2005 Ford Cvpi

In its recall notice dated August 26, 2013, Ford Motor Company (Ford) notified NHTSA of a safety defect condition that may result in loss of steering in approximately 355,000 model year (MY) 2005 through 2011 Ford Crown Victoria and Mercury Grand Marquis vehicles built at the St. Thomas Assembly Plant, MY 2005 through 2007 Lincoln Town Car vehicles built at the Wixom Assembly Plant, and certain MY 2008 through 2011 Lincoln Town Car vehicles built at the St. Thomas Assembly Plant and that are currently registered or were originally sold in Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, or Wisconsin (NHTSA Recall 13V-385, Ford Recall 13S08).Ford's recall addresses a corrosion related defect in the lower intermediate shaft that may result in separation of the steering column lower bearing and loss of steering control.Ford's recall will remedy the defect condition by instructing dealers to replace the lower intermediate shaft and to inspect and repair the upper intermediate shaft and steering column lower bearing as necessary.A retaining clip will be installed if the lower bearing has separated.Ford's investigation of steering column separations in the subject vehicles identified a defect condition in the lower intermediate shaft that could result in separation of the column lower bearing.According to Ford's August 26th defect report, severe corrosion of the lower intermediate shaft may cause the lower intermediate shaft swing link joint(s) to stiffen or seize.Ford determined that forces acting on the upper intermediate shaft because of seized swing links may eventually cause the upper intermediate shaft to collapse, which may result in separation of the column lower bearing and loss of steering control.Analysis of ODI complaints and Ford complaints and warranty identified 22 incidents of steering separation (12 complaints and 10 non-duplicative warranty claims) that may be related to the lower intermediate shaft defect condition.All 22 incidents involved vehicles in the recall region, where 419,210 or roughly half (52%), of the subject vehicles were sold.Ford's investigation also determined that column lower bearing separation may occur in vehicles that experienced upper intermediate shaft collapse in prior frontal impact collisions if the shaft was not properly diagnosed and repaired.Ford identified 13 steering separation incidents outside the recall region (6 complaints and 7 non-duplicative warranty claims) where 386,003 of the subject vehicles were sold.Ford did not find evidence of the lower intermediate shaft corrosion issue in these vehicles.Six of the vehicles had known prior collisions and the histories of the remaining 7 were unknown.To address concerns with possible steering separations in vehicles outside the region for safety recall 13V-385, Ford is conducting a Regional Program (13R01) to inspect and repair the steering assemblies of those vehicles as necessary.The lower intermediate shaft will be replaced only if it fails the inspection, the upper intermediate shaft will be repaired if it fails a Ford-specified measurement test.In the event the steering column lower bearings are found out of position, they will be re-seated and secured with a retaining clip.Based on Ford's field actions, this investigation is closed.The VOQs cited above can be viewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10505992, 10479893, 10477192, 10475950, 10474596

