2001 Ford F-450 Sd

IN A DECEMBER 3, 2007 LETTER, FORD ADVISED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL TO REPLACE THE CAM POSITION SENSOR (CPS) IN APPROXIMATELY 1.2 MILLION SUBJECT VEHICLES TO ADDRESS REPORTS OF ENGINE STALLING.A NEW DESIGN CPS WITH IMPROVED PERFORMANCE AND DURABILITY WILL BE INSTALLED AS A REMEDY.OWNER NOTIFICATIONS WILL BEGIN IN DECEMBER 2007. THE SUBJECT VEHICLES ARE DURABLE, FULL-SIZED, MEDIUM DUTY TRUCKS COMMONLY USED FOR COMMERCIAL PURPOSES, RESCUE/EMERGENCY RESPONSE, AND COMMERCIAL OR RECREATIONAL TOWING.CPS FAILURE IS COMPARABLE TO UNEXPECTEDLY TURNING THE KEY OFF SINCE THE SIGNAL IT PRODUCES IS VITAL TO THE ELECTRONIC ENGINE CONTROL SYSTEM.CPS SIGNAL LOSS TERMINATES FUEL INJECTION RESULTING IN AN ENGINE STALL.ONCE STALLED, THE ENGINE MAY RESTART RIGHT AWAY, OR MAY RESTART AFTER A DELAY (TYPICALLY 5 TO 10 MINUTES), OR MAY NOT RESTART AT ALL.IN ADDITION TO EXPOSING THE DRIVER AND OTHER MOTORISTS TO CRASH RISK DUE TO LOSS OF MOTIVE POWER OR VEHICLE DISABLEMENT, ENGINE STALLING ALSO EFFECTS THE POWER ASSISTED STEERING AND BRAKING. THROUGH CONSUMER INTERVIEWS, ODI DETERMINED THAT CPS FAILURES OCCURRED WITHOUT ANY FORM OF WARNING, AT ANY VEHICLE SPEED (50% AT HIGHWAY SPEEDS), AND UNDER ANY DRIVING CONDITION, SUCH AS ACCELERATING.CONSUMERS REPORTED THAT ABOUT A THIRD OF THE VEHICLES FAILED TO RESTART, WITH ANOTHER THIRD REPORTING DELAYED RESTARTING.HALF THE VEHICLES THAT DID RESTART EXPERIENCED ANOTHER STALL ON THE SAME OR A SUBSEQUENT DRIVE CYCLE (BEFORE CPS REPLACEMENT) RE-EXPOSING THOSE CONSUMERS TO THE RISKS ASSOCIATED WITH A STALLING EVENT.IN THEIR VOQ REPORTS, HALF OF THE ODI COMPLAINANTS DESCRIBED DIFFICULTY CONTROLLING THE VEHICLE DUE TO LOSE OF POWER ASSIST SYSTEMS, ESPECIALLY THOSE WHO WERE TOWING AT THE TIME OF THE INCIDENT. THE ONE ALLEGED INJURY INCIDENT OCCURRED IN AN INTERSECTION WHEN A SUBJECT VEHICLE STALLED WHILE TURNING ACROSS ONCOMING LANES OF TRAFFIC.ALTHOUGH UNSUBSTANTIATED, THE COMPLAINANT ALLEGED AN INJURY TO A CHILD OCCUPANT DURING ODI'S INTERVIEW.THE OTHER CRASH ALLEGATIONS MOSTLY INVOLVED LOW SPEED, LOSS OF CONTROL INCIDENTS OFTEN CAUSED BY LACK OF POWER ASSIST; NO INJURIES ARE REPORTED IN THESE INCIDENTS, AND PROPERTY DAMAGE, IF ANY, WAS MINIMAL.CONSUMERS ALSO REPORTED OTHER INCIDENTS WITH SIGNIFICANT SAFETY RISKS, SUCH AS DISABLEMENT IN A LANE OR ON A SHOULDER OF A HIGH-SPEED ROADWAY OR INTERSTATE, OR EXTENDED DISABLEMENT IN REMOTE AREAS DURING SEVERE WEATHER CONDITIONS. THE POPULATION ABOVE IS FORD'S ESTIMATE OF THE 1.4 MILLION SUBJECT VEHICLES PRODUCED THAT ARE CURRENTLY REGISTERED.THE FORD COMPLAINT AND WARRANTY COUNTS NOTED ABOVE ARE CURRENT AS OF FORD'S LAST SUBMISSION DATED JUNE 21, 2007; THEY DO NOT INCLUDE F-450, F-550, OR ECONOLINE COUNTS AS THESE PRODUCTS WERE NOT FORMALLY WITHIN SCOPE OF THE INVESTIGATION WHEN FAILURE INFORMATION WAS REQUESTED.WARRANTY DATA ANALYSIS INDICATES THAT ABOUT HALF THE CLAIMS INVOLVED A STALL WHILE DRIVING EVENT ( FORD'S ASSESSMENT) AND THAT POOR CPS DURABILITY WAS A LONGSTANDING CONCERN.FORD REPORTED THAT THE NEW CPS DESIGN SHOULD MEET OR EXCEED THEIR 10 YEAR, 150K MILE LIFE EXPECTANCY DESIGN REQUIREMENT.

