2022 Ford F-150

21S53 – Loose/Sagging Underbody Insulators – 2021-2022 Ford F-150

by
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August 12, 2022 NHTSA CAMPAIGN NUMBER: 22V623000

Damaged Driveshaft May Fracture

A fractured driveshaft can cause a loss of drive power, or a loss of vehicle control if the driveshaft contacts the ground. Additionally, unintended movement could occur while parked if the parking brake is not engaged. Any of these scenarios increases the risk of a crash.

 

NHTSA Campaign Number: 22V623

Manufacturer Ford Motor Company

Components POWER TRAIN, STRUCTURE

Potential Number of Units Affected 58,203

 

Summary

Ford Motor Company (Ford) is recalling certain 2021-2022 F-150 vehicles. Underbody heat and noise insulators may loosen and contact the aluminum driveshaft, which could damage the driveshaft and cause it to fracture.

 

Remedy

Dealers will inspect and repair the driveshaft, as necessary, and properly attach the underbody insulators, free of charge. Owner notification letters were mailed September 1, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 22S53.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Vehicle has a Recall

 

August 15, 2022

NEW VEHICLE DEMONSTRATION / DELIVERY HOLD –
Safety Recall 22S53
Certain 2021-2022 Model Year F-150 Vehicles Equipped with Crew Cab, 145” Wheelbase,
4×4, One-Piece Aluminum Driveshaft, and MFAL BHDAA (Less Sound Insulation Packs)*
Loose/Sagging Underbody Insulators

*This corresponds to Equipment Packages XL & XLT 301A and below, and Tremor 400A.

 

AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
F-150 2021-2022 Dearborn January 22, 2020 through November 2, 2021
F-150 2021-2022 Kansas City June 1, 2020 through October 15, 2021

The eleventh VIN position is the assembly plant code.

  • F – Dearborn Assembly (Dearborn, Michigan) = DTP
  • K – Kansas City Assembly (Claycomo, Missouri) = KCAP

Affected vehicles are identified in OASIS and FSA VIN Lists.

 

REASON FOR THIS SAFETY RECALL

In some of the affected vehicles, underbody insulators may have been installed in error. If installed, the underbody insulators may loosen and contact the aluminum driveshaft, resulting in marking or scoring of the driveshaft. Over time, the aluminum driveshaft may fracture, which can result in loss of motive power while driving, unintended vehicle movement while the vehicle is in park if the parking brake is not applied, and secondary damage to surrounding components. A fractured driveshaft may also contact the ground which may cause loss of control of the vehicle while driving. A fractured driveshaft increases the risk of injury or crash.

 

SERVICE ACTION

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers will inspect if either the driver or passenger-side underbody insulator(s) are present. If either underbody insulator is present, the dealer will secure the underbody insulator(s) and inspect the driveshaft, fuel vapor lines and electrical connectors for damage and repair as required. This service must be performed on all affected vehicles at no charge to the vehicle owner.

 

OWNER NOTIFICATION MAILING SCHEDULE

Owner letters are expected to be mailed the week of September 5, 2022. Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

PLEASE NOTE:

Federal law requires dealers to complete this recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $21,000 per vehicle. Correct all vehicles in your new vehicle inventory before delivery. 

 

SOLD VEHICLES

  • Ford has not issued instructions to stop selling/delivering or driving used vehicles under this safety recall. Owners should contact their dealer for an appointment to have their vehicles remedied as soon as practicable. Owners can continue to safely drive their vehicles.
  • Immediately contact any of your affected customers whose vehicles are not on your VIN list but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date.
  • Correct other affected vehicles identified in OASIS which are brought to your dealership.
  • Dealers are to prioritize repairs of customer vehicles over repairs of new and used vehicle inventory.

 

STOCK VEHICLES

  • Correct all affected units in your new vehicle inventory before delivery.
  • Use OASIS to identify any affected vehicles in your used vehicle inventory.

 

DEALER-OPERATED RENTAL VEHICLES

The Fixing America’s Surface Transportation (FAST) Act law effective June 2016 prohibits a rental company from selling, renting or leasing vehicles subject to a safety or compliance recall. Please consult your legal counsel for legal advice.

 

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this recall.