FRACTURE (CRACKING) OF THE SUBJECT VEHICLE (SV) WHEEL, WHICH WAS PREVIOUSLY INVESTIGATED UNDER PRELIMINARY EVALUATION PE03-009 (SAFETY RECALL 03V-279), OCCURS IN THE MODEL YEAR (MY) 2003 TO 2005 POLICE INTERCEPTOR VEHICLES ONLY; CIVILIAN SPECIFICATION AND OTHER MY VEHICLES ARE UNAFFECTED BY THIS CONDITION.FOR THE AFFECTED SUBJECT WHEELS, A FATIGUE CRACK OCCURS IN THE HEAT AFFECTED ZONE OF THE RIM MATERIAL ADJACENT TO THE CIRCUMFERENTIAL WELD THAT ATTACHES THE RIM TO THE OUTBOARD WHEEL DISC.THE CRACK INITIATES UNDER THE OUTBOARD TIRE BEAD NEAR THE HEEL (WHERE AIR LEAKAGE CANNOT BE ASSURED) AND SUBSEQUENTLY GROWS CIRCUMFERENTIALLY THROUGH CYCLIC BENDING AS THE WHEELS ROLLS.ALTHOUGH THE VAST MAJORITY OF RIM CRACKS EITHER PRESENTED NO SYMPTOMS OR WERE DETECTED SAFELY VIA RECURRING SLOW AIR LEAKAGE, ODI IDENTIFIED 6 INCIDENTS WHERE RAPID AIR LEAKAGE LEADING TO A FULL OR PARTIAL DEFLATION OF THE TIRE WAS ALLEGED.FOR THESE WHEELS, EVIDENCE INDICATED THAT MULTIPLE CRACKS HAD FORMED IN DIFFERENT AREAS OF THE RIM AND SUBSEQUENTLY GROWN TOGETHER.TWO OF THE INCIDENTS RESULTED IN A CRASH, ONE DURING A HIGH SPEED PURSUIT.ALTHOUGH THE MINORITY OF CASES, FORD?S ASSESSMENTS OF FIELD RETURN WHEELS SHOWED THAT MULTIPLE CRACKS EXIST IN APPROXIMATELY 17 PERCENT OF THE CRACKED WHEELS REPLACED UNDER A FORD EXTENDED WARRANTY PROGRAM.IN A WHEEL WITH MULTIPLE CRACKS, AS THE AREA BETWEEN THE CRACKS IS REDUCED BY GROWTH A HIGH STRESS CONDITION (SUCH AS WOULD OCCUR IN AN AGGRESSIVE VEHICLE MANEUVER DURING A HIGH-SPEED PURSUIT) MAY CAUSE THE CRACKS TO JOIN TOGETHER RAPIDLY.IF THE CRACKS ARE OF SUFFICIENT SIZE, THE STRUCTURAL INTEGRITY OF THE RIM MAY BE COMPROMISED RESULTING IN RAPID AIR LOSS AND RIM DEFORMATION.FOR POLICE VEHICLES USED AT HIGH SPEED, RAPID DEFLATION AND LOSS OF RIM STRUCTURAL INTEGRITY AFFECTS VEHICLE CONTROL AND MAY INCREASE THE RISK OF A CRASH.FATIGUE IS THE FUNDAMENTAL FRACTURE MECHANISM; THEREFORE, WHEEL FRACTURE CAN BE EXPECTED TO OCCUR (AND AT AN INCREASED INCIDENCE LEVEL) AS LONG AS THE AFFECTED WHEELS REMAIN IN SERVICE.IN DECEMBER 2004 (WITHIN MY 2005 SV PRODUCTION) FORD INTRODUCED A SHOT PEEN PROCESS INTO THE MANUFACTURE OF SV WHEELS.SHOT PEEN WHEELS, WHICH ARE IDENTIFIED BY UNIQUE PART NUMBER STAMPINGS, HAVE NOT EXHIBITED FRACTURE IN POLICE SERVICE TO DATE.UNDER 07V-079, FORD WILL INSPECT SVS REGISTERED FOR POLICE USE AND REPLACE EARLIER DESIGN LEVEL WHEELS WITH SHOT PEEN WHEELS.POLICE AGENCIES SHOULD BE ADVISED THAT MY 2005 VEHICLES BUILT AFTER DECEMBER 2004 ARE NOT WITHIN THE SCOPE OF THIS RECALL (SINCE THEY WERE ORIGINALLY MANUFACTURED WITH SHOT PEEN WHEELS).AGENCIES SHOULD BE DILIGENT IN ENSURING THAT NON-SHOT PEEN WHEELS ARE REMOVED FROM OUT-OF-SCOPE VEHICLES OR OTHER WHEEL SUPPLY INVENTORIES.

