2005 Ford F-150: complaints, problems and recalls

I AM A INSPECTOR OF FINAL ASSEMBLY AT THE MILAN VISTEON PLANT IN MILAN, MI RESPONSIBLE FOR THE FINAL INSPECTION OF FORD F-150 FUEL TANKS. THESE TANKS ARE CURRENTLY INVOLVED IN A SAFETY RECALL DUE TO PROCESS FAILURES IN THE THEMOFORMING STAGES. I HAVE BEEN ORDERED BY MY SUPERVISORS TO CIRCUMVENT QUALITY CHECKLISTS AND HAVE BEEN TOLD TO PLACE MISSED IDENTIFICATION STICKERS ON TANKS AS WELL AS QUALITY CHECK VERIFICATION MARKS DIRECTLY ON THE TANKS REGARDLESS OF MY DIRECT KNOWLEDGE OF THESES QUALITY STEPS HAPPENING IN ORDER TO MEET PRODUCTION GOAL…

Owner-reported narrative. Look up ODI 10093621 at NHTSA ↗

THE COMPLAINANT PURCHASED A TRUCK FOR HIS BUSINESS AT THE COLORADO RIVER FORD DEALERSHIP IN BULLHEAD CITY AZ. THE DEALERSHIP OBTAINED THE TRUCK FROM CALIFORNIA AND HAD SAME DELIVERED TO BULLHEAD CITY. THE COMPLAINANT PICKED UP THE TRUCK AT THE DEALERSHIP AND IMMEDIATELY NOTED A PRONOUNCED ENGINE KNOCK. CALLING THE SERVICE DEPARTMENTS ATTENTION TO THIS PROBLEM THEY TOLD THE COMPLAINANT THAT THE NOISE WAS NORMAL. THE COMPLAINANT THEN MADE THEM START UP TWO SIMILAR TRUCKS ON THE LOT THAT DID NOT MANIFEST THE SAME KNOCK. THE COMPLAINANT REQUESTED A…

Owner-reported narrative. Look up ODI 10107826 at NHTSA ↗

WHILE SHIFTING THE VEHICLE INTO PARK AND GETTING OUT OF THE VEHICLE, THE VEHICLE WENT INTO REVERSE. THE CONSUMER WAS ABLE TO GET BACK INTO THE VEHICLE AND STOPPED THE VEHICLE. THE TRUCK WAS TOWED TO THE DEALER. THE DEALER HAD TO REPLACE THE TRANSMISSION LEVEL LINKAGE. *SC *JB

Owner-reported narrative. 35,000 miles reported. Look up ODI 10111716 at NHTSA ↗

A WEEK AFTER I HAD PICKED UP MY NEW 2005 FORD F150 LARIAT THE 5.4L ENGINE STARTED KNOCKING AND SPUTTERING. AFTER TAKING IT BACK TO THE DEALER THEY DETERMINED THAT THE PROBLEM WAS RELATED TO FAULTY SPROCKETS ON THE CAM SHAFTS (BULLETIN SSM-18342). I BROUGHT IT IN FOR SERVICE AND A WEEK AFTER GETTING IT BACK THE KNOCKING AND SPUTTERING IS STILL THERE AND GETTING WORSE. NOW I'M GOING BACK TO THE DEALER INSISTING THE ENGINE BE REPLACED. I DON'T EXPECT A LOT OF COOPERATION.*AK

Owner-reported narrative. 200 miles reported. Look up ODI 10114321 at NHTSA ↗

ON 3-17-05 BRAKE PEDDLE WENT TO THE FLOOR. I HAD JUMP THE CURB TO AVOID ANOTHER CAR. HAD TOWED TO MIKE SHAD FORD AND WAS TOLD "THEY COULD NOT DUPLICATE THE PROBLEM!" ON 3-22-05 COMING TO A RED LIGHT MY BRAKES FAILED AGAIN. I APPLIED THE EMERGENCY BRAKE AND STOPPED. I TOOK THE TRUCK BACK TO THE SAME DEALER AND THE SERVICE MANAGER CONFIRMED THE FAILURE.

Owner-reported narrative. 3,150 miles reported. Look up ODI 10114603 at NHTSA ↗

FORD F150 2005 , AFTER ABOUT 100 TO 150 MILES ON TRUCK DRIVING ON A ROAD WITH SLIGHT HILLS NOTICED VIBRATION , AT OR ABOUT 2100 TO 2400 RPMS IN ANY GEAR FLAT OR HILLY SURFACE AND AT ANY SPEED AS LONG AS 2100 TO 2400 RPMS ARE REACHED , TRUCK VIBRATES THROUGH OUT THE TRUCK , CONTACTED DEALERSHIP WHERE PURCHASED 3 TIMES FIRST WAS TOLD TO BRING TRUCK BACK IN FOR FURTHER TESTING , SECOND TIME DRIVABLE TECH WENT FOR RIDE NOTICED VIBRATION , THIRD TIME SERVICE MANAGER DROVE TRUCK NOTICED VIBRATION , CONTACTED FORD , FORD STATES ISSUE IS NORMAL FOR TRU…

Owner-reported narrative. 110 miles reported. Look up ODI 10116770 at NHTSA ↗

IN AUTO ACCIDENT AT A HIGH RATE OF SPEED,, AROUND 45 MPH.. HIT TRUCK AND THE AIRBAGS FAILED TO DEPLOY.. THE IMPACT WAS SO HARD I SPLIT THE OTHER TRUCK IN HALF.. I WAS DRIVING A F150, 2005. I BROKE MY NECK IN TWO PLACES...

