OPERATION OR WHEN TRANSMISSION PROBLEM HAS BEEN DETECTED.. THE LIGHT COMES ON EVERY TIME VEHICLE IS DRIVING NOW, AND STAYS ON ENTIRE TIME.
NHTSA ODI #10959856
Official recalls
6Jul 28, 2008
KNAPHEIDE IS RECALLING 108 MY 2006-2008 PRO SERIES TRUCK BEDS EQUIPPED WITH AN ICC BUMPER WHICH INCLUDED A PROVISION FOR A BALL HITCH. THERE MAY BE AN INSUFFICIENT WELD ATTACHING THE HITCH CHANNEL TO THE SUPPORTING STRUCTURE.
Consequence & remedy
Consequence: THIS COULD RESULT IN BENDING OF THE HITCH CHANNEL OR THE HITCH COULD BE PULLED OFF THE VEHICLE, INCREASING THE RISK OF A CRASH.
Remedy: KNAPHEIDE WILL OFFER TWO REMEDIES TO ITS CUSTOMERS: (1) FOR THOSE CUSTOMERS WHO DO NOT USE THE HITCH, THE HITCH WILL BE REMOVED FROM THE TRUCK BED AND REPLACED WITH AN ICC BUMPER; OR (2) FOR THOSE CUSTOMERS WHO NEED A HITCH, A RECEIVER HITCH ASSEMBLY WILL BE ADDED TO THE EXISTING HITCH ASSEMBLY AND ALL SUSPECT WELD JOINTS WILL BE RE WELDED. THE RECALL BEGAN ON AUGUST 15, 2008. OWNERS MAY CONTACT KNAPHEIDE AT 1-877-473-5763.
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.
Feb 28, 2008
FORD IS RECALLING 87,515 MY 2008 F250, F-350, F-450, AND F-550 VEHICLES FOR FAILING TO COMPLY WITH ALL THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 207, "SEATING SYSTEMS." SOME 40% SPLIT AND CAPTAIN'S CHAIR DRIVER'S SEATS, EQUIPPED WITH LUMBAR SUPPORTS, MAY HAVE IMPROPER WELDS AT THE JOINT OF THE SEAT BACK PIVOT BRACKET AND THE SEAT BACK FRAME.
Consequence & remedy
Consequence: IN THE EVENT OF A CRASH, THE SEAT SIDE PIVOT BRACKET MAY CRACK OR BREAK, INCREASING THE RISK OF INJURY TO THE SEAT OCCUPANT.
Remedy: DEALERS WILL ADD A REINFORCEMENT TO THE DRIVER'S SEAT BACK FRAME ON THE 40% SPLIT OR CAPTAIN'S CHAIR SEAT EQUIPPED WITH LUMBAR SUPPORT OR, IF NECESSARY, THE SEAT BACK FRAME WILL BE REPLACED. THE RECALL BEGAN ON MARCH 28, 2008. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Nov 21, 2007
CERTAIN VEHICLES FAIL TO CONFORM TO THE REQUIREMENTS SPECIFIED IN FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 208, 'OCCUPANT CRASH PROTECTION.' THE DRIVER AIR BAG MODULE MAY NOT HAVE BEEN PROPERLY ASSEMBLED.
Consequence & remedy
Consequence: THIS CONDITION MAY PREVENT THE DRIVER AIR BAG FROM PROPERLY DEPLOYING AND REDUCE OCCUPANT PROTECTION IN THE EVENT OF A CRASH.
Remedy: DEALERS WILL REPLACE YOUR DRIVER AIR BAG MODULE FREE OF CHARGE. THE RECALL BEGAN ON NOVEMBER 20, 2007. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Mar 26, 2007
ON CERTAIN TRUCKS EQUIPPED WITH A 6.4L DIESEL ENGINE, EXCESSIVE TEMPERATURES IN THE DIESEL PARTICULATE FILTER IN THE EXHAUST SYSTEM MAY RESULT FROM EXCESS HYDROCARBONS IN THE EXHAUST.
Consequence & remedy
Consequence: LACK OF POWER OR ROUGH OPERATION, UNUSUAL NOISES FROM THE ENGINE OR EXHAUST, WHITE SMOKE FROM THE EXHAUST, AND POTENTIALLY A VISIBLE FLAME OUT THE TAILPIPE CAN OCCUR.
