Case file
“Ford Needs to Recall Diesels Also”: The Cruise Control Switch Fires on the 7.3 Power Stroke
Published · 6 min read
In the summer of 2006, the owner of a 2000 F-250 diesel sent NHTSA a short complaint: the truck had caught fire at the cruise control cancel switch, "like the others", and it had not been recalled. Ford had just recalled the same switch on the same trucks, but only on those with gasoline engines.
It took Ford until October 2009 to add the diesels. This case file follows the switch from the first recalls to what it means for anyone buying a 7.3 today.
The part
The speed control deactivation switch is a small pressure switch on the brake master cylinder, which on these trucks sits on the driver's side of the engine bay. When you press the brake pedal, brake pressure trips it and the cruise control lets go.
According to Ford's 2009 recall filing, the switch "may leak internally and then overheat, smoke, or burn," and a fire "could occur with or without the engine running." verified That is why so many owners found their truck burning in the driveway.
The timeline
One of Ford's first switch recalls on pickups and SUVs: owners are told to have the switch disconnected until parts arrive. NHTSA: “a fire at the switch could occur.”
Super Duty trucks, the Excursion and E-Series vans are added, but only with “gasoline or natural gas engines”. Dealers install a fused wiring harness.
Within weeks, owners of 7.3 trucks report the same fire at the same switch. Several are told their truck is not covered because it is a diesel.
2003 Super Duty and Excursion added, again gasoline and natural gas engines only.
The diesels are added: 1993-1997 and 1999-2003 F-250 to F-550 Super Duty and the 2000-2003 Excursion. NHTSA: a fire “could occur with or without the engine running.” The same fused harness.
Complaints keep coming after the diesel recall, from trucks that never had the repair. One owner was told the letter had been mailed; it never arrived.
Recall dates are the dates NHTSA received each report (NHTSA recalls database); quotes are NHTSA's summary and consequence text. Owner complaints from the 7.3 Power Stroke set of our buying guide (607 NHTSA complaints).
The fix was the same each time: dealers installed a fused wiring harness in line with the switch, so a failing switch blows a fuse instead of starting a fire. verified
What the owners reported
| Filed | Truck | What the owner describes | NHTSA complaint |
|---|---|---|---|
| 2006 | 2000 F-250 | Fire at the cruise control cancel switch; “Ford needs to recall diesels also” | 10164643 |
| 2006 | 2000 F-250 | Fire under the hood at the switch while driving the children to school | 10166181 |
| 2006 | 1996 F-350 | Switch fire five minutes after parking; VIN not in 06V-286 “because the vehicle had a diesel engine” | 10167413 |
| 2007 | 1997 F-250 | Fire while idling in the driveway, melted the brake fluid reservoir; Ford said no recall | 10185054 |
| 2007 | 2001 F-350 | Flames from the wiring while idling; VIN not in 06V-286 because it has a diesel | 10199622 |
| 2007 | 2000 F-250 | Burning smell after a drive, then fire at the brake pressure switch connection; Ford said no recall | 10207041 |
| 2008 | 2000 F-250 | Fire at the master cylinder sensor in the driveway; not in 06V-286, a diesel | 10220044 |
| 2008 | 2000 F-250 | Cruise stopped working; three weeks later flames at the wiring beside the master cylinder | 10238811 |
| 2009 | 2000 F-250 | Smoke while driving, melted wire at the brake pressure switch; the recall left out diesels | 10274620 |
| 2010 | 1997 F-350 | Weak brake pedal and brake fluid smell, then flames near the master cylinder | 10322892 |
| 2011 | 2001 F-350 | Fire after 11 months in a garage; Ford says the 09V-399 letter was mailed, it never arrived | 10389855 |
| 2011 | 2001 F-250 | Fire in the driveway; the mechanics and the dealer pointed to the cruise control | 10424079 |
| 2011 | 1996 F-250 | Burning plastic smell while driving; the cruise control burned a hole in the brake fluid reservoir | 10432898 |
13 complaints in the 7.3 Power Stroke set that put a fire, smoke or melting at the speed control switch or its place on the brake master cylinder; every keyword match was read.
