2012 Ford F-150
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
Vehicles › Ford › F-150 › 2012
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
These records cover every 2012 Ford F-150. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
4 recalls name the 2012 Ford F-150. Newest first.
Ford Motor Company (Ford) is recalling certain 2011-2013 F-150 vehicles equipped with a 6-speed automatic transmission. The transmission may unexpectedly downshift into first gear, regardless of vehicle speed.
Unexpectedly downshifting into first gear may result in a loss of vehicle control, increasing the risk of a crash.
Ford will notify owners, and dealers will reprogram the powertrain control module, free of charge. The recall began March 4, 2019. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S07.
Ford Motor Company (Ford) is recalling certain model year 2011-2012 Ford F-150 trucks, 2012 Ford Expedition, Lincoln Navigator, and Ford Mustang vehicles. The affected vehicles are equipped with an automatic transmission that may unexpectedly downshift to first gear, regardless of vehicle speed.
An unexpected downshift into first gear can cause the vehicle to slow down suddenly without warning and the rear tires may slide or lock, increasing the risk of a crash.
Ford will notify owners, and dealers will reprogram the powertrain control module with updated software, free of charge. The recall began on September 19, 2016. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 16S19.
Ford IS recalling certain model year 2011-2012 ford F-150, 2012 expedition and lincoln navigator, and 2012-2013 mustang vehicles, for failing to comply with the requirements of federal motor vehicle safety standard nos. 102, "transmission shift lever sequence, starter interlock, and transmission braking effect" and 108 lamps, reflective devices and…
If this condition exists, the transmission may not go into reverse or when the driver pushes the shift lever in the reverse r position and the vehicles transmission does go in reverse, the r may not illuminate on the dashboard of the F-150, expedition, or navigator models and/or the backup lamp on the rear of the F-150, expedition, navigator, or mustang vehicles may not illuminate. these conditions increase the risk of a crash or a pedestrian being struck due to the vehicles not signaling it IS in reverse.
Ford will notify owners, and dealers will inspect and replace the trs as necessary, free of charge. the safety recall began on june 11, 2012. owners may contact ford motor company customer relationship center at 1-866-436-7332.
Ford IS recalling certain model year 2012 F-150 vehicles manufactured from november 6, 2011, through november 15, 2011. incorrect software for the occupant classification system module (ocsm) was installed on the vehicles either at the time of manufacturing or during the course of replacement of the module as part of a service repair. under certain…
A failure to deploy, failure to deploy as intended, or a deployment when not intended, increases the risk of injury to the passenger side seat occupant.
Ford will notify owners, and dealers will replace the ocsm free of charge. the safety recall began on may 21, 2012. owners may contact the ford motor company customer relationship center at 1-866-436-7332.
The contact owns a 2012 Ford F-150. The contact stated that while driving approximately 45 MPH in 4th or 5th gear, the transmission unexpectedly downshifted into 1st gear. The contact pulled to the side of the road and manually shifted into 2nd gear and drove to the residence. The dealer was contacted and confirmed that the failure with the powertrain control module and the downshifting had been repaired in 2021. The manufacturer was informed about the failure. The failure mileage was approximately 100,200.
I have a 2012 F150 that has a safety, hazard with the transmission. It’s a 6 R80 transmission and the lead frame assembly is suddenly downshifting. from six gear to second year I have contacted the Ford motor company. They say they cannot do anything. That the safety issue is expired, but I bought the truck used and was unaware of the safety issue. And now I’m having problems with it. I need the safety issue fixed as soon as possible. Thank you. Sincerely, [XXX]. [XXX] United States Air Force , XXX INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
The contact owns a 2012 Ford F-150. The contact stated that while driving at an undisclosed speed, the transmission unexpectedly downshifted to first gear. The failure was a persistent failure, with the power train warning light illuminated. The dealer was contacted by phone and made aware of the failure. The vehicle was taken to the dealer where it was diagnosed with a failed lead frame and transmission. The contact was informed that the lead frame and transmission needed to be replaced. The contact received notification of NHTSA Campaign Number: 19V075000 (Power Train). The contact was uncertain if the recall repair was completed and the dealers did not confirm. The contact was informed that the failure was not associated with the recall repair. The manufacturer was contacted by phone and a case was filed. The failure mileage was approximately 175,000.