Remedy: DEALERS WILL REPROGRAM THE POWER TRAIN CONTROL MODULE. THE RECALL BEGAN ON APRIL 3, 2007. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Mar 26, 2007
ON CERTAIN TRUCKS EQUIPPED WITH A 6.4L DIESEL ENGINE, INSUFFICIENT CLEARANCE OF THE BATTERY POSITIVE (B+) WIRE TO THE RIGHT HAND SPLASH SHIELD BOLT MAY RESULT IN THE BATTERY B+ WIRE CONTACTING THE SPLASH SHIELD BOLT.
Consequence & remedy
Consequence: LONG TERM CONTACT COULD CAUSE WIRE CHAFE, RESULTING IN COPPER WIRE BEING EXPOSED. IF THIS CONDITION OCCURS, THE BATTERY B+ WIRE COULD SHORT TO GROUND INCREASING THE RISK OF A FIRE.
Remedy: DEALERS WILL INSPECT THE BATTERY B+ WIRE LOCATION AND, IF NECESSARY, REPOSITION THE WIRE. THE RECALL BEGAN ON APRIL 3, 2007. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
1PE13014 · Alleged Loss Of Steering
Opened May 7, 2013 · Closed Jan 31, 2014
Status: closed (inferred from source dates) · Steering; Steering:gear Box (other Than Rack And Pinion)
The Office of DefectsInvestigation (ODI) opened PE13-014 after identifying five complaints alleging steering gear failure in model year (MY) 2008 Ford F-250 and F-350 Super Duty pick-up trucks and to evaluate the relationship between the design history of the steering gear assembly and the alleged defect.As background, ODI investigated steering gear sector shaft fractures in approximately 1.3 million MY 1999 - 2001 Ford Super Duty pick-up trucks and MY 2000 - 2001 Ford Excursion sport utility vehicles in Engineering Analysis EA01-009.The investigation determined that the sector shaft failures were the result of extraordinary, possibly multiple, impacts and not the result of fatigue.No defect in design, manufacturing or materials was identified in the sector shaft.EA01-009 was closed August 19, 2003 with 169 complaints, resulting in a rate of 12.9 incidents per 100,000 vehicles after approximately one year of service.Ford increased the diameter of the sector shaft from 1.375 inches to 1.625 inches at the start of MY 2005 production, increasing the resistance of the steering gear assembly to torsional overload by approximately 48% and changing the failure mode from sector shaft fracture to cracked or broken sector shaft gear teeth.The redesigned steering gear assembly was used in approximately 1.1 million MY 2005 through 2009 Ford Super Duty pick-up trucks, including the subject vehicles.Figure 1 shows the basic steering system design used in Ford Super Duty trucks investigated in EA01-009 and PE13-014. Figure 2 shows the locations of failures resulting from impact related torsional overloading of the sector shaft for the subject vehicles and the prior generation Ford Super Duty trucks investigated in EA01-009.Figure 3 shows an example of a failed sector shaft investigated in EA01-009 and comparisons of fracture surfaces of sector shafts failing from fatigue loading and from torsional overload.Ford provided field return part analysis of failed steering gears from MY 2005 through 2009 Super Duty trucks found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload (Figure 4).Laboratory analysis found no evidence of fatigue or material property defects in any of the fractures.Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns (Figure 5).Analysis of failures by time in service indicates a random failure pattern/distribution, consistent with incidents of impact induced overload (Figure 6). The complaint rate for the subject vehicles after approximately 5 to 6 years, 7.1 incidents per 100,000 vehicles, is lower than the rate observed in EA01-009. Furthermore, similar to the condition investigated in EA01-009, a number of incident records include evidence of impact loads (e.g., curb strikes) and several alleged crashes include incidents in which information suggests that the steering gear failure was most likely a result of crash forces, rather than the cause of the crash.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at ww
Additional source detail variants (2)
Steering
The Office of DefectsInvestigation (ODI) opened PE13-014 after identifying five complaints alleging steering gear failure in model year (MY) 2008 Ford F-250 and F-350 Super Duty pick-up trucks and to evaluate the relationship between the design history of the steering gear assembly and the alleged defect.As background, ODI investigated steering gear sector shaft fractures in approximately 1.3 million MY 1999 - 2001 Ford Super Duty pick-up trucks and MY 2000 - 2001 Ford Excursion sport utility vehicles in Engineering Analysis EA01-009.The investigation determined that the sector shaft failures were the result of extraordinary, possibly multiple, impacts and not the result of fatigue.No defect in design, manufacturing or materials was identified in the sector shaft.EA01-009 was closed August 19, 2003 with 169 complaints, resulting in a rate of 12.9 incidents per 100,000 vehicles after approximately one year of service.Ford increased the diameter of the sector shaft from 1.375 inches to 1.625 inches at