NHTSA Complaint #10262623 — 2005 FORD F-150

WHILE DRIVING, THE VACUUM SOLENOID FOR THE 4 WHEEL DRIVE TRIES TO ENGAGE THE 4 WHEEL DRIVE - EVEN AT HIGHWAY SPEEDS- RESULTING IN A HORRIBLE SOUND. THE SOUND WAS "LIKE I HAD RUN OVER A SHOPPING CART OR HIT SOMETHING IN THE ROAD AND WAS DRAGGING IT UNDER THE TRUCK". THIS HAPPENED 5 TIMES IN TWO DAYS IN LESS THAN 30 MILES OF TOTAL DRIVING. THE NOISE IS SO LOUD AND ALARMING THAT IT MADE ME IMMEDIATELY APPLY THE BRAKES AND PULL TO THE SIDE OF THE ROAD BECAUSE I THOUGHT I HAD HIT SOMETHING/SOMEONE. AT FIRST I WONDERED IF MY MUFFLER OR DRIVE SHAFT OR SOME OTHER PART HAD FALLEN OFF OF THE TRUCK. THIS "FALSE ENGAGEMENT" OF THE 4 WHEEL DRIVE HAPPENS WITHOUT ANY WARNING IN ALL KIDS OF DRIVING CONDITIONS (SLOW, FAST, BREAKING OR ACCELERATING). A NEW, REDESIGNED (NOW HAS A COVER ON IT TO KEEP MOISTURE OUT- WHICH WAS CAUSING THE FAILURE) VACUUM SOLENOID WAS INSTALLED ON TRUCK - A $27.00 PART. DEALERSHIP KEPT OLD PART. TECH. AT DEALER TOLD ME THAT THIS PART WILL GO BAD AT SOME POINT AND NEED REPLACING ON ALL THE TRUCKS WITH THE PART. HE SAID "NOT IF BUT WHEN". FORD KNEW ABOUT THE PROBLEM - HENCE THE REDESIGNED PART. FORD HAS NOT NOTIFIED OWNERS OF THIS PART AND IT'S IMPENDING FAILURE. *TR