The contact owns a 2012 Ford F-150. The contact stated that the transmission seized while driving 15 MPH and making a left turn onto the highway in oncoming traffic, and the vehicle suddenly stopped. The wrench symbol was displayed. The instrument panel was blank. The contact stated that the transmission unexpectedly downshifted. The failure had occurred several times while driving at various speeds. The contact logged into the Ford account and became aware of Customer Satisfaction Program: 19N01. The vehicle was towed to the dealer, but the dealer referred the contact to the manufacturer. The manufacturer was contacted and informed the contact that the program had expired and opened a case. The failure mileage was approximately 150,000.
On XXX, I brought my 2012 Ford F-150 (VIN: [XXX]) to an authorized dealership (Ed Morse Ford Geneseo) to complete mandatory safety recall 19S07 (Molded Lead Frame Software Update). The vehicle was fully operational, shifting safely, and completely functional upon arrival. Immediately upon completion of the safety recall software flash, during the direct drive home from the dealership, the transmission suffered a total mechanical failure. The vehicle began slipping, chattering, and downshifting violently, rendering it completely undrivable and unsafe on public roads. It required an emergency tow to a repair facility. A formal diagnostic inspection by a certified transmission specialist confirmed that the transmission computer contained absolutely zero diagnostic trouble codes (DTCs), establishing that the failure was a direct result of electronic fluid-pressure shock caused by the dealership wiping the adaptive shifting strategy module during the recall software installation. The dealership and Ford Corporate (Case ID: # XXX) have summarily denied liability and refused to remedy the vehicle, claiming it constitutes an out-of-warranty mechanical wear issue. This explanation is invalid as the failure occurred immediately following a federal safety intervention. To restore essential transportation, I was forced to pay an independent automotive facility $5,984.00 out of pocket to replace the ruined transmission assembly. Ford's safety recall update directly caused a severe mechanical failure, creating an immediate highway safety hazard and subsequent heavy financial damage. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
While Driving power steering failed, in addtion this complaint is noted on numerous Ford formums and websites for my year and model truck.
While driving the truck suddenly shifted into first year with the automatic transmission. This was the third time that this has happened.
The contact owns a 2012 Ford F-150. The contact stated that while driving at various speeds, the transmission unexpectedly downshifted to first gear, almost causing the wheels to lock up. The power train warning light illuminated, and the instrument cluster became inoperable; however, the tachometer was operational. Upon investigation, the contact discovered that the VIN was included in NHTSA Campaign Number: 19V075000 (Power Train). The vehicle was taken to the dealer, where a PCM reprogramming was completed; however, the failure persisted. The dealer informed the contact that the leadframe needed to be replaced. The vehicle was not repaired and remained with the dealer. The manufacturer was notified of the failure but informed the contact that the leadframe replacement was not covered based on the manufactured date. The contact associated the failure with NHTSA Campaign Number: 26V237000 (Power Train); however, the VIN was not included. The failure mileage was approximately 145,000.
The contact owns a 2012 Ford F-150. The contact stated that while driving approximately 60-70 MPH, the transmission unexpectedly downshifted into first gear. The transmission warning light was intermittently illuminated. The vehicle was taken to an O'Reilly Auto Parts Store and DTC: P0717 (Input/Turbine Shaft Speed Sensor A) and C2775 (Electronic Stability Program / Traction Control System) was retrieved. The vehicle was not repaired. The contact related the failure to NHTSA Campaign Number: 19V075000 (Power Train); however, the VIN was not included in the recall. The manufacturer was made aware of the failure. The failure mileage was unknown.
