After a preliminary review of consumer complaints and other information related to alleged defects, NHTSA obtains information from the manufacturer(including data on complaints, crashes, injuries, warranty claims, modifications, and part sales) and determines whether further analysis is warranted. If warranted, the investigator will conduct a more detailed and complete analysis of the character and scope of the alleged defect.
NHTSA Action Number: PE13003
Date Opened: 2013-02-21
Date Closed: 2014-02-28
Manufacturer’s Name: Ford
Motor Company
Component Description: ENGINE
Summary Description: Electronic Throttle Body Malfunction
Summary
On February 21, 2013, the Office of Defects Investigations (ODI) opened Preliminary Evaluation PE13-003 to investigate allegations of electronic throttle body (ETB) failures resulting in sudden reduction of engine power in model year (MY) 2009-2013 Ford Escape, Fusion, Mariner and Milan vehicles. During this investigation, Ford identified a condition in subject vehicles equipped with 2.5L and 3.0L engines that may result in a sudden reduction of engine power.According to Ford, the ETB internal motor contacts may develop a high resistance material buildup condition on the commutator, resulting in intermittent electrical connectivity and reduced engine power. When this condition occurs, the Malfunction Indicator Lamp (MIL) or Wrench light will illuminate and the vehicle may enter a limited limp home mode.Ford?s trade name for the feature is Failure Mode Effects Management (FMEM) mode.In this mode, engine power and vehicle speed are reduced, while full function of the power steering, power braking, lighting, and climate control systems are maintained.ODI?s complaint analysis indicate that the predominant failure mode involved reduced motive power associated with the limited limp home mode with engine speeds limited to approximately 900 RPM. Analysis of warranty claims provided by Ford identified 59,807 claims related to ETB replacements and approximately 50 percent of claims are associated with diagnostic trouble codes (DTC) P2111, Throttle Body Stuck Open, and P2112, Throttle Body Stuck Closed.Ford described several factors where the ETB motor may fail resulting in DTCs P2111 or P2112 but the failure is not an existing stuck open or closed ETB valve position.According to Ford, the ETB control strategy provides the driver with three FMEM modes that allow varying degrees of vehicle mobility depending on the severity of the fault detected.DTCs associated with stuck open or closed throttle valves are designated the highest failure severity resulting in engine speeds limited to high idle corresponding to the limited limp home mode.Vehicles are not likely to unexpectedly stall as a result of this condition, but drivers may characterize the reduced functionality as a stall, even though their vehicle may still has motive capability.Other FMEM limp modes may result in reduced engine performance but will maintain vehicle speed above 20mph. During this investigation, Ford and its suppliers, Delphi and Igarashi, updated the powertrain control module (PCM) software to include a throttle body motor cleaning cycle during key-on and modified the ETB internal motor components design, surface finish and material composition to improve durability. Additionally, Ford developed a remedy procedure and issued a special Customer Satisfaction Program (CSP) 13N03 extending the ETB warranty coverage and instructing dealers to update the powertrain calibration to improve vehicle performance in the event that intermittent electrical connectivity of the throttle body motor contacts occurs. The program extends the 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 January 31, 2015 regardless of mileage.Owners of the affected vehicles will be contacted by mail to take their vehicle to a Ford dealer who will reprogram the PCM to the latest calibration. The bulletin was sent to dealers on January 17, 2014 and the owner letter mailing began on January 27, 2014. See the investigative file for copies of Ford's bulletin and owner letter. This preliminary evaluation is closed. The closing of this investigation does not constitute a finding that
NHTSA Action Number: PE13002
Date Opened: 2013-02-07
Date Closed: 2013-07-03
Manufacturer’s Name: Volvo Trucks North America
Component Description: POWER TRAIN:AUTOMATIC TRANSMISSION
Recall Campaign: 13V268
Summary Description: Stop Lamp Switch Signal
Summary
