1991 FORD F-150

6 recalls, 357 complaints - 52 TSBs

FUEL SYSTEM, GASOLINE

Defect Description

THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. VEHICLE DESCRIPTION: 1990-1993 FORD F-SERIES VEHICLES EQUIPPED WITH DUAL FUEL TANKS AND 4.9, 5.0,5.8, OR 7.5 LITER GASOLINE FUELED ENGINES. SOME VEHICLES CAN EXPERIE... Read more

Consequence

SHOULD THIS OCCUR, THE CAPACITY OF THE RECEIVING TANK MAY BE EXCEEDED AND FUEL MAY OVERFLOW FROM THE FILLER CAP.

Remedy

FORD IS EXTENDING THE WARRANTY FOR POTENTIAL FUEL CROSS-FLOW TO 12 YEARS OF SERVICE OR 150,000 MILES FROM THE VEHICLE'S WARRANTY START DATE, WHICHEVER OCCURS FIRST. THIS COVER WILL AUTOMATICALLY TRANSFER TO SUBSEQUENT OWNERS AT NO CHARGE. IF A VEHICLE ALREADY HAS MORE THAN 150,000 MILES, THIS OVER... Read more

1,556,221 vehicles affected

Manufacturer: FORD MOTOR COMPANY

TIRES:TREAD/BELT

Defect Description

THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. EQUIPMENT DESCRIPTION: FORD IS REPLACING ALL FIRESTONE WILDERNESS AT 15, 16, AND 17 INCH TIRES MOUNTED ON FORD TRUCKS AND SUVS. FORD REPORTS TREAD SEPARATION CAN... Read more

Consequence

SHOULD THE TREAD SEPARATE AT HIGHWAY SPEEDS, A VEHICLE CRASH COULD OCCUR, POSSIBLY RESULTING IN PERSONAL INJURY OR DEATH.

Remedy

THE REPLACEMENT/REIMBURSEMENT PROGRAM FOR THIS CAMPAIGN EXPIRED ON MARCH 31, 2002. HOWEVER, CUSTOMERS CAN CONTACT FORD AT 1-877-917-3673 OR GO ON-LINE TO WWW.FORD.COM FOR POSSIBLE ASSISTANCE.

13,000,000 vehicles affected

Manufacturer: FORD MOTOR COMPANY

TIRES:TREAD/BELT

Defect Description

TIRE DESCRIPTION: FIRESTONE WILDERNESS AT, SIZE P235/75R15, PRODUCED AT THE DECATUR, ILLINOIS TIRE PLANT AND ALL FIRESTONE RADIAL ATX AND RADIAL ATX II TIRES, SIZE P235/75R15. OPERATION OF THESE TIRES AT LOW INFLATION PRESSURES, HIGH SPEED, AND IN HOT WEATHER, CAN CONTRIBUTE TO SEPARATION OF THE T... Read more

Consequence

IF THE TREAD SEPARATES FROM THE TIRE, THE DRIVER CAN LOSE CONTROL OF THE VEHICLE, POSSIBLY RESULTING IN A CRASH CAUSING INJURY OR DEATH.

Remedy

THE REPLACEMENT/REIMBURSEMENT PROGRAM FOR THIS CAMPAIGN EXPIRED ON AUGUST 29, 2001. HOWEVER, CUSTOMERS SHOULD CONTACT FIRESTONE CUSTOMER SERVICE AT 1-800-465-1904 FOR POSSIBLE ASSISTANCE.

14,400,000 vehicles affected

Manufacturer: BRIDGESTONE/FIRESTONE, INC.

ELECTRICAL SYSTEM:IGNITION

Defect Description

THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.

Consequence

THIS CONDITION COULD CAUSE OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN AREA OF THE VEHICLE.

Remedy

DEALERS WILL REPLACE THE IGNITION SWITCH.

7,900,000 vehicles affected

Manufacturer: FORD MOTOR COMPANY

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

Defect Description

A MALFUNCTIONING CHECK VALVE WITHIN THE FUEL PUMP ASSEMBLY CAUSES A PORTION OF THE UNUSED FUEL FROM ONE TANK TO BE RETURNED TO THE SECOND TANK. WHEN THIS OCCURS, THE CAPACITY OF THE SECOND TANK CAN BE EXCEEDED, CAUSING FUEL SPILLAGE.

Consequence

SPILLED FUEL CAN RESULT IN A FIRE WHEN EXPOSED TO ASOURCE OF IGNITION.

Remedy

REPLACEMENT OF THE FUEL PRESSURE REGULATOR AND INSTALLATION OF REDUNDANT CHECK VALVES.

1,131,000 vehicles affected

Manufacturer: FORD MOTOR COMPANY

STEERING: STEERING WHEEL/HANDLE BAR

Defect Description

KEYS ATTACHED TO THE KEY RING OF AN IGNITION KEY WHILE IT IS IN THE VEHICLE IGNITION CAN BECOME LODGED IN THE STEERING LOCK RECEIVER AS THE STEERING WHEEL IS BEING TURNED.

Consequence

THE LODGED KEYS CAN CAUSE LOSS OF STEERING CONTROL, WHICHCAN RESULT IN AN ACCIDENT WHEN THE VEHICLE IS BEING USED ON THE HIGHWAY.

Remedy

A SHIELD WILL BE POSITIONED BETWEEN THE STEERING WHEEL AND THE IGNITION SWITCH AND HELD IN PLACE BY THE STEERING LOCK BAND.

2,419 vehicles affected

Manufacturer: FAIRMONT TAMPER

Complaint Statistics

357 total complaints 12 crashes 52 fires 8 injuries

Top Reported Components

Component	Complaints
FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY	49
FUEL SYSTEM, GASOLINE:STORAGE:AUXILLARY TANK:SELECTOR DEVICES	42
ELECTRICAL SYSTEM:IGNITION:SWITCH	25
FUEL SYSTEM, GASOLINE:STORAGE:AUXILLARY TANK	21
FUEL SYSTEM, GASOLINE	19
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP	13
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP	13
TIRES:TREAD/BELT	10
VEHICLE SPEED CONTROL	10
ELECTRICAL SYSTEM:IGNITION	9

Incident date: Apr 7, 2025

I own two Nuna RAVA convertible car seats that fall under recall 24C002 due to a defect in the harness adjuster mechanism, which may cause contamination and compromise the proper securing of the child. While Nuna acknowledges this defect, they are only offering a cleaning kit and new seat pad as a r... Read more

Incident date: Mar 18, 2021

THE TRUCK WONT CRANK. WHEN THE KEY IS TURNED OFF AND REMOVED SOME ELECTRICAL SYSTEMS STILL WORK AND CAUSE SMOKING. I HAVE HAD TO DISCONNECT THE BATTERY IN FEAR THE TRUCK WILL BURN DOWN. FORD WAS CONTACTED ABOUT THE ISSUE AND SAID THEY CANT DO ANYTHING BECAUSE THEIR RECORDS FOR RECALLS ONLY GO 10 YEA... Read more

Incident date: Sep 15, 2015

FUEL SPILLING OUT AROUND NECK WHILE PARKED AT WORK, ALSO REAR FUEL TANK PUMPING GAS INTO FRONT GAS TANK WHILE DRIVING.... *TR

Incident date: Oct 4, 2013

TL* THE CONTACT OWNS A 1991 FORD F-150. THE CONTACT STATED THAT ONE OF THE TANKS IN THE VEHICLE WOULD NOT WORK AND CAUSED THE VEHICLE TO STALL. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, BUT COULD NOT BE REPAIRED. THE DETAILS OF THE DIAGNOSTIC TEST COULD NOT BE PROVIDED. THE VIN WAS NOT INCLU... Read more

Incident date: Nov 30, 2014

WHILE THE ENGINE IS RUNNING, THE DUAL TANKS CROSS-FLOW INTO ONE ANOTHER. ONE TANK HAS OVER-FILLED THE OTHER TANK AND VISA VERSA TO INCLUDE SPILLAGE. I HAVE CONTACTED THE LOCAL DEALER AND FORD ABOUT IT BUT THEY SAY THEY CAN'T DO ANYTHING FOR ME AS FAR AS A RECALL IS CONCERNED EVEN THOUGH THIS ISSUE... Read more

Incident date: May 16, 2013

TL* THE CONTACT OWNS A 1991 FORD F-150. THE CONTACT STATED THAT THE FUEL PUMP ASSEMBLY CAUSED A PORTION OF THE UNUSED FUEL FROM ONE TANK TO BE RETURNED TO THE SECOND TANK. WHEN THE FAILURE OCCURRED, THE CAPACITY OF THE SECOND TANK WAS EXCEEDED AND WOULD CAUSE FUEL SPILLAGE. THE CONTACT BELIEVED THA... Read more

Incident date: May 16, 2013

Incident date: Apr 2, 2014

TL* THE CONTACT OWNS A 1991 FORD F-150. THE CONTACT STATED THAT A PORTION OF THE UNUSED FUEL FROM ONE TANK WAS BEING RETURNED TO THE SECOND TANK, CAUSING A FUEL SPILLAGE. THE CONTACT ALSO STATED THAT THE FUEL PRESSURE WAS LOW. THE CONTACT WAS NOT DIAGNOSED. THE MANUFACTURE WAS MADE AWARE OF THE FAIL... Read more

Incident date: May 28, 2013

TL* THE CONTACT OWNS A 1991 FORD F-150. THE CONTACT STATED THAT THE VEHICLE FAILED TO START. THE VEHICLE WAS TOWED TO THE DEALER WHO STATED THE FUEL PUMP FAILED. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRED. THE MANUFACTURER WAS CONTACTED ABOUT THE FAILURE. THE FAILURE MILEAGE WAS 145,000. ... Read more

Incident date: May 28, 2013

Incident date: May 23, 2012

TL* THE CONTACT OWNS A 1991 FORD F-150. THE CONTACT STATED THAT A PORTION OF THE UNUSED FUEL FROM ONE TANK WAS BEING RETURNED TO THE SECOND TANK, CAUSING FUEL SPILLAGE. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL PRESSURE REGULATOR AND INSTALLATION OF REDUNDANT CHECK VAL... Read more