DURING A SEPTEMBER 23, 2004 MEETING AND IN SUBSEQUENT DISCUSSIONS IN NOVEMBER, FORD ADVISED THE OFFICE OF DEFECTS INVESTIGATION (ODI) OF THEIR PLANS TO INTRODUCE AN IMPROVED STEEL WHEEL FOR MANUFACTURING AND SERVICE COMPONENT USE ON THE SUBJECT VEHICLES, INDICATING THIS WOULD OCCUR IN DECEMBER 2004.THE NEW WHEEL DESIGN INCORPORATES AN ADDITIONAL MANUFACTURING PROCESS (SHOT PEENING) WHICH LOWERS TENSILE STRESS IN THE SURFACE LAYER OF THE RIM MATERIAL ADJACENT TO THE CIRCUMFERENTIAL WELD. THEORETICALLY THIS SHOULD IMPROVE RIM DURABILITY BY REDUCING FATIGUE CRACK INITIATION SITES.INDICATIONS FROM FORD?S ACCELERATED TESTING METHODS SHOW AN IMPROVEMENT IN THE PERFORMANCE OF THE NEW WHEEL.IN ADDITION TO PRIOR SAFETY RECALL 03V279 AND SERVICE ACTION (SA) 03M03, FORD WILL ANNOUNCE A NEW EXTENDED WARRANTY SA FOR VEHICLES BUILT PRIOR TO DECEMBER 2004 THAT SUFFER RIM FRACTURES IN SERVICE.THE NEW WHEEL DESIGN WILL BE USED AS A REMEDY.FORD ADVISES THAT A SA IS SUFFICIENT FOR ADDRESSING FUTURE WHEEL FAILURES (INCLUDING RECALL 03V279 REMEDY WHEEL FAILURES) BECAUSE: 1) FAILURE RATES ARE LOW BASED ON FORD?S ANALYSIS, AND 2) DRIVER WARNINGS (REPETITIVE SLOW AIR LOSS, AND OR STEERING WHEEL VIBRATION) ALLOW EARLY AND SAFE DETECTION OF CRACKED WHEELS.ODI HAS RECEIVED 25 VEHICLE OWNER QUESTIONNAIRE (VOQ) REPORTS (INVOLVING 22 VEHICLES) WHICH ALLEGE A RIM FRACTURE OF ONE OR MORE STEEL WHEELS.ABOUT HALF THE REPORTS INVOLVE VEHICLES BUILT WITH THE REMEDY WHEEL USED FOR RECALL 03V279, AND MOST OF THE REMAINING VEHICLES WERE SUBJECT TO THE RECALL.THE PROCESS OF IDENTIFYING PERTINENT FORD COMPLAINTS IS MADE DIFFICULT BY FORD?S PRIOR RECALL AND WARRANTY PROGRAM ACTIVITIES.THE MANUFACTURER COMPLAINT AND WARRANTY COUNTS, WHICH PRIMARILY INVOLVE FAILURES OF RECALL 03V279 REMEDY WHEELS, ARE BASED ON ANALYSIS CONDUCTED TO DATE AND ARE CONSIDERED TO BE CONSERVATIVE.FURTHER INVESTIGATION IS REQUIRED, THUS ODI IS UPGRADING THIS INVESTIGATION TO AN ENGINEERING ANALYSIS (EA).DURING THE EA, PERTINENT FAILURE REPORTS AND CONSEQUENCES WILL BE IDENTIFIED AND REVIEWED.ODI AND FORD WILL DISCUSS DETAILS FOR CONDUCTING AN AUDIT ANALYSIS OF FAILED WHEELS REPLACED UNDER THE NEW SA.ADDITIONALLY, ODI IS AWAITING FORD?S LAB ANALYSIS OF TWO WHEELS WHICH WERE THE SUBJECT OF VOQ REPORTS, ONE OF WHICH WAS INVOLVED IN THE NOTED CRASH EVENT.A DETERMINATION WILL BE MADE AS TO WHETHER FORD?S SERVICE ACTION IS SUFFICIENT FOR ADDRESSING ONGOING RIM FRACTURES.

