1994 Ford F-250

EA05-005 IS CLOSED WITH FORD?S ACTIONS IN RECALLS 05V-017, 05V-388, AND 06V-286, RECALLING APPROXIMATELY 6.7 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).THE BRAKE SYSTEMS IN THESE RECALLED VEHICLES GENERATE A VACUUM THAT CAN POTENTIALLY CAUSE THE SCDS TO FAIL AND, IN CERTAIN SWITCH INSTALLATION ORIENTATIONS, CATCH FIRE.FORD IS ALSO INCLUDING THE ENTIRE POPULATION OF 1998 EXPLORERS.FORD HAS INFORMED ODI THAT TESTING TO DETERMINE THE CAUSE OF FAILURES IN THE 1998 EXPLORERS WILL CONTINUE AFTER THIS INVESTIGATION IS CLOSED.ODI BELIEVES THAT THE VEHICLES EXHIBITING THE FACTORS CAUSING SCDS FAILURE DESCRIBED IN THIS REPORT CORRELATE WELL WITH THE OBSERVED FAILURE RATES ON THESE VEHICLES BY MODEL AND MODEL YEAR.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE NON-RECALLED VEHICLES MANUFACTURED WITH SCDS THAT ARE NOT INCLUDED IN FORD?S RECALLS.ODI WILL CONTINUE TO MONITOR THE NON-RECALLED POPULATION FOR INCIDENCE OF ENGINE COMPARTMENT FIRES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE ATTACHED CLOSING REPORT FOR DETAILS.

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CONSUMER COMPLAINTS REPORT THAT BOLTS WHICH RETAIN THE AXLE PIVOT BRACKET TO THE FRAME CROSS MEMBER CAN LOOSEN OR FAIL, CAUSING THE INBOARD END OR THE AXLE TO BECOME DETACHED FROM THE VEHICLE.OWNERS ALLEGE THAT THIS COULD RESULT IN LOSS OF STEERING CONTROL, HOWEVER THE COMPLAINT DATA SHOWS ONLY ONE INCIDENT WHERE THE VEHICLE LEFT THE ROADWAY FOLLOWING AXLE SEPARATION, WITH NO DAMAGE TO THE VEHICLE.IN ADDITION TO THE 225 CONSUMER COMPLAINTS, THERE WERE 4,315 WARRANTY CLAIMS RELATED TO THE FRONT SUSPENSION AND MEMBERS, AND 22 VEHICLES WERE REPLACED FOR GOODWILL.DOCUMENTS SUBMITTED BY FORD, UNDER REQUEST FOR CONFIDENTIAL TREATMENT INDICATE THAT THE BOLTS WERE INADEQUATE FOR THE DURABILITY REQUIREMENTS OF THE VEHICLE.ALSO, BOLTS WERE FOUND TO HAVE BEEN INADEQUATELY TORQUED AT ONE OR MORE ASSEMBLY PLANTS.OTHER FACTORS, SUCH AS WAX TREATMENT OF THE FRAME, CONTRIBUTED TO THE PROBLEM.INCREASED BOLT DIAMETER AND INCREASED TORQUE APPARENTLY CORRECTED THE PROBLEM.A SERVICE BULLETIN, 96-20-13, WAS ISSUED TO ADVISE DEALERS OF THIS CORRECTIVE ACTION.IN THESE DOCUMENTS, FORD ALSO REPORTED THAT A VEHICLE, EQUIPPED FOR SIMULTANEOUS CATASTROPHIC FAILURE OF ALL PIVOT BRACKET FASTENERS, WAS EVALUATED RESULTING IN A SLIGHT VEHICLE PULL TO ONE SIDE WITH NO LOSS OF VEHICLE CONTROL.ODI HAS NOT REPLICATED FORD'S VEHICLE TESTING, HOWEVER ANALYSIS OF THE DESIGN OF THE FRONT SUSPENSION INDICATES THAT EVEN IF THE INBOARD END OF THEAXLE BECAME DISCONNECTED FROM THE FRAME, THE OUTBOARD END WOULD REMAIN FIRMLY ATTACHED TO THE LEAF SPRING WITH TWO U-BOLTS.THIS WOULD RETAIN THE WHEEL IN ITS APPROXIMATE POSITION, ALTHOUGH THE WHEEL ALIGNMENT WOULD BE GREATLY IN ERROR.THEREFORE IT IS UNLIKELY THAT CONTROL OF THE VEHICLE WOULD BE LOST.OWNERS REPROT MANY SIGNIFICANT NOISES IN THE SUSPENSION, SUCH AS CREAKING, GROANING, CLUNKING, AND SQUEAKING, PRIOR TO NOTICING ANY SEPARATION OF THE AXLE.THIS PROVIDES WARNING OF THE LOOSENING OF THE BOLTS TO THE DRIVER, AND SHOULD NOT BE IGNORED.FORD HAS STATED THAT REPAIRS WILL BE COVERED UNDER THE VEHICLE'S BUMPER WARRANTY.COMPLAINTS ABOUT WARRANTY COVERAGE BY A FORD DEALER SHOULD BE ADDRESSED TO FORD, OR TO APPROPRIATE STATE AND LOCAL AGENCIES.A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND 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.