Read in order, the complaints tell the story by themselves. Through 2009, the owners describe the fire, look up the recall and are told it does not apply.
"Ford told me there was no recall for this switch for my truck because it is a diesel."
Owner of a 2000 F-250 7.3, after flames at the wiring beside the master cylinder, 2008. NHTSA complaint 10238811
That owner had a shop replace the switch and install the fused harness at their own cost, the same parts the gasoline trucks got for free.
Seven of the 13 fires started with the truck parked or idling: in the driveway, five minutes after parking, after 11 months in a garage. That is the pattern the recall warns about.
The warning signs owners noticed first: the cruise control stopped working, a smell of burning plastic or brake fluid, a soft brake pedal, or smoke from the driver's side by the brake master cylinder. aggregated
"Cruise control ceased working. Since this did not appear to be a serious issue… I continued driving."
The same 2000 F-250 owner. Three weeks later the wiring at the switch was on fire. NHTSA complaint 10238811
Why the diesels came last
The recall filings do not say why. What they do show is the order: the 2006 and 2007 Super Duty recalls name "gasoline or natural gas engines", and the 2009 campaign names the diesel F-250 to F-550 Super Duty and the diesel Excursion. verified We found no Ford statement on the reason, so we do not guess at one.
What it means for a 7.3 today
The youngest truck in this recall is now more than 20 years old, and many have changed hands several times since 2009. A truck that never had the repair still has an unfused switch.
- Run the VIN for 09V-399 (Ford's number 09S09) at NHTSA's recall lookup or at a Ford dealer. An open recall is a free repair, even now.
- Ask for the record if it shows as done, especially on a truck from an estate, a farm or a long storage.
- Do not ignore a dead cruise control on one of these trucks. It is the warning sign owners mention most.
- Look at the switch with the hood up: brake fluid around the master cylinder, or melted or burned wiring at the switch connector, is a reason to stop and have it checked.
Our 7.3 buying guide and the 7.3 recalls page list this recall with the others on the engine.
What we cannot tell you
- How many trucks burned. These are the owners who filed a complaint with NHTSA and named the switch, not a count of fires.
- Whether a given fire was the switch. The owners and their mechanics say so; NHTSA does not investigate each complaint.
- Ford's reasons for the order of the recalls.
FAQ
Is the 7.3 Power Stroke included in the cruise control switch recall?
Yes, since October 2009. Recall 09V-399 covers 1993-1997 and 1999-2003 F-250 to F-550 Super Duty diesels and the 2000-2003 Excursion diesel. Earlier recalls (06V-286, 07V-078) covered only gasoline and natural gas engines.
Can a 7.3 Power Stroke catch fire when it is turned off?
Owners report it, and the recall says so: the switch stays powered, and NHTSA's summary of 09V-399 says a fire could occur with or without the engine running. Seven of the 13 switch fires in our set started with the truck parked or idling.
What is the fix for the speed control deactivation switch?
A fused wiring harness installed in line with the switch, free at a Ford dealer under the recall. Check the VIN for 09V-399 to see whether it was done.
Go deeper
- Buying a used 7.3 Power Stroke · 7.3 won't start or dies while driving
- 7.3 Power Stroke recalls · 7.3 Power Stroke platform page · VIN lookup
- Diesel truck recalls and warranty extensions by engine
Sources. NHTSA recalls database: campaigns 05V-388, 06V-286, 07V-078 and 09V-399, summary, consequence and remedy text (US government public domain). NHTSA owner complaints on the 7.3 Power Stroke, the set of our buying guide; every complaint matching the switch and fire keywords was read, and the 13 kept are listed above with their numbers. Quotes normalized for capitalization. Torque Index takes no paid placement.