 

OWNER REFUNDS

  • This safety recall must still be performed, even if the owner has paid for a previous repair. Claiming a refund will not close the recall on the vehicle.
  • Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. Owners are directed to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121-6251.
  • Dealers are also pre-approved to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed.
  • Refunds will only be provided for the cost associated with driveshaft replacement.

 

RENTAL VEHICLES

  • PASS INSPECTION: Vehicles that pass the applicable driveshaft, fuel systems, and electrical inspections are NOT affected and are not approved for rental vehicles. Refer to the 22S53 technical instructions for additional information.
  • FAIL INSPECTION: Vehicles that fail either the applicable driveshaft, fuel systems, or electrical inspections
    • Parts are NOT available:
      • PARTS ESCALATION PROCESS (Vehicle Off Road) process has been followed and COPIS ticket with VOR flagged has been submitted.
      • Prior approval is required from the SSSC, submit contact type long-term rental for consideration and approval if appropriate.
  • A ten-digit prior-approval code is required from the SSSC for rental vehicles, a new approval code is required from SSSC every 30 days.
  • If rental vehicles are needed beyond December 31, 2022, dealers will have to contact SSSC for an extension.
  • Approval for all rental vehicles for this program will end on December 31, 2022.
  • Follow Extended Service Plan (ESP) guidelines for dollar amounts. Prior approval is required from the SSSC.

 

PARTS REQUIREMENTS / ORDERING INFORMATION SSSC Web Contact Site:

Parts are not yet available to repair all vehicles. Until parts are available to repair all vehicles, dealers may only order parts and repair vehicles, which are customer-owned vehicles currently in the dealership and unsold vehicles with a signed sales contract.

 

Driveshaft – Only replace the driveshaft if marks are present per the technical instructions.

Part Number Description Order Quantity
*-4602-* Driveshaft (part number varies by vehicle – use Ford ECat to identify the specific part number by VIN) As Required

NOTE: The Driveshaft flange to pinion flange bolt part number N800594-S100 has been removed from the parts list for this program, and may be reused.  Refer to the 22S53 Technical Information on updated instructions for thread cleaning and application of thread adhesive.

 

Rivet Part Number’s   Description Order Quantity
Any of the following part numbers may be used:

W702554-S900
W702554-S437
W708777-S900C
W719880-S417
Rivets

(Pack of 4, 5 needed per DTP vehicles,

2 needed per KCAP vehicles)

NOTE: Part numbers ending in S900C are packages of 100

  

 

 

2 DTP
1 KCAP

 

Aluminum Driveshaft, and MFAL BHDAA (Less Sound Insulation Packs) Loose/Sagging Underbody Insulators

Repair Part Number Description Order Quantity
All PM-13-BeBay Motorcraft Anti-Corrosion Coating

(16 fl. Oz per container, applied to all rivets liberally, 2 Oz. per repair, repair 8 vehicles per can)

Check dealer inventory before ordering additional quantities

 As Needed
or

Equivalent (use OSP)
All TA-2-B 21S53 - Loose/Sagging Underbody Insulators - 2021-2022 Ford F-150 | small light Motorcraft Seam Sealer

(9.5 fl. Oz per tube, applied to all rivets liberally, 1 Oz per rivet, 1-5 Oz per vehicle, repair 1-5 vehicles per tube)

Check dealer inventory before ordering additional quantities

 As Needed
or

Equivalent (use OSP)
Driveshaft Replacement XG-1-E1 21S53 - Loose/Sagging Underbody Insulators - 2021-2022 Ford F-150 | small light Motorcraft® Premium Long-Life Grease 1
Driveshaft Replacement XT-10QLVC MERCON® LV Automatic Transmission Fluid  (12 per case, 1 Quart bottle required) 1

 

Obtain the parts below locally:

Part Number Description Quantity Needed
Obtain Locally Zinc coated steel or Aluminum washers, ¼ inch ID, 2-inch OD, Thickness 2mm (Max). 5 needed per DTP Vehicle Claim as Misc. Other
2 needed per KCAP Vehicle Claim as Misc. Other
Obtain Locally LOCTITE 243 Blue Medium Strength Threadlocker or equivalent – Specification WSK-M2G349-A7 1 tube needed per vehicle Claim as Misc. Other

 

