2012 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 2012 Ford F-550 chassis with an Earth Roamer RV. The contact stated while driving at approximately 65 MPH, the vehicle was making an abnormal sound coming from the engine compartment. The contact stated that the turbocharger needle on the instrument cluster fell to zero. The contact stated no warning light was illuminated. The contact stated that the vehicle was losing motive power while depressing the accelerator pedal. The contact stated that the abnormal banging sound was louder, and the vehicle lost motive power. The contact pulled off the highway and then stated that the power steering had failed. The contact was turned off and restarted the vehicle; however, the power steering and the abnormal engine sound remained present. The contact was able to drive several yards before the vehicle stalled. The contact had the vehicle towed to an independent mechanic who diagnosed the vehicle and determined that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was informed of the failure. The failure mileage was approximately 72,000.

NHTSA ID

11590361

Incident

May 17, 2024

Mileage

72,000 mi

The contact owns a 2012 Ford F-550. The contact stated that while driving at approximately 15 MPH, the vehicle stalled without warning. The contact made multiple attempts to restart the vehicle; however, the vehicle repeatedly failed to start up. Due to the failure, the contact called the dealer and had the vehicle towed there for an inspection. The contact then called an independent mechanic who informed him that based on what he described; his vehicle had experienced engine failure. The manufacturer had yet to be notified of the failure. The vehicle had yet to be diagnosed or repaired. The failure mileage was 35,800.

NHTSA ID

11462602

Incident

Apr 21, 2022

Mileage

35,800 mi

WHILE DRIVING VEHICLE ON TRAIL IT WAS NOTICED THAT SMOKE AND FIRE WERE COMING FROM THE UNDERCARRIAGE. DRIVER ATTEMPTED TO PUT THE FIRE OUT WITH THE VEHICLE SUPPLIED FIRE EXTINGUISHER. AFTER THE EXTINGUISHER RAN OUT THE VEHICLE FIRE ACCELERATED AND TOTALLY ENGULFED THE VEHICLE.*DT*JB

NHTSA ID

11354215

Incident

Sep 2, 2020

TL* THE CONTACT OWNS A 2012 FORD F-550. WHILE THE CONTACT WAS HAULING SAND AND REGROUND GRAVEL UP A HILL, THE EMERGENCY BRAKE WAS ENGAGED AND THE GEAR SHIFTER WAS PLACED INTO PARK. THE ENGINE WAS RUNNING AND THE CONTACT EXITED THE VEHICLE. WHEN THE CONTACT RE-ENTERED THE VEHICLE, SHIFTED GEARS, AND RELEASED THE EMERGENCY BRAKE TO DRIVE, THE ENGINE STALLED. THE VEHICLE ROLLED DOWN THE HILL. THE CONTACT WAS ABLE TO STOP THE VEHICLE. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS NOT TAKEN TO A DEALER. THE CONTACT STATED FAILURE OCCURRED TWICE JUNE 05,2019 AND SEPT.6, 2019. THERE WAS A FULL TANK OF FUEL IN THE VEHICLE. WHILE DRIVING UP A HILL HAULING SAND AND GRAVEL, THE CONTACT STOPPED ON THE HILL, RELEASED THE BRAKE PEDAL, DEPRESSED THE ACCELERATOR PEDAL, AND THE ENGINE STALLED WITHOUT WARNING. THE VEHICLE STARTED TO ROLL DOWN THE HILL IN REVERSE WITH NO POWER. THE CONTACT SHIFTED INTO PARK AND THE BRAKES COULD NOT STOP THE VEHICLE DUE TO THE LACK OF POWER. THE CONTACT QUICKLY CUT INTO THE BANK; HOWEVER, THE REAR END OF THE VEHICLE WENT UP ON THE BANK AND THE VEHICLE ROLLED OVER ON THE PASSENGER SIDE DOWN THE EMBANKMENT. THE CONTACT SUSTAINED INJURIES TO THE HEAD AND KNEE, AND A BROKEN LEFT HAND, NECK, RIBS, LOWER BACK, ARM, AND LEGS. MEDICAL ATTENTION WAS NOT RECEIVED. THE FRONT PASSENGER WAS NOT INJURED. A POLICE REPORT WAS NOT FILED. THE VEHICLE WAS PULLED OUT OF THE BANK TO THE TOP OF THE HILL AND REMAINED ON THE HILLSIDE. THE VEHICLE WAS NOT TAKEN TO A DEALER OR AN INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND DID NOT ASSIST. THE APPROXIMATE FAILURE MILEAGE WAS 55,000. *PM CONSUMER STATED BOTH INCIDENTS HAPPENED AT THE SAME PLACE.*JB

