NHTSA Complaint #10713933 — 2005 FORD F-150

I ATTEMPTED TO START MY TRUCK, IT TURNED OVER BUT WOULD NOT START. I HAD THE TRUCK TOWED TO THE LOCAL FORD DEALERSHIP WHERE I PURCHASED IT NEW, AND FOUND THE CAUSE OF THE NO START CONDITION TO BE THE FUEL PUMP DRIVER MODULE. (PART NUMBER 5L3A-9D370-AA) I ASKED TO HAVE THE PART SAVED FOR MY INSPECTION. WHAT I FOUND WAS VERY DISTURBING. THE ALUMINUM CASE OF THE MODULE WAS CRACKED IN HALF AND HAS A DIME SIZE HOLE ERODED THRU. BY CHANCE, ONE OF MY WORK ASSOCIATED WHO HAS A 2004 F150 HAD A FLAT TIRE THIS MORNING (JUST THREE DAYS AFTER MY EXPERIENCE WITH THIS PROBLEM) AND HAD THE SPARE TIRE DOWN. I LOOKED UNDERNEATH HIS TRUCK AND FOUND HIS TRUCK TO HAVE A MODULE IN AS POOR CONDITION AS THE ONE I HAD REPLACED. I TOOK A PICTURE THAT I WOULD BE HAPPY TO FORWARD. TWO ADDITIONAL WORK ASSOCIATES WITH 2004 - 2005 F150'S HAVE EXPERIENCED THIS SAME PROBLEM WITH THEIR TRUCKS, I HAVE ALSO READ SEVERAL ONLINE POSTS TODAY OF THIS VERY SAME PROBLEM. THIS IS NOT AN ISSUE OF NORMAL WEAR OF A PART, THIS IS A DEFINITE DESIGN FLAW AND SAFETY ISSUE. THE MODULE IN QUESTION IS MOUNTED ABOVE THE SPARE TIRE ON THE DRIVERS SIDE REAR AXLE. THE TIRE IS MOUNTED FOR STORAGE TO THE UNDERSIDE OF THE TRUCK. THE ALUMINUM COVER OF THE MODULE IS MOUNTED AGAINST THE STEEL AXLE AND SEEMS TO ACT LIKE A SACRIFICIAL ANODE AS THE MODULE COVER ERODES AND CRACKS TO THE POINT OF NEAR TOTAL DESTRUCTION EXPOSING A CIRCUIT BOARD TO THE ELEMENTS. IT WOULD SEEM THIS MODULE WOULD BE PLACED IN AN AREA THAT WOULD BE LESS LIKELY TO DESTROYED BY THE ELEMENTS OR ENCAPSULATED OR COATED IN A WAY THAT PROTECT IT. ANY VEHICLE THAT CAN BECOME SUBJECT TO STALL FROM A FAILED PART IS A SAFETY CONCERN AND ON THIS SCALE SHOULD BE CAUSE FOR RECALL CONSIDERATION. THE COST FOR THIS REPAIR "PARTS AND LABOR" AT A DEALERSHIP IS APPROXIMATELY $400.00. *TR