NHTSA Complaint #10425280 — 2004 FORD F-150

(SUMMER, 2007, 28K) AT HIGHWAY SPEED (60 MPH) HUGE GRINDING NOISE AND VIBRATION, LIGHT IN DASH CAME ON BY ITSELF SHOWING, "4X4" TURNED ON, SLOWED TO 20 MPH, HUGE CLUNK AS 4 WHEEL DRIVE SYSTEM ENGAGED WITHOUT DRIVERS REQUESTING IT TO ENGAGE. FORD ROADSIDE ASSISTANCE WAS CONTACTED AND FORD TOWED VEHICLE TO FORD DEALER, FORD DEALER "REPROGRAMMED" SOMETHING, SAID IT HAD MOISTURE IN A SENSOR, CAUSING THE 4X4 TO TRY TO ENGAGE. (SEPTEMBER 12, 2011, 69,980 MILES) AT HIGHWAY SPEED, (58 MPH) DURING MILD ACCELERATION, 1500 - 1800 RPM, A MILD GRINDING SOUND FROM UNDER FRONT END, BY TAKING FOOT OFF GAS PEDDLE THEN REAPPLYING GAS THE GRINDING SOUND STOPS. CONTACTED FORD DEALER, THEY SAID DRIVE IT IN, CONTACTED FORD CUSTOMER SATISFACTION DEPARTMENT, THEY SAID TO HAVE DEALER CHECK IT OUT, FORD DEALER INVESTIGATED AND SAID THERE IS A PROBLEM WITH VOLUME OF VACUUM THAT IS NECESSARY TO PREVENT THE 4X4 SYSTEM FROM ENGAGING WHILE DRIVING ON THE HIGHWAY AT HIGHWAY SPEEDS. FORD DEALER INDICATED THAT IT MAYBE UNSAFE TO DRIVE LIKE THIS AND THAT THIS IS NORMAL FOR THE VACUUM SYSTEM TO FAIL LIKE THIS, REPRESENTATIVE AT FORD CUSTOMER SATISFACTION DEPARTMENT SAID THAT THEIR DEALER KNOWS HOW TO DIAGNOSE AND CURE PROBLEMS BEST, AND SINCE THE VEHICLE HAS MORE THAN 36K IT IS NOT A CONCERN TO FORD. MY CONCERN IS THAT STEEL GEARS THAT ARE SUGGESTED TO BE ENGAGED AT A WALKING PACE ON SOFT PAVEMENT ARE AUTOMATICALLY FORCING THEMSELVES TO LOCK TOGETHER ON DRY PAVEMENT AT 60 MPH, AND FORD AND THE FORD DEALER SHOW LITTLE CONCERN FOR THIS CONDITION SINCE THE VEHICLE HAS MORE THAN 36K AND SINCE NO EXTENDED WARRANTY PURCHASED FROM THE DEALERSHIP. *TR