Ford E-Series brake, steering assist repairs not done correctly, investigation finds

Federal safety regulators have issued an open recall query into 2021-22 Ford E-Series vehicles often used as shuttle buses and ambulances that were already recalled for loss of power brakes and steering assist because problems have resurfaced, according to the National Highway Transportation Safety Administration.

A NHTSA query document, dated Tuesday, says that agency investigators will reexamine all 44,219 of the E-350 and E-450 vehicles initially recalled two years ago for sudden loss of power steering fluid that can result in a loss of power steering and power brake assist, increasing the risk of a crash.

The federal Office of Defects Investigation noted in its paperwork that it was aware of 11 incidents where customers had records of repair done and they don't appear to be fixed.

"The vehicles in the complaints include ambulances and a wheelchair lift-equipped school bus," federal safety regulators said. "In meeting with Ford about the post-remedy failures on January 26, 2024, Ford informed ODI they would file a new recall to update the power steering pressure line components on any vehicle that had not yet been inspected and also any vehicle which had passed inspection within the last 12 months."

Ford spokeswoman Maria Buczkowski told the Detroit Free Press on Friday, "We are working with NHTSA to support its investigation."

In February 2022, Ford recalled an estimated 44,219 of the E-350 and E-450 vehicles for a sudden loss of power steering fluid that can result in a loss of power steering and power brake assist, increasing the risk of a crash, NHTSA said.

Earlier this week, a Detroit Free Press investigation spotlighted a situation where Ford is reinspecting repairs on potentially defective air bags in vehicles that may have been sent home with customers as fixed when the air bags were installed incorrectly, not installed at all or installed with bags that don't deploy properly. The investigation was based on a whistleblower filing obtained by the Free Press.

Meanwhile, concern about reinspection of the E-350 and E-450 vehicles with dual rear wheels came to the attention of regulators because of consumer complaints in 2023 alleging the fixes had passed Ford's inspection process but weren't fixed. Consumer complaints filed at no cost on the website nhtsa.gov are monitored by the government and automakers to identify trends and concerns.

A consumer complaint from the owner of a 2022 Ford E-350 filed with NHTSA on March 31 said: While driving 60 mph and depressing the brake pedal, the vehicle failed to stop. There was no warning light illuminated. The driver "desperately depressed on the brake pedal and the vehicle eventually came to a complete stop." The vehicle was towed to the dealer and the mechanic stated that the power steering pump needed to be replaced, and that the vehicle was previously repaired.

Ford is aware of 628 warranty reports and one field report received from March 10, 2022, to Oct. 30, 2023, related to a pressure line leak or disconnection after passing inspection, the automaker wrote in a document submitted to NHTSA. The automaker is aware of one noninjury accident related to this matter, Ford said.

A recall query is an investigation opened by safety regulators when a remedy to solve an issue appears inadequate. If investigators feel additional information is needed, they may request an engineering analysis. This is the first step toward gathering information.

The initial recall fix had involved Ford updating parts in the vehicles and inspecting them to check the connection between the power steering pressure line and the hydraulic brake booster unit to prevent a sudden loss of power steering fluid, according to NHTSA.

In May, Ford shareholders voiced concern about recall and warranty costs. Ford CEO Jim Farley has told industry analysts this year that getting control of warranty and recall issues is a top priority.

Contact Phoebe Wall Howard: 313-618-1034 or phoward@freepress.com. Follow her on X at @phoebesaid