AN ENGINEERING ANALYSIS CLOSING REPORT IS INCLUDED.

ENGINE SHUTS DOWN WITHOUT WARNING AT SPEEDS 50 TO 70 MPH AND WON'T RESTART SOMETIMES. IT MIGHT RESTART AFTER AN HOUR AND RUN FOR ABOUT 10 TO 15 MINUTES AND STOP AGAIN AND WON'T START AGAIN TILL NEXT MORNING. IS INTERMITTENTLY AND RANDOMLY STOPPING DEAD, LIKE TURNING OFF THE KEY. MECHANIC CANNOT MAKE IT HAPPEN IN SHOP!

NHTSA ID

11365982

Incident

Oct 17, 2020

Mileage

103,000 mi

DIMMER SWITCH SHUTS OFF ALL THE LIGHTS AT NIGHT WHEN I DRIVE AT NIGHT

NHTSA ID

11075204

Incident

Jan 1, 2018

Mileage

140,000 mi

TL* THE CONTACT OWNS A 1994 FORD F-250 EQUIPPED WITH DOMINATOR SPORT ATZ TIRES, SIZE: LT265/75R16. WHILE DRIVING 35 MPH, THE CONTACT FELT A VIBRATION IN THE FRONT PASSENGER SIDE TIRE. THE TIRE WAS ROCKING FROM SIDE TO SIDE. IN ADDITION, THE CONTACT STATED THAT THE BELT WAS SEPARATED FROM THE FRONT PASSENGER SIDE TIRE. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND REFERRED THE CONTACT TO NHTSA. THE APPROXIMATE VEHICLE FAILURE MILEAGE WAS 265,000 AND THE TIRE FAILURE MILEAGE WAS 185.

NHTSA ID

10992338

Incident

Mar 15, 2017

Mileage

265,000 mi

TL* THE CONTACT OWNS A 1994 FORD F-250. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE FRONT FUEL TANK WOULD EXTRACT FUEL FROM THE REAR FUEL TANK CAUSING THE FUEL TO LEAK OUT THE FRONT FUEL TANK. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER HAD BEEN NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 63,000.

NHTSA ID

10630448

Incident

Jul 1, 2014

Mileage

63,000 mi

TL* THE CONTACT OWNS A 1994 FORD F-250. THE CONTACT STATED THE FUEL PRESSURE REGULATOR HAS WORN OUT AND CAUSE FUEL TO LEAK IN ONE OF THE DUAL FUEL TANKS. THE FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A VEHICLE FIRE. THE CONTACT NOTICE A RECALL FOR THE PREVIOUS YEAR MODEL REGARDING THE FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY (00V424000). HE HAD NOT CALLED THE MANUFACTURER TO SEE IF HIS VEHICLE IS INCLUDED IN THIS RECALL. THE CONTACT STATED THE VEHICLE CAN CAUSE A FIRE WHILE DRIVING. THE FAILURE MILEAGE WAS 79,000.