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.

DURING THE INITIAL RECALL CAMPAIGN IN 2001, THE SUBJECT VEHICLES WERE INSPECTED BY FORD DEALERSHIPS USING A TEST TOOL THAT WOULD DETECT A DEFECTIVE FRONT SEAT OUTBOARD SEAT BELT BUCKLE ASSEMBLY.APPROXIMATELY ONE MILLION VEHICLES PASSED THE INSPECTION TEST FOR ONE OR BOTH FRONT BUCKLES.SUBSEQUENT TO THE RECALL SERVICE ACTION, ODI RECEIVED 15 CONSUMER REPORTS ALLEGING THAT A PASSED INSPECTION BUCKLE SUBSEQUENTLY FAILED TO LATCH OR INADVERTENTLY UNLATCHED DURING USE.IN ADDITION, FORD HAS IDENTIFIED 543 OWNER AND FIELD REPORTS ALLEGING BUCKLE FAILURE SUBSEQUENT TO PASSING THE INSPECTION TEST.FORD TESTED AND EXAMINED OVER 100 WARRANTY-RETURNED BUCKLES AND FOUND THAT 44% OF THE BUCKLES HAD NO PROBLEM OR A CONDITION NOT RELATED TO THE RECALL INSPECTION (NON-LATCH RELATED BUCKLE DAMAGE OR FOREIGN CONTAMINATION).WARRANTY CLAIMS WERE HIGHEST DURING THE 18-MONTH PERIOD AFTER THE START OF THE RECALL (JULY 2001) AND HAVE BEEN DECLINING DURING THE PAST 24 MONTHS.OVER THE PAST 12 MONTHS, FORD HAS RECEIVED APPROXIMATELY 12 WARRANTY CLAIMS PER MONTH OUT OF A VEHICLE POPULATION OF ABOUT ONE MILLION.COMPLAINTS COUNTS ARE ALSO DECREASING.DURING THE PAST SEVEN MONTHS, ODI HAS RECEIVED ONLY TWO COMPLAINTS. 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 RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

UNDER RECALL CAMPAIGN (01V227), FORD RECALLED APPROXIMATELY 1.3 MILLION VEHICLES TO INSPECT AND IF NECESSARY REPLACE THE FRONT DRIVER AND/OR PASSENGER SEAT BELT BUCKLE.APPROXIMATELY 1.1 MILLION OWNERS RESPONDED BY TAKING THEIR VEHICLES TO A DEALER FOR INSPECTION OF THE BUCKLE USING A SPECIALIZED BUCKLE TEST TOOL.FORD REPORTED THAT 829,927 VEHICLES HAD BOTH BUCKLES PASS THE TOOL TEST AND ANOTHER 167,336 VEHICLES HAD ONE BUCKLE PASS.ODI AND FORD RECEIVED COMPLAINTS ALLEGING SEAT BELT BUCKLE FAILURE SHORTLY AFTER PASSING THE ORIGINAL RECALL INSPECTION SERVICE.COMPLAINANTS ALLEGED THAT THE BUCKLE FAILED BY EITHER NOT LATCHING OR FALSE-LATCHING (PARTIAL ENGAGEMENT OF THE LATCH TO THE LATCH PLATE).A FALSE-LATCHED BUCKLE MAY RELEASE WITH MINOR MOVEMENT OR IMPACT AGAINST THE BUCKLE HOUSING INCLUDING INADVERTENT RELEASE WHILE THE VEHICLE IS IN MOTION.ODI IS UPGRADING THIS RECALL QUERY TO AN ENGINEERING ANALYSIS (EA05-004) TO FURTHER ANALYZE THE FIELD PERFORMANCE OF THOSE VEHICLES THAT FORD DEALERS PASSED (ONE OR BOTH BUCKLES) USING FORD'S INSPECTION TEST (997,263 VEHICLES).