CERTAIN 2021-2022 MODEL YEAR F-150 VEHICLES EQUIPPED WITH A CREW CAB, 145″ WHEELBASE, 4X4, ONE-PIECE ALUMINUM DRIVESHAFT, AND MFAL BHDAA (LESS SOUND INSULATION PACKS) – LOOSE/SAGGING UNDERBODY INSULATORS

SERVICE PROCEDURE

GAS ENGINES – VEHICLES MANUFACTURED AT DEARBORN TRUCK ASSEMBLY PLANT

Table Of Contents

Underbody Insulator Presence – 1
Check for DTCs – 3
Inspection – 3
Driveshaft – 3
Zones 1, 3 and 4 – 3
Zone 2 – 5
Driver Side Insulator – 7
Vapor Line – 7
Securing Underbody Insulators – 9
Appendix A – Acceptable Photos – 13

 

Underbody Insulator Presence

1. With the vehicle in NEUTRAL, position it on a hoist. Please follow Workshop Manual (WSM) procedures in Section 100-02.

2. Are either one or both of the underbody insulators present on the vehicle? See Figure 1.

Yes – Proceed to step 3.

No – This recall is complete.

 

NOTE: The driver side insulator is located directly above the fuel tank.

NOTE: The passenger side insulator is located directly above the exhaust.

NOTE: Insulators are highlighted for illustration purposes only.

 

Review the video link below before starting this repair procedure:

https://bcove.video/3rdmqR0

 

Materials List

Ruler/Scale/Straight Edge 13 mm (1/2 in) Drill Stop Small Brush
Drill 6.7 mm (17/64 in) Drill Bit Marker
1/4″ Rivet Gun 5.1 mm (13/64 in) Drill Bit – Rivet W719880-S417 Tape

 

NOTE: A ¼” air over hydraulic rivet gun was used for the service trials for this program, however a pneumatic rivet gun or a manual rivet gun may also be used. However, it may not be possible to access and properly secure the rivets into the floor pan using a manual rivet gun. It is important to always confirm the rivet is properly secured to the floor pan of the vehicle.

 

Check for DTCs

3. Using the Ford Diagnostic and Repair System (FDRS), check the Powertrain Control Module (PCM) for DTCs. Are either of the following DTC’s present in the PCM, P0442 and/or P0456?

Yes – Please follow Workshop Manual (WSM) procedures for pinpoint test HX in Section 303-13, then proceed to step 4.

No – Proceed to step 4.

 

Inspection

4. Remove the driveshaft. Please follow WSM procedures in Section 205-01.

NOTE: Do NOT discard the driveshaft flange to pinion flange bolts.

 

Zones 1, 3 and 4

5. Inspect Zones 1, 3 and 4 of the rear driveshaft for any marks caused by the front and/or rear edges of the passenger side insulator. Are there any marks present in Zones 1, 3 or 4? See Figure 2.

Yes – Proceed to step 6.

No – Proceed to step 8.

 

6. What is the current odometer reading?

> 2,500 miles – Proceed to step 7.

< 2,500 miles – Proceed to step 8.

 

7. Place a straight edge along the driveshaft over the wear mark and attempt to fit a 0.018in (0.45mm) feeler gauge between the flat edge and the wear mark. Can the feeler gauge fit between the straight edge and anywhere along the wear mark? See Figures 3 and 4.

Yes – Does not pass inspection. Contact the SSSC and provide a picture of the driveshaft with the feeler gauge fitting between the straight edge and wear mark. Once approved, rear driveshaft replacement will be required, but do not install at this time. Proceed to step 10.

No – Passes inspection. Proceed to step 8.

 

Zone 2

8. Inspect Zone 2 (transition from larger tube diameter to smaller diameter section) of the driveshaft tube for any marks caused by the front edge of the passenger side insulator. Are there any marks present? See Figure 5.

Yes – Does not pass inspection. Proceed to step 9.

No – Passes inspection. Driveshaft may be reused. Proceed to step 10.

 

9. Inspect the marks found on Zone 2. Is the aluminum tube surface grain pattern worn off, completely smooth, or have an appearance of necking? See Figures 6 through 9.

Yes – Does not pass inspection. Contact the SSSC and provide a picture of the driveshaft with the grain pattern worn off. Be sure to show a clear image of the grain pattern missing. Once approved, rear driveshaft replacement will be required, but do not install at this time. Proceed to step 10.