NHTSA ID

10354665

Incident

Aug 7, 2010

Mileage

79,000 mi

1994 F250 SITTING IN DRIVEWAY, 10 O'CLOCK AT NIGHT, CAUGHT ON FIRE, EXTENSIVE DAMAGE, TRUCK DESTROYED. *TR

NHTSA ID

10354511

Incident

Sep 6, 2010

IN AUGUST, 2009, MY FORD TRUCK CAUGHT ON FIRE WHILE PARKED AND PLUGGED IN TO WARM THE ENGINE. THE FIRE DEPARTMENT CAME TO PUT THE FIRE OUT AND I HAD MY VEHICLE TOWED WITH THE INTENTION OF GETTING IT REPAIRED. I WROTE TO FORD MOTOR COMPANY'S CLAIMS DEPARTMENT TO INFORM THEM WHAT HAPPENED, INCLUDING PICTURES, AND ADVISED THEM THAT THE VEHICLE WAS AVAILABLE TO THEM FOR INSPECTION. THEIR RESPONSE WAS THAT MY VEHICLE WAS NOT "INVOLVED IN ANY OPEN RECALLS THAT WOULD HAVE CONTRIBUTED TO THE CIRCUMSTANCES DESCRIBED." IN NOVEMBER, 2009, I RECEIVED A RECALL NOTICE FROM FORD MOTOR COMPANY REGARDING THE SPEED CONTROL DEACTIVATION SWITCH. THE RECALL LETTER DESCRIBES PRECISELY WHAT HAPPENED TO MY VEHICLE. IT STATES, IN PART, "FORD CANNOT BE CONFIDENT THAT OVER MANY YEARS IN SERVICE, A SPEED CONTROL DEACTIVATION SWITCH WILL NOT LEAK BRAKE FLUID, POSING THE RISK OF A FIRE. THIS CONDITION MAY OCCUR EITHER WHEN THE VEHICLE IS PARKED OR WHEN IT IS BEING OPERATED." AFTER WRITING TO THE FORD CLAIMS DEPARTMENT AGAIN, ASKING FOR A RE-EVALUATION OF THIS PROBLEM, THEIR RESPONSE WAS THAT THEY WERE UNABLE TO OFFER ME ANY ASSISTANCE. THEY NEVER EXAMINED MY TRUCK, THEREFORE, THEY CANNOT POSSIBLY DETERMINE THE CAUSE OF THE FIRE. THERE HAS BEEN NO EFFORT ON FORD'S PART TO ACKNOWLEDGE OR REMEDY MY SITUATION, YET, I NOW RECEIVED ANOTHER RECALL NOTICE (MARCH, 2010) REGARDING POSSIBILITY OF FIRE TO THIS VEHICLE! *TR

NHTSA ID

10328562

Incident

Aug 31, 2009

Mileage

254,000 mi

THEY WILL NOT GIVE ME THE PARTS TO FIX IT. *TR THE CONSUMER STATED THE NEAREST DEALER IS 250 MILES FROM HIS HOME. HE ALSO STATED HE IS A MECHANIC AND CAN PERFORM THE REPAIRS HIMSELF. UPDATED 11/25/09

NHTSA ID

10293052

Incident

Oct 1, 2009

MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODES P0603 (POWERTRAIN CONTROL MODULE KEEP ALIVE MEMORY ERROR) OR P0605 ( POWERTRAIN CONTROL MODULE READ ONLY MEMORY ERROR). *TT

OIL LEAK AT HIGH PRESSURE PUMP FITTINGS AND/OR PLUG. THIS INCLUDES SUPER DUTY F-SERIES. OASIS. *TT

POOR IDLE QUALITY AND/OR LOW OUTPUT AFTER THE ENGINE RETURNS TO IDLE SPEED. *TT

HARD STARTING AFTER THE FUEL INJECTORS HAVE BEEN REPLACED. *TT

HESITATION, STUMBLE, LACK OF POWER, ROUGH IDLE AND POOR PERFORMANCE ON VEHICLES WITH 7.3L DI TURBO DIESEL BUILT FROM 2/9/94. *TT

A NO-START OR REDUCED POWER CONDITION MAY OCCUR INTERMITTENTLY. *TT