NHTSA ID

11256086

Incident

Jun 5, 2019

Mileage

55,000 mi

I HAVE ONLY USED THE TRUCK FOR FIVE MONTHS AND HAVE HAD SEVERAL BUSINESS INTERRUPTIONS AND ISSUES WITH THE TRUCK FROM THE GAS TANK LEAKING, PROBLEMS WITH THE BRAKES AND THE BOX HOIST THAT WOULD NOT RAISE. I HAVE HAD THE BOX HOIST FIXED MULTIPLE TIMES BUT THE WELD KEEPS BREAKING. I AM SURE FORD KNOWS ABOUT THE HOIST PROBLEM BUT THEY HAVE NOT ISSUED ANY RECALLS FOR IT. AS A CONSUMER I FEEL CHEATED. MY RECENT PROBLEM IS THE ENGINE, IT HAD STALLED UNEXPECTEDLY AND SHUT DOWN COMPLETELY FOR NO REASON AT ALL AND WITHOUT WARNING WHILE MY SON WAS DRIVING ON THE HIGHWAY. IT WAS A SAFETY ISSUE AND PUT MY SON'S LIFE AT RISK. I LOOKED UP THE ABOVE VIN NUMBER ON THE INTERNET BUT COULD NOT FIND DIRECT RECALLS RELATING TO IT. FORD HAS PUT OUT RECALLS ON SOME OF THE ENGINES FOR FORD F550S YR 2012 BUT ONLY FOR AMBULANCE TYPE TRUCKS NOT DUMP TRUCKS. I AM COMPLAINING BECAUSE MY DUMP TRUCK HAS THE SAME ENGINE STALLING PROBLEM AS ON THE AMBULANCE TYPE F550S FROM YEAR 2012, WHEN IT UNEXPECTEDLY SHUTS DOWN COMPLETELY AND WITHOUT WARNING. *JS

NHTSA ID

11252148

Incident

Jul 15, 2019

ECM LOOSING INFORMATION, ON HIGH WAY TRUCK SHUT DOWN WOULD NOT MOVE DUE TO EMISSION AND PCM PROBLEM. ECM NEED TO REFLASH ON UPDATED VERSION OR REPLACE

NHTSA ID

11164007

Incident

Oct 12, 2018

Mileage

267,000 mi

TL* THE CONTACT OWNS A 2012 FORD F-550. THE CONTACT STATED THAT THE CAM SHAFT FRACTURED INTERNALLY WITHIN THE CYLINDER HEAD AND DESTROYED THE ENGINE ASSEMBLY. THE DEALER (MATHEWS FORD OREGON, 2811 NAVARRE AVE, OREGON, OH 43616, (419) 698-4444) AND THE MANUFACTURER INDICATED THAT THE VEHICLE'S THREE YEAR WARRANTY HAD EXPIRED AND SERVICE WAS DENIED PER THE CAMPAIGN FOR CUSTOMER SATISFACTION NUMBER: 17B30. THE DEALER PREVIOUSLY REPLACED THE ENGINE ASSEMBLY ONCE BEFORE AND INDICATED THAT THE PART NEEDED TO BE REPLACED A SECOND TIME. THE DEALER AND AN INDEPENDENT MECHANIC INDICATED THAT THE ENGINE ASSEMBLY WOULD NEED TO BE REPLACED. THE MANUFACTURER PROVIDED NO ASSISTANCE OTHER THAN THE DEALER REPAIRING THE VEHICLE. THE FAILURE MILEAGE WAS NOT AVAILABLE. *TT CONSUMER STATED ENGINE CAM FOLLOWERS FELL OFF AND DESTROYED THE ENGINE THIS HAS HAPPENED TWICE. UPDATED 10/5/18*JB

NHTSA ID

11104106

Incident

May 14, 2015

Mileage

114,484 mi

TL* THE CONTACT OWNS A 2012 FORD F-550. WHILE DRIVING ON AN INCLINE AT 60 MPH, THE ENGINE POWER LOSS INDICATOR ILLUMINATED. SUDDENLY, THE CONTACT HEARD A LOUD POP SOUND AND THE ENGINE STALLED AND LOST POWER. THE VEHICLE WAS TOWED TO WORTHINGTON FORD (2950 N BELLFLOWER BLVD, LONG BEACH, CA 90815, (562) 420-3333) WHERE IT WAS DIAGNOSED THAT THE HIGH PRESSURE FUEL PUMP FAILED AND THE ENGINE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND STATED THAT THE VEHICLE WAS OUT OF WARRANTY. THE APPROXIMATE FAILURE MILEAGE WAS 100,000.

NHTSA ID

11083152

Incident

Jun 15, 2016

Mileage

100,000 mi

Touchscreen navigation system - arabic language - blank screen

Some 2012-2016 vehicles equipped with a touchscreen navigation system and the language set to Arabic may exhibit a blank screen. This may be the result of the ribbon cables not being fully seated inside the front display interface module (FDIM) or an improper software configuration of the FDIM.

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: A POSSIBLE INTERMEDIATE CLUTCH PISTON LIP SEAL IS WORN AND CAN CAUSE AN INTERMEDIATE ROUGH CLUTCH PISTON BORE TO SLIP 1-3 AND/OR NO 2-3 UPSHIFT CONDITION. MODEL 2012-2013 E SERIES, F-450, 550, 53 MOTORHOME, F 59 STRIPPED CHASSIS. *PE

FORD: IN SOME DIESEL TRUCKS, THE MIL MAY ILLUMINATE AND IS MOST COMMON WITH TRUCKS OPERATING IN LOW SPEED DRIVING AND/OR OPERATING IN STATIONARY IDLE MODE FOR AN EXTENDED PERIODS OF TIME, WHERE THE EXHAUST REGENERATION PROCESS IS NOT FULLY COMPLETED. MODEL 2012 F-450, F-550 SUPER DUTY. *PE

FORD: WHEN TRUCK IS PREVENTED, AFTER AN EXTENDED TIME PERIOD OF STATIONARY IDLENESS OR LOW SPEED DRIVING, IT FAILS TO COMPLETE EXHAUST REGENERATION PROCESS AND ILLUMINATES MIL AND DTC P207F WITH/WITHOUT DTC P204F. MODEL 2012 F-450, 550. *PE