2006 Ford E350

This investigation was opened based on one complaint and reports from four transportation fleets alleging 182 blower motor control switch failures.ODI was concerned that these melting and burning switches could lead to an open flame that could spread throughout the vehicle.After a comprehensive review of all data related to overheating blower motor control switches in the subject vehicles, ODI did not identify the existence of a safety defect trend.ODI reviewed 1,036 complaints, claims, and field reports of failed blower motor control switches and determined that only two fires were likely to have been caused by a failing subject blower motor control switch.This represents a failure rate of 0.2 R/100K on a population of 1,076,975 vehicles that have been in service for up to 14 years.ODI has found that when the subject switches do fail and begin to melt, they are constructed in a manner that typically prevents the failing switch from igniting and developing into an open flame.Ford Motor Company has agreed to take two actions to further reduce the likelihood an overheated blower motor switch in the subject vehicles.Ford informed ODI that it has implemented a series of design changes to the subject switch that will help prevent it from developing internal high resistance short circuits.Ford has also informed ODI that it would release a Technical Service Bulletin (TSB-11-11-21) instructing subject vehicle owners to replace the electrical connector at the same time a failed switch is replaced.In light of the low rate of failure resulting in open flame and fire spread on the subject vehicles, and Ford's actions to reduce the likelihood of a switch failure through switch design changes and a TSB, further use of agency resources does not appear to be warranted.The closing of this investigation does not constitute a finding by NHTSA that no safety-related defect exists.The agency reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following (ODI) numbers: 10427875, 10114393, 10257890For additional information, see the attached closing report.

ODI has received 1 complaint and reports from 4 transportation fleets alleging 182 switch failures.Each fleet operates mini buses built on a Ford E350 or E450 cutaway chassis.The OEM HVAC blower switches have melted, smoked, burned or experienced open flame and become inoperable on vehicles in each fleet.Some drivers have reported a burning smell or smoke coming from the dash.One fleet reported a vehicle fire.No injuries were sustained.However, the bus was carrying special needs children when the driver noticed smoke coming from the dash.The driver was able to evacuate the children prior to the vehicle becoming engulfed in flames.This PE has been upgraded to an Engineering Analysis (EA) to determine if the blower motor switch failures create a situation where a vehicle fire is possible and presents a safety risk to the driver and other passengers.

Brakes line rapture on front left line in driveway with foot on pedal had had feel of having brakes put van in drive started out of car port got on the down grade of the driveway pushed brake pedal and had no brakes to stop the vehicle I sideswiped a tree to keep from rolling In to to neighbors house

NHTSA ID

11632071

Incident

Jun 13, 2024

AFTER MANY TIMES AT SEVERAL DEALERSHIPS EXPLAINING LOSS OF POWER, SHAKING AND BUCKING WHILE ON THE HIGHWAY, SMOKE WHEN STARTING, ROUGH RUNNING. DEALERS NOT ABLE TO FIX SPECIFIC PROBLEM. I STATED THAT WHEN FUEL FILTER WAS CHANGED BY MY MECHANIC HE TELLS ME MY TANK IS DELAMINATING AND NEEDS TO BE REPLACED. I TELL ONE DEALER AND SHOW HIM THE CONTENTS OF THE FILTER REPLACEMENT WHICH IS RUSTY METAL AND FLAKES AND HE SAYS HOW DO I NOT KNOW THAT THAT DIDN'T COME FROM SOMEONE ELSE TRUCK.THAT WAS FROM KENNEDY FORD IN JENKINTOWN PA. I SAID TO REMOVE THE FUEL FILTER AND CHECK THEY REFUSED. I HAVE AN EXTENDED WARRANTY WITH FORD WHICH COST OVER 4000.00 AND THIS IS THE SECOND TIME AROUND I PAID FOR SAID WARRANTY. I CALLED FORD EXTENDED WARRANTY AT THAT TIME AND THEY SAID IT WAS COVERED UNDER THE TANK CODE 6010. I HAVE A 100.00 DEDUCTIBLE WHICH I HAVE USED SO MANY TIME FOR REPAIRS OF THIS TRUCK. I KNOW I'M NOT THE ONLY ONE COMPLAINING ABOUT THIS PROBLEM.

