Ford Recalls

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NHTSA safety recall results (848)

Recall information provided by National Highway Traffic Safety Administration

Exterior lighting: Headlights

CERTAIN HEADLAMP ASSEMBLIES IMPORTED AND SOLD AS AFTERMARKET EQUIPMENT BY SONAR AUTO PARTS FOR USE ON 2004-2007 FORD F150 PICKUP TRUCKS. DURING PRODUCTION, THE HEADLAMPS WERE INTERNALLY MISALIGNED AND THEY FAIL THE PHOTOMETRY REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.

Recall consequence: THE PURPOSE OF THIS STANDARD IS TO REDUCE TRAFFIC CRASHES AND DEATHS AND INJURIES BY PROVIDING ADEQUATE ILLUMINATION OF THE ROADWAY.
Recall action: SONAR WILL NOTIFY OWNERS AND OFFER A FULL REIMBURSEMENT FOR ANY NONCOMPLIANT HEADLAMPS. THE RECALL IS EXPECTED TO BEGIN DURING SEPTEMBER/OCTOBER 2007. OWNERS CAN CONTACT SONAR AT 866-557-4264.

Power train: Automatic transmission: Cooling unit and lines

ON CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITH THE 4.6L ENGINE AND 6R TRANSMISSION, THE BOLT SECURING THE TRANSMISSION OIL COOLER LINE FITTINGS AT THE TRANSMISSION MAY NOT HAVE BEEN SUFFICIENTLY TORQUED DURING VEHICLE ASSEMBLY. AS A RESULT, THE BOLT MAY LOOSEN AND THE TRANSMISSION OIL COOLER LINES MAY DISENGAGE FROM THE TRANSMISSION, CAUSING A TRANSMISSION FLUID LEAK.

Recall consequence: IF LEAKING TRANSMISSION FLUID CONTACTS THE CATALYTIC CONVERTER, IT MAY POSE A RISK OF FIRE.
Recall action: DEALERS WILL INSPECT AND HAVE THE TRANSMISSION COOLER LINE ATTACHMENT BOLT TIGHTENED FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 30, 2007. OWNERS MAY CONTACT FORD AT 1-800-392-3673.

Power train: Axle assembly

ON CERTAIN TRUCKS BUILT WITH DANA REAR AXLES, THE REAR AXLE MAY HAVE A HOUSING THAT WAS BUILT USING STEEL THAT WAS THINNER THAN SPECIFIED.

Recall consequence: THROUGH NORMAL USE, THE AXLE HOUSING COULD FATIGUE AND DEVELOP A CRACK WHICH COULD RESULT IN A WHEEL END LOCK-UP OR SEPARATION, POSSIBLY RESULTING IN A CRASH.
Recall action: DEALERS WILL REPLACE THE AXLE FREE OF CHARGE. THE RECALL BEGAN ON JUNE 12, 2007. OWNERS MAY CONTACT FORD AT 1-800-248-0186.

Electrical system: Battery

ON CERTAIN TRUCKS EQUIPPED WITH A 6.4L DIESEL ENGINE, INSUFFICIENT CLEARANCE OF THE BATTERY POSITIVE (B+) WIRE TO THE RIGHT HAND SPLASH SHIELD BOLT MAY RESULT IN THE BATTERY B+ WIRE CONTACTING THE SPLASH SHIELD BOLT.

Recall consequence: LONG TERM CONTACT COULD CAUSE WIRE CHAFE, RESULTING IN COPPER WIRE BEING EXPOSED. IF THIS CONDITION OCCURS, THE BATTERY B+ WIRE COULD SHORT TO GROUND INCREASING THE RISK OF A FIRE.
Recall action: DEALERS WILL INSPECT THE BATTERY B+ WIRE LOCATION AND, IF NECESSARY, REPOSITION THE WIRE. THE RECALL IS EXPECTED TO BEGIN ON OR ABOUT MARCH 30, 2007. OWNERS MAY CONTACT FORD AT 1-800-392-3673.

Power train: Automatic transmission: Control module (tcm, pcm)

ON CERTAIN TRUCKS EQUIPPED WITH A 6.4L DIESEL ENGINE, EXCESSIVE TEMPERATURES IN THE DIESEL PARTICULATE FILTER IN THE EXHAUST SYSTEM MAY RESULT FROM EXCESS HYDROCARBONS IN THE EXHAUST.

Recall consequence: LACK OF POWER OR ROUGH OPERATION, UNUSUAL NOISES FROM THE ENGINE OR EXHAUST, WHITE SMOKE FROM THE EXHAUST, AND POTENTIALLY A VISIBLE FLAME OUT THE TAILPIPE CAN OCCUR.
Recall action: DEALERS WILL REPROGRAM THE POWER TRAIN CONTROL MODULE. THE RECALL IS EXPECTED TO BEGIN ON OR ABOUT MARCH 30, 2007. OWNERS MAY CONTACT FORD AT 1-800-392-3673.