the start of MY 2005 production, increasing the resistance of the steering gear assembly to torsional overload by approximately 48% and changing the failure mode from sector shaft fracture to cracked or broken sector shaft gear teeth.The redesigned steering gear assembly was used in approximately 1.1 million MY 2005 through 2009 Ford Super Duty pick-up trucks, including the subject vehicles.Figure 1 shows the basic steering system design used in Ford Super Duty trucks investigated in EA01-009 and PE13-014. Figure 2 shows the locations of failures resulting from impact related torsional overloading of the sector shaft for the subject vehicles and the prior generation Ford Super Duty trucks investigated in EA01-009.Figure 3 shows an example of a failed sector shaft investigated in EA01-009 and comparisons of fracture surfaces of sector shafts failing from fatigue loading and from torsional overload.Ford provided field return part analysis of failed steering gears from MY 2005 through 2009 Super Duty trucks found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload (Figure 4).Laboratory analysis found no evidence of fatigue or material property defects in any of the fractures.Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns (Figure 5).Analysis of failures by time in service indicates a random failure pattern/distribution, consistent with incidents of impact induced overload (Figure 6). The complaint rate for the subject vehicles after approximately 5 to 6 years, 7.1 incidents per 100,000 vehicles, is lower than the rate observed in EA01-009. Furthermore, similar to the condition investigated in EA01-009, a number of incident records include evidence of impact loads (e.g., curb strikes) and several alleged crashes include incidents in which information suggests that the steering gear failure was most likely a result of crash forces, rather than the cause of the crash.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at ww
Steering:gear Box (other Than Rack And Pinion)
The Office of DefectsInvestigation (ODI) opened PE13-014 after identifying five complaints alleging steering gear failure in model year (MY) 2008 Ford F-250 and F-350 Super Duty pick-up trucks and to evaluate the relationship between the design history of the steering gear assembly and the alleged defect.As background, ODI investigated steering gear sector shaft fractures in approximately 1.3 million MY 1999 - 2001 Ford Super Duty pick-up trucks and MY 2000 - 2001 Ford Excursion sport utility vehicles in Engineering Analysis EA01-009.The investigation determined that the sector shaft failures were the result of extraordinary, possibly multiple, impacts and not the result of fatigue.No defect in design, manufacturing or materials was identified in the sector shaft.EA01-009 was closed August 19, 2003 with 169 complaints, resulting in a rate of 12.9 incidents per 100,000 vehicles after approximately one year of service.Ford increased the diameter of the sector shaft from 1.375 inches to 1.625 inches at the start of MY 2005 production, increasing the resistance of the steering gear assembly to torsional overload by approximately 48% and changing the failure mode from sector shaft fracture to cracked or broken sector shaft gear teeth.The redesigned steering gear assembly was used in approximately 1.1 million MY 2005 through 2009 Ford Super Duty pick-up trucks, including the subject vehicles.Figure 1 shows the basic steering system design used in Ford Super Duty trucks investigated in EA01-009 and PE13-014. Figure 2 shows the locations of failures resulting from impact related torsional overloading of the sector shaft for the subject vehicles and the prior generation Ford Super Duty trucks investigated in EA01-009.Figure 3 shows an example of a failed sector shaft investigated in EA01-009 and comparisons of fracture surfaces of sector shafts failing from fatigue loading and from torsional overload.Ford provided field return part analysis of failed steering gears from MY 2005 through 2009 Super Duty trucks found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload (Figure 4).Laboratory analysis found no evidence of fatigue or material property defects in any of the fractures.Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns (Figure 5).Analysis of failures by time in service indicates a random failure pattern/distribution, consistent with incidents of impact induced overload (Figure 6). The complaint rate for the subject vehicles after approximately 5 to 6 years, 7.1 incidents per 100,000 vehicles, is lower than the rate observed in EA01-009. Furthermore, similar to the condition investigated in EA01-009, a number of incident records include evidence of impact loads (e.g., curb strikes) and several alleged crashes include incidents in which information suggests that the steering gear failure was most likely a result of crash forces, rather than the cause of the crash.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at ww
Illustration