2011 Ford F-550

The Office of Defects Investigation (ODI) opened this RQ to investigate allegations that the scope and remedy of safety recall 13V-535 were inadequate. Recall 13V-535 was limited to a relatively small population of Ambulance Package vehicles and ODI received complaints of pickup trucks and Fire Engine Prep Package vehicles being affected by the same defect. Ford manufactured approximately 555,985 subject vehicles between February 22, 2010 and January 30, 2015 that may be affected by defective EGT sensors and Powertrain Control Module (PCM) software calibration. The subject vehicles are equipped with four (4) EGT sensors to monitor engine operating conditions. An EGT sensor fault may produce false exhaust over-temperature signals. If these signals are produced, the Powertrain Control Module (PCM) implements a Failure Management Effects Mode (FMEM) and the driver receives a Stop Safely Now (SSN) system warning on the instrument cluster message center. The FMEM triggers a 70% reduction in available engine power over a period of no more than 45 seconds, during which it may not be possible to accelerate or maintain vehicle speed. The PCM then commands the engine to shut down when vehicle speed reaches approximately 1 mph. There is no immediate restart capability. Depending on the PCM software calibration, ignition key position and ambient temperature conditions, the engine may not restart until the end of a 10-60 minute cool down period.Ford and its component supplier(s) made numerous changes to the PCM software calibration and the design, material and manufacture of the EGT sensors over the period of subject vehicle production. This continuous product improvement affected vehicle performance regarding the alleged defect. Ford acknowledges the defect condition in the subject vehicles but argues that an unreasonable risk to motor vehicle safety is limited to Ambulance Package and Fire Engine Prep Package vehicles where commanded shutdown could impact emergency response and patient care. Ford also argues that the defect trend is in decline. Ford also initiated a new safety recall (15V-175) to address the 13V-535 remedy concerns in the Ambulance Package vehicles and Fire Engine Prep Package vehicles. The 15V-175 remedy reprograms the PCM with a new software calibration that stops a single EGT sensor fault to cause the vehicle to enter the FMEM shutdown mode.Ford also initiated an EPA emissions recall (14E03) for all subject vehicles that reprograms the PCM with the software calibration employed in safety recall 15V-175. Finally, Ford initiated a Customer Satisfaction Program (15M01) providing extended warranty coverage of 8 years or 80,000 miles for the the EGT sensors on certain MY2011-2012 subject vehicles.Due to the EPA emissions recall, that had a 66.6% completion rate in Ford's December 2015 progress report to the EPA, the defect trend is in decline. ODI is not aware of any crashes, deaths or injuries related to the alleged defect.ODI believes the alleged defect poses a safety risk but notes that the EPA emissions recall is addressing the safety problem.Compelling issuance of a duplicate recall would not represent a wise use of agency resources.Accordingly, this Recall Query is closed.This action is not a finding that no defect exists and NHTSA will take further action if such action is warranted.

The Office of Defects Investigation (ODI) is aware of 1 incident related to the alleged defect. By letter dated January 10, 2014, Almared, Inc. (doing business as A-1 Alternative Fuel Systems) has notified ODI that it has conducted a safety recall (NHTSA Recall No. 14V-040) to address a safety defect in 18 model year 2011-2012 Ford F-550 transit buses manufactured between May 2011 and April 2013. These vehicles have been altered by A-1 to contain one or more compressed natural gas (CNG) fuel containers. According to A-1, the brackets securing passenger side CNG fuel containers to the vehicle chassis may fracture, resulting in a CNG fuel container that is unsecured. A-1 has reportedly inspected all 18 affected vehicles and repaired all vehicles equipped with the defective mounting bracket by installing a new bracket of an improved design. The new bracket has added strength as a result of the following design revisions: the cantilevered mounting plate is reinforced with additional support plates, the cantilevered position is mounted higher on the bracket above the CNG fuel container center line position (thus reducing the moment arm), and it is constructed of heavier gauge steel plate that is also dimensionally wider, which provides for a greater bonding surface area with the vehicle chassis.Based on the recall action taken by Almared, Inc., this investigation is closed.

The contact owns a 2011 Ford F-550. The contact stated while starting the vehicle, there was a loud knocking sound coming from the engine. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic and was diagnosed with a failure in cylinder #8 and with engine failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline for assistance. The approximate failure mileage was 49,000. The VIN was not available.

NHTSA ID

11629240

Incident

Dec 6, 2024

Mileage

49,000 mi

The contact's local fire department owns a 2011 Ford F-550. The contact stated that while driving at 45 MPH, the vehicle stalled out as several warning lights appeared on the instrument panel. The contact made multiple attempts to restart the engine but the failure persisted. Due to the failure, the vehicle was towed to an independent mechanic where a diagnostic was performed. The mechanic discovered diesel fuel in the oil reservoir which had resulted in engine failure. Upon investigation, the mechanic referred the contact to the manufacturer for assistance. The manufacturer was notified of the failure and informed the contact that the vehicle was not covered under warranty or recall. The manufacturer then referred the contact to the NHTSA Hotline to file a safety complaint. The vehicle was not repaired. The failure mileage was approximately 6,500.

NHTSA ID

11628877

Incident

May 31, 2024

Mileage

6,500 mi

TRUCK WILL SHAKE UNCONTROLLABLY AT HIGHWAY SPEEDS. WE HAVE HAD THE FRONT END/DRIVE SHAFT/NEW TIRES/WHEELS EITHER REPLACED OR GONE THROUGH. NOTHING HAS IMPROVED.

