2019 Ford F-450

The Office of Defect Investigations (ODI) has received 27 complaints alleging diesel fuel leaks due to a fracture in the secondary fuel filter housing in model year (MY) 2015-2021 Ford Motor Company (Ford) F-250, 350, 450, and 550 Super Duty vehicles equipped with 6.7L diesel engines. Of these complaints, 12 describe an engine compartment fire. The proximity of the secondary fuel filter to high heat sources creates a potential for autoignition thermal events and fires. ODI has contacted the vehicle manufacturer, Ford, and the filter manufacturer, Allevard Sogefi USA (Sogefi), and learned that the low-pressure fuel system is capable of a maximum operating pressure of 8.5 Bar, while the secondary fuel filter is only tested to seven (7) Bar during the manufacturing process. Additionally, changes starting in 2022 by both Ford and Sogefi align with a lack of similar complaints on MY 2022 and newer vehicles. ODI is opening this Preliminary Evaluation (PE) to evaluate the severity of the potential problem and to fully assess the potential safety-related problems. To review the ODI reports cited in the Opening Resume ODI Report Identification Number document, go to NHTSA.gov.

In January 2021, the Office of Defects Investigation (ODI) opened a Recall Query (RQ21-001) to assess allegations of post-recall remedy uncommanded tailgate openings in model year (MY) 2017-2019 F-250/350/450 Ford trucks. Besides the recall remedy launched in January 2020, Ford also implemented a production update in November 2019.  At the time of the RQ opening, ODI had received eleven (11) Vehicle Owner Questionnaires (VOQs). ODI sent an Information Request (IR) to Ford in February 2021. In numerous meetings after receiving their IR response, Ford highlighted the drop in claims since the recall and production update and communicated how they were unable to verify the owners’ complaints or replicate the concern. Despite this, Ford began developing ways to prevent uncommanded tailgate openings from various human, mechanical or electrical causes. Based on testing, Ford issued a Customer Satisfaction program, 21M05-S1/S2/S3, to further address the potential of unintended tailgate openings. This work was applied to vehicles being produced as of December 20, 2021.  The program began for already delivered vehicles on July 22, 2022. The covered models include 2017-2022 F-250, 350, 450, 550, 650 and 750 Super Duty and 2020-2022 F-600 Super Duty trucks. ODI has received 39 VOQs between February 24, 2020, and December 15, 2023, alleging uncommanded tailgate openings.  In a detailed analysis, none of the vehicles in the VOQs were found to have received the Customer Satisfaction update. Since ODI has not received any complaints of post-Customer Satisfaction program tailgate openings, this office is closing this Recall Query. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

By letter dated December 4, 2019, Ford Motor Company (Ford) notified the Office of Defects Investigation (ODI) of a safety defect that may exist in model years (MY) 2017 through 2019 Ford Super Duty F-250, F-350, F-450 vehicles equipped with an electric tailgate. Following the receipt of five consumer complaints alleging unintended tailgate opening without vehicle operator knowledge, while the vehicles were in motion, NHTSA opened this investigation to assess the manufacturer's data including warranty claims, field reports, design changes, etc.In vehicles equipped with an electric tailgate, water can enter the electrical wiring system and may cause a short circuit resulting in the unintended activation and release of the tailgate latch. This could allow unintended opening of the tailgate while the vehicle is in motion.Analysis of the data provided by Ford found that the frequency of a tailgate opening unintended was high in vehicles equipped with electric tailgates. Unintended tailgate opening without vehicle operator knowledge may result in loss of unrestrained cargo, increasing the risk of a crash. In response to this investigation, Ford decided to conduct recall 19V-864.Owners will be notified by mail and instructed to take their vehicle to a Ford dealer to modify the tailgate/frame wiring harnesses by adding jumper pigtails to isolate the tailgate release control circuits, and will install a new tailgate handle release switch. With recall action 19V-864 taken by Ford Motor Company this investigation is closed. Further use of agency resources does not appear to be warranted.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist on other model or MY vehicles outside of the recall scope. The agency reserves the right to take further action if warranted by the circumstances.The ODI reports cited above can be reviewed at: http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID using the following complaint identification numbers: 10984283,11004227,11082643,11090089,11104638,11115381,11140680,11141071, 11141075,11141174,11141200,11141331,11141447,11141547,11141548,11142572, 11142618,11142657,11153541,11153959,11157225,11160936,11165124,11165590, 11166199,11166802,11170049,11171409,11171509,11171685,11180009,11182035, 11186146,11191151,11191353,11193045,11194958,11203615,11206443,11209199, 11229482,11230768,11233349,11233436,11255126,11265643.