I WAS DRIVING FOR APPROX. 5 MIN AND MY HEADLIGHTS JUST CUT OFF. I PULLED OVER TURNED THE LIGHT SWITCH ON AND OFF AND STILL NO HEAD LIGHTS. THE PARK LIGHTS WOULD WORK JUST FINE. I HAD TO DRIVE HOME USING MY BRIGHT LIGHTS. LUCKILY, NO ONE WAS WALKING BECAUSE I WOULD NOT HAVE BEEN ABLE TO SEE THEM AT ALL. I TOOK THE CAR IN TO THE FORD DEALERSHIP AND THEY SAID IT WAS THE LIGHT CONTROL MODULE THAT COST OVER $600 JUST FOR THE PART.

NHTSA ID

10584825

Incident

Mar 1, 2014

Mileage

168,999 mi

LOW SPEED STEERING FAILURE. COULD NOT CONTROL STEERING AT LOW SPEED. - STEERING WHEEL RESISTED MOVEMENT TO CONTROL VEHICLE. VEHICLE IMMEDIATELY BROUGHT TO FORD DEALER AND FOUND THAT 5W1Z*3B676*AA STEERING SHAFT ASSEMBLY WORN CAUSING STEERING/CONTROL PROBLEM. ORIGINAL OWNER WITH FORD EXTRA CARE WARRANTY - REPAIR NOT COVERED AT $538.63. HISTORY OF STEERING FAILURES ON THESE VEHICLES - FORD SHOULD RECALL/REIMBURSE FOR REPAIRS. I SPOKE TO A FORD ESP REPRESENTATIVE AND WAS TOLD THAT NO MATTER HOW MANY FAILURES OCCUR, REGARDLESS OF ACCIDENT OR INJURY, FORD DOES NOT MONITOR NON-FORD WEBSITES FOR FREQUENCY OF FAILURES. IF THE FREQUENCY OF FAILURE, ACCIDENT, INJURY OR FATALITIES IS HIGH ENOUGH, THEY WILL ISSUE RECALL AND REIMBURSE COST OF REPAIRS MADE AT FORD DEALER. *TR

NHTSA ID

10503669

Incident

Mar 18, 2013

Mileage

58,741 mi

I AM HAVING A PROBLEM WITH OUR 2005 CROWN VIC HEADLIGHTS GOING OUT WITHOUT WARNING WHILE DRIVING. WINDSHIELD WIPERS ONLY WORKS ON HIGH. *TR

NHTSA ID

10427139

Incident

Jul 18, 2011

Mileage

13,700 mi

DRIVING VEHICLE...HEADLAMPS TURNED OFF ON THEIR OWN...PROBLEM TRACED TO LAMP CONTROL MODULE...PROBLEM WITH THIS PART HAS BEEN INVESTIGATED BY NHTSA PREVIOUSLY...FORD NEEDS TO BE HELD ACCOUNTABLE FOR FAILURES OF THIS PART.