Incident date: Dec 2, 2011

I WAS DRIVING TO WORK AND THE ENGINE CAUGHT FIRE. *TR

Fire

Incident date: Dec 2, 2011

I WAS DRIVING TO WORK AND THE ENGINE CAUGHT FIRE. *TR

Fire

Incident date: May 10, 2011

THE FUEL TANK STRAPS ON MY 1991 FORD F-150 HAVE RUSTED AND CAUSED MY FUEL TANKS TO LEAK GASOLINE. *TR

Incident date: Nov 5, 2009

TL*THE CONTACT OWNS A 1991 FORD F-150. WHILE DRIVING AT AN UNKNOWN SPEED, THE CONTACT NOTICED THAT FUEL WAS LEAKING. THE FAILURE OCCURRED INTERMITTENTLY. THE CONTACT WAS INFORMED BY THE MANUFACTURER THAT THE VEHICLE WAS NOT INCLUDED IN RECALL 01I008000 (FUEL SYSTEM, GASOLINE). THE VEHICLE HAD NOT BE... Read more

Incident date: Nov 2, 2010

TL*THE CONTACT OWNS A 1991 FORD F-150. THE CONTACT STATED THAT WHILE DRIVING LESS THAN 1 MPH, THERE WAS A STRONG FUEL ODOR. THE CONTACT PULLED OVER AND NOTICED THAT FUEL LEAKING FROM THE GAS CAP. THE CONTACT CALLED THE DEALER WHO STATED THAT THEY COULD NOT CHECK THE VIN BECAUSE THE SYSTEM WAS OUTDAT... Read more

Incident date: Jul 14, 1993

TL* THE CONTACT OWNS A 1991 FORD F150. THE CONTACT STATED THE FUEL GAUGE THAT WOULD SWITCH FROM ONE FUEL TANK TO THE OTHER FAILED. HE PREVIOUSLY RECEIVED NOTIFICATION OF NHTSA CAMPAIGN ID NUMBER: 93V125000 (FUEL SYSTEM, GASOLINE: STORAGE: TANK ASSEMBLY) BUT FAILED TO TAKE THE VEHICLE TO THE DEALER F... Read more

Incident date: Mar 7, 2009

TL* THE CONTACT OWNS A 1991 FORD F-150. THE VEHICLE WAS EQUIPPED WITH A DUAL FUEL TANK. THE CONTACT OBSERVED FUEL LEAKAGE IN THE SECOND FUEL TANK SPILLING FUEL INTO THE FIRST FUEL TANK AND CAUSING AN EXCESSIVE OVERFLOW. THERE WERE TWO RECALLS UNDER NHTSA CAMPAIGN ID NUMBERS 01I008000 (FUEL SYSTEM, ... Read more

Incident date: Aug 3, 2006

TL*THE CONTACT OWNS A 1991 FORD F150 PICKUP TRUCK. HIS VEHICLE EXHIBITS A NO-START CONDITION. HE HAD TO REPLACE THE STARTER AND THE SOLENOID. NONE OF THE REPAIRS HAVE REMEDIED THE FAILURE. THE VEHICLE WAS NOT TAKEN TO THE DEALER DUE TO THE DIAGNOSTIC TESTING FEE. THE FAILURE MILEAGE WAS 89,953.

Incident date: Aug 10, 2007

TL*- THE CONTACT OWNS A 1991 FORD F150 PURCHASED MARCH 2007. THE VEHICLE HAD DUAL FUEL STORAGE TANKS THAT BEGAN LEAKING. THE CONTACT WAS ADVISED THAT FUEL WAS LEAKING FROM THE VEHICLE AND THEN NOTICED THAT IT HAD LEAKED ONTO THE DRIVEWAY. ALTHOUGH THERE WAS A RECALL ON THE VEHICLE NHTSA CAMPAIGN N... Read more

Incident date: Aug 1, 2008

TL*THE CONTACT OWNS A 1991 FORD F150 4X4 XLT 300. THE VEHICLE HAS DUAL TANKS AND CAN TRAVEL APPROXIMATELY 100 MILES ON ONE TANK. WHEN SWITCHING TO THE OTHER TANK, THE VEHICLE COULD ONLY TRAVEL APPROXIMATELY 20 MILES BEFORE RUNNING OUT OF FUEL. THROUGH RESEARCH, THE CONTACT DISCOVERED THAT THE CHE... Read more

Incident date: Aug 20, 2008

RECALL 93V125000. MY 1991 FORD F150 IS EXPERIENCING THE PROBLEM THIS RECALL ADDRESSED. I CALLED THE FORD 800# AND THEY COULD NOT AND WOULD NOT TELL ME IF MY VEHICLE HAD THIS RECALL PERFORMED ON IT, TO CONTACT A DEALER. I CONTACTED A DEALER WHO SAID THEY COULD NOT TELL ME EITHER. I HAVE OWNED TH... Read more

Incident date: Aug 20, 2008

Incident date: Jul 23, 2007

1991 FORD F150 PICK UP WITH FUEL TANK SYSTEMS PROBLEMS. CUSTOMER STATES THAT A RECALL WAS DONE IN 1994 FOR THE FUEL TANK DELIVERY SYSTEM AND NOW IT IS GONE BAD AGAIN AND HE WANTS TO BE REIMBURSED FOR THE REPAIRS DONE**CC *JB

Incident date: Jun 1, 2007

WHILE DRIVING 60 MPH, THE REAR DRIVER SIDE TIRE (SENTRY TRU-TRAC APT, SIZE LT235/75R15, DOT-CHHK) SUDDENLY HAD 28" OF TREAD SEPARATED FROM STEEL BELTS. TIRE DID NOT GO FLAT. THE SEPARATED TIRE TREAD DAMAGED PICK- UP TRUCK QTR PANEL, AND BENT THE WHEEL WELL SPLASH PANELS' METAL SUPPORT ARM INTO THE R... Read more

Incident date: Jan 14, 2007

TL* THE CONTACT OWNS A 1991 FORD F150. THE CONTACT CALLED REGARDING RECALL # 93V125000. THE VEHICLE WAS MIXING GASOLINE IN THE OTHER VALVE. THE CONTACT STATED THAT THE SITUATION WAS MESSY AND HAZARDOUS. THE CURRENT AND FAILURE MILEAGE WERE 110629.*AK THE CUSTOMER STATES THIS VEHICLE HAS DUAL ... Read more

Incident date: Jul 10, 1997

THE PAINT ON THE FRONT HOOD HAS PEELED RIGHT DOWN TO THE METAL. THIS HAS BEEN SLOWLY OCCURRING FOR ABOUT 10 YEARS NOW. FORD AND AUTO BODY SHOPS SAY IT IS DUE TO POOR OR NO UNDERCOAT, YET FORD SAYS TO BAD. APPARENTLY THEY HAD A RECALL ON THIS AT ONE TIME BUT MY TRUCK WAS NO PEELING THEN IT STARTED A ... Read more

Incident date: Oct 26, 2006

F150 FORD FUEL TANK VALVES TRANSFERRED FRONT TANK FUEL TO REAR TANK MAKING REAR TANK OVERFLOW. CITY TRUCK STOPPED ME TO TELL ME THAT GAS WAS POURING ALL OVER THE STREET. *JB

Incident date: Jan 19, 2006

DT*: THE CONTACT STATED THE FUEL PUMP IS CAUSING THE UNUSED FUEL FROM ONE TANK TO RETURN TO THE SECONDARY TANK CAUSING SPILLAGE. THERE IS A NHTSA RECALL, # 93V125000, REGARDING THE FUEL SYSTEM TANK ASSEMBLY. THE VEHICLE HAS THE SAME PROBLEMS AS INDICATED IN THE RECALL; HOWEVER IT IS NOT INCLUDED ... Read more

Incident date: Aug 24, 2001

ON AUGUST 24, 2001, A FIRE SPONTANEOUSLY BEGAN UNDER THE HOOD OF MY 1991 FORD F150 PICKUP TRUCK WHILE IT WAS TURNED OFF AND PARKED IN THE DRIVEWAY AT NIGHT. THE FIRE CAUSED EXPENSIVE DAMAGE TO THE VEHICLE AND WOULD HAVE PROBABLY CAUGHT MY HOUSE ON FIRE HAD THE TRUCK BEEN PARKED IN THE GARAGE. I CH... Read more

Fire

Incident date: Aug 24, 2001

Fire

Incident date: Jun 1, 2005

DT: THE CONTACT OWNED A 1991 FORD F150. HE STATED THAT THE ABS BRAKES MALFUNCTIONED. NEEDED TO REPLACE THE ABS SENSOR IN THE DIFFERENTIAL UNIT AND THE ABS MODULE CONTROL. THE TOTAL COST TO REPAIR THEM WAS MORE THAN $1200.00. THE FORD MECHANIC TOLD CONTACT THAT THIS WAS A KNOWN PROBLEM FOR THE AB... Read more

Incident date: Apr 19, 2005

1991 FORD F150 DEVELOPED PROBLEMS WITH THE FUEL TANK LEAKING.*MR FUEL IN THE TANK WAS LEAKING INTO THE FRONT TANK CAUSING THE FRONT TANK TO OVERFLOW. THE MANUFACTURER INDICATED THERE WAS A RECALL ON THIS PART BUT THE CONSUMER STATED HE NEVER RECEIVED A RECALL NOTICE. THE RECALL WAS ONLY GOOD FOR ... Read more

Incident date: Jul 12, 2005

DT: HAD A PROBLEM WITH THE VEHICLE AND TOOK IT TO THE LOCAL MECHANIC THAT SAID THERE WAS A RECALL. CONTACTED FORD, AND THEY SAID THE RECALL EXPIRED AT 150,000 OR 12 YEARS. THE FUEL WAS RUNNING THROUGH THE ENGINE. THE VEHICLE WOULD NOT START. THERE WAS A DEFECTIVE CHECK VALUE. DRIVING DOWN THE R... Read more

Incident date: May 1, 2005

I OWN A 1991 F150 PICKUP. SOMETHING IS HAPPINING WITH FUEL TANKS. ITS LIKE FUEL FROM THE FRONT TANK IS BEING TRANSFERED TO THE BACK TANK, RESULTING IN OVERFLOWING FUEL FROM THE BACK. I THINK THE MFG. SHOULD REPAIR THE PROBLEM AS IT IS A BAD SAFETLY ISSUE.

