2008 FORD F-450 SD Power Train Problems

The contact owns a 2008 Ford F-450. The contact stated while driving at approximately 65 MPH, the transfer case exploded, and the front windshield shattered. No injuries were sustained; however, several other vehicles sustained cosmetic damage. No warning light was illuminated. A Police report was filed. The vehicle was not drivable and was towed to an independent mechanic for a diagnostic test. The contact was informed that the transfer case, drive shaft assembly, fuel injection pump, fuel lines, and transmission wiring harness needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure and confirmed that there was no recall associated with the failure. The manufacturer referred the contact to the NHTSA Hotline to report the failure. The failure mileage was 164,176.

Mileage: 164,176

I WAS MAKING A LEFT HAND TURN AFYER STOPING AT A TRAFFIC LIGHT AND LOSS POWER. THE ENGINE LIGHT CAME ON AND THE TURBO PRESSURE GAUGE DROPPED. I TOOK THE TRUCK INTO THE DEALER AND THE DEALER TOLD ME THAT A MANAFOLD BOLT HAD BROKEN WHICH CAUSED A BAD EXHUAST LEAK. REPAIR COST WAS $3500. I DROVE THE TRUCK LESS THAN 50 MILES OVER THE NEXT TWO DAYS AND THE PROBLEM HAPPENED AGAIN WITH LOSS OF POWER AND ENGINE LIGHT ON. I TOOK THE TRUCK BACK THE DEALER AND WAS INFORMED THAT THE HIGH PRESSURE FUEL PUMP HAD EXPLODED AND SENT METAL DEBRIS THROUGH OUT THE FUEL SYSTEM. I WAS THEN TOLD THE REPAIR COST WERE GOING TO $7500 ($6000 FOR PARTS AND $1500 FOR LABOR). THIS IS A BAD FORD ENGINEERING DESIGN PROBLEM AND SHOULD BE PAID FOR BY FORD AS WELL AS A RECALL ON ALL MODELS USING THE SAME HPFP ASSEMBLY.

Mileage: 124,000

DRIVING ON INTERSTATE WHEN SUDDENLY FELT TRUCK VIBRATION. AS I PULLED OFF TO EXIT - HEARD AND FELT WHAT SOUNDED LIKE AN EXPLOSION FROM UNDERNEATH. WHEN GOT OUT TO LOOK UNDERNEATH, NOTED THAT HALF OF THE TRANSFER CASE WAS GONE; THERE WAS OIL SPILLED ALL OVER THE GROUND AND GEARS LAYING ON TOP OF THE CROSS MEMBER. HAD TRUCK TOWED TO THE DEALERSHIP WHERE PURCHASED. TECHNICIAN SAID THE DRIVE SHAFT AND TRANSFER CASE NEEDED REPLACING. UNABLE TO SAY WHY IT OCCURRED. CHARGES OVER $3,000.00. HAD JUST RECENTLY HAD IN SHOP BECAUSE OF NOISE FROM WHAT I THOUGHT WAS THE DRIVE SHAFT, BUT TECHNICIAN COULDN'T FIND ANYTHING WRONG AT THAT TIME. BOUGHT THIS USED TRUCK JUST 9 MONTHS EARLIER 2014. PLAN TO SPEAK TO OWNER OF DEALERSHIP TO SEE IF WE CAN NEGOTIATE THIS HUMONGOUS CHARGE. *TR

Mileage: 85,600

DRIVING DOWN THE ROAD AT 65 MPH PULLING A HORSE TRAILER, TRANSFER CASE BLEW UP, BREAKING THE FRONT DRIVE SHAFT, WHICH WIPED OUT THE BRAKE LINES, TRAILER BRAKE LINE AND THE FUEL LIFT PUMP AND LINES. HAD NO POWER OR BRAKES. HAD FORD FIX THE TRUCK, BUT THEY WOULD NOT TAKE ANY RESPONSIBILITY FOR THE FAILURE. THE REASON FOR THE FAILURE WAS NOT FOUND. *TR

Mileage: 50,000

MOTOR REPLACED AND/OR REBUILT BY DEALER TWICE SINCE PURCHASED. *TR

Mileage: 23,000

TL* THE CONTACT OWNS A 2008 FORD F-450 SD. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 50 MPH, THE TRANSFER CASE EXPLODED, CAUSING THE PARTS AND FLUID TO SHOOT OUT FROM THE VEHICLE. THE CONTACT MERGED TO THE SHOULD OF THE ROAD AND SHUT OFF THE ENGINE. THE VEHICLE WAS TOWED TO THE DEALER BUT WAS NOT DIAGNOSED FOR THE FAILURE. THE TECHNICIAN ADVISED THE CONTACT THAT A DIAGNOSTIC TEST WOULD NEED TO BE PERFORMED AND THE TRANSFER CASE WOULD NEED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND ADVISED THAT THE VEHICLE WAS NOT INCLUDED IN ANY RECALLS. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 123,000.