VEHICLE WOULD QUIT PULLING. HAD TO PULL TO SHOULDER AND SHUT OFF. AFTER FIFTEEN OR TWENTY MINUTES, IT WOULD START AND RUN FAIRLY NORMAL FOR A FEW MILES AND THEN DO THE SAME THING OVER AGAIN. THIS WENT ON UNTIL I GOT TO MY DESTINATION WHICH WAS A COUPLE HUNDRED MILES. *TR

NHTSA ID

10366464

Incident

Aug 21, 2010

Mileage

83,000 mi

2001 FORD F450 DIESEL FUEL TANK LINER FAILED AND RESULTED IN FUEL DELIVERY WHILE TOWING. THIS CAUSED 10 MPH SPEED ON THE INTERSTATE WHILE PULLING A HORSE TRAILER. JUST SPENT $1800.00 FOR NEW TANK AND WAS TOLD THAT IT WOULD HAPPEN AGAIN. THIS PROBLEM SHOULD HAVE BEEN RESOLVED WITH THE NEW TANK AND NOT JUST INSTALLING ANOTHER ONE THAT WILL FAIL ALSO. *TR

NHTSA ID

10365197

Incident

Oct 24, 2010

Mileage

58,400 mi

JAN 23, 2007-THE TRUCK WAS TAKEN TO THE SHOP DUE TO MISSING WHILE DRIVING AND STALLING OUT. DIAGNOSTICS WERE DONE, CHANGED THE FUEL FILTER AND REPLACE CAM SHAFT SENSOR. FEB. 12, 2007 - SAME ISSUES MISSING IN ENGINE AND STALLED OUT. TAKEN TO AUTO REPAIR SHOP . CLEANED ALL CABLES AND CHARGED BATTERIES. MARCH 2, 2007 - MISSING IN ENGINE AND STALLS OUT. DIAGNOSTICS TIME 60 OR 65 NO POWER . REPLACE AIR FILTER AND UNSTICK TURBO JULY 9, 2007- MISSING IN ENGINE AND STALLING OUT. TAKEN TO SHOP. DIAGNOSTICS DONE. REPLACED WIRE ASSEMBLY AND GASKET. SEPT. 12, 2007 - STILL MISSING REPLACED FUEL FILTER WHINING IN SHOP FOR STATE INSPECTION. SEPT. 24, 2007 - ENGINE MISSING , WHILE IN SHOP TO REPLACE TRANSMISSION ADDED CAN OF CARB CLEANER NOV. 21, 2008 - MISSING, STALLED ON ROAD, WOULD NOT START TOWED TO THE SHOP , DIAGNOSTICS DONE. REPAIR SHOP DID RESEARCH AND FOUND OUT ABOUT PROBLEMS WITH FUEL TANKS PEELING AND SLIVERING INSIDE WHICH WOULD GET IN INJECTORS AND CAUSE MISSING AND STALLING OF ENGINE. DIAGNOSTICS WERE DONE. REMOVED AND DRAINED FUEL TANK, REPLACED FUEL TANK ADDED CARB CLEANER, REPLACED FUEL FILTER, CLEANED FUEL PICK UP FILTER AND LINES . *TR