Incident date: Jun 4, 2005

DT: CONSUMER STATES: THE REAR SPRING SHACKLES RUSTED OFF. ITIS APART THAT SHOULD NOT WEAR, AND SHOULD NOT BE HOOKED TO THE FRAME AT ALL. IT IS TOTALLY RUSTED ON BOTH SIDES. CAUSING THE VEHICLE TO SWAY AT 40-50 MPH. *AK

Incident date: Jan 1, 1901

1991 FORD F150 XLT HAVING PROBLEMS WITH FUEL SPILLING OUT OF THE TANK WHILE DRIVING DUE TO FAULTY EXTERNAL CHECK VALVES.*MR THE DEALER ALSO FOUND EVIDENCE OF SEEPAGE FROM THE TANK BEING PRESSURIZED TO THE REAR FUEL PUMP SUPPLY PRESSURE. THEY BLAME THAT PROBLEM ON FAULTY EXTERNAL CHECK VALVES WHIC... Read more

Incident date: Apr 9, 2005

SATURDAY AFTERNOON, ABOUT 8 GALLONS OF GASOLINE SPRAYED OUT OF MY FORD 1991 F150 XLT [XXX] WHILE DRIVING ABOUT 15 MILES. THE FORD DEALER ALSO FOUND EVIDENCE OF SEEPAGE FROM THE FRONT FUEL TANK BEING PRESSURIZED TO REAR FUEL PUMP SUPPLY PRESSURE AND BLAMES THE PROBLEM ON FAULTY EXTERNAL CHECK VALVES ... Read more

Incident date: Jun 30, 2004

OVERHEATING COOLING SYSTEM NOT WORKING. *JB

Incident date: May 1, 2000

CONSUMER COMPLAINED ABOUT THE FUEL GAUGE SYSTEM REGISTERING A QUARTER TANK OF FUEL, WHEN IN REALITY, VEHICLE HAD NO FUEL AND STOPPED RUNING. THE DEALER WAS NOT NOTIFIED AT THIS TIME.*AK CONSUMER STATED THE DUAL FUEL TANK FAILED. *TT

Incident date: Jan 27, 2005

ALTERNATOR WIRING HARNESS AND ALTERNATOR CAUGHT FIRE, COULD EASILY HAVE DESTROYED VEHICLE. AND NEARBY GOVERNMENT BUILDING. I NOTICED SMOKE AND SECURED A FIRE EXTINGUISHER TO REMEDY. *JB

Fire

Incident date: Dec 1, 2004

THERE WERE TWO DUAL TANKS ON THE TRUCK. WHILE DRIVING OR PARKING THE FRONT FUEL TANK PUMPED FUEL INTO THE REAR TANK. THIS CAUSED AN OVERFLOW OF GASOLINE FROM THE FILLER NECK ONTO THE GROUND. CONSUMER WAS ABLE TO DRIVE VEHICLE TO THE DEALER FOR INSPECTION. MECHANIC DETERMINED THAT THIS VEHICLE WA... Read more

Incident date: Oct 15, 2004

CONSUMER STATES THAT WHEN HE TAKES THE CAP OFF OF HIS REAR GAS TANK, THE FUEL SPILLS ALL OVER. HE STATES THAT THERE IS A RECALL MENTIONING THIS MALFUNCTION. THIS IS RECALL #01100800. HE STATES THAT HE IS CONSTANTLY SMELLING GAS FUMES. *NM

Incident date: Sep 15, 2004

WHILE DRIVING, A LOUD NOISE WAS HEARD COMING FROM THE FRONT OF THE VEHICLE. THE CONSUMER NOTICED WHILE ACCELERATING THE NOISE BECAME LOUDER. THE CONSUMER WAS ABLE TO DRIVE IT TO THE DEALER FOR INSPECTION. THE MECHANIC WAS UNABLE TO DUPLICATE THE PROBLEM. PLEASE FILL IN ADDITIONAL INFORMATION. *J... Read more

Incident date: Jun 14, 1994

1991 FORD F-150 4X4 PICKUP BAD PAINT I SHOULD NOT HAVE TO PAY FOR THIS FORD SHOULD BE RESPONSIBLE THEY PAINTED MANY OTHER VEHICLES, WHY NOT MINE? I AM THE ORIGINAL OWNER. *AK

Incident date: Aug 15, 2003

THE FUEL VALVE MALFUNCTIONED. RECALL 01I008000 WAS ISSUED, HOWEVER, THIS VEHICLE IDENTIFICATION NUMBER WAS NOT INCLUDED IN THE RECALL. *AK THE FUEL ONLY PUMPED FROM THE REAR. *SC *JB

Incident date: Aug 23, 2001

WHILE DRIVING AT ANY SPEED THE PUMP ON VEHICLES WITH DUEL FUEL TANKS MALFUNCTIONS. THE PROBLEM IS THE FUEL CROSS FLOW PUMP. WHEN THE PUMP KICKS IN, AND BOTH FUEL TANKS ARE FULL, THIS WILL SEND THE FUEL INSIDE OF THE CAB OF THE VEHICLE. *AK

Incident date: Oct 17, 2003

I HAVE A 1991 FORD F-150 TRUCK WITH THE PAINT PEELING, I WAS TOLD THERE WAS A RECALL ON THEM, JUST LAST YEAR, OR THE YEAR BEFORE? THE DEALERSHIP HERE WILL NOT GIVE ME THE TIME OF DAY, I ALSO FOUND OUT OUT ABOUT ABOUT SOME FUEL TANK PROBLEMS! *LA

Incident date: Oct 17, 2003

Showing 50 of 357 complaints.

Technical Service Bulletins, 1991 FORD F-150

52 manufacturer communications from 45 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
103000 POWER TRAIN:AUTOMATIC TRANSMISSION	11
061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE	3
357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER	3
980000 UNKNOWN OR OTHER	3
106000 POWER TRAIN:AXLE ASSEMBLY	3
061000 ENGINE AND ENGINE COOLING:ENGINE	2
103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER	2
114000 ELECTRICAL SYSTEM:WIRING	2

980000 UNKNOWN OR OTHER

INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS. *SLC

138600 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:HEATER CORE

SOME VEHICLES MAY EXHIBIT HEATER CORE LEAKS. *SLC

103600 POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES

SUBJECT REGARDING CONTAMINATION FROM PRIOR TRANSMISSION CONCERNS OR EXCESS WEAR MAY BE TRAPPED IN THE TRANSMISSION FLUID COOLING SYSTEM. *TT

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

TRANSMISSION- E40D/4R100-1989-99-MAIN CONTROLS, SEPARATOR PLATES AND SEPARATOR PLATE GASKETS USAGE CHART. YD

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

TRANSMISSION-E40D-NO 2-3 UPSHIFT. SOME VEHICLES MAY EXHIBIT A NO 2-3 UPSHIFT CONDITION. *AK

103600 POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES

VEHICLES MAY EXPERIENCE SOLID PARTICLE CONTAMINANTS FROM PRIOR TRANSMISSION CONCERNS OR EXCESS WEAR, MAY BE TRAPPED IN THE TRANSMISSION FLUID COOLING SYSTEM IS NOT PROPERLY FLUSHED, FLUID IN-LINE FILTER KIT. *MJS

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

INFORMATION REGARDING THE NEW TRANSMISSION COOLER FLUSHER- SERVICE TIP. *MJS

114000 ELECTRICAL SYSTEM:WIRING

SUBJECT ON A WIRE HARNESS TERMINAL REPAIR KIT AVAILABLE FOR REPAIRING ELECTRICAL WIRING HARNESSES. *TT

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

INFORMATION ON IDENTIFYING NON-APPROVED / ALTERNATE REFRIGERANTS WHICH COULD CAUSE SAFETY, AND PERFORMANCE CONCERNS IF INSTALLED IN FORD A/C SYSTEMS. *TT

353400 EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC.

EXPERIENCING A WHINE / BUZZ TYPE NOISE IN THE SPEAKERS OF THE ENTERTAINMENT RADIO OR TWO-WAY RADIO ON VEHICLES WITH AN IN-TANK ELECTRIC FUEL PUMP. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

SOME VEHICLES MAY EXPERIENCE AXLE WIND UP AND / OR CLUNKING, POPPING, RATCHETING TYPE NOISES WHEN MAKING CORNERING MANEUVERS ON VEHICLES EQUIPPED WITH A FOUR WHEEL DRIVE HI OR LOW RANGE MODE. *TT

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

FORD MOTOR COMPANY NOW RECOMMENDS SAE 5W-30 VISCOSITY GRADE FOR SERVICING ANY FORD GASOLINE-POWERED VEHICLE REGARDLESS OF MODEL YEAR. *TT

110000 ELECTRICAL SYSTEM

FORD MOTOR COMPANY HAS RELEASED A NEW ELECTRICAL GREASE ( F8AZ - 19G208-AA ) TO REDUCE THE POSSIBILITY OF MOISTURE CORROSION AT THE TERMINALS. *YC

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

INFORMATION ON A NEW TRANSMISSION FLUID USAGE CHART. *YC

190000 TIRES

INFORMATION ON TIRE COMPANY TELEPHONE NUMBERS FOR CUSTOMER ASSISTANCE. *YC

063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

INFORMATION ON A BUZZING OR RATTLE NOISE FROM THE EXHAUST SYSTEM. *TT

020000 SUSPENSION

SOME VEHICLES MAY EXHIBIT A DRIFT OR PULL TO THE LEFT WHILE BRAKING. *TT

354600 EQUIPMENT:MECHANICAL:WRECKER AND WHEEL LIFT DEVICES

RECOMMENDED GUIDELINES FOR TOWING BEHIND RECREATIONAL VEHICLES. *TT

034500 SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC

THE USE OF PETROLEUM-BASED GREASE AS A LUBRICANT IN SERVICING DISC BRAKES IS NO LONGER ACCEPTABLE. *YC

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

ANNOUNCING THE FORD OEM AIR CONDITIONING RETROFIT KIT AVAILABILITY. *YC

980000 UNKNOWN OR OTHER

SOME VEHICLES MAY EXHIBIT A FLASHING TRANSMISSION CONTROL INDICATOR LAMP (TCIL) AND DIAGNOSTIC TROUBLE CODES (DTCS) 62,628, AND/OR 1728. *YC