The Office of Defects Investigation (ODI) received Early Warning Reporting (EWR) data from the manufacturer that indicated some number of subject vehicles equipped with the subject automated manual transmission had allegedly experienced a condition where the clutch failed to automatically disengage the transmission from the engine as intended. This may result in extended stopping distances and/or unintended forward motion of a vehicle previously at rest.To date, ODI is aware of 134 subject vehicles with one or more complaints or field reports related to this condition.Also, ODI is aware of 164 subject vehicles with one or more warranty claims related to this condition.By letter dated June 25, 2013, Volvo Trucks North America (Volvo) notified ODI that it has initiated a safety recall (NHTSA Recall No. 13V268 and Volvo Recall No. RVXX1303) to address a safety defect in approximately 23,003 model year (MY) 2007 through 2014 Volvo VAH, VHD, VNL, VNM and VT model trucks. The affected vehicles were manufactured from December 20, 2006 through May 22, 2013 and were originally equipped with the subject automated manual transmissions.According to Volvo, reports of the subject transmission clutch mechanism failing to automatically disengage as intended are associated with the removal of a brake pedal micro switch that provided a redundant signal to the transmission control module indicating the brakes had been applied.Previously, Volvo had removed this brake pedal micro switch from new vehicle production and from certain vehicles already in-service via two field service campaigns (SP 432-024 and SP 432-026) because it decided the switch was unnecessary and/or a maintenance issue.In the absence of this redundant brake pedal micro switch, the clutch mechanism may fail to disengage the transmission from the engine at low vehicle speed should the stop lamp switch fail to send and/or the transmission control module fail to receive the primary signal.At the time of this closing, Volvo is evaluating available remedies and will provide NHTSA with details when the recall remedy procedure has been finalized.Volvo will notify affected owners by mail by August 25, 2013.Please see NHTSA Recall No. 13V268 for details.Accordingly, this investigation is closed.
NHTSA Action Number: RQ13001
Date Opened: 2013-02-04
Date Closed: 2013-06-06
Manufacturer’s Name: General Motors, LLC
Component Description: EXTERIOR LIGHTING:BRAKE LIGHTS
Summary Description: Brake Light Malfunction
Summary
The Office of Defects Investigation (ODI) opened Recall Query RQ13-001 on February 4, 2013 in response to complaints alleging that the brake lights do not operate properly on model year (MY) 2005-2008 Pontiac G6 vehicles. Complainants allege that the brake lights illuminate when the brake pedal is not depressed, and turn off once the brake pedal is applied. In addition the driver may have difficulty shifting out of PARK, or the cruise control may not engage properly. In response to ODI?s Information Request, General Motors (GM) submitted a significant number of warranty claims and over 1, 100 reports that potentially relate to the alleged problem. ODI is continuing its analysis of this data. One of the GM reports also alleged a vehicle crash. ODI has received a total of 314 complaints, one alleging a crash.Based on the agency's current analysis, ODI has upgraded its investigation to an Engineering Analysis (EA13-005) to determine whether the subject vehicles present a safety related defect trend, and to further evaluate scope.The ODI complaints cited above can be reviewed at: http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID, see the attached list for ODI numbers.
NHTSA Action Number: PE13001
Date Opened: 2013-01-15
Date Closed: 2013-04-11
Manufacturer’s Name: Daimler Trucks North America, LLC
Component Description: ELECTRICAL SYSTEM
Recall Campaign: 13V074
Summary Description: SmartPlex Multiplexer Module Failure
Summary
The Office of Defects Investigation (ODI) received Early Warning Reporting (EWR) data from the manufacturer that indicated some number of subject vehicles may allegedly experience a SmartPlex electronic multiplexing switch hub module failure. This failure may result in inadvertent activation of accessory equipment such as external lighting, outriggers, crane, or power takeoff.By letter dated March 1, 2013, Daimler Trucks North America LLC (DTNA) notified ODI that it has initiated a safety recall (NHTSA Recall No. 13V-074 and DTNA Recall No. FL-639) to address a safety defect in approximately 161 model year (MY) 2012 through 2013 Freightliner 108SD, 114SD and Business Class M2 trucks.The affected population was manufactured from December 3, 2011 through October 12, 2012 and originally equipped with a certain SmartPlex electronic multiplexing switch hub module with a suspect serial number. According to DTNA, unpassivated flux residue may be present on the printed circuit board assembly in the switch hub module. Under certain heat and humidity conditions, this flux residue may lead to intermittent short circuits, thereby activating certain outputs in the switch hub module.According to DTNA, they identified the issue with the switch hub module on vehicles undergoing the assembly process.DTNA states they have not received any customer or field reports related to the switch hub module.To date, ODI is unaware of any switch hub module failures on in-service vehicles.DTNA will notify affected owners by mail no later than April 29, 2013. Affected vehicles will be inspected and if the switch hub module is in the suspect range the module will be replaced.Repairs will be performed by DTNA authorized service facilities.Accordingly, this investigation is closed.
