NHTSA Complaint #715116 — 1997 FORD F-150

IN MAY 99 HEARD RATTLE FROM LEFT REAR. FOUND SPRING CLAMP MISSING BUSHING, NO BIG DEAL. BUT DID NOTICE BOTTOM LEAF WAS KICKED OUT ON AFT END (AND KICKED IN OF FWD END) APPX 1/4 TO 3/8". WHILE DEALER REPLACE LUGS: NUTS ON RECALL SAID LEAF SPRING NO BIG DEAL. I WRAPPED LOOSE CLAMP IN TAPE TO STOP RATTLE. NOW IN 11/99 WHILE WASHING CAR I NOTICED LOWER LEAF IS KICKED OUT CONSIDERABLY FARTHER, NOW MEASURING A FULL 1". I HAVE CONTACTED FORD CAC, AND THE DEALER WILL PROBABLY INSTALL A KIT PER SB99-6477. HOWEVER, I VIEW THIS AS A VERY BIG PROBLEM/SAFETY ISSUE BECAUSE THE FORD TSB KIT ONLY REPLACES THE EXISTING CLAMP FOR THE TWO UPPOER LEAFS. THE LOWER LEAF IS "ADJUSTED" BACK INTO PLACE. INTERNET RESEARCH SHOWS NUMEROUS PEOPLE WITH SAME COMPAINT. THIS IS NOT A SATISFACTORY SOLUTION. IN MY CURRENT SITUATION THE LOWER LEAF, AT A 1" AFT KICKOUT, IS CONTACTING THE FWD INSIDE AND AFT OUTSIDE U-BOLT. THERE CAN BE NO OTHER OUTCOME TO THIS THAN FOR THE SPRING TO EXERT ENOUGH FORCE OVER TIME TO WEAKEN BOTH U-BOLTS TO THE POINT OF FAILURE. IN MY CASE I'LL BE WATCHING LIKE A HAWK. HOWEVER WERE IT NOT FOR THE INITIAL RATTLE I DOUBT THAT I WOULD HAVE EVER SEEN THE PROBLEM UNTIL AT SOME POINT IN THE FUTURE WHEN MY AXLE FELL OFF. I'VE BEEN HAPPY WITH THE TRUCK AND FORD IN GENERAL UNTIL NOW, BUT I FEEL LIKE THEY NEED TO WAKE UP AND ADDRESS THIS. LOOKING AT CHEVROLET TRUCKS THEY HAVE WHAT SEEMS TO BE A BETTER DESIGN PHILOSOPHY; THE CHEVROLET TRUCK HAS "SQUARE" U-BOLTS, THREADS DOWN , WHICH STRADDLE THE LEAF SPRING ASSEMBLIES WITH CLOSE TOLERANCE TO KEEP THE STACK TOGETHER ON TOP OF AXLE. FORD'S DESIGN HAS THE U-BOLTS ON EITHER SIDE OF THE SPRING STACK, THREADS UP, AND RELIES ON THE COMPRESSION FORCE TO KEEP THE STACK TOGETHER INSTEAD OF THE U-BOLT ITSELF. I WOULD ENCOURAGE YOU TO LOOK AT THIS ISSUE; OVER TIME AS THESE TRUCKS ACQUIRE MORE MILEAGE THERE MAY BE SOME U-BOLT FAILURES. *AK