106000 POWER TRAIN:AXLE ASSEMBLY

CONCERNS WITH AXLE WIND-UP AND / OR CLUNKING, POPPING, RATCHETING TYPE NOISES WHEN MAKING CORNERING MANEUVERS. *TT

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

SOME VEHICLES MAY EXHIBIT A FLASHING TRANSMISSION CONTROL INDICATOR LAMP (TCIL) AND DIAGNOSTIC TROUBLE CODES (DTCS) 62, 628, AND / OR 1728 MAY BE STORED IN MEMORY. *TT

980000 UNKNOWN OR OTHER

FUEL ECONOMY- CUSTOMER EXPECTATIONS VERSUS VEHICLE USAGE. *JD

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

FLUID- TRANSMISSION FLUID USAGE CHARTS. *JD

061110 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:BELTS AND ASSOCIATED PULLEYS

ACCESSORY DRIVE BELTS- FEAD BELT COMES OFF- VEHICLES WITH 4.9L ENGINE. *JD

160000 STRUCTURE

FRAME- RIVET REPLACEMENT WITH BOLTS- SERVICE TIPS. *JD

021242 SUSPENSION:FRONT:SPRINGS:LEAF SPRING ASSEMBLY:HANGER,BRACKET

NOISE- "POPPING/CREAKING"- FRONT FRAME OR SUSPENSION BRACKETS- FRAME- "POPPING/CREAKING"- FASTENER REPLACEMENT. *JD

103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER

TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP. *TW

103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER

TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP. *TW

114000 ELECTRICAL SYSTEM:WIRING

WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS. *TW

131000 VISIBILITY:WINDSHIELD

WINDSHIELD AND INTERIOR GLASS - FOG/FILM. *TW

101000 POWER TRAIN:CLUTCH ASSEMBLY

SERVICE TIP INFORMATION REGARDING THE REVERSE CLUTCH PISTON AND PISTON SEAL USAGE. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

4X4 FRONT AXLES MUST USE HYPOID 4X4 GEAR OIL P/N F1TZ-19580-A & HIGH TEMP 4X4 FRONT AXLE & WHEEL BEARING GREASE WHEN SERVICING. IT IS NOT RECOMMENDED TO USE HEAVIER WEIGHT LUBES IN THESE FRONT AXLES.

036000 SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP

THE USE OF PETROLEUM-BASED GREASE AS A LUBRICANT IN SERVICING DISC BRAKES IS NO LONGER ACCEPTABLE BECAUSE IT MAY BE INCOMPATIBLE WITH THE RUBBER MATERIAL USED IN THE DISC BRAKE SYSTEM. IF PETROLEUM-BASED GREASE IS USED TO LUBRICATE ANY PAR

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

VEHICLES EXPERIENCING OCCASIONAL HARSH REVERSE ENGAGEMENT CONCERNS. *TW

013000 STEERING:GEAR BOX (OTHER THAN RACK AND PINION)

STEERING GEAR-REPLACEMENT OF BENDIX, STEERING GEAR WITH NEW ROSS STEEERING GEAR. *SD

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

REVISED DESIGN TRANSMISSION REAR CASE BUSHING. *TW

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

DELAYED FORWARD ENGAGEMENT AND/OR HEAT STAINED FORWARD CLUTCH PLATES AFTER INSTALLING CENTER SUPPORT SERVICE. *TW

111000 ELECTRICAL SYSTEM:12V/24V/48V BATTERY

UNKNOWN

021000 SUSPENSION:FRONT

UNKNOWN

061000 ENGINE AND ENGINE COOLING:ENGINE

UNKNOWN

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

UNKNOWN

062000 ENGINE AND ENGINE COOLING:COOLING SYSTEM

UNKNOWN

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

UNKNOWN

114100 ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD

UNKNOWN

138000 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM

UNKNOWN

162200 STRUCTURE:BODY:BUMPERS

UNKNOWN

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

UNKNOWN

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

KNOCKING NOISE ON INITIAL START-UP. *TW

061000 ENGINE AND ENGINE COOLING:ENGINE

REVISED OIL PAN GASKET. *TW

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

NEW DESIGN TRANSMISSION RANGE SENSOR. *TW

NHTSA Safety Investigations, FORD F-150

Investigations opened by NHTSA into potential safety defects. These are separate from recalls and may or may not result in a recall.

EA, Open , Model Year: 2015

Unintended Transmission Downshift and Rear Wheel Lock-up

On March 21, 2025, NHTSA’s Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE25002) to investigate instances of unexpected transmission downshifting without driver input in model year (MY) 2015-2017 Ford F-150 vehicles (subject vehicles) manufactured by Ford Motor Company (F... ord). The complaints allege that, without warning or driver input, the subject vehicles experienced a sudden and rapid deceleration often accompanied by temporary rear wheel lockup, seizure, or skidding, resulting in a loss of vehicle control that increases the risk of crash and injury to all motorists, including those not within the subject vehicles. The MY 2015 and MY 2016 F-150 vehicles were equipped with the “6R80” transmission, while the MY 2017 vehicles were equipped with either the “6R80” transmission or the “10R80” transmission. This investigation was limited to MY 2015-2017 Ford F-150 with the “6R80” transmission. ODI identified 329 Vehicle Owners Questionnaires (VOQs) related to this investigation and sixty percent of these consumers were interviewed to confirm the details of their allegations. Consumers reported that their vehicles’ transmission suddenly downshifted to a lower gear, often to 1st or 2nd gear, without driver input or advance warning. Consumers described the downshift events to be regular and repeated occurrences, with some consumers stating that they no longer drive the vehicle due to safety concerns. Forty-three percent of consumers reported experiencing at least one wheel lockup event, during which the rear tires locked, screeched, or skidded during the transmission downshift. ODI also found that 114 of the 329 consumers reported having their vehicle’s molded lead frame or valve body assembly (which comes with a molded lead frame) replaced, 80 of which were confirmed through consumer submitted repair invoices. In its response to ODI’s Information Request, Ford provided an assessment of potential root cause of failure for the subject vehicles and how this failure is different from the failure associated with MY 2011-2014 Ford F-150 vehicles that was addressed by four safety recalls (16V-248, 19V-075, 19V-433, and 24V-444). Ford has identified that the defect in the recalled vehicle population involved lead frame supplier production issues resulting in signal loss from the Output Shaft Speed (OSS) sensor. Ford has identified that the alleged defect in the subject vehicle population involved degradation of electrical connections within the lead frame due to thermal cycling and vibration over extended time in service resulting in signal loss from the Transmission Range Sensor (TRS). Signal loss from the TRS can result in an unintended shift to neutral, unintended upshift, or unintended downshift which are regulated by a gear “shift map” based on the vehicle’s speed at the time of signal loss. According to Ford’s “shift map”, at speeds between 35-64 mph, the maximum allowable downshift would be to 2nd gear (i.e. a 6th to 2nd gear downshift event) which Ford has designated to represent the worst-case scenario for subject vehicles. Ford has also acknowledged that the worst-case scenario may also involve temporary wheel lockup. However, Ford has stated that the failure mechanism in the MY 2011-2014 F-150 vehicles—previously addressed through recalls—primarily involved OSS sensor signal loss that could result in 6th to 1st gear downshift events. This OSS-related failure mode is distinct from the TRS-related signal loss identified in the subject vehicle population. ODI has identified an additional potential safety defect associated with the alleged defect in the subject vehicles. Preliminary testing performed by NHTSA’s Vehicle Research Test Center (VRTC) showed that when the TRS experiences an intermittent signal loss, one possible outcome is a change in vehicle direction. Specifically, if a vehicle is operating in reverse up an incline when the TRS signal loss occurs, then the vehicle may shift into neutral causing the vehicle to change directions and roll forward. ODI is opening this Engineering Analysis (EA) to, among other things, perform component-level testing and vehicle testing, as well as review additional technical information to better understand the alleged defect that has been identified. To review the reports cited in the Opening Resume ODI Report Identiﬁcation Number document, go to NHTSA.gov.Read more

