NHTSA Complaint #11671531 — 2016 FORD EDGE

The transfer case on my 2016 Ford Edge Titanium AWD cracked and failed at approximately 76,000 miles. For months prior, the vehicle showed warning signs including a strong burning smell inside the cabin, jerky movement while reversing, and rubbing or grinding noises during low-speed turns. I sought help multiple times, but the issue was not diagnosed despite repeated service visits. Eventually, the vehicle was taken to another repair facility where, during a test drive, the transfer case fully cracked while the mechanic was driving. According to the technician, the vehicle began smoking and was no longer safe to operate, and he immediately turned around to avoid further risk. The mechanic explicitly told me he was thankful it happened to him and not to me or my family, as it could have been much worse had it occurred on the road. The damaged part has since been replaced, but I have photographs of the failed transfer case attached to this complaint. Safety Risk: The failure made the vehicle inoperable and unsafe to drive, with serious risk of mechanical seizure or loss of control if it had occurred under different conditions (e.g., on the highway or in traffic). There were no dashboard alerts or warning lights—only progressive, difficult-to-pinpoint symptoms. Problem Prevalence and TSB History: Afterward, I discovered that transfer case failures are a known issue on Ford Edge models, and that the 2016 model year has an unusually high number of Technical Service Bulletins (TSBs) related to powertrain and drivability issues. These include: TSB 18-2057, related to strong cabin odors TSB 18-2255, related to transfer case leaks and driveability problems Given the number of complaints online and the pattern reflected in these TSBs, this points to a broader reliability and safety issue with this component in this model year. Inspection History: The vehicle was evaluated multiple times for these issues and was ultimately diagnosed by a certified repair technician af