NHTSA ID

10406402

Incident

Jun 7, 2011

Mileage

128,925 mi

DRIVING A 2005 CROWN VICTORIA IN THE EARLY AM (IT WAS DARK) ON A CITY STREET WITHOUT STREET LIGHTS. THE HEADLIGHTS WENT OFF. STOPPED THE CAR IMMEDIATELY. TURNED LIGHTS OFF AND BACK ON. ALL LIGHTS EXCEPT THE HEADLIGHTS WORKED. EXPERIMENTED WITH THE LIGHT SWITCH AND TURN SIGNAL LEVER. DISCOVERED THE BRIGHTS WORKED WHEN PULLING THE LEVER (MANUAL OPERATION OF THE BRIGHTS). AFTER ABOUT THREE MINUTES THE HEADLIGHTS TURNED THEMSELVES BACK ON. TOOK THE CAR TO A FORD DEALERSHIP. TOLD THEM WHAT HAD HAPPENED. THEY REPORTED LATER IN THE DAY THAT NOTHING COULD BE FOUND THAT WAS WRONG. I GOOGLED THE PROBLEM AND WAS OVERWHELMED WITH HITS. WHEN I GOT THE CAR AFTER WORK I ASKED THE SERVICE MANAGER IF ANYONE ELSE HAD ENCOUNTERED THE SAME PROBLEM. AT FIRST HE WAS RELUCTANT BUT AFTER INFORMING HIM I HAD GOOGLED THE PROBLEM AND HAD DISCOVERED THAT IT HAD HAPPENED TO OTHERS. AT THAT POINT HE DID TELL ME THAT THEY HAD OTHER CUSTOMERS COMPLAINING OF THE SAME (OR SIMILAR) PROBLEM. TO CORRECT IT I WOULD HAVE TO REPLACE THE LCM (LIGHT CONTROL MODULE). WHICH COSTS $511.00 PLUS LABOR AND TAX. (I DID NOT DO IT AT THAT TIME) THIS IS A VERY SERIOUS PROBLEM. IF I HAD NOT BEEN AS CALM AS I WAS AN ACCIDENT COULD HAVE VERILY EASILY OCCURRED. THERE HAS BEEN NO RECALL ON THIS VEHICLE/PART. WHY NOT? *TR

NHTSA ID

10363022

Incident

Oct 29, 2010

Mileage

72,356 mi

HEADLIGHT CONTROL MODULES ON FORD CROWN VICTORIA POLICE CARS. LIGHTS GO OUT WHILE DRIVING DOWN THE ROAD AT NIGHT. WE HAVE HAD APPROXIMATELY 15 OF THESE FAIL IN OUR AREA WHICH ONLY INVOLVES 4 POLICE AGENCIES. WE HAVE HAD 2 UNEXPLAINED FATALITIES IN FORD CROWN VICTORIA POLICE INTERCEPTORS WHICH OCCURRED AT NIGHT WHILE RUNNING LIGHTS AND SIRENS. THE LIGHTS GO OUT AND AN ENGINEER IN CANADA TOLD ME TO PUSH ON THE BOX LOCATED ABOVE THE GAS PEDAL WITH MY FOOT. WHILE DOING THIS THE LIGHTS CAME BACK ON. TAKE FOOT OFF THEY GO OUT. FORD WILL NOT RECONIZE THIS AS A PROBLEM AND WILL NOT WARRANTY THIS EVEN THOUGH THE CAR ONLY HAD 30000 MILES ON IT AND 3YRS 2 MONTHS OLD. COST US $690.00 FOR REPAIRS

NHTSA ID

10322795

Incident

May 13, 2009

Mileage

30,000 mi

TL* THE CONTACT OWNS A 2005 FORD CVPI. SINCE PURCHASING THE VEHICLE THE CONTACT NOTICED THAT THE WHEELS ON THE VEHICLE HAD BEGUN TO SHOW SIGNS OF RUST. THE CONTACT CALLED THE DEALERSHIP REGARDING NHTSA RECALL #07V079000 COMPONENT: WHEELS AND WAS INFORMED THAT THE RECALL DID NOT APPLY TO HIS VEHICLES VIN NUMBER. THE VEHICLE HAD NOT BEEN DIAGNOSED BY THE DEALERSHIP AT THE TIME OF THE COMPLAINT. THE CURRENT AND FAILURE MILEAGES WERE 172000.

NHTSA ID

10318607

Incident

Mar 9, 2010

Mileage

172,000 mi

LINGERING PROBLEM WITH 2005 FORD CROWN VICTORIA POLICE INTERCEPTOR WITH SUSPECTED CRACKED WHEELS. VEHICLE HAS ALL SYMPTOMOLOGY VEHICLE WAS MANUFACTURED FOR THE 2005 MY IN 08/2004. NHTSA CAMPAIGN ID NUMBER: 07V079000 . FORD REFUSES TO ADDRESS THE PROBLEM. *TR

NHTSA ID

10303278

Incident

May 1, 2009

Mileage

90,000 mi