PE, Closed , Model Year: 2015

Unintended Transmission Downshift and Rear Wheel Lock-up

On March 21, 2025, NHTSA’s Office of Defects Investigation (ODI) opened this Preliminary Evaluation (PE25002) to investigate instances of unexpected transmission downshifting without driver input in model year (MY) 2015-2017 Ford F-150 vehicles (subject vehicles) manufactured by Ford Motor Company... (Ford). The complaints allege that, without warning or driver input, the subject vehicles experienced a sudden and rapid deceleration often accompanied by temporary rear wheel lockup, seizure, or skidding, resulting in a loss of vehicle control that increases the risk of crash and injury to all motorists, including those not within the subject vehicles. The MY 2015 and MY 2016 F-150 vehicles were equipped with the “6R80” transmission, while the MY 2017 vehicles were equipped with either the “6R80” transmission or the “10R80” transmission. This investigation was limited to MY 2015-2017 Ford F-150 with the “6R80” transmission. ODI identified 329 Vehicle Owners Questionnaires (VOQs) related to this investigation and sixty percent of these consumers were interviewed to confirm the details of their allegations. Consumers reported that their vehicles’ transmission suddenly downshifted to a lower gear, often to 1st or 2nd gear, without driver input or advance warning. Consumers described the downshift events to be regular and repeated occurrences, with some consumers stating that they no longer drive the vehicle due to safety concerns. Forty-three percent of consumers reported experiencing at least one wheel lockup event, during which the rear tires locked, screeched, or skidded during the transmission downshift. ODI also found that 114 of the 329 consumers reported having their vehicle’s molded lead frame or valve body assembly (which comes with a molded lead frame) replaced, 80 of which were confirmed through consumer submitted repair invoices. In its response to ODI’s Information Request, Ford provided an assessment of potential root cause of failure for the subject vehicles and how this failure is different from the failure associated with MY 2011-2014 Ford F-150 vehicles that was addressed by four safety recalls (16V-248, 19V-075, 19V-433, and 24V-444). Ford has identified that the defect in the recalled vehicle population involved lead frame supplier production issues resulting in signal loss from the Output Shaft Speed (OSS) sensor. Ford has identified that the alleged defect in the subject vehicle population involved degradation of electrical connections within the lead frame due to thermal cycling and vibration over extended time in service resulting in signal loss from the Transmission Range Sensor (TRS). Signal loss from the TRS can result in an unintended shift to neutral, unintended upshift, or unintended downshift which are regulated by a gear “shift map” based on the vehicle’s speed at the time of signal loss. According to Ford’s “shift map”, at speeds between 35-64 mph, the maximum allowable downshift would be to 2nd gear (i.e. a 6th to 2nd gear downshift event) which Ford has designated to represent the worst-case scenario for subject vehicles. Ford has also acknowledged that the worst-case scenario may also involve temporary wheel lockup. However, Ford has stated that the failure mechanism in the MY 2011-2014 F-150 vehicles—previously addressed through recalls—primarily involved OSS sensor signal loss that could result in 6th to 1st gear downshift events. This OSS-related failure mode is distinct from the TRS-related signal loss identified in the subject vehicle population. ODI has identified an additional potential safety defect associated with the alleged defect in the subject vehicles. Preliminary testing performed by NHTSA’s Vehicle Research Test Center (VRTC) showed that when the TRS experiences an intermittent signal loss, one possible outcome is a change in vehicle direction. Specifically, if a vehicle is operating in reverse up an incline when the TRS signal loss occurs, then the vehicle may shift into neutral causing the vehicle to change directions and roll forward. Based on NHTSA’s analysis of consumer data, information provided by Ford, and preliminary testing conducted by NHTSA’s VRTC, this Preliminary Evaluation is being upgraded to an Engineering Analysis (EA26001). During this Engineering Analysis, the agency plans to, among other things, perform component-level testing and vehicle testing, as well as review additional technical information to better understand the alleged defect that has been identified from this Preliminary Evaluation. To review the reports cited in the Closing Resume ODI Report Identiﬁcation Number document, go to NHTSA.gov.Read more

RQ, Closed , Model Year: 2014

Unintended Transmission Downshift

In September 2016, Ford Motor Company (Ford) issued safety recall 16V-248 which included certain model year (MY) 2011-2012 Ford F-150 vehicles equipped with 6-speed (6R80) automatic transmissions. This recall was in response to allegations of unintended, unexpected vehicle transmission downshifting ... to a lower gear without warning, often accompanied by temporary rear wheel lock-up, increasing the risk of a crash and/or injury, and included approximately 153,581 vehicles. Ford identified the root cause of the unintended, unexpected vehicle transmission downshifting to a lower gear to be intermittent signal loss from the transmission’s Output Shaft Speed (OSS) sensor due to solder joint cracks on the OSS circuit board as a result of manufacturing process issues. The OSS sensor is mounted onto the molded lead frame and transmits changes in transmission shaft speed to the Powertrain Control Module (PCM). The remedy program described in safety recall 16V-248 involved reprogramming of the PCM to prevent unintended vehicle transmission downshifting from occurring. In December 2017, the Office of Defects Investigation (ODI) opened a Recall Query (RQ17-010) to assess the scope and remedy effectiveness of safety recall 16V-248. As a result of this ODI investigation, Ford issued safety recall 19V-075 to expand the scope of 16V-248 to include MY 2011-2013 Ford F-150 vehicles equipped with 6-speed (6R80) automatic transmissions and included approximately 1,263,051 vehicles. The remedy program described in safety recall 19V-075 involved reprogramming of the PCM to prevent unintended vehicle transmission downshifting from occurring. In June 2019, Ford issued safety recall 19V-433 as the remedy program used to service MY 2013 Ford F-150 5.0L and 6.2L vehicles in accordance with safety recall 19V-075 did not contain the necessary updates to prevent unintended vehicle transmission downshifting from occurring and included approximately 107,857 vehicles. On March 27, 2024, ODI opened this Recall Query (RQ24-005) to investigate the scope of the above-described safety recalls. At the time that this investigation was opened, ODI had received 86 Vehicle Owner Questionnaires (VOQs) reporting allegations of unintended, unexpected vehicle transmission downshifting to a lower gear without warning, often accompanied by temporary rear wheel lock-up, in MY 2014 Ford F-150 vehicles. As a result of this Recall Query, Ford filled safety recall 24V-444 on June 14, 2024, to include MY 2014 Ford F-150 vehicles and expand the scope of safety recalls 16V-248, 19V-075 and 19V-433. The remedy program described in safety recall 24V-444 involved reprogramming of the PCM to prevent unintended vehicle transmission downshifting from occurring and included approximately 552,188 vehicles. In its May 2024 response to ODI’s information request, Ford concluded that a predominant root cause for the intermittent OSS signal loss has not been identified outside of the original safety recall (16V-248). Ford’s investigation also concluded that the primary causes of the defect in MY 2014 F-150 vehicles were related to the molded lead frame and the control assembly transmission main. In the May 2024 response, Ford identified 2,184 total reports that described unintended vehicle transmission downshifting and rear wheel lock-up events; 1,441 warranty claims and 743 reports from consumer complaints, field reports, consumer surveys, and lawsuits/legal claims. Note that the values presented here and in the table above represent the total number of reports which can include a single consumer with multiple reports of the same event as well as a consumer with reports of multiple distinct events. Of the 1,441 warranty claims, 551 warranty claims involved repair of the molded lead frame (38%) and 509 warranty claims involved repair of the control assembly transmission main (35%). Ford has also stated that the PCM programming used to prevent unintended vehicle transmission downshifting was implemented starting with MY 2015 vehicle #1 production and onward. In view of the safety recall action being taken by Ford, ODI is closing this Recall Query (RQ24-005). The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.Read more

PE, Closed , Model Year: 2015

Seatbelt Pretensioner Fire

On June 18, 2018, the Office of Defects Investigations (ODI) opened a Preliminary Evaluation (PE18-008) to investigate complaints alleging post-crash fires at the B pillar in the area of the seat belt pretensioners on MY 2014-2018 Ford F-150 Regular Cab, and Super Crew Cab Vehicles. On August 24, 20... Read more

AQ, Closed , Model Year: 2015

Champion Ford Edinboro / Steering Shaft

NHTSA opened AQ17-001 to determine whether Champion Ford Edinboro, Inc. (Champion Ford), of Edinboro, Pennsylvania, complied with the requirements of the National Traffic and Motor Vehicle Safety Act, 49 U.S.C. Chapter 301 (Safety Act) and its implementing regulations. The Safety Act requires, among... Read more

RQ, Closed , Model Year: 2015

Brake Master Cylinder Failure

On June 8, 2020, Ford Motor Company issued a safety recall (NHTSA Recall No. 20V-332) of 292,311 model year (MY) 2014-2017 Ford F-150 vehicles equipped with 3.5L Ecoboost engines and built from 9/1/2014 to 8/1/2016. Ford stated that the causes of brake fluid loss in the master cylinder are brake flu... id contamination that can interfere with rear cup seal function, and rolling of the rearmost cup seal.Prior to total loss of the front brakes, depending on the amount of brake fluid loss in the master cylinder, the driver may receive an audible chime, message center alert and red brake warning indicator in the instrument cluster, and may experience a change in brake pedal travel and increased pedal effort. It should be noted that a small number of late-built MY 2014 and early-built MY 2017 F-150 vehicles are included in the recall along with the subject vehicles (MY 2015-2016).This Recall Query is closed based on the safety recall issued by Ford. The ODI reports cited above can be viewed at NHTSA.gov under the following ID numbers:10734951 10839988 10862418 10872737 10873438 10876359 10881590 10883442 10885352 10888026 10888524 10891826 10891829 10891886 10893632 10894688 10894844 10896122 10896446 10898079 10899093 10899198 10902944 10903776 10904695 10908281 10910101 10913678 10913867 10914016 10914164 10914288 10914361 10914382 10914483 10914507 10915027 10915894 10916302 10916346 10916578 10920258 10925699 10926076 10926148 10926179 10927388 10927402 10927459 10927578 10928457 10928906 10930128 10936207 10940199 10943902 10948941 10950413 10954419 10956798 10969452 10969971 10984389 10985533 10991033 10993430 10993826 10994249 11000331 11000746 11001283 11001291 11001403 11001550 11002014 11002827 11003801 11004795 11005551 11010248 11010341 11011291 11011502 11012944 11013023 11013826 11014954 11015390 11018677 11018771 11020059 11021249 11021632 11022034 11022116 11022243 11023791 11025448 11030416 11030852 11039991 11082190 11082307 11083373 11083998 11089076 11091017 11092142 11093509 11096406 11096501 11097550 11097885 11099405 11099859 11100723 11101189 11101357 11101515 11101631 11102242 11102281 11102299 11102326 11102360 11102481 11104187 11104212 11104877 11109739 11110958 11111028 11111445 11111776 11112143 11112145 11112331 11112445 11112504 11112969 11112970 11114501 11115336 11115612 11118050 11118324 11119688 11119741 11120003 11120625 11120839 11121496 11122946 11123817 11124180 11124313 11124735 11129689 11129763 11129799 11130736 11131008 11132384 11139389 11139955 11154079 11163050 11183075 11189767 11192325 11193564 11195772 11196715 11205224 11205725 11208030 11208558 11209657 11210390 11217868 11218183 11218476 11218533 11218548 11218703 11218773 11219228 11219556 11220778 11221408 11221528 11221888 11222322 11222604 11222909 11228582 11228780 11229191 11229412 11229541 11229673 11230311 11230525 11230553 11230595 11230606 11230664 11231440 11231744 11231985 11232226 11232462 11233423 11233425 11233557 11233595 11233614 11233857 11233864 11234025 11234577 11234715 11234752 11240161 11240184 11240219 11240344 11241143 11241328 11241565 11241737 11241755 11241979 11242032 11242096 11242101 11242222 11242430 11242723 11243775 11244070 11244092 11244223 11244613 11244872 11245199 11245233 11245259 11245846 11246001 11251825 11252130 11252506 11252570 11252595 11252809 11254026 11254116 11254385 11254816 11255210 11255273 11255487 11256470 11257328 11257549 11258458 11258978 11265268 11267540 11269887 11279423 11281670 11287382 11291824 11297512 11298972 11301103 11306644 11310503 11315450 11316153 11318273 11319339 11319344 11319751Read more