NHTSA ID

10351211

Incident

Jan 20, 2007

Mileage

60,351 mi

F450 STAKE BODY DUMP TRUCK STARTED HESITATING AT ALL SPEEDS. FOUND OUT THAT THE DIESEL FUEL GAS TANKS ARE DELAMINATING ON THE INSIDE AND CLOGGING THE FUEL SYSTEM. THIS REPAIR COSTS $2,400. A BIG TRUCK DRIVING DOWN THE ROAD THAT IS RUNNING FINE AND THEN ALL OF A SUDDENLY STARTS TO HESITATE IS EXTREMELY DANGEROUS. FORD TRUCKS SEEM TO BE THE ONLY ONES HAVING THIS PROBLEM. I FEEL FORD SHOULD BE REQUIRED TO RECALL THESE TRUCKS AND FIX THE PROBLEM FOR SAFETY PURPOSES. *TR

NHTSA ID

10325568

Incident

Apr 13, 2010

Mileage

90,000 mi

OUR 2001 F-450 DIESEL TRUCK HAS LOST POWER. WE HAD THE FUEL FILTER CHANGED AND HAD TO HAVE THE SENDING UNIT CLEANED OUT DUE TO SEDIMENT IN THE BOTTOM OF THE TANK FROM THE TAKE PEELING. IT IS DOING IT AGAIN AND I HEARD OF A LOT OF THESE DIESEL TRUCKS HAVING THE SAME PROBLEM. THIS TRUCK ONLY HAS 90,000 MILES ON IT. I WOULD LIKE REIMBURSEMENT FOR THIS NEW TANK I HAVE TO BUY WHICH IS $500.00. *TR

NHTSA ID

10239819

Incident

Dec 10, 2007

Mileage

85,000 mi

NO PROBLEMS 2 LEFT BUSINESS ,WENT 2 BLOCKS FIRE STARTED 3 5500 DOLLARS IN PARTS, 35 HOURS IN LABOR TIME, HAVE DETAILED RECEIPTS OF PARTS REPLACED. *JB

NHTSA ID

10176574

Incident

Nov 27, 2006

Mileage

338,261 mi

MY WIFE PUT OUR TRUCK IN GEAR AND IT TOOK OFF WITH HER. LUCKILY I HAD JUST MOVED FROM THE BACK OF THE VEHICLE. THE CLUTCH DID NOT RELEASE THE TRANSMISSION. I HAD TO REACH IN AND SHUT TRUCK OFF. *NM

NHTSA ID

10146078

Incident

Dec 22, 2005

Mileage

39,665 mi

FAILURE IN LINING OF FUEL TANK IN F SERIES TRUCKS WITH DIESEL ENGINES. LINING FALLS APART SUCKING INTO FUEL SYSTEM CAUSING RAPID LOSS OF SPEED AND POWER. I HAVE BEEN HAVING THE FUEL TANK, AND ASSORTED FUEL COMPONENTS REPLACED 4 TIMES TOTAL THAT I AM AWARE OF. POSSIBLY MORE AS I AM ONLY RESPONSIBLE FOR 2 F SERIES TRUCKS. OTHER MGRS ARE RESPONSIBLE FOR MORE.

NHTSA ID

10120800

Incident

May 11, 2005

Mileage

120,000 mi

This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for testing and containment. We don't have evidence that these test results have contributed to a product failure.

This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for testing and containment. We don't have evidence that these test results have contributed to a product failure.

FORD: THE RESTRAINT CONTROL MODULE (RCM) WHEN USING VCM II, WOULD HAVE AN ERROR CODE 35 AND DIAGNOSTIC TROUBLE CODE (DTC) B1035, AND DIFFICULTY ATTEMPTING PROGRAMMABLE MODULE INSTALLATION (PMI). MODEL 2001-2004 F-SUPER DUTY. *PE

1999-2008 F250-F550 SUPER DUTY 4X4 WITH ELECTRONIC SHIFT TRANSFER CASE NOT ENGAGING 4X4. *NJ

DRIVE AWAY SHUDDER OR VIBRATION. *EH

VACUUM PUMP INOPERATIVE OR RUNS CONTINUOUSLY - CLIMATE CONTROL DEFAULTS TO DEFROST MODE. *TT