At approximately 146,451 miles, the transmission molded leadframe on my 2012 Ford F-150 failed while I was driving approximately 60 mph on a highway. Without warning, the transmission harshly downshifted, the truck lost power, the speedometer stopped working, the wrench warning light came on, the seat belt warning light illuminated, and the transmission entered fail-safe (limp) mode. I could not maintain highway speed. This created a serious safety hazard. The unexpected downshift and sudden loss of power in moving traffic could have caused a crash. I was fortunate that no vehicle was directly behind me when the failure occurred. After a diagnostic code appeared, I identified the problem with my own code reader, and a Ford dealership confirmed the failure was the transmission molded leadframe. Ford declined to cover the repair because its Customer Satisfaction Program had expired. They acknowledged that it was a defective part, though. This leaves me paying to replace a part they know is defective and is highly severe and extremely dangerous, as it presents an immediate risk of a high-speed crash. I believe this is a serious safety defect because it can occur without warning and cause an unexpected downshift, sudden loss of power, loss of the speedometer, and fail-safe transmission operation while the vehicle is moving. I don't have the part, but I can ask that they save it. The vehicle has only been inspected by 2 dealerships. One diagnosed the issue. Again, no warning lights that the part was failing until it actually failed. That led to the first dealership misdiagnosing the issue. I believe this is a serious defect and can cause crashes, injury, or fatalities.
In my F 150 with41,000 miles on it I was traveling down a road about 45 mph and all of a sudden transmission went from 6th gear to first gear . This was a stressful situation as my dog got slammed around and I was stunned as the engine was revving high rpm and truck could only go 10mph. If i had been on a busy highway or interstate then it might’ve cost my dog and I’s lives! There was a car behind me going same speed and good thing he was paying attention or there would’ve been a bad rear end accident . I tried driving it locally at low speeds but it keeps doing it so basically an unsafe truck that I can’t use. I see numerous recalls for other years 2015i-17 and one for 2014 but none currently for my 2012. Please research and advise when you can. Thx [XXX] And just to be clear this is a dangerous safety recall need not a CSP solution. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
The contact owns a 2012 Ford F-150. The contact stated that while the vehicle was parked, the contact was unable to unlock the door while using the remote unlock feature. The lights to indicate that the vehicle was unlocked flashed, but the contact was unable to open the door. Additionally, the contact attempted to open the door manually right after using the key, but the door failed to open. The dealer was not contacted. The manufacturer was not aware of the failure. The failure mileage was approximately 147,000.
Just had another incident where driving along about 30mph and all of a sudden vehicle slams into first gear from 4th gear. Luckily neither I or my dog was injured. And also lucky that another vehicle wasn’t following closely as this safety issue could easily cause a rear end collision. I have reported this to Ford customer support and their corporate office. This is a safety defect from years ago that wasn’t fixed from 2 other recalls. There are a lot of Ford F150 owners from many different gens and years now once again having this same dangerous issue. Ford refuses to my 012 F150 and says they closed the recall in 2019 and now address it as a Customer Service Program which they then put a ten year warranty/150k miles on. Well that might’ve been fair but they backdated that warranty to when truck was originally sold- well that unfair and unethical attempt to make trucks from 2015 and older pay for the lead frame replacement and updated software correction… I’ve heard it costs $1300 and up depending on which Ford Dealership is used. Now to add to their unfair and costly solution out of the blue they have decided to cover 2014 trucks on a new safety recall. Why not cover all 12th generation F150s experiencing this dangerous issue? Why are us 012 and 013 affected owners being discriminated against??Please investigate this sneaky, haphazard program for me. I just tried again to drive my truck but after driving 2 miles and shutting truck off then starting and driving it goes backfrom 3rd to first gear. Please advise . Ford has now issued at least 3 different recalls since 2015 and none of them have been a permanent, safe solution.
Backup camera interments . I have original stereo and system. No aftermarket components to effect backup camera
The contact owns a 2012 Ford F-150. The contact stated that the vehicle was previously serviced under NHTSA Campaign Number: 19V075000 (Power Train), but the failure persisted. The contact stated while driving at 40 MPH, the transmission would unexpectedly downshift from sixth gear to first gear. The dealer was contacted; however, the vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 40,500.
I am filing this complaint because I believe I was the victim of odometer fraud in connection with the purchase of a vehicle from a private seller. At the time of the sale, I relied on the odometer reading and the seller’s representations about the vehicle’s mileage. After purchasing the vehicle, I discovered evidence indicating that the odometer had been rolled back by approximately 90,000 miles. I was not informed of any mileage discrepancy before the sale, and I would not have purchased the vehicle, or would have paid significantly less, had I known the vehicle’s true mileage. Because of the apparent odometer rollback, the vehicle’s value has been substantially reduced, and I have suffered financial harm. I am requesting that this matter be investigated and that any appropriate action be taken under applicable odometer fraud laws. I am also seeking reimbursement or other appropriate relief for my losses. I have attached copies of the documents and evidence I have available, including the title, bill of sale (if applicable), vehicle history information, communications with the seller, and any other documentation supporting my complaint.