PE, Closed , Model Year: 2013

Master Cylinder External Leak

On May 23, 2016, Ford Motor Company (Ford) submitted a Defect Information Report (DIR) to NHTSA regarding a master cylinder defect that could result in loss of the front brake circuit in approximately 225,012 model year 2013 through 2014 Ford F-150 vehicles equipped with 3.5-liter GTDI engines and b... uilt at the Dearborn Truck Plant from August 1, 2013 through August 22, 2014; and the Kansas City Assembly Plant from August 1, 2013 through August 31, 2014 (NHTSA Recall #16V-345, Ford Recall #16S24).Ford indicated that the rearmost cup seal in the brake master cylinder may roll, resulting in leakage from the brake fluid reservoir to the brake booster.According to Ford's DIR, Depending on the amount of brake fluid loss from the brake master cylinder into the brake booster, the driver will experience an audible chime, message center alert, red brake warning light in the instrument cluster and may begin to experience a change in brake pedal travel and feel.In the event that a loss of brake fluid is substantial enough to reduce brake function to the front wheels, the driver may experience longer pedal travel, increased pedal effort, and extended stopping distance, increasing the risk of a crash.Full braking function would remain in the rear wheel brake circuit.Ford's recall will replace the master cylinder and, if the master cylinder is leaking, also replace the brake booster.Seventy-three (73) of the complaints received by ODI contained vehicle identification number (VIN) information required to determine date of build and recall applicability.ODI's analysis found that 66 complaints to ODI and 278 complaints to Ford involving vehicles built in the range covered by 16V-345, resulting in an overall complaint rate of 152.9 incidents per 100,000 vehicles.Twelve (12) crash incidents were reported, including 11 with VIN information.All 11 crash incidents with VIN information reported involve vehicles covered by Ford's recall.ODI's analysis identified 7 ODI complaints and 36 Ford complaints in the 194,139 subject vehicles built outside of the build range for 16V-345, resulting in a complaint rate of 22.1 incidents per 100,000 vehicles.Ford indicated that warranty return analyses identified issues with minor internal leakage between circuits due to internal contamination caused by supplier assembly plant cleanliness concerns in these vehicles.Ford assessed the internal leak condition as an early-life condition with minimal safety risk that does not result in loss of fluid or circuit failure.ODI will continue to monitor complaints in subject vehicles not included in 16V-345.No complaints have been identified in MY 2013 through 2014 Ford F-150 vehicles equipped with other engine options.The recall action initiated by the manufacturer appears to address the safety risks identified by this investigation.This preliminary evaluation is closed.The ODI reports cited above can be reviewed at http://www-odi.nhtsa.dot.gov/owners/SearchSafetylssues under the following identification numbers:10870768, 10870747, 10870511, 10870395, 10870055, 10869981, 10865843, 10865521, 10865342, 10865043, 10864862, 10864714, 10864360, 10863982, 10863527, 10862333, 10862047, 10861735, 10861190, 10860378, 10860118, 10855381, 10855356, 10854785, 10853751, 10853295, 10853012, 10852349, 10852134, 10852037, 10851317, 10851268, 10851109, 10850015, 10849862, 10846488, 10846335, 10846193, 10846006, 10840414, 10840377, 10839994, 10839985, 10839981, 10839833, 10839825, 10839816, 10838782, 10838510, 10818273, 10817706, 10809601, 10788886, 10788369, 10785526, 10779854, 10776834, 10766291, 10762034, 10761412, 10760663, 10758997, 10750065, 10749886, 107Read more

EA, Closed , Model Year: 2011

Brake Vacuum Pump Failure

On February 15, 2016, Ford Motor Company initiated Customer Satisfaction Program 15N05 to extend warranty coverage for the electric vacuum pump in certain model year (MY) 2011 through 2012 Ford F-150 pickup trucks equipped with 3.5L GTDI engines.The program extends coverage for up to 10 years of ser... vice or 150,000 miles from the warranty start date of the vehicle, all vehicles are eligible for the program through July 30, 2016 regardless of mileage.Ford's program covers all repairs related to electric vacuum pump (EVP) malfunctions including excessive noise, vibration, or change in brake pedal feel while applying the brakes at cold start. Ford states that the engine intake manifold is the primary source of vacuum for the brake booster and is fully compliant to motor vehicle safety standards without the supplemental vacuum supplied by the EVP.The company also contends that failure modes related to the EVP are progressive and provide warning to operators by way of noise and vibration before an operator to experience any temporary change in brake pedal feel.ODI's analysis of warranty data found that the majority of claims involved consumer concerns with EVP noise or vibration from the left front fender area when the vehicle is first started. Continued operation in this mode with pump motor noise will eventually result in the EVP seizing or becoming non-functional.Component failure analysis indicated that Ford and its supplier, Continental, identified a pump crank drive corrosion condition due to moisture entry through the vacuum intake.Corrosion damage to EVP internal components may eventually result in a blown fuse in the power distribution box and total loss of EVP function.Analysis of consumer complaints, field reports, and warranty data related to EVP failures found thatincidents predominantly occurred in driveways and parking lots in the periods immediately after cold engine starts.Many consumers operated their vehicle for some period of time with a blown EVP fuse without realizing that the pump had failed or that the vehicle had a brake system malfunction.Consumers who did experience braking performance issues reporteda temporary hard brake pedal condition at start-up followed by more consistent normal pedal feel after few seconds.On June 22, 2015, Ford developed a remedy procedure and issued TSB 15-0105 instructing dealers to replace the vacuum pump and install a new vacuum pump harness kit. In addition to reviewing test data submitted by Ford, ODI assessed safety risks associated with the alleged defect under various operating conditions, including: 1) baseline system performance with full engine and EVP vacuum available using exemplar parts, 2) disabled EVP and booster vacuum regulated to simulate worst case conditions for engine intake manifold vacuum supply to the brake booster (approximately 300 mbar); and 3) all source vacuum to the brake booster removed and Optimized Hydraulic Braking (OHB) mode active to represent complete loss of brake booster function (note: this condition is a more severe brake boost system failure mode than the alleged defect).ODI also analyzed all complaints and warranty claims to identify incidents alleging brake system performance concerns related to EVP failures.These analyses identified no brake performance issues or resulting changes in stopping distances either on highway or city traffic conditions.Two complaints alleging EVP malfunctions caused or contributed to rear-end collisions during attempted decelerations from road speeds are not believed to be related to the alleged defect.The EVP provides supplemental vacuum during initial start-up and idleRead more

PE, Closed , Model Year: 2011

Brake Vacuum Pump Failure

On June 22, 2015, the Office of Defects Investigations (ODI) opened Preliminary Evaluation PE15-026 to investigate incidents of increased brake pedal effort at cold start and extended stopping distance while driving in traffic, resulting from failures of the electric brake vacuum assist pump in mode... l year (MY) 2011-2012 Ford F-150 pickup trucks equipped with 3.5L GTDI engines. In response to ODI's Information Request (IR) for PE15-026, Ford provided ODI with 396 complaints and field reports relating to incidents of increased brake pedal effort or malfunctions in the electric vacuum pump (EVP). ODI's analysis of the data provided by Ford identified 7 crashes and 1,851 warranty claims related to either a hard brake pedal condition or reduced brake effectiveness. Additionally, ODI identified one report in its database alleging an injury to an occupant of a vehicle struck in the rear by a subject F-150 vehicle with a failed EVP as documented in the police accident report referencing a dealer assessment of the pump.According to Ford, the subject vehicles utilize a traditional brake vacuum booster to provide power assist for braking and the EVP is intended to operate to maintain consistent brake pedal feel. The engine intake manifold is the primary source of vacuum for the booster and is fully compliant to motor vehicle safety standards without the EVP. Ford described the conditions related to a change in brake pedal feel as limited and temporary and provided component failure analysis showing evidence of water entry into the EVP which caused internal pump corrosion. Ford indicated that the EVP failure mode is progressive and provides warning to operators by way of noise and vibration before an operator is likely to experience any temporary change in brake pedal feel. Damage to the EVP motor bearing may eventually result in a blown EVP fuse and total loss of EVP function. Ford provided test data showing the brake pedal forces and pedal travel curves over time for 0.3g decelerations to a stop from 80kph (50mph) for: 1) normal system (full engine and EVP vacuum available); 2) Ford's approximation of worst case booster performance with EVP failure (EVP disabled and booster vacuum regulated to 300mbar to simulate cold start, all accessory loads on, and starting at 0 vacuum); and 3) with all source vacuum to the brake booster removed and Hydraulic Boost Compensation (HBC) active to represent complete loss of brake booster function. The Ford tests showed that the brake pedal forces required for achieving the 0.3g decelerations were relatively low for the normal condition, 35-40 N (8-9 lbf), increased by approximately 2-3 times normal when the EVP is disabled, 75-115 N (17-26 lbf), and increased by about 5-6 times normal for the complete brake booster failure condition, 205-215 N (46-48 lbf). This Preliminary Evaluation has been upgraded to Engineering Analysis (EA15-006) to test for EVP malfunctions under other vehicle operating conditions (e.g., low-speed driveway braking after cold-start with failed EVP), potential human factors contributions and to further assess the scope, frequency, and safety-related consequences of the alleged defect.The VOQs associated with the opening of this investigation are:10565994, 10575987, 10598351, 10604687, 10605701, 10607811, 10610491, 10615536, 10617828, 10619545, 10643075, 10650578, 10662151, 10664415, 10666988, 10668069, 10678844, 10695537, 10700874, 10706217, 10706271, 10712465, 10723033, 10723792, 10726960, 10730549, 10730721, 10730735, 10730837, 10730909, 10731008, 10731135, 10731157, 10731165, 10731395, 10731758, 10732609, 10732878, 10733375, 10733804, 10734558, 10734613, 10743859, 10744214, 10Read more