NHTSA ID

11115882

Incident

Jul 31, 2018

Mileage

107,000 mi

MICHELIN TIRE BLOW OUT LT 225/75R16 LTX MS2 DOT B3JH 009X 4413 INSIDE REAR PASSENGER SIDE BLOW OUT 35K MILES ON A 70K WARRANTY 2006 FORD RV CUTAWAY E350 SUPER DUTY 6.8 V10 PHOENIX CRUISER 2400 VIN 1FDWE35S2 6HB19410

NHTSA ID

11064095

Incident

Jan 12, 2017

Mileage

80,700 mi

TL* THE CONTACT OWNS A 2006 FORD E-350 EQUIPPED WITH BF GOODRICH TIRES, TIRE LINE: COMMERCIAL TA, TIRE SIZE: LT245/75R16 AND DOT NUMBER: BF11JD114411. THE CONTACT STATED THAT WHILE DRIVING AT APPROXIMATELY 65 MPH, SHE HEARD A LOAD EXPLOSIVE NOISE AND LOSS CONTROL OF THE VEHICLE MOVING ACROSS SEVERAL LINES OF TRAFFIC BUT WAS ABLE TO REGAIN CONTROL AND STOP ON THE SIDE OF THE ROADWAY. THE CONTACT STATED THAT UPON EXITING THE VEHICLE, THE REAR PASSENGER SIDE TIRE TREAD WAS MISSING BUT STILL HAD AIR. THE SPARE TIRE WAS PLACED ON THE VEHICLE. THE VEHICLE AND THE TIRE WERE TAKEN TO AN INDEPENDENT TIRE STORE WHERE THREE OF THE FOUR TIRES WERE REPLACED FREE OF CHARGE BUT THE CONTACT STATED SHE HAD TO PAY FOR THE FOURTH TIRE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE CONTACT WAS NOT MADE AWARE OF THE NHTSA CAMPAIGN NUMBER: 12T019000 (TIRES) PRIOR TO THE FAILURE. THE VEHICLE FAILURE MILEAGE WAS 127,469 AND THE TIRE FAILURE MILEAGE WAS 10,000.

NHTSA ID

11002864

Incident

Jun 11, 2017

Mileage

127,469 mi

FAILURE TO REPLACE RECALLED TIRES. -- MADE OVER A HALF DOZEN CALLS TO BF GOODRICH AND DISCOUNT TIRE. ALVIN AT GOODRICH SAID HE WAS SENDING ME A DAMAGE CLAIMS PACKAGE IN THE MAIL -- NEVER RECEIVED. BROUGHT VEHICLE INTO DISCOUNT TIRE (NOV. 15TH, 2016)FOR INSPECTION AND REPLACEMENT, THEN SENT HOME. CALLED BACK MITCH AT DISCOUNT TIRE (96TH LN N., BROOKLYN PARK, MN) AND HE TOLD ME HE'D DEFINITELY CALL ME BACK BEFORE THE END OF THE DAY -- HE NEVER DID. CALLED MITCH THE NEXT DAY AND HE AGAIN SAID HE'D DEFINITELY CALL ME BACK BEFORE THE END OF THE DAY. AGAIN HE DIDN'T. CALLED GOODRICH TIRE NOV.19TH,2016 AND THEY SAID THEY WOULD CHECK ON THE DELAY - JOE FROM GOODRICH CALLED BACK AND SAID HE GOT NO RESPONSE FROM MITCH AT DISCOUNT TIRE. CALLED DANNY AT DISCOUNT TIRE AND TOLD I NEEDED TO COME BACK IN (MONDAY NOV. 21ST) JUST TO MEASURE TREAD DEPTH, BUT STILL NOT REPLACE (TREAD DEPTH IS STILL ABOUT 9/32 IN.(60%+ USABLE DEPTH)). BY MONDAY I'D COME DOWN WITH AN ILLNESS SO NEVER MADE IT IN (NOT THAT I SHOULD SINCE THIS WAS JUST ANOTHER "PUT OFF" PLOY. SO WHAT I'M GETTING FROM GOODRICH AND DISCOUNT TIRE IS: -- STALLING -- NOT CALLING BACK -- MAKING NEEDLESS TRIPS TO THEIR SHOP. THESE ARE DANGEROUS DELAMINATING TIRES -- RECALL NUMBER 12T-019 DOT BE1LJD114910 LT 245/75R16. TIRE BLOWOUT (NOV. 1ST,2016) DAMAGED THE VAN'S RIGHT REAR QUARTER PANEL, WHEEL WELL AND TAILPIPE. I WAS LUCKY, I'VE READ THAT DELAMINATION OF THESE TIRES OFTEN CAUSES WHEEL LOCKUP AND SUBSEQUENT VEHICLE ROLL-OVER. SO THEY ARE ENDANGERING MY LIFE AND OTHERS ON THE ROAD BY NOT REPLACING THESE TIRES.

