2008 Ford F-350

The Office of DefectsInvestigation (ODI) opened PE13-014 after identifying five complaints alleging steering gear failure in model year (MY) 2008 Ford F-250 and F-350 Super Duty pick-up trucks and to evaluate the relationship between the design history of the steering gear assembly and the alleged defect.As background, ODI investigated steering gear sector shaft fractures in approximately 1.3 million MY 1999 - 2001 Ford Super Duty pick-up trucks and MY 2000 - 2001 Ford Excursion sport utility vehicles in Engineering Analysis EA01-009.The investigation determined that the sector shaft failures were the result of extraordinary, possibly multiple, impacts and not the result of fatigue.No defect in design, manufacturing or materials was identified in the sector shaft.EA01-009 was closed August 19, 2003 with 169 complaints, resulting in a rate of 12.9 incidents per 100,000 vehicles after approximately one year of service.Ford increased the diameter of the sector shaft from 1.375 inches to 1.625 inches at the start of MY 2005 production, increasing the resistance of the steering gear assembly to torsional overload by approximately 48% and changing the failure mode from sector shaft fracture to cracked or broken sector shaft gear teeth.The redesigned steering gear assembly was used in approximately 1.1 million MY 2005 through 2009 Ford Super Duty pick-up trucks, including the subject vehicles.Figure 1 shows the basic steering system design used in Ford Super Duty trucks investigated in EA01-009 and PE13-014. Figure 2 shows the locations of failures resulting from impact related torsional overloading of the sector shaft for the subject vehicles and the prior generation Ford Super Duty trucks investigated in EA01-009.Figure 3 shows an example of a failed sector shaft investigated in EA01-009 and comparisons of fracture surfaces of sector shafts failing from fatigue loading and from torsional overload.Ford provided field return part analysis of failed steering gears from MY 2005 through 2009 Super Duty trucks found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload (Figure 4).Laboratory analysis found no evidence of fatigue or material property defects in any of the fractures.Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns (Figure 5).Analysis of failures by time in service indicates a random failure pattern/distribution, consistent with incidents of impact induced overload (Figure 6). The complaint rate for the subject vehicles after approximately 5 to 6 years, 7.1 incidents per 100,000 vehicles, is lower than the rate observed in EA01-009. Furthermore, similar to the condition investigated in EA01-009, a number of incident records include evidence of impact loads (e.g., curb strikes) and several alleged crashes include incidents in which information suggests that the steering gear failure was most likely a result of crash forces, rather than the cause of the crash.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.The ODI complaints cited above can be reviewed at ww

Items in my bed and liner caught on fire. Engine regeneration for emissions got so hot melted all of the bed liner and caught a new large tv on fire. Ford has a glue on heat shield under bed which fell off. Exhaust gets so hot it caught on fire. They should have put a metal fixed plate or something fixed no a cheap glue on piece of foil. I inspected other trucks all missing!

NHTSA ID

11711591

Incident

Dec 31, 1969

I have had multiple incidents of my truck shutting off completely while driving. The latest incident resulted in a "catastrophic engine failure". In the latest incident occurring in April 2025, I was driving on [XXX] . [XXX] is a two-lane highway with no divider, navigating through mountainous terrain. I was driving up a hilly area when my truck shut off, and I lost all power steering. There is no shoulder on this part of the freeway, with an approximate 40-foot embankment. I was able to navigate the vehicle to the side of the road and position it just before the beginning of a guard rail beginning allowing me some grace. Due to no shoulder space, I was effectively parked on the white containment line of the road. I had my [XXX] daughter and wife in the car. I had to wait for a break in traffic to be able to open the driver's door due to the proximity to the active highway. I was safely get the truck towed to the nearest FORD dealership, where it was determined the engine was in "catastrophic failure" due to oil engine overfill. I informed FORD that my last oil change was with the FORD dealership and within the recommended time frame. I was informed by a technician that there is an ongoing issue with this engine make (6.4-liter, diesel). The technician stated that FORD is aware of the issue. The technician stated that fuel gets mixed with the oil and causes an "engine oil overfill". None of these issues stems from negligence but rather an unakknowledged issue by FORD. There was a check engine light that appeared at the time of failure. The check engine light had come on, at which point I contacted a mechanic to schedule an appointment. When I arrived for my appointment, the check engine light had disappeared, and I was told that no codes would alert if the actual check engine light was not on during the inspection. That same scenario occurred on approximately 3 occasions. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11710743

Incident

Apr 30, 2025

Vehicle died while driving on the freeway. Towed to the local Ford who did a diagnostic and test they found that the engine is completely done with as there was an engine oil overfill, and it filled the CAC system and melted cylinder eight piston. they’re saying that they will need to replace the entire engine and HP fuel pump in order to repair and I see many others have experienced this same problem.