PE, Closed , Model Year: 2011

Reduced power during hard acceleration

On May 22, 2013, the Office of Defects Investigation (ODI) opened PE13-018 to investigate 95 complaints alleging incidents of reduced engine power during hard accelerations in model year (MY) 2011 through 2013 Ford F-150 trucks.ODI was aware of three technical service bulletins (TSBs) issued by Ford... for a condition that was related to moisture accumulation in the Charge Air Cooler (CAC) for the turbochargers.A Preliminary Evaluation was opened to gather information to assess whether the subject vehicles contain a safety related defect.The subject vehicles are powered by Ford?s 3.5L EcoBoost engine which uses twin turbochargers to obtain a balance of fuel economy and engine power based on the driver?s demand.When the driver requests more power from the engine, as in accelerating to pass, merge, ascend hills or haul a load the two turbochargers will spin up compressing the air which is then used to increase the power created by the combustion in the engine.The compressed air, which gains heat by the compression process, is passed through a Charge Air Cooler (CAC) which is designed to lower the temperature of the air in order to make the combustion process even more efficient (Figures 1 and 2).In response to ODI?s Information Request letter, Ford indicated that a misfire condition could occur after steady-speed operation under significantly humid and rainy conditions.Ford?s analysis found that under those conditions, condensation could form and accumulate on the inside of the CAC tubes which could then be ingested into the engine during particularly hard acceleration near wide-open throttle.An engine misfire of up to three cylinders could occur if the amount of condensed water released from the CAC exceeded the engine?s operating threshold for water ingestion.Ford noted that due to regulations set by the EPA, the powertrain software would disable up to two of the misfiring cylinders for no more than 30 seconds and until the driver tips out the throttle in order to protect the catalytic converter from damage. Ford?s testing of this condition on the subject vehicles showed that a vehicle experiencing such a condition would continue to maintain its speed as well as accelerate, albeit at a lower rate than expected by the driver.Similar results were obtained in testing done by NHTSA?s Vehicle Research and Testing Center in East Liberty, Ohio (Figure 6).In an ongoing process to address the problem Ford issued a series of TSBs where a deflector shield was installed onto the CAC (Figures 3, 4 and 5).In January 2014 Ford indicated that its data shows that the TSBs have been effective in resolving the problem, that for the MY 2013 vehicles their remedy is 100% effective and the latest TSBs for MY 2011 ? 2012 are 95% effective.The 525 complaints to ODI and the total 4,120 unique VIN complaints listed in the Failure Report are incidents of alleged reduced power or driveability symptoms and not all are necessarily related to the condition created by water ingestion.Reduced power conditions can occur for a variety of reasons including faults with ignition coils, spark plugs, a catalytic converter, the throttle body, turbocharger, fuel pump/filter, powertrain control module (hardware or software) or transmission shifting problems.Ford also noted that in a large number of warranty claims on the subject vehicles, the CAC was replaced or a TSB procedure was performed when the symptoms exhibited were inconsistent with a CAC water ingestion related issue.Given these circumstances, further use of the agency resources in this matter does not appear to be warranted.Accordingly, this investigation is closed.The closing ofRead more

EA, Closed , Model Year: 1997

Fuel Tank Strap Failure Due to Corrosion

One or both of the steel straps holding up the fuel tank and attaching it to the truck frame can corrode and fail (break or separate).If one strap fails, the tank may tilt and drop and possibly contact the road surface.If both straps break, the entire tank may drop to the road.If either failure occu... rs while the vehicle is being driven, contact with the road can abrade the tank and create a hole from which gasoline can spill.When the tank drops, it remains attached to the vehicle only by the fuel filler hose and/or supply lines, or in rare instances, by the skid plate, if present.In some cases the weight of the tank sufficiently strained the hoses and fittings and caused separation and subsequent fuel leaks from those connections.The fire hazard created by leaking gasoline is increased by the possible presence of sparks created by the metal tank being dragged along the road.Corrosion of the straps appears to be caused by prolonged exposure to road deicers, frequently road salt, used to treat snow or ice covered roads.States in which large quantities of deicers are applied to roads during the winter season (salt belt states) account for the predominant portion of strap failures.Vehicles in these salt belt states are prone to experience corrosion related failures more frequently and earlier in a vehicle?s life cycle.Ford reports approximately 97 percent of reports it received relating to strap failure involve vehicles that were operated in these high corrosion areas, and 95 percent of the reports to NHTSA involved such vehicles.Approximately one-third of F-150 U.S. production was sold in salt belt states.ODI has included in the above counts reports it has received from consumers and reports it has received from Ford in which either the complaint involved confirmed strap corrosion or ODI's assessment of available information suggests corrosion caused the reported problem.Among the incidents reported to NHTSA, 441 involved one or both straps failing due to corrosion, 353 involved the fuel tank dropping and/or dragging on the ground, and 180 involved fuel leakage.ODI has received four reports of strap failure in which the leaking fuel ignited but self-extinguished, and one incident in which fire destroyed the vehicle and injured its driver.Ford reported the same injury incident and three other unique fire incidents, including two in which the leaking fuel ignited and fire destroyed the vehicle.There were no injuries associated with the three unique Ford incidents.Ford has agreed to conduct a recall to repair the subject vehicles.The recall will cover vehicles that were originally sold or are currently registered in salt belt states (regardless of vehicle age).The vehiclesincluded in the recall are those subject vehicles that are, or have ever been, registered in Connecticut, Delaware, Iowa, Illinois, Indiana, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, or the District of Columbia.Ford's recall action appears to adequately address the problem at this time.The above vehicle population (1,340,349) includes subject vehicles originally delivered or sold in salt belt states.ODI does not know the current or historical locations of all subject vehicles.According to Ford approximately 73% of the recall population is currently registered (a 27% attrition rate).Ford is also recalling certain MY 1997-1999 F-250 vehicles (under 8,500 GVWR), and MY2002-2003 Lincoln Blackwood vehicles for the same condition, resulting in an estimated 1.1 million total vehiclesRead more

PE, Closed , Model Year: 1997

Fuel Tank Strap Corrosion/Rust

One or both of the steel straps holding up the fuel tank and attaching it to the truck frame can corrode and break.If one strap breaks, the tank may tilt and drop and possibly contact the road surface.If both straps break, the entire tank may drop to the road.If either failure occurs while the vehic... Read more

EA, Closed , Model Year: 2004

Inadvertent airbag deployment

ODI opened this investigation based on reports of inadvertent airbag deployment.Data provided by Ford indicated that the airbag clockspring jumper wire, which is situated inside the steering wheel assembly, was installed in a manner that would allow it to rub (abrade) against a sharp metal edge on t... Read more

PE, Closed , Model Year: 2005

INADVERTENT AIRBAG DEPLOYMENT

FORD REPORTS THAT THE INADVERTENT AIRBAG DEPLOYMENTS ARE MOST LIKELY CAUSED BY THE AIRBAG HORN MOUNTING PLATE'S SHARP METAL EDGE THAT EVENTUALLY CAN CHAFE/CUT THE AIRBAG CLOCKSPRING JUMPER WIRE LEADING TO A SHORT-TO-GROUND CONDITION.ONE HUNDRED EIGHTY TWO (182) OF THE 230 REPORTS WERE FOR AIRBAG DEP... Read more

PE, Closed , Model Year: 2003

CNG REGULATOR LEAK

THE AGENCY HAS CLOSED THIS INVESTIGATION BASED ON ITS REVIEW OF COMPLAINT REPORTS, DISCUSSIONS WITH COMPLAINANTS AND FIELD AND TECHNICAL DATA PROVIDED BY FORD.THE SUBJECT VEHICLES ARE 1/2 TON PICKUP TRUCKS AND ARE NATURAL GAS VEHICLES (NGV) THAT ARE FUELED BY GASOLINE OR COMPRESSED NATURAL GAS.THE A... Read more