NHTSA ID

10984561

Incident

Nov 1, 2016

Mileage

210,000 mi

TL* THE CONTACT OWNS A 2006 FORD E-350. WHILE DRIVING APPROXIMATELY 35 MPH, THE VEHICLE LOST THE ABILITY TO ACCELERATE AND THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. THE CONTACT PULLED THE VEHICLE OVER TO THE SIDE OF THE ROAD. THE CONTACT ALSO STATED THAT THE SAME FAILURE OCCURRED APPROXIMATELY FIVE TIMES PREVIOUSLY. THE DEALER DIAGNOSED THAT THE TURBO CHARGER FAILED AND THE SENSOR ASSEMBLY NEEDED REPLACEMENT. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 43,748. UPDATED 01/10/2017*CT UPDATED 7/3/18*JB *TR

NHTSA ID

10924127

Incident

Jun 16, 2016

Mileage

43,748 mi

2006 FORD E-350 CUTAWAY WITH THOMAS BUS BODY HAS SEVERE RUST DAMAGE TO STRUCTURAL FLOOR SUPPORT BEAM IMMEDIATELY IN FRONT OF REAR WHEELS.

NHTSA ID

10818998

Incident

Mar 5, 2015

Mileage

134,813 mi

I HAVE BCT TIRES THAT ONLY HAVE 10K MILES ON THEM, AND AROUND 2 YEARS OLD THEY ARE SIZE LT 275 75 R 16 LOAD E I HAVE THEM MOUNTED ON A 2006 FORD E450 BOX ON THE REAR, THIS IS THE SECOND BLOW OUT THAT I HAVE EXPERIENCED WHERE THE TIRE SEPARATES JUST ABOVE THE BEAD. MY TRUCK IS NOT OVER WEIGHT, NOR DO I DRIVE OFF ROAD OR ABUSE THE TIRES. I BOUGHT THEM THROUGH CHERRY TIRE IN MAYBROOK NY 12543. THE OWNER JUST SOLD, AND THE NEW OWNER CLAIMS TO HAVE NO KNOWLEDGE OF HOW TO ASSIST ME WITH GETTING IN TOUCH WITH A USA REP FOR THEM. I FIND THAT THIS IS A VERY DANGEROUS CONDITION AS I WAS ON THE HIGHWAY AND "BANG" JUST BLEW BOTH TIMES ? AFTER DOING SOME RESEARCH AND FINDING OUT THESE WERE CHINA TIRES, JUST TODAY I PURCHASED NEW ALL 4 ON THE REAR OF THIS TRUCK. I HAVE IN MY POSSESSION THE 2 BLOWN TIRES, AND THE OTHER 2 THAT ARE STILL INTACT. THE FIRST BLEW ON THE INNER PASS REAR, THE SECOND ON THE OUTER DRIVERS SIDE. *TR

NHTSA ID

10714792

Incident

Apr 4, 2015

Mileage

135,430 mi

When performing any transmission fluid changes or topoffs involving MERCON SP, MERCON LV has replaced all versions of MERCON SP and can be used going forward. Mixing MERCON LV and MERCON SP in the same transmission is acceptable. After 30-Jun-2023, MERCON SP ATF will no longer be manufactured and will only be available until inventory depletes.

These SKUs are Trailer Brake Control Modules. The customer communication requested return of unsold inventory due to an internal software issue. The internal software issue leads to a false check trailer brake message and Trailer Brake Controller fault whenever the brake pedal is pressed. This will cause the part to be replaced, due to repetitive dashboard warning light, even though it sends signals to the trailer brakes properly.

FORD: WHEN SHIFTING BETWEEN PARK, REVERSE AND/OR DURING 2-3 SHIFT, AN INTERMITTENT CLUNK OCCURS WITH A TORQSHIFT TRANSMISSION. MODEL 2003-2014 F-SUPER DUTY, E SERIES, EXCURSION, F-53 MOTORHOME CHASSIS, LOW CAB FORWARD. *PE

FORD: ON SOME TRUCKS, THERE IS A NO CRANK SITUATION AND IF VOLTAGE ON TRANSMISSION RANGE SENSOR AT PIN 21, IS LESS THAN 5 VOLTS, DISCONNECT THE ENGINE COOLING FAN CLUTCH, ELECTRONICALLY, AND RECHECK VOLTAGE. MODEL 2003-2007 F SUPER DUTY, 2004-2010 E SERIES, 2003-2005 EXCURSION.

FORD: THERE MAY BE A LACK OF RPM, HESITATION, OR ROUGH RUNNING CONCERNS WHEN THE VEHICLE IS IN IDLE. THERE MAY BE TWO TROUBLE CODES STORED. THE PROBLEM MAY BE CAUSED BY AFTERMARKET GENERATORS INSTALLED OR MODIFICATIONS TO THE FRONT END DRIVE. E-350/450. *RM

FORD: RUNS ROUGH, LACKS POWER, HARD START, NO START. SOME VEHICLES AND TRUCKS EQUIPPED WITH 6.0L ENGINE MAY EXHIBIT A RUNS ROUGH, LACKS POWER, HARD TO START, NO START CONCERN WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) P0611 CODE OR VARIOUS INJECTOR CIRCUIT CODES. *PE