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Ford's EPAS quality


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So as much as I love Ford, I have to vent a little with how pissed off I am. I have an 11 Explorer Limited ordered from the factory. Ford has had EPAS issues with the Explorer since 2011. For a while they denied it with NHTSA and BBB complaints growing. Ford released TSBs in 12 or 13 about updating the software to resolve the problem. The 1st TSB made it so if youbhad the software updated without a failure and then it failed, it was on your dime if outside the 3/36k. If you didnt have the software uodated and it failed, it would be replaced once. This left many owners paying the $1,500+ to replace it.

 

Lockups and accidents were happening from it so Ford came out with another software update. This new software prevented the EPAS from totaling shutting down from failure until you shut off the car. So if it failed (yellow warning on dash), it allowed you to get to a safe place first instead of completely losing power steering (red warning on dash upon restart).

 

The final update from Ford was the 11-12MY would get a warranty extension for 10yr/150k for a 1 time replacement letting all the 13+ owners hanging out to dry. There have been many 13-15s and even 16s that have had failures.

 

So I had an EPAS failure at 100,558 miles (ESP for 6yr/125k) in Sept of 2016. Epas was covered and drove away after a couple days at the dealer (#2 installed). The very next morning, the EPAS failed again with my wife driving it. Dropped it back off at dealer and it was replaced again at 100,608 miles (#3 installed).

 

This brings me to last week, the Ex went in for some major work.. PTU replaced, Water pump and timing chain as well as spark plugs replaced. Now what else could be bad, how about another EPAS..... So dealer confirmed it bad again, (#4 installed) with 133,xxx miles on it. Drop my wife off yesterday after a week in the shop for my wife to pick it up and she texts me in a matter of a few minutes saying the steering feels stiff. Figured she wasnt used to it after having an 18 Navigstor as a rental for a week..

 

So now this morning, my wife sends me this pic.. seriously?? After 7 years, Ford cant get their crap together with their EPAS system? So once again, it is going in today for its FIFTH EPAS.

 

Seriously, how many power steering pumps do replace on a 7 year vehicle? This is absolutely ridiculous that this happens and makes me worry a lot about the future with it.

 

Thank you for letting me vent.. this should probably have gone in the Explorer section but really wanted/hoped Ford would read this (even though nothing will be done).

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That many epas racks going bad back to back is not common from my experience. The early ones yes. After it had been replaced once I would be surprised it failed again unless something else is wrong like harness rub or pin fit issues in the connector. Another possibility is binding suspension can cause epas to set codes. However, without the codes or diagnosis its purely speculation. The only thing that I see like that is alternators. Fords replacement alternators are unbelievable.

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That many epas racks going bad back to back is not common from my experience. The early ones yes. After it had been replaced once I would be surprised it failed again unless something else is wrong like harness rub or pin fit issues in the connector. Another possibility is binding suspension can cause epas to set codes. However, without the codes or diagnosis its purely speculation. The only thing that I see like that is alternators. Fords replacement alternators are unbelievable.

Tech notes from the 1st 2 replacements. Both original and replacement had the same code.

 

 

Tech Comments VERIFIED CONCERN. CHECKED CODES WITH IDS. GOT CODE P07AE. PERFORMED PIN POINT TEST F IN MANUAL. F1- YES, F2- YES, F4- YES. REMOVED AND REPLACED STEERING GEAR PER TEST. PROGRAMMED MODULE AND CHECKED ALIGNMENT. ADJUSTED FRONT TOE. RETEST OK.

 

As far as the 3rd replacement, it was making a bang/thud sound when you turned from 10 to 2 o clock. It sounded like bad strut mounts but everything on the front was good. I was there when they traced it to the steering rack (I remember hearing it when it was first put in but it is my wife's daily driver and she never paid attention to it). I even had a front strut mount changed out thinking that was it last year.

 

So that one didnt fail electronically but this latest one did again. It wont be ready till next week so Ill post the codes once I get the work order.

Edited by blwnsmoke
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P07AE can set due to an internal rack failure. BUT with *SO* many "failures" it most likely lies outside of the rack. P07AE can also set due to tire pressure issues, severe pulls from tires or bad alignment, or bound ball joints, tie rod ends or strut mounts/struts. ANYTHING that causes constant drag on the rack can overheat it and set that code. While it IS possible it could be a severe misfortune of racks, I highly doubt it.

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  • 3 months later...

ok, so just to resurrect this thread because I'm at my witts end...  So after bringing it back for the 3rd time, they said they were able to find a wiring harness issue and the tech was able to duplicate the issue and fixed it.  This lasted a few days if I recall correctly until it failed again.  The 4th time back, they worked with the Ford hotline and Ford recommended replacing some battery cable that connects the EPAS to the battery under the hood (or some junction box).  

After this replacement, I was able to go roughly 5,000 miles until it failed again a little over a week ago.  Dropped it back off at the dealership, called Ford to start a case and dealt with the covering service manager for the one on vacation.  After 4 or 5 days in the shop, my water pump went on my F350 with 44k on it.  They got it right in the next day for me as a big favor (needed to plow a 24 hour snow storm the day after) and inquired about the Explorer.  The temp SM stated that they have been working with the Ford hotline again and that the front ball joints were basically frozen.  He said when they disconnected the front end (forget what they did), they could barely turn the front wheels left to right etc.  There was so much resistance on it.  

So now the dealership replaced both lower control arms and I believe both tie rods.  Another alignment was done and off we drove Monday afternoon after the dealer has had it for a little over a week.  This now brings me to Saturday night when we are heading out to eat (my wife and kids with me) and sure as shit, another EPAS failure.  

So lets go over what has happened so far.  2 EPAS units replaced, wiring harness, some type of battery/power cable that powers the EPAS, 2 lower control arms (with ball joints) and tie rods and an alignment done after just about every repair so far.  Tires are fine and air pressure is fine.  

Here is what I'm thinking and looking for opinions on it.  2nd EPAS put in which could have been defective out of the box... but maybe not, 3rd EPAS went in and went out as well.   Battery cable and wire harness was never the issue... maybe the ball joints as suggested here binding was the cause of the #2 and #3 failing..  and now that the dealer found this, thought the EPAS would be ok by just resetting it now that it won't work as hard.  But maybe the damage has already been done to it after 3 failures of it (2 prior to the front end work being found bad).

Either way, I'm on my way back in tomorrow on my nice 35 drive with no Power Steering..  it will be fun!!!

For those who work for Ford..  is there any action I can take personally with Ford?  The rep who created my case refused to send it to the regional CS manager because it wasn't at the dealer...  they said they would close the case if she escalated it to them without the dealer looking at it.  My issue is that it's been worked on 5 times now...  so having the dealer "diagnose the problem first" is a problem for me.  I know I have 138,000 miles on it but I am still under my Ford ESP till 156,000 miles.  Yes they are responsible for fixing it but seriously, I'm completely at the mercy of Ford and all these visits.. all the time I've had to take out of my day to pick up, drop off, get rentals, etc...  this is really getting old and I frankly don't have any trust in the vehicle.  

I'm glad I have a 2020 Explorer on order but seriously, still want this problem fixed.

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