Engine and engine cooling: Engine: Diesel

ON CERTAIN LOW CAB FORWARD CHASSIS TRUCKS, THE UNSEALED INJECTION PRESSURE REGULATOR CONNECTOR IS EXPOSED TO THE OUTSIDE ENVIRONMENT DUE TO ITS LOCATION ON THE BACK OF THE ENGINE, AND THE ENGINE'S LOCATION IN THE VEHICLE. THE CONNECTOR HAS A HEAT INSULATION SLEEVE THAT MAY RETAIN WATER AROUND THE CONNECTOR.

Recall consequence: OVER TIME, THE COLLECTED WATER MAY POTENTIALLY CORRODE THE CONNECTOR LEADS RESULTING IN VARIOUS ENGINE PERFORMANCE CONCERNS INCLUDING; RUNNING ROUGH DIFFICULT OR UNABLE TO BE STARTED, OR ENGINE STALL INCREASING THE RISK OF A CRASH.
Recall action: DEALERS WILL REPLACE THE INJECTION PRESSURE REGULATOR CONNECTOR AND INSPECT FOR CORROSION AND REPLACE THE HEAT INSULATION. IF CORROSION IS PRESENT, THE CONNECTOR WILL BE REPLACED. IF CORROSION IS NOT PRESENT, DIELECTRIC GREASE WILL BE APPLIED FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN ON OR ABOUT JANUARY 28, 2007. OWNERS MAY CONTACT FORD AT 1-800-392-3673.

Visibility: Windshield

CERTAIN PASSENGER VEHICLES FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 212, 'WINDSHIELD MOUNTING.' THE WINDSHIELD MAY NOT BE PROPERLY SECURED TO THE VEHICLE BODY.

Recall consequence: IF THE WINDSHIELD IS NOT PROPERLY RETAINED TO THE VEHICLE, WIND NOISE, SQUEAK/RATTLES AND/OR WATER LEAKS MAY OCCUR. ALSO, LOSS OF WINDSHIELD RETENTION MAY REDUCE OCCUPANT PROTECTION IN THE EVENT OF A CRASH.
Recall action: DEALERS WILL REPLACE THE WINDSHIELD FREE OF CHARGE. THE RECALL BEGAN ON NOVEMBER 22, 2006. OWNERS MAY CONTACT FORD AT 1-800-392-3673.

Power train: Driveline

ON CERTAIN HYBRID VEHICLES, THE INTERMEDIATE SHAFT MAY NOT HAVE BEEN PROPERLY HEAT TREATED AND MAY FRACTURE WHILE THE VEHICLE IS BEING DRIVEN.

Recall consequence: IF A FRACTURE OCCURS, THE POWERTRAIN WILL LOSE THE ABILITY TO TRANSMIT TORQUE TO THE DRIVE WHEELS AND THE TRANSMISSION WILL NOT HOLD THE VEHICLE STATIONARY WHEN PLACED IN THE PARK POSITION, WHICH COULD RESULT IN A CRASH.
Recall action: DEALERS WILL INSPECT THE DRIVETRAIN INTERMEDIATE SHAFT AND REPLACE IT IF NECESSARY. THE RECALL IS EXPECTED TO BEGIN ON OR BEFORE OCTOBER 23, 2006. OWNERS MAY CONTACT FORD AT 1-800-392-3673.

Interior lighting

CERTAIN PICKUP TRUCKS FAIL TO COMPLY WITH EITHER THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD (FMVSS) NO. 105, 'HYDRAULIC AND ELECTRIC BRAKE SYSTEMS' OR FMVSS NO. 135, 'PASSENGER CAR BRAKE SYSTEMS.' THESE VEHICLES WERE BUILT WITH A SOFTWARE ERROR IN THE INSTRUMENT CLUSTER.

Recall consequence: THIS ERROR COULD PREVENT THE ANTILOCK BRAKE SYSTEM (ABS) WARNING LIGHT FROM ILLUMINATING IF THE ABS MODULE EVER BECAME INOPERATIVE.
Recall action: DEALERS WILL RECALIBRATE THE INSTRUMENT CLUSTER IN THESE VEHICLES. THE RECALL IS EXPECTED TO BEGIN ON FEBRUARY 15, 2006. OWNERS MAY CONTACT FORD AT 1-800-392-3673.

Visibility

ON CERTAIN TRUCKS, PASSENGER CARS AND SPORT UTILITY VEHICLES, THE WINDSHIELD WIPER MOTOR MAY HAVE BEEN PRODUCED WITHOUT GREASE BEING APPLIED TO THE OUTPUT SHAFT GEAR.

Recall consequence: AFTER A PERIOD OF CONTINUOUS USE ON THE HIGH SPEED SETTING, LACK OF GREASE ON THE OUTPUT SHAFT GEAR MAY CAUSE THE GEAR TO DISTORT OR FRACTURE DURING OPERATION RESULTING IN A LOSS OF WIPER FUNCTION. INOPERATIVE WIPERS UNDER INCLEMENT WEATHER CONDITIONS COULD CAUSE A CRASH DUE TO IMPAIRED VISIBILITY.
Recall action: DEALERS WILL INSPECT THE WIPER MOTOR FOR THE PRESENCE OF GREASE AND GREASE THE WIPER MOTOR GEARS IF NECESSARY. THE RECALL BEGAN ON NOVEMBER 22, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673 OR LINCOLN/MERCURY AT 1-800-521-4140.