While accelerating onto the interstate, the vehicle suddenly downshifted into limp mode and the repair wrench showed on the screen. Fortunately, it was late at night as I was traveling and there were no vehicles behind me. This occurred 4 days after getting my vehicle back from having the oil pan replaced. It didn't happen again until a month later, when it occurred 3 times in 2 days before I stopped driving it. The dealer says it is a lead frame issue that had a previous recall; 19N01. The dealer also says that this recall is closed. My vehicle had less than 101k miles on it when the problem began.
Transmission randomly down shifting many gears at speed, almost causing accident
The onboard speed sensor (OSS) failed, causing my vehicle to abruptly, and without advanced warning of a problem, to shift from 6th gear at 65mph, to 3rd gear. This caused an immediate deceleration in the middle of a flow of traffic travelling at highway speeds. Several cars behind me were forced to brake hard, nearly causing a multi-vehicle accident, putting those drivers, myself and my passengers all in danger. Ford had issued an extended warranty to cover this known defect in the leadframe assembly, but because it was never issued as a recall notice, I never received the notification or the option to bring the truck in for repairs. It is riduclously dangerous and negligent that this was never issued as a recall, when it has been acknowledged by Ford and is both wide-spread and extremely dangerous to both the vehicle driver as well as other drivers on the road.
Our 2012 Ford F-150 truck had no issues and no dashboard lights when it randomly downshifted while driving and almost caused an accident. On Sat, May 9, 2026, my husband pulled onto the road and got up to 40 mph when the speedometer stopped working and the truck randomly downshifted. The car behind us had to swerve to avoid a collision. On Mon, May 11, 2026 we called the Ford garage they told us the Customer Service Program (#19N01) is no longer valid as it is over 10 years now. The truck only has 128,000 miles and we were never notified of a CSP when we purchased it in 2020. The Ford Customer Service Representative said the CSP was issued in 2019 but we purchased the vehicle in 2020 and were never notified of an issue. I now have a $1,500 repair bill for the leadframe that Ford will not reimburse us for and also see that they still have NUMEROUS transmission and speed control issues with their vehicles. I opened a case with Ford on May 14, 2026 [XXX] ) but their representative Iomar was not helpful. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
Recall 19S07 was performed on my vehicle. The dealership attempted the repair multiple times, and although the software update was eventually completed, the diagnostic trouble codes indicating a lead frame failure remained present immediately afterward. The recall did not resolve the defect condition. I was then required to pay out-of-pocket to replace the lead frame in order to correct the same issue the recall was intended to address. The sequence was: •Recall attempted multiple times •Update completed •Fault condition remained (lead frame codes) •Paid repair required to resolve condition The manufacturer directed me back to the dealership rather than addressing the incomplete recall remedy.
The contact owns a 2012 Ford F-150. The contact stated that while driving at an undisclosed speed, the accelerator pedal was depressed; however, the vehicle failed to accelerate as intended. The contact stated that the transmission unexpectedly downshifted from third gear to first gear. The contact stated that several unknown warning lights were illuminated. The vehicle was driven to the shoulder of the road, and it was turned off. The contact stated that while attempting to restart the vehicle, the vehicle started. The vehicle was driven to the residence. The failure was a persistent failure. The vehicle was not diagnosed or repaired by an independent mechanic or a dealer. The manufacturer was made aware of the failure and filed a case. The contact associated the failure with Customer Satisfaction Program: 19N01. The contact was informed that the repair was not covered under warranty because of the age of the vehicle. The failure mileage was approximately 132,000.
