NHTSA Complaint #11589387 — 2014 FORD FIESTA

On a long road trip with my mother while accelerating onto a highway I heard a metal object from the front right of my car drop onto the road. Subsequently, I heard a minor clanking/rattling noise every now and then but everything was operating normally and I could not connect any driving actions to this noise. Later on I looked under the vehicle for any loose hanging objects but could see none. When I got home I went to my home Ford dealer they were charging an exorbitant diagnostic fee so I went to a different dealer with a more reasonable fee. I was asked if I recently had my brakes serviced to which I replied yes. I was told there was a missing upper right caliper bolt. This explained the noise I heard of a metal object dropping. I brought it to the attention of the service manager of my home dealer. I was reimbursed by my home dealer for the cost of the diagnosis and repair at the other dealer. Some months later there was management shakeup of personnel and I learned that the service manager and technicians that I spoke with were replaced. I didn't think much at the time that it was anything more than carelessness but I came across some new information. The use of Torque to Yield (TTY) bolts in vehicle safety related components presents a safety hazard. These type of bolts are one-time or single use. They are indistinguishable from traditional bolts. Once torqued to specification, the loosening of these bolts will cause them to fail. They complicate routine maintenance, require more precise equipment, and leave a lot to chance of human error. Improper installation or reuse of these bolts will lead to catastrophic failure. General ignorance among professional trained mechanics, as well as auto part stores, DIY vehicle owners, as well as lack of labeling, and lack of proper warning from vehicle manufacturers is a recipe for disaster. Vehicle manufacturers should not use these bolts for safety related vehicle components. Vehicle owners should be informed.