NHTSA ID

11387852

Incident

Sep 30, 2019

Mileage

155,000 mi

TL* THE CONTACT OWNS A 2011 FORD F-550. THE CONTACT STATED HE RECEIVED A NOTICE THAT THE VEHICLE HAD TWO LININGS IN THE INTERNAL PART OF THE VEHICLE WHICH BOTH UNEXPECTEDLY DETACHED AND CONTAMINATED THE FUEL IN FUEL TANK. THE CONTACT STATED THE FAILURE CAUSED THE ENGINE TO FAIL. THE VEHICLE WAS TOWED TO A UNKNOWN LOCAL DEALER FOR A DIAGNOSTIC TESTING WHICH TOOK THREE MONTHS. THE DIAGNOSIS RESULTS WAS CONTAMINATION FROM THE FUEL TANK. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE HOWEVER OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 24,000. *BF*JB

NHTSA ID

11321894

Incident

Mar 15, 2015

Mileage

24,000 mi

ENGINE SHUTTING OFF & WILL NOT RE-START AFTER. WILL RESTART AFTER IT SITS FOR A COUPLE HOURS. HAS BEEN INTO TUTTLECLICK FORD SEVERAL TIMES FOR REPAIR OF THIS ISSUE. STILL NOT FIXED.

NHTSA ID

10993685

Incident

Jun 6, 2017

Mileage

22,555 mi

TL* THE CONTACT OWNS A 2011 FORD F-150. THE CONTACT STATED THAT THE CHECK ENGINE LIGHT ILLUMINATED ON THE INSTRUMENT PANEL AND THE VEHICLE STALLED SHORTLY AFTER THE FAILURE. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE INTERIOR LINING OF THE FUEL TANK SHED INTO THE FUEL TANK AND DAMAGED THE ENGINE. THE DEALER STATED THAT BOTH FUEL TANKS WOULD HAVE TO BE REPLACED AND THE ENGINE WOULD NEED TO BE CLEANED. TWO YEARS LATER, AFTER THE CONTACT'S VEHICLE WAS OUT OF WARRANTY, THE FAILURE RECURRED. THE DEALER CONFIRMED THE VEHICLE WOULD REQUIRE THE SAME REVISIONS AS BEFORE; HOWEVER, IT WOULD BE PERFORMED AT THE CONTACT'S EXPENSE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 18,000. UPDATED 02/05/16*LJ UPDATED 02/11/16.*JB

NHTSA ID

10789548

Incident

Oct 1, 2012

Mileage

18,000 mi

TL* THE CONTACT OWNS A 2011 FORD F-550. WHILE AT A STOP SIGN, THE VEHICLE STALLED AND THE LOW POWER WARNING MESSAGE DISPLAYED ACROSS THE MESSAGE BOARD. THE CONTACT WAS ABLE TO RESTART THE VEHICLE WHICH WAS THEN TOWED TO A DEALER. THE TECHNICIAN STATED THAT THERE WAS CONTAMINATION IN THE FUEL LINE AND THAT THE FUEL SYSTEM NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 19,633. UPDATED 11/06/15*LJ *CN

NHTSA ID

10759202

Incident

Oct 23, 2014

Mileage

19,633 mi

TL*THE CONTACT OWNS A 2011 FORD F-550. THE CONTACT STATED THAT WHILE DRIVING AT APPROXIMATELY 5 MPH, THE VEHICLE STALLED. THE VEHICLE WAS ABLE TO RESTART AFTER MULTIPLE ATTEMPTS. THE VEHICLE WAS TOWED TO A DEALER FOR DIAGNOSTIC TESTING THE MECHANIC DIAGNOSED CONTAMINATION IN THE FUEL. THE VEHICLE WAS REPAIRED. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBER: 13V535000 (ENGINE). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 19,000. MA 07/30/15 UPDATED 9/19/2017*CN

NHTSA ID

10678302

Incident

Aug 4, 2014

Mileage

19,000 mi

Some vehicles may exhibit a no start condition with an illuminated malfunction indicator lamp (MIL) and a DTC P161A after PCM replacement. This may be due to the parameter reset procedure not being properly completed. To clear this DTC, use the Ford Integrated Diagnostic System (IDS) service tool or Ford J2534 Diagnostic Software, select - Toolbox - Body - Security - PATS Functions - Parameter Reset. Follow the on-screen instructions to complete the procedure. This procedure will transfer the existing Key ID information between the modules without the need of having 2 programmed PATS keys present. There is no need to program keys when the PCM is going to be replaced. Additional information can be found in the Workshop Manual (WSM), Section 419-01. Missing or lost keys are not warrantable.

FORD: NO SERVICE ACTION IS RECOMMENDED FOR THIS CONDITION. PLEASE USE AT YOUR DISCRETION. VARIOUS 2010-2015 VEHICLES MAY EXPERIENCE A TURBULENCE NOISE, SIMILAR TO AN HELICOPTER NOISE, AT HIGHWAY SPEEDS WHEN THE REAR DOOR WINDOW(S) OR SUNROOF ARE OPEN. *TA

FORD: CERTAIN 2011-2015 FORD F-SUPER DUTY WITH 6.7 DIESEL ENGINES MAY EXPERIENCE A VIBRATION BUZZ NOISE FROM THE DIESEL FUEL CONDITIONING MODULE (DFCM) AND/OR MAY 10/1/1 PRESSURE FUEL LINES W/O DIAGNOSTIC TROUBLE CODE POOSA. *TA

FORD 2011-2012 F250, F350, F450, F550 : INFORMATION REGARDING F-SUPER DUTY VEHICLES EQUIPPED WITH A 6.7L ENGINE AND BUILT BEFORE 10/11/2011 MAY EXHIBIT A MIL ON WITH DTCS, P207F, P20EE, P2200, P2201, P2209, P164A, P2A00 OR P0133. *LJ