NHTSA ID

11661000

Incident

Apr 5, 2025

Items inside bed caught on fire due to exhaust cleaning system getting so hot to burn off pollution in DPF pipe. Dangerous truck to drive contacted ford. No one contacted me. Other ford diesels caught on fire due to this. I’m retired military and don’t have money to buy 50k trucks. Only 80k on truck.

NHTSA ID

11645692

Incident

Mar 6, 2024

Death wobble. First experience was September 2019

NHTSA ID

11533462

Incident

Jul 20, 2023

The contact owns a 2008 Ford F-350. The contact stated that on several occasions while the accelerator pedal was depressed, the contact noticed a burning odor throughout the vehicle. The contact stated that the rear driver’s and passenger’s side wheels inadvertently locked without warning then released. No warning lights were illuminated. The vehicle was taken to the dealer where the brake pedal and plunger rod was replaced with a longer plunger rod; however, the failure recurred. The contact stated that while driving at an undisclosed speed, he depressed the brake pedal however, the vehicle failed to stop. The contact stated that he had to applied pressure to the brake pedal that was depressed down to the floorboard. As a result, the vehicle glided to a stop. No warning lights were illuminated. The vehicle was taken back to the dealer where it was diagnosed that brake pedal and the brake master cylinder needed to be replaced. The vehicle was repaired; however, the failure recurred after the vehicle was retrieved from the dealer. The contact stated that while the accelerator pedal was depressed, the front driver’s side wheel locked without warning and then released. The contact stated that he steered the vehicle off the roadway and was informed by another motorist that there was smoke underneath the vehicle. The contact stated that he was assist by Law Enforcement and advised to call the NHTSA Hotline. The vehicle was then taken back to the dealer where it was diagnosed that the brake caliper, front brake lock, brake pads, master cylinder and other undisclosed brake parts needed to be replaced. The vehicle was repaired; however, the failure recurred. The contact was advised by the technician to take the vehicle to Bob’s 151 transmission Center where it was diagnosed that the ABS had failed and needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and the contact was informed that the vehicle was too old, and no further assistance was provided. The contact stated that th

NHTSA ID

11523641

Incident

May 10, 2023

Mileage

70,000 mi

Steering went out , wouldn’t return to center

NHTSA ID

11507117

Incident

Feb 9, 2023

Power steering pump replaced with new unit. Major steering issues. Will not turn at some points. Almost caused 3 accidents on 10/22/2021. Have had front end and power steering pump replaced.

NHTSA ID

11437889

Incident

Oct 22, 2021

In monitoring our technical service inquiries and technical service bulletins from Ford, there is the potential for moderate to severe steering wheel oscillation (wobble) to occur. After extensive testing and outside feedback, the following details have been established to correct or prevent steering wheel oscillation occurrences in lifted 05-16 Ford Super Duty 4wd pickups.

FORD: THE MALFUNCTION INDICATOR LAMP (MIL) ON AND DIAGNOSTIC TROUBLE CODES (DTCS) P0713 AND/OR P0710 REGARDING TORQSHIFT TRANSMISSION. MODEL 2008-2009 F-53 MOTORHOME CHASSIS, LOW CAB FORWARD, 2008-2010 F-250, F-350, 2008-2011 E-350, E-450, F-450, F-550, 2011 F-53 MOTORHOME CHASSIS, F-50 COMMERCIAL STRIPPED CHASSIS. *PE

FORD SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. DEMONSTRATION/DELIVERY HOL CUSTOMER SATISFACTION PROGRAM 08B03. CERTAIN 2008 MODEL F-350, 4X4, 10,001 LBS AND OVER GVW, 156 WHEEL BASE VEHICLES EQUIPPED WITH A TWO-PIECE DRIVE SHAFT, FUEL TANK STOPPER BRACKET INSTALLATION. *PE UPDATED 9/5/08 CSC LETTER WAS ADDED TO BULLETIN. 10/20/08. *PE UPDATED 10/24/08. *PE UPDATED 10/13/10. *PE UPDATED 9/21/11. *PE

FORD: SOME FORD SUPER DUTY TRUCKS MAY EXHIBIT A LACK OF POWER WITH A DIAGNOSTIC TROUBLE CODE AT FULL OPERATING TEMPERATURE DURING ACCELERATION. *RM

FORD: SOME CONTINENTAL TIRES MIGHT HAVE UNEVEN WEAR, VIBRATION, OR THE POSSIBLE TREAD DETACHMENT. 2008-2009 F250/F350. *RM UPDATED 8/3/11. *PE

FORD: IF THERE IS AN INTERMITTENT LACK OF POWER, SURGE, OR HESITATION WHILE DRIVING THE BRAKES WILL OVERRIDE ACCELERATION. *RM