NHTSA Preliminary Evaluation PE15026

On June 22, 2015, the Office of Defects Investigations (ODI) opened Preliminary Evaluation PE15-026 to investigate incidents of increased brake pedal effort at cold start and extended stopping distance while driving in traffic, resulting from failures of the electric brake vacuum assist pump in model year (MY) 2011-2012 Ford F-150 pickup trucks equipped with 3.5L GTDI engines. In response to ODI's Information Request (IR) for PE15-026, Ford provided ODI with 396 complaints and field reports relating to incidents of increased brake pedal effort or malfunctions in the electric vacuum pump (EVP). ODI's analysis of the data provided by Ford identified 7 crashes and 1,851 warranty claims related to either a hard brake pedal condition or reduced brake effectiveness. Additionally, ODI identified one report in its database alleging an injury to an occupant of a vehicle struck in the rear by a subject F-150 vehicle with a failed EVP as documented in the police accident report referencing a dealer assessment of the pump.According to Ford, the subject vehicles utilize a traditional brake vacuum booster to provide power assist for braking and the EVP is intended to operate to maintain consistent brake pedal feel. The engine intake manifold is the primary source of vacuum for the booster and is fully compliant to motor vehicle safety standards without the EVP. Ford described the conditions related to a change in brake pedal feel as limited and temporary and provided component failure analysis showing evidence of water entry into the EVP which caused internal pump corrosion. Ford indicated that the EVP failure mode is progressive and provides warning to operators by way of noise and vibration before an operator is likely to experience any temporary change in brake pedal feel. Damage to the EVP motor bearing may eventually result in a blown EVP fuse and total loss of EVP function. Ford provided test data showing the brake pedal forces and pedal travel curves over time for 0.3g dec