No – Passes inspection. Driveshaft may be reused. Proceed to step 10.

 

Driver Side Insulator

10. Inspect the driver side insulator for any edges hanging down or touching the fuel tank. Is the insulator hanging down or touching the fuel tank? See Figure 10.

Yes – Does not pass inspection. Proceed to step 11.

No – Passes inspection. Proceed to step 13.

 

11. Remove the fuel tank to gain access to the vapor line. Please follow WSM procedures in Section 310-01.

12. Inspect the vapor line for any damage caused by the driver side insulator. Is there any damage to the line? See Figures 11 through 13.

Yes – Does not pass inspection. Replace the damaged line. Please follow WSM procedures in Section 310-01, then proceed to step 13.

No – Passes inspection. Proceed to step 13.

 

Securing Underbody Insulators

NOTE: Perform steps 13 through 22 ONLY on the side(s) where the insulator(s) are present.

13. Measure and mark the four locations on the passenger side insulator and mark the one location on the driver side insulator. See Figures 14 and 15.

 

14. Use the 5.1 mm (13/64 in) drill bit for rivet part number W719880-S417 or the 6.7mm (17/64 in) drill bit for all other rivet part numbers to drill a hole through the insulator and into the floor. See Figure 16.

NOTE: Use the 13 mm (1/2 in) drill stop to ensure you do not drill through the carpet.

 

15. Repeat step 14 for the remaining four marked locations.

16. Using a small brush, apply a layer of the anti-corrosion coating to the edges of the newly drilled holes.

17. Install the washer onto the rivet. See Figure 17.

NOTE: All approved listed rivet part numbers may not look identical to the photos in the technical instructions.

 

18. Apply a thick layer of seam sealer to the rivet, and the backside of the washer. See Figure 18.

 

19. Using a 1/4″ rivet gun, install the rivet and washer to the drilled hole. See Figure 19.

NOTE: To ensure the rivet is properly secured, apply as much force to the rivet gun as possible.

 

20. Attempt to move the washer/rivet to confirm it is properly secured.

21. Using a small brush, apply a layer of the anti-corrosion coating to the washer and rivet.

22. Repeat steps 17-21 for the remaining four drilled holes.

 

23. Install the fuel tank if it was removed in the inspection. Please follow WSM procedures in Section 310-01.

24. Using an air blow gun, remove any debris from threaded holes in axle flange. See Figure 20.

NOTE: Make sure that the mating faces are clean and free of foreign material.

 

25. Inspect the original driveshaft flange to pinion flange bolts for rust in the threads and replace if rusted or damaged. Clean threads of the original driveshaft flange to pinion flange bolts with a wire brush and coat the threads with LOCTITE 243 Blue Medium Strength Threadlocker or equivalent. See Figure 21.

 

26. Install the driveshaft. Please follow WSM procedures in Section 205-01.

 

CERTAIN 2021-2022 MODEL YEAR F-150 VEHICLES EQUIPPED WITH A CREW CAB, 145″ WHEELBASE, 4X4, ONE-PIECE ALUMINUM DRIVESHAFT, AND MFAL BHDAA (LESS SOUND INSULATION PACKS) – LOOSE/SAGGING UNDERBODY INSULATORS

 

SERVICE PROCEDURE

DIESEL ENGINES

Table Of Contents

Underbody Insulator Presence – 1
Inspection – 3
Driveshaft – 3
Zones 1, 3 and 4 – 3
Zone 2 – 5
Securing Underbody Insulators – 7
Appendix A – Acceptable Photos – 11

 

Underbody Insulator Presence

1. With the vehicle in NEUTRAL, position it on a hoist. Please follow Workshop Manual (WSM) procedures in Section 100-02.

2. Are either one or both of the underbody insulators present on the vehicle? See Figure 1.

Yes – Proceed to step 3.

No – This recall is complete.

 

NOTE: The driver side insulator is located directly above the fuel tank.

NOTE: The passenger side insulator is located directly above the exhaust.

NOTE: Insulators are highlighted for illustration purposes only.