The component involved is the Electronic Power Assisted Steering (EPAS) system. It intermittently fails and returns unexpectedly, causing sudden changes in steering effort and jerking of the steering wheel. This creates a serious safety risk because vehicle control can change without warning, especially at highway speeds. The steering system (rack and pinion/EPAS assembly) has been replaced twice, but the issue persists. Replaced parts are not available for inspection. No manufacturer inspection has confirmed a permanent fix. This failure puts my safety and others at risk due to unpredictable steering behavior and potential loss of control. Other owners have reported similar EPAS failures, including sudden loss of steering assist, near-collision events, and accidents documented in public complaint records. The vehicle has received repeated repairs for this issue, including two rack and pinion replacements, without resolution. No police or insurance inspection has occurred. Warning symptoms include intermittent steering assist loss, sudden changes in steering resistance, and inconsistent steering feel. These occur without consistent warning, making the failure unpredictable and dangerous. This appears to be a recurring defect in the EPAS system that has not been reliably resolved through repair attempts or existing recall actions.
The antilock brake system locked up causing me not to be able to stop the vehicle .The shift gear froze up .When I put my foot on the brake pedal it was frozen, I could not control the pedal Also the shift level gear did not work presenting a safety hazard when I tried to put it in park. The Sudden Transmission Downshift which was a safety recall happened There were no warning lamps or lights prior to this incident. The accident caused me to total my vehicle My safety was at risk I injured my leg, I filed a police report I also filed a claim with the Ford company which they quickly denied stating that the recall on the parts had expired I only had liability insurance and my truck was a total loss. I hope I'm still in the time frame to put in a claim
Rear wheel and steering lock up while traveling at 70mph on interstate causing broken controls on steering wheel . Vehicle is unsafe to drive. Truck was taken to Rivertown Ford 1680 Whittlesey Rd Columbus Ga 31904 for recall repair. Truck was released to me with no signals no wipers. The steering is very loose and hard to control
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
The Office of Defects Investigation (ODI) opened an investigation based on consumer allegations of transmissions unexpectedly downshifting to a lower gear without input from the driver on model year (MY) 2011-2013 Ford F-150, Expedition and Navigator vehicles. ODI has received 455 unique reports related to the alleged problem that were not covered under a previous recall for this issue (16V-248).Expedition and Navigator complaint rates are lower than F-150 complaints. Of those 455 reports, 34.7% claimed that the rear wheels locked up when the transmission downshifted. There were 4 accident claims with no injuries. There are many instances where drivers report leaving their lane or the road because of this issue.In response to ODI's Information Request (IR) letter, Ford Motor Company (Ford) responded with 783 unique reports related to the alleged problem. There were 6 accident claims with 3 injuries. Ford also submitted 1206 warranty claims related to transmission downshifting failures. The failure can occur at any time, but typically at higher speed, and include symptoms such as sudden transmission downshifting, loss of speedometer, erratic shifting of transmission, and transmission stuck in one gear. The failures typically occur without warning and may result in the rear wheels momentarily locking up. The driver often had to fully stop the vehicle and restart it to get the vehicle to shift properly.On February 2nd, 2019 Ford notified ODI that it would conduct a safety recall (19V-075) to remedy transmission downshifting failures on all 2011-2013 F-150 vehicles. Ford will also offer extended warranties to 2011-2013 Expedition and Navigator vehicles with the same issue. Per Ford, some vehicles may experience an intermittent loss of Transmission Output Speed Sensor (OSS) signal to the Powertrain Control Module (PCM), potentially resulting in a temporary unintended downshift into first gear. Ford will reprogram the PCM with software that will prevent an unintended downshift into first gear and illuminate the Malfunction Indicator Light in the event of an intermittent OSS signal loss.The recall action initiated by the manufacturer appears to address the safety risks of concern to ODI.Accordingly, the investigation is closed.The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the identification (ODI) numbers found in the attached list.