NHTSA Action Number: EA12009
Date Opened: 2012-12-12
Date Closed: 2014-06-12
Manufacturer’s Name: Ford Motor Company
Component Description: VEHICLE SPEED CONTROL:ACCELERATOR PEDAL
Recall Campaign: 14E028
Summary Description: Floor mat interference with accelerator
Summary
On May 27, 2014, Ford Motor Company submitted recall 14E-028 (Ford recall #14S07) to correct a safety-related problem with certain driver's side Ford optional all-weather floor mats sold for use in model year 2006 through 2011 model year Ford Fusion, Mercury Milan, Lincoln Zephyr, and Lincoln MKZ vehicles built at Hermosillo Assembly Plant (HAP) from November 9, 2007, to October 31 ,2010.NHTSA testing determined that the original accessory all-weather mat with a single retention clip (Figure 1), may interfere with accelerator pedal return to idle with the mat retained by the clip and rotated clockwise.Both the single- and double-clip (Figure 2) all-weather floor mats may interfere with the accelerator pedal return to idle when the mats are not secured by the retention clip(s).Testing showed that this can occur if the mats are moved forward from the clipped position approximately two inches into a position in which the rear edge of the mats will abut the retention clip(s) when installed singly and align with the clip(s) when stacked on another floor mat.The pedal interference incidents reviewed by the Office of Defects Investigation (ODI) include 1 crash and 9 incidents with allegations of brake friction materials smoking and/or requiring repair for heat related damage.The crash incident occurred after the parking brake was applied at speed, resulting in loss-of-control vehicle yaw event caused by lock-up of the rear tires.The spin-out resulted in a side impact collision with an oncoming vehicle in an opposing lane of traffic. For the 29 incidents with sufficient information available to make an assessment; 23 (79%) were controlled by the driver either shifting to neutral, turning the engine off, or both; 4 (14%) were ended by the driver either kicking the pedal free (2) or pulling the mat away from the pedal (2); and 2 (7%) were ended by the pedal freeing itself from the mat with no apparent driver action.None of the drivers who reacted to the incident by shifting to neutral or turning the engine off reported any difficulties with either action.The subject mats were sold by Ford and Lincoln dealers directly to customers as an optional accessory equipment item or, beginning in November 2007, the mats were also available as a factory installed accessory if ordered with a new vehicle.Ford estimates that approximately 82,579 affected driver's side all weather floor mats were sold worldwide; either over the counter through Ford dealerships or as original equipment.Owners that purchased the subject all-weather floor mats as a factory installed accessory with their new vehicle will be notified to return their all weather floor mats to their Ford or Lincoln Dealership in exchange for replacement mats.Owners of all other potentially affected vehicles will be notified that, if they have an affected Ford driver's side all weather floor mat, they should return their mats to the dealership in exchange for replacement mats.The VOQs associated with the closing of this investigation are: 10327597, 10332233, 10334211, 10335336, 10339330, 10348772 (and duplicate 10342572), 10372674, 10379562, 10415911, 10426255, 10434107, 10521053, 10554966.This investigation is hereby closed.
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