 

Review the video link below before starting this repair procedure:

https://bcove.video/3rdmqR0

 

Materials List

Ruler/Scale/Straight Edge 13 mm (1/2 in) Drill Stop Small Brush
Drill 6.7 mm (17/64 in) Drill Bit Marker
1/4″ Rivet Gun 5.1 mm (13/64 in) Drill Bit – Rivet W719880-S417 Tape

 

NOTE: A ¼” air over hydraulic rivet gun was used for the service trials for this program, however a pneumatic rivet gun or a manual rivet gun may also be used. However, it may not be possible to access and properly secure the rivets into the floor pan using a manual rivet gun. It is important to always confirm the rivet is properly secured to the floor pan of the vehicle.

 

Inspection

3. Remove the driveshaft. Please follow WSM procedures in Section 205-01.

NOTE: Do NOT discard the driveshaft flange to pinion flange bolts.

 

Zones 1, 3 and 4

4. Inspect Zones 1, 3 and 4 of the rear driveshaft for any marks caused by the front and/or rear edges of the passenger side insulator. Are there any marks present in Zones 1, 3 or 4? See Figure 2.

Yes – Proceed to step 5.

No – Proceed to step 7.

 

5. What is the current odometer reading?

> 2,500 miles – Proceed to step 6.

< 2,500 miles – Proceed to step 7.

 

6. Place a straight edge along the driveshaft over the wear mark and attempt to fit a 0.018in (0.45mm) feeler gauge between the flat edge and the wear mark. Can the feeler gauge fit between the straight edge and anywhere along the wear mark? See Figures 3 and 4.

Yes – Does not pass inspection. Contact the SSSC and provide a picture of the driveshaft with the feeler gauge fitting between the straight edge and wear mark. Once approved, rear driveshaft replacement will be required, but do not install at this time. Proceed to step 9.

No – Passes inspection. Proceed to step 7.

 

Zone 2

7. Inspect Zone 2 (transition from larger tube diameter to smaller diameter section) of the driveshaft tube for any marks caused by the front edge of the passenger side insulator. Are there any marks present? See Figure 5.

Yes – Does not pass inspection. Proceed to step 8.

No – Passes inspection. Driveshaft may be reused. Proceed to step 9.

 

8. Inspect the marks found on Zone 2. Is the aluminum tube surface grain pattern worn off, completely smooth, or have an appearance of necking? See Figures 6 through 9.

Yes – Does not pass inspection. Contact the SSSC and provide a picture of the driveshaft with the grain pattern worn off. Be sure to show a clear image of the grain pattern missing. Once approved, rear driveshaft replacement will be required, but do not install at this time. Proceed to step 9.

No – Passes inspection. Driveshaft may be reused. Proceed to step 9.

 

Securing Underbody Insulators

NOTE: Perform steps 9 through 18 ONLY on the side(s) where the insulator(s) are present.

9. Measure and mark the four locations on the passenger side insulator and mark the one location on the driver side insulator. See Figures 10 and 11.

 

10. Use the 5.1 mm (13/64 in) drill bit for rivet part number W719880-S417 or the 6.7mm (17/64 in) drill bit for all other rivet part numbers to drill a hole through the insulator and into the floor. See Figure 12.

NOTE: Use the 13 mm (1/2 in) drill stop to ensure you do not drill through the carpet.

 

11. Repeat step 10 for the remaining four marked locations.

12. Using a small brush, apply a layer of the anti-corrosion coating to the edges of the newly drilled holes.

13. Install the washer onto the rivet. See Figure 13.

NOTE: All approved listed rivet part numbers may not look identical to the photos in the technical instructions.

 

14. Apply a thick layer of seam sealer to the rivet, and the backside of the washer. See Figure 14.

 

15. Using a 1/4″ rivet gun, install the rivet and washer to the drilled hole. See Figure 15.

NOTE: To ensure the rivet is properly secured, apply as much force to the rivet gun as possible.

 

16. Attempt to move the washer/rivet to confirm it is properly secured.

17. Using a small brush, apply a layer of the anti-corrosion coating to the washer and rivet.

18. Repeat steps 13-17 for the remaining four drilled holes.

 

19. Using an air blow gun, remove any debris from threaded holes in axle flange. See Figure 16.

NOTE: Make sure that the mating faces are clean and free of foreign material.