On February 15, 2016, Ford Motor Company initiated Customer Satisfaction Program 15N05 to extend warranty coverage for the electric vacuum pump in certain model year (MY) 2011 through 2012 Ford F-150 pickup trucks equipped with 3.5L GTDI engines.The program extends coverage for up to 10 years of service or 150,000 miles from the warranty start date of the vehicle, all vehicles are eligible for the program through July 30, 2016 regardless of mileage.Ford's program covers all repairs related to electric vacuum pump (EVP) malfunctions including excessive noise, vibration, or change in brake pedal feel while applying the brakes at cold start. Ford states that the engine intake manifold is the primary source of vacuum for the brake booster and is fully compliant to motor vehicle safety standards without the supplemental vacuum supplied by the EVP.The company also contends that failure modes related to the EVP are progressive and provide warning to operators by way of noise and vibration before an operator to experience any temporary change in brake pedal feel.ODI's analysis of warranty data found that the majority of claims involved consumer concerns with EVP noise or vibration from the left front fender area when the vehicle is first started. Continued operation in this mode with pump motor noise will eventually result in the EVP seizing or becoming non-functional.Component failure analysis indicated that Ford and its supplier, Continental, identified a pump crank drive corrosion condition due to moisture entry through the vacuum intake.Corrosion damage to EVP internal components may eventually result in a blown fuse in the power distribution box and total loss of EVP function.Analysis of consumer complaints, field reports, and warranty data related to EVP failures found thatincidents predominantly occurred in driveways and parking lots in the periods immediately after cold engine starts.Many consumers operated their vehicle for some period of time with a blown EVP fuse without realizing that the pump had failed or that the vehicle had a brake system malfunction.Consumers who did experience braking performance issues reporteda temporary hard brake pedal condition at start-up followed by more consistent normal pedal feel after few seconds.On June 22, 2015, Ford developed a remedy procedure and issued TSB 15-0105 instructing dealers to replace the vacuum pump and install a new vacuum pump harness kit. In addition to reviewing test data submitted by Ford, ODI assessed safety risks associated with the alleged defect under various operating conditions, including: 1) baseline system performance with full engine and EVP vacuum available using exemplar parts, 2) disabled EVP and booster vacuum regulated to simulate worst case conditions for engine intake manifold vacuum supply to the brake booster (approximately 300 mbar); and 3) all source vacuum to the brake booster removed and Optimized Hydraulic Braking (OHB) mode active to represent complete loss of brake booster function (note: this condition is a more severe brake boost system failure mode than the alleged defect).ODI also analyzed all complaints and warranty claims to identify incidents alleging brake system performance concerns related to EVP failures.These analyses identified no brake performance issues or resulting changes in stopping distances either on highway or city traffic conditions.Two complaints alleging EVP malfunctions caused or contributed to rear-end collisions during attempted decelerations from road speeds are not believed to be related to the alleged defect.The EVP provides supplemental vacuum during initial start-up and idle
On June 22, 2015, the Office of Defects Investigations (ODI) opened Preliminary Evaluation PE15-026 to investigate incidents of increased brake pedal effort at cold start and extended stopping distance while driving in traffic, resulting from failures of the electric brake vacuum assist pump in model year (MY) 2011-2012 Ford F-150 pickup trucks equipped with 3.5L GTDI engines. In response to ODI's Information Request (IR) for PE15-026, Ford provided ODI with 396 complaints and field reports relating to incidents of increased brake pedal effort or malfunctions in the electric vacuum pump (EVP). ODI's analysis of the data provided by Ford identified 7 crashes and 1,851 warranty claims related to either a hard brake pedal condition or reduced brake effectiveness. Additionally, ODI identified one report in its database alleging an injury to an occupant of a vehicle struck in the rear by a subject F-150 vehicle with a failed EVP as documented in the police accident report referencing a dealer assessment of the pump.According to Ford, the subject vehicles utilize a traditional brake vacuum booster to provide power assist for braking and the EVP is intended to operate to maintain consistent brake pedal feel. The engine intake manifold is the primary source of vacuum for the booster and is fully compliant to motor vehicle safety standards without the EVP. Ford described the conditions related to a change in brake pedal feel as limited and temporary and provided component failure analysis showing evidence of water entry into the EVP which caused internal pump corrosion. Ford indicated that the EVP failure mode is progressive and provides warning to operators by way of noise and vibration before an operator is likely to experience any temporary change in brake pedal feel. Damage to the EVP motor bearing may eventually result in a blown EVP fuse and total