Owner-reported narrative. Look up ODI 10120138 at NHTSA ↗

DT: THERE IS A LOUD CLANKING NOISE IN THE REAR END WHEN TAKING OFF AND WHEN SHIFTING GEARS. IT JUMPS SO BAD SOMETIMES YOU HAVE TO STOP THE VEHICLE AND LET IT COOL OFF BEFORE RESUMING RIDE. IT'S BEING HAVING THIS PROBLEM FOR THE PAST 2000 MILES. HAVE TAKEN TO THE MANUFACTOR AND THE DEALER. IT'S BEEN AT THE DEALER 3 TIMES FOR THIS PROBLEM ALONE. NO PARTS HAVE BEEN REPLACED. THE DEALER TOLD CONSUMER THAT IF THERE WAS NO RECALL THEY COULDN'T FIX IT BECAUSE ALL THE TRUCKS 2005 F150 REGULAR CABS HAVE THE SAME PROBLEM.*AK

Owner-reported narrative. 3,000 miles reported. Look up ODI 10120295 at NHTSA ↗

Reported: 2006-02-06 (February 6, 2006)

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.

Consequence: THIS ERROR COULD PREVENT THE ANTILOCK BRAKE SYSTEM (ABS) WARNING LIGHT FROM ILLUMINATING IF THE ABS MODULE EVER BECAME INOPERATIVE.

Remedy: DEALERS WILL RECALIBRATE THE INSTRUMENT CLUSTER IN THESE VEHICLES. THE RECALL BEGAN ON FEBRUARY 27, 2006. OWNERS MAY CONTACT FORD AT 1-800-392-3673.

Reported: 2008-05-07 (May 7, 2008)

FORD IS RECALLING 605,684 MY 2005-2006 F-150 AND LINCOLN MARK LT VEHICLES EQUIPPED WITH 5.4L 3-VALVE ENGINES. THE BRAKE BOOSTER VACUUM SUPPLY HOSE ATTACHED TO THE INTAKE MANIFOLD FITTING MAY SWELL OVER TIME AND LOSE RETENTION FORCE. THIS CONDITION COULD ALLOW THE HOSE TO BECOME DETACHED FROM THE FITTING DURING AN INTAKE MANIFOLD BACKFIRE. SHOULD THE HOSE DETACH FROM THE INTAKE MANIFOLD, SEVERAL BRAKE APPLICATIONS WITH POWER ASSIST WILL BE AVAILABLE BEFORE THE VACUUM RESERVE IS DEPLETED.

Consequence: ONCE THE BRAKE BOOSTER VACUUM RESERVE IS DEPLETED, THE DRIVER WILL HAVE FOUNDATION BRAKE FUNCTION, BUT WITH INCREASED BRAKE PEDAL EFFORT. REDUCED VEHICLE BRAKING COULD LEAD TO A CRASH.

Remedy: DEALERS WILL REPLACE A RUBBER HOSE ON THE BRAKE BOOSTER VACUUM SUPPLY TUBE ASSEMBLY. THE RECALL BEGAN ON JUNE 27, 2008. OWNERS MAY CONTACT FORD AT 1-800-392-3673.

Reported: 2011-02-23 (February 23, 2011)

FORD IS RECALLING CERTAIN MODEL YEAR 2004-2006 F-150 PICK UP TRUCKS AS WELL AS CERTAIN MODEL YEAR 2006 LINCOLN MARK LT VEHICLES. IF THE CLOCKSPRING JUMPER WIRE COMES IN CONTACT WITH THE DRIVER SIDE FRONTAL AIR BAG LOWER HORN PLATE, THE WIRE INSULATION MAY BECOME CHAFED, CREATING A POTENTIAL FOR A SHORT CIRCUIT. IF THIS OCCURS THE AIR BAG WARNING LAMP MAY ILLUMINATE INDICATING THAT SERVICE IS REQUIRED.

Consequence: THE DRIVER SIDE FRONTAL AIR BAG COULD INADVERTENTLY DEPLOY INCREASING THE RISK OF INJURY OR LOSS OF VEHICLE CONTROL IF OCCURRING WHILE IN MOTION.

Remedy: FORD WILL NOTIFY OWNERS AND INSTRUCT THEM TO TAKE THEIR VEHICLES TO A FORD OR LINCOLN/MERCURY DEALER TO HAVE A NEW CLOCKSPRING JUMPER WIRE INSTALLED THAT INCORPORATES A PROTECTIVE MESH COVER. REPAIRS WILL BE PERFORMED FREE OF CHARGE. THIS SAFETY RECALL BEGAN ON SOME VEHICLES IN MARCH 2011. THE RECALL CAMPAIGN ON THE EXPANDED POPULATION IS EXPECTED TO BEGIN ON OR ABOUT MAY 9, 2011. OWNERS MAY CONTACT THE FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.