NHTSA Complaint #10824124 — 2009 FORD F-150

FORD MOTOR COMPANY HAS INSTALLED DEFECTIVE FASTENERS ON THE EXHAUST MANIFOLDS OF NUMEROUS MODULAR V8 (4.6L & 5.4L) EQUIPPED F-150S. THIS IS A WELL DOCUMENTED ISSUE AMONG SEVERAL F-150 OWNERS THROUGHOUT THE US AND CANADA FOR MANY MODEL YEARS. THE PROBLEM WITH THESE MANIFOLD FASTENERS (STUDS) IS THAT AFTER THE NORMAL HEAT CYCLES OF DRIVING AND SITTING, THEY BEGIN TO DETERIORATE AT AN EXCELLED RATE. ONCE A STUD OR STUDS HAVE FAILED, ENGINE EMISSIONS LEAVE THE EXHAUST SYSTEM PRIOR TO REACHING THE CATALYTIC CONVERTER. THE WAY TO REPAIR THIS IS BY REMOVING THE EXHAUST SYSTEM AND MANIFOLDS IN ORDER TO EXTRACT THE BROKEN STUD OR STUDS AND REPLACE THEM WITH IMPROVED PARTS, IN MANY CASES THE ENTIRE ENGINE MUST BE REMOVED FROM THE VEHICLE DUE TO CLEARANCE ISSUES. NOT ONLY IS THIS ISSUE VERY COSTLY TO THE CONSUMER AND THE ENVIRONMENT IT IS ALSO AN ARDUOUS PROCESS TO BE REPAIRED EVEN BY SOMEONE THAT IS MECHANICALLY INCLINED. MY 2009 F-150 CURRENTLY HAS THIS SAME ISSUE. EVIDENCE THAT THIS HAS BEEN A CONSISTENT PROBLEM FOR ALMOST A DECADE: SERVICE BULLETIN NO.: 17320 COMPONENT(S): ENGINE AND ENGINE COOLING NHTSA ID NUMBER: 10008169