loss of EVP function. Ford provided test data showing the brake pedal forces and pedal travel curves over time for 0.3g decelerations to a stop from 80kph (50mph) for: 1) normal system (full engine and EVP vacuum available); 2) Ford's approximation of worst case booster performance with EVP failure (EVP disabled and booster vacuum regulated to 300mbar to simulate cold start, all accessory loads on, and starting at 0 vacuum); and 3) with all source vacuum to the brake booster removed and Hydraulic Boost Compensation (HBC) active to represent complete loss of brake booster function. The Ford tests showed that the brake pedal forces required for achieving the 0.3g decelerations were relatively low for the normal condition, 35-40 N (8-9 lbf), increased by approximately 2-3 times normal when the EVP is disabled, 75-115 N (17-26 lbf), and increased by about 5-6 times normal for the complete brake booster failure condition, 205-215 N (46-48 lbf). This Preliminary Evaluation has been upgraded to Engineering Analysis (EA15-006) to test for EVP malfunctions under other vehicle operating conditions (e.g., low-speed driveway braking after cold-start with failed EVP), potential human factors contributions and to further assess the scope, frequency, and safety-related consequences of the alleged defect.The VOQs associated with the opening of this investigation are:10565994, 10575987, 10598351, 10604687, 10605701, 10607811, 10610491, 10615536, 10617828, 10619545, 10643075, 10650578, 10662151, 10664415, 10666988, 10668069, 10678844, 10695537, 10700874, 10706217, 10706271, 10712465, 10723033, 10723792, 10726960, 10730549, 10730721, 10730735, 10730837, 10730909, 10731008, 10731135, 10731157, 10731165, 10731395, 10731758, 10732609, 10732878, 10733375, 10733804, 10734558, 10734613, 10743859, 10744214, 10
On May 22, 2013, the Office of Defects Investigation (ODI) opened PE13-018 to investigate 95 complaints alleging incidents of reduced engine power during hard accelerations in model year (MY) 2011 through 2013 Ford F-150 trucks.ODI was aware of three technical service bulletins (TSBs) issued by Ford for a condition that was related to moisture accumulation in the Charge Air Cooler (CAC) for the turbochargers.A Preliminary Evaluation was opened to gather information to assess whether the subject vehicles contain a safety related defect.The subject vehicles are powered by Ford?s 3.5L EcoBoost engine which uses twin turbochargers to obtain a balance of fuel economy and engine power based on the driver?s demand.When the driver requests more power from the engine, as in accelerating to pass, merge, ascend hills or haul a load the two turbochargers will spin up compressing the air which is then used to increase the power created by the combustion in the engine.The compressed air, which gains heat by the compression process, is passed through a Charge Air Cooler (CAC) which is designed to lower the temperature of the air in order to make the combustion process even more efficient (Figures 1 and 2).In response to ODI?s Information Request letter, Ford indicated that a misfire condition could occur after steady-speed operation under significantly humid and rainy conditions.Ford?s analysis found that under those conditions, condensation could form and accumulate on the inside of the CAC tubes which could then be ingested into the engine during particularly hard acceleration near wide-open throttle.An engine misfire of up to three cylinders could occur if the amount of condensed water released from the CAC exceeded the engine?s operating threshold for water ingestion.Ford noted that due to regulations set by the EPA, the powertrain software would disable up to two of the misfiring cylinders for no more than 30 seconds and until the driver tips out the throttle in order to protect the catalytic converter from damage. Ford?s testing of this condition on the subject vehicles showed that a vehicle experiencing such a condition would continue to maintain its speed as well as accelerate, albeit at a lower rate than expected by the driver.Similar results were obtained in testing done by NHTSA?s Vehicle Research and Testing Center in East Liberty, Ohio (Figure 6).In an ongoing process to address the problem Ford issued a series of TSBs where a deflector shield was installed onto the CAC (Figures 3, 4 and 5).In January 2014 Ford indicated that its data shows that the TSBs have been effective in resolving the problem, that for the MY 2013 vehicles their remedy is 100% effective and the latest TSBs for MY 2011 ? 2012 are 95% effective.The 525 complaints to ODI and the total 4,120 unique VIN complaints listed in the Failure Report are incidents of alleged reduced power or driveability symptoms and not all are necessarily related to the condition created by water ingestion.Reduced power conditions can occur for a variety of reasons including faults with ignition coils, spark plugs, a catalytic converter, the throttle body, turbocharger, fuel pump/filter, powertrain control module (hardware or software) or transmission shifting problems.Ford also noted that in a large number of warranty claims on the subject vehicles, the CAC was replaced or a TSB procedure was performed when the symptoms exhibited were inconsistent with a CAC water ingestion related issue.Given these circumstances, further use of the agency resources in this matter does not appear to be warranted.Accordingly, this investigation is closed.The closing of
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.