Mileage: 123,000

FIRST TIME IT WAS MY RADIATOR, I REPLACED IT. SECOND TIME IT WAS AND INJECTOR, I HAD THAT FIXED. NOW IT IS MY TURBO AND ENGINE. FORD REFUSES TO COVER IT UNDER WANRRENTY, MANY PEOPLE HAVE HAD ISSUES WITH THESE MODELS. *TR

Mileage: 30,000

CPSC#X1190467A. 2008 FORD F450. CONSUMER STATED WHILE DRIVING THE TRUCK EXPLODED. HE LOST CONTROL OF THE TRUCK AND RAN OFF THE ROAD. THE TRANSFER CASE HAD EXPLODED AND SENT METAL INTO MY TRANSMISSION AND BUSTED IT. *LN THE CONSUMER STATED THE FUEL LINE WAS CUT AND THE WIRING WAS BURNED AS WELL. THE VEHICLE WAS TOWED TO THE DEALER, WHERE THEY INFORMED THE CONSUMER THE EXPLOSION OCCURRED AS A RESULT OF A FACTORY DEFECT. THE CONSUMER SUFFERED MINOR INJURIES. *JB

TRUCK WAS RECALLED TO GIVE WARNING WHEN THE TRUCK GOES INTO REGENERATION. WHEN THE CHECK ENGINE LIGHT WOULD COME ON NOW FORD CURRENT FIX IS FOR THE MESSATO DISPLAY FOR JUST A FEW SECONDS. SO IT CAN BE IN THE REGENERATION MODE AND YOU WILL NOT KNOW IT. BACK TO THE SAME OLD SAFETY AND FIRE HAZARD AS BE FORE THE RECALL.. BEEN AT THE DEALER SEVERAL TIMES TO CORRECT THE PROBLEM. LAST TIME 10/11/10. *TR

Mileage: 22,624

INJECTORS TURBO EXHAUST AND ALOT MORE PROBLEMS, BEEN TOWED 6 TIMES BEEN TO THE DEALER OVER 30 TIMES WENT THROUGH LEMON LAW DIDN'T QUALIFY VEHICLE TO HEAVY. *TR

Mileage: 4,000

DRIVING AS NORMAL ON FWY HEARD A LOUD NOISE THOUGHT I GOT A FLAT. STOPPED VEHICLE ON SHOULDER, BRAKING WAS DIFFICULT AND WHITE SMOKE WAS AROUND THE CAR. I GOT OUT AND DID NOT SEE ANY FLAT TIRES BUT I SAW SMOKE BETWEEN THE CAB AND BED OF THE TRUCK. I RAN BACK TO THE DRIVER DOOR AND SAW A SMALL FIRE ON THE FLOOR NEXT TO THE 4X4 SHIFTER FOR THE TRANSFER CASE. I IMMEDIATELY GRABBED MY 3 YEAR OLD DAUGHTER FROM HER CAR SEAT AS THE CAB FILLED WITH SMOKE AND RAN APPROXIMATELY 300 FEET AWAY AND TOLD MY DAUGHTER TO STAY. I JUMPED INTO THE BACK OF THE TRUCK GRABBED A LARGE FIRE EXTINGUISHER AND DISCHARGED IT INTO THE HOLE IN THE FLOORBOARD NEXT TO THE TRANSFER CASE IT WENT OUT AND IMMEDIATELY CAME STARTED UP AGAIN. I THEN CALLED 911. SOME PEOPLE STOPPED AND HELPED ME REMOVE A FEW POSSESSIONS FROM THE TRUCK BED. WITHIN 3 MINUTES THE TRUCK FIRE FLASHED AND WE ALL STOOD BACK AND VIDEO TAPED THE VEHICLE BURN TO THE GROUND. THE WITNESSES SAID WHAT APPEARED TO BE SOMETHING METAL CAME OFF OF MY TRUCK STRUCK THEIR CAR AND THE REASON THEY PULLED OVER IS BECAUSE THEY THOUGHT THEY HAD A FLAT BUT WHEN THEY LOOKED BACK THEY SAW FIRE UNDERNEATH MY TRUCK AND RAN TO HELP. THE FD ARRIVED THEY SHOT FOAM ON THE FIRE BUT IT CONTINUED TO GO OUT THEN START BACK IT TOOK THEM APPROXIMATELY 30 MIN TO EXTINGUISH. I AM VERY MECHANICAL AND BELIEVE MECHANICAL FAILURE IN THE EXHAUST CANNINSTERS THAT COLLECT THEN BURN HYDRO CARBON PARTICLES BEFORE THEY ARE RELEASED INTO THE CAT CONVERTER, SENT EXCESSIVE HEAT TO THE TRANSMISSION THEN THE TRANSFER CASE(DIRECTLY BELOW THE FUEL LINES), THUS MELTING THE FUEL LINES WHICH DRIPPED ON THE RED HOT TRANSFER CASE AND STARTED THE FIRE. THE VEHICLE WAS IN THE SHOP PREVIOUSLY UNDER A FORD RECALL FOR SHOOTING FLAMES OUT OF THE TAIL PIPES SO I ASSUME THEY MUST HAVE RESTRICTED THE FLAMES WHICH KEPT THE MORE HEAT INSIDE THE VEHICLE EXHAUST SYSTEM AND IS SERIOUSLY DANGEROUS! MY DAUGHTER AND I WOULD HAVE BEEN KILLED IF THE AIR BAGS HAD DEPLOYED OR AN ACCIDENT. *TR

Mileage: 13,000