PE, Closed , Model Year: 2005

LOSS OF BRAKE POWER-ASSIST

BY LETTER DATED MAY 5, 2008, FORD MOTOR COMPANY (FORD) NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA RECALL NUMBER 08V-208) TO ADDRESS A MANUFACTURING DEFECT IN APPROXIMATELY 605,684 MODEL YEAR (MY) 2005 AND 2006 FORD F-150 AND LINCOLN MARK LT VEHICLES ORIGINALLY EQUIPPED WITH THE ... 5.4L DISPLACEMENT, 3-VALVE PER CYLINDER, V-8 ENGINE.THE RECALLED VEHICLES WERE BUILT FROM JULY 18, 2004 THROUGH MAY 31, 2006 AT THE DEARBORN TRUCK PLANT; FROM MAY 4, 2004 THROUGH MAY 31, 2006 AT THE KANSAS CITY ASSEMBLY PLANT; AND FROM APRIL 19, 2004 THROUGH MAY 31, 2006 AT THE NORFOLK TRUCK PLANT.THE VEHICLES WERE MANUFACTURED WITH THE SAME DEFECTIVE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY UNIQUE TO THE 5.4L V-8 ENGINE.FORD F-150 VEHICLES EQUIPPED WITH OPTIONALLY AVAILABLE 4.2L V6 AND 4.6L V-8 ENGINES ARE NOT INCLUDED IN THIS RECALL ACTION BECAUSE THEY UTILIZE A DIFFERENT, ONE-PIECE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY THAT DOES NOT EXHIBIT AN APPARENT DEFECT TREND. THE RECALLED VEHICLES UTILIZE A TWO-PIECE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY COMPRISED OF A STANDPIPE ASSEMBLY AND VACUUM HOSE.THE STANDPIPE ASSEMBLY ATTACHES TO A FITTING ON THE ENGINE AIR INTAKE MANIFOLD UTILIZING A FLEXIBLE RUBBER HOSE AND PLASTIC ELBOW.THE VACUUM HOSE ATTACHES TO THE OPPOSITE END OF THE STANDPIPE ASSEMBLY AND CONNECTS TO A CHECK VALVE FITTING AT THE BRAKE BOOSTER ASSEMBLY.ACCORDING TO FORD, THE PORTION OF THE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY ATTACHED TO THE INTAKE MANIFOLD MAY SWELL OVER TIME AND LOSE RETENTION FORCE, WHICH MAY ALLOW THE HOSE TO BECOME DETACHED FROM THE INTAKE MANIFOLD.SHOULD THE BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY BE DISRUPTED, APPLICATION OF THE BRAKE PEDAL MAY DEPLETE THE VACUUM RESERVE AND CONSEQUENTLY RESULT IN LOSS OF BRAKE POWER-ASSIST. TO CORRECT THE SAFETY DEFECT, FORD WILL INSTALL AN IMPROVED DESIGN BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY THAT UTILIZES A HOSE CLAMP AT THE INTAKE MANIFOLD ATTACHMENT. THIS REMEDY WILL BE PROVIDED FREE OF CHARGE FOR ALL RECALLED VEHICLES.LATER PRODUCTION FORD F-150 AND LINCOLN MARK LT VEHICLES BUILT AFTER MAY 2006 WERE MANUFACTURED WITH A HOSE CLAMP AT THE BRAKE BOOSTER VACUUM SUPPLY HOSE/INTAKE MANIFOLD ATTACHMENT AND ARE NOT AFFECTED. TO DATE, THE OFFICE OF DEFECTS INVESTIGATION (ODI) IS AWARE OF 324 NON-DUPLICATIVE COMPLAINTS AND 14 NON-INJURY CRASHES RELATED TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF 4,465 SUBJECT VEHICLES THAT EXPERIENCED ONE OR MORE WARRANTY CLAIMS TO REPAIR OR REPLACE THE SUBJECT BRAKE BOOSTER VACUUM SUPPLY HOSE ASSEMBLY. THE ACTION TAKEN BY FORD IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.Read more

PE, Closed , Model Year: 1997

STEERING COLUMN

PE, Closed , Model Year: 1998

SPARE TIRE WEAR

DP, Closed , Model Year: 1998

SPARE TIRE MOUNTING

THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION WAS PETITIONED TO COMMENCE A DEFECT INVESTIGATION OF THE SUBJECT VEHICLES BY A LETTER SIGNED BY WILLIAM F. ALLARD AND DATED 15-FEB-98.THE PETITION ALLEGES THAT THE SPARE TIRE MOUNTING PLACES THE TIRE SIDEWALL DIRECTLY IN CONTACT WITH THE METAL UNDER... Read more

RQ, Open , Model Year: 1997

REAR SUSPENSION SPRING BREAKAGE

IN JULY 1998, FORD SUBMITTED A PART 573 NOTIFICATION TO NHTSA CONCERNING BROKEN REAR SPRINGS ON CERTAIN 1997-98 FORD F150 TRUCKS, WITH FOUR-WHEEL DRIVE.FORD STATED THAT FATIGUE FRACTURE OF THE REAR SPRINGS MAY OCCUR IF THE SPRING ARE OVER STRESSES(SIC) BY VEHICLE OVERLOADING.THE BROKEN PIECE OF THE ... Read more

EA, Closed , Model Year: 1997

ALLEGED LOSS OF THROTTLE CONTROL

THE DETAILS OF INFORMATION AND DATA EVALUATED DURING THIS INVESTIGATION ARE STATED IN THE ENGINEERING ANALYSIS CLOSING REPORT, DATED SEPTEMBER 30, 1999.A SAFETY-RELATED DEFECT TREND RESULTING FROM INTERFERENCE BY THE FLOOR MAT WITH PROPER OPERATION OF THE THROTTLE IN THE SUBJECT VEHICLES WAS NOT IDE... Read more

PE, Closed , Model Year: 1997

LOSS OF THROTTLE CONTROL

There is no summary currently available

RQ, Closed , Model Year: 1994

INADVERTENT AIR BAG DEPLOYMENT

There is no summary currently available

RQ, Closed , Model Year: 1997

AUTOMATIC TRANSMISSION CONTROL

ON SEPTEMBER 4, 1997, FORD FILED A DEFECT INFORMATION REPORT CONCERNING APPROXIMATELY 15,000 1997 MODEL YEAR F-150 TRUCKS, MANUFACTURED FROM FEBRUARY 16 THROUGH MARCH 4, 1996, AND BUILT AT THE NORFOLK OR KANSAS CITY ASSEMBLY PLANTS.THESE VEHICLES COULD HAVE INCORRECTLY MANUFACTURED AUTOMATIC TRANSMI... Read more

RQ, Closed , Model Year: 1997

ICE FORMATION IN THE THROTTLE BODY

There is no summary currently available

EA, Closed , Model Year: 1997

WHEEL SEPARATION

BY LETTER DATED MAY 6, 1998, THE MANUFACTURER ADVISED NHTSA OF ITS DECISION TO INITIATE A SAFETY RECALL OF APPROXIMATELY 1,520,000 OF THE SUBJECT VEHICLES, INCLUDING F-250 LIGHT DUTY TRUCKS, AND NAVIGATOR VEHICLES BUILT AT THE NORFOLK, MICHIGAN TRUCK, KANSAS CITY, AND ONTARIO TRUCK ASSEMBLY PLANTS B... Read more

PE, Closed , Model Year: 1997

WHEEL SEPARATION FROM VEHICLE

IN ADDITION TO THE A FAILURE REPORT TABULATIONS GIVEN ABOVE, THE MANUFACTURER REPORTED THAT AN ADDITIONAL 33 OWNER AND FIELD REPORTS HAVE BEEN FILED WHICH REFER TO PROBLEMS (LUG NOT TORQUE LOSS, LUG BOLT FRACTURE) THAT DID NOT INVOLVE ACTUAL WHEEL SEPARATION, BUT WHICH MAY BE POTENTIALLY RELEVANT EV... Read more

PE, Closed , Model Year: 1997

FAILURE TRANSMISSION PARK ENGAGEMENT/LOC

BY LETTER DATED SEPTEMBER 4, 1997, THE MANUFACTURER ADVISED NHTSA THAT A SAFETY-RELATED RECALL ACTION WOULD BE INITIATED TO CORRECT A POTENTIAL FAILURE OF THE TRANSMISSION SHIFT CABLE IN APPROXIMATELY 15,000 OF THE SUBJECT VEHICLES.THE SUSPECT CABLES WERE SUPPLIED TO FORD BY TELEFLEX AUTOMOTIVE AND ... Read more

EA, Closed , Model Year: 1997

SEAT BELT ANCHORAGE SEPARATION

FORD NOTIFIED ODI THAT THEY ARE CONDUCTING A RECALL TO INSPECT AND, AS NECESSARY, REPAIR THE SEAT BELT ANCHORAGE ATTACHMENTS ON 1997 FORD F150 VEHICLES BUILT FROM THE BEGINNING OF PRODUCTION THROUGH APRIL OF 1996.ODI'S DATABASE CONTAINS ONE COMPLAINT ALLEGING THE CENTER FRONT SEAT BELT ANCHORAGE WAS... Read more

PE, Closed , Model Year: 1997

SEAT BELT ANCHORAGE SEPARATION

ODI'S DATABASE CONTAINS ONE COMPLAINT ALLEGING THE CENTER FRONT SEAT BELT ANCHORAGE WAS NOT BOLTED TO THE FLOOR.FORD SUBMITTED 28 ADDITIONAL FIELD REPORTS AND WARRANT CLAIMS ALLEGING THAT A SEAT BELT WAS NOT BOLTED TO THE FLOOR, NOT ATTACHED, NOT HOOKED UP, OR THE OWNER COMPLAINTED THAT THE SEAT BEL... Read more

FORD F-150 - All Years Overview

Complete safety history for the FORD F-150 across all model years (1991, 2026).

419 Total Recalls

47,330 Total Complaints

30 Investigations

2,343 Reported Crashes

2,348 Reported Fires

87 Reported Deaths

FORD F-150 - Year by Year

Compare recalls and complaints across model years. Click any year to see full details.

Year	Recalls	Complaints
2026	1	3	View
2025	12	167	View
2024	10	257	View
2023	11	564	View
2022	22	775	View
2021	28	1,256	View
2020	11	859	View
2019	9	1,647	View
2018	19	2,778	View
2017	18	1,749	View
2016	14	2,508	View
2015	14	2,150	View
2014	8	1,905	View
2013	3	3,930	View
2012	4	2,434	View
2011	6	2,966	View
2010	1	1,134	View
2009	2	400	View
2008	1	455	View
2007	7	623	View
2006	14	741	View
2005	14	1,364	View
2004	16	2,431	View
2003	11	523	View
2002	10	964	View
2001	19	1,451	View
2000	17	1,274	View
1999	18	1,323	View
1998	18	1,624	View
1997	26	3,285	View
1996	7	383	View
1995	7	788	View
1994	13	908	View
1993	13	753	View
1992	9	553	View
1991 (current)	6	357
1990	0	25	View
1989	0	19	View
1987	0	2	View
1984	0	2	View

Other FORD Models

Model	Recalls	Complaints
MUSTANG	1,104	11,600	View
RANGER	928	10,371	View
F-350 SD	776	2,363	View
F-450 SD	692	624	View
F-250 SD	638	3,635	View
EXPLORER	624	42,549	View
F-550 SD	578	603	View
EXPEDITION	555	11,534	View

Vehicle Safety

Consumer Safety

Infrastructure

Public Health

1991 FORD F-150

Complaint Statistics

Top Reported Components

Technical Service Bulletins, 1991 FORD F-150

Most Affected Components

NHTSA Safety Investigations, FORD F-150

FORD F-150 - All Years Overview

FORD F-150 - Year by Year

Other FORD Models