 

20. Inspect the original driveshaft flange to pinion flange bolts for rust in the threads and replace if rusted or damaged. Clean threads of the original driveshaft flange to pinion flange bolts with a wire brush and coat the threads with LOCTITE 243 Blue Medium Strength Threadlocker or equivalent. See Figure 17.

 

21. Install the driveshaft. Please follow WSM procedures in Section 205-01.

 

CERTAIN 2021-2022 MODEL YEAR F-150 VEHICLES EQUIPPED WITH A CREW CAB, 145″ WHEELBASE, 4X4, ONE-PIECE ALUMINUM DRIVESHAFT, AND MFAL BHDAA (LESS SOUND INSULATION PACKS) – LOOSE/SAGGING UNDERBODY INSULATORS

 

SERVICE PROCEDURE

HYBRID ENGINES

Table Of Contents

Underbody Insulator Presence – 1
Inspection – 3
Driveshaft – 3
Zones 1, 3 and 4 – 3
Zone 2 – 5
ECT Sensor Connectors – 7
Remove Passenger Side Insulator – 8
Clean Sheet Metal Surface – 8
Secure Driver Side Insulator – 9
Appendix A – Acceptable Photos – 13

 

Underbody Insulator Presence

1. With the vehicle in NEUTRAL, position it on a hoist. Please follow Workshop Manual (WSM) procedures in Section 100-02.

2. Are either one or both of the underbody insulators present on the vehicle? See Figure 1.

Yes – Proceed to step 3.

No – This recall is complete.

 

NOTE: The driver side insulator is located directly above the fuel tank.

NOTE: The passenger side insulator is located directly above the exhaust.

NOTE: Insulators are highlighted for illustration purposes only.

 

Review the video link below before starting this repair procedure:

https://bcove.video/3rdmqR0

 

Materials List

Ruler/Scale/Straight Edge 13 mm (1/2 in) Drill Stop Small Brush
Drill 6.7 mm (17/64 in) Drill Bit Marker
1/4″ Rivet Gun 5.1 mm (13/64 in) Drill Bit – Rivet W719880-S417 Tape

 

NOTE: A ¼” air over hydraulic rivet gun was used for the service trials for this program, however a pneumatic rivet gun or a manual rivet gun may also be used. However, it may not be possible to access and properly secure the rivets into the floor pan using a manual rivet gun. It is important to always confirm the rivet is properly secured to the floor pan of the vehicle.

 

Inspection

3. Remove the driveshaft. Please follow WSM procedures in Section 205-01.

NOTE: Do NOT discard the driveshaft flange to pinion flange bolts.

 

Zones 1, 3 and 4

4. Inspect Zones 1, 3 and 4 of the rear driveshaft for any marks caused by the front and/or rear edges of the passenger side insulator. Are there any marks present in Zones 1, 3 or 4? See Figure 2.

Yes – Proceed to step 5.

No – Proceed to step 7.

 

5. What is the current odometer reading?

> 2,500 miles – Proceed to step 6.

< 2,500 miles – Proceed to step 7.

 

6. Place a straight edge along the driveshaft over the wear mark and attempt to fit a 0.018in (0.45mm) feeler gauge between the flat edge and the wear mark. Can the feeler gauge fit between the straight edge and anywhere along the wear mark? See Figures 3 and 4.

Yes – Does not pass inspection. Contact the SSSC and provide a picture of the driveshaft with the feeler gauge fitting between the straight edge and wear mark. Once approved, rear driveshaft replacement will be required, but do not install at this time. Proceed to step 9.

No – Passes inspection. Proceed to step 7.

 

Zone 2

7. Inspect Zone 2 (transition from larger tube diameter to smaller diameter section) of the driveshaft tube for any marks caused by the front edge of the passenger side insulator. Are there any marks present? See Figure 5.

Yes – Does not pass inspection. Proceed to step 8.

No – Passes inspection. Driveshaft may be reused. Proceed to step 9.

 

8. Inspect the marks found on Zone 2. Is the aluminum tube surface grain pattern worn off, completely smooth, or have an appearance of necking? See Figures 6 through 9.

Yes – Does not pass inspection. Contact the SSSC and provide a picture of the driveshaft with the grain pattern worn off. Be sure to show a clear image of the grain pattern missing. Once approved, rear driveshaft replacement will be required, but do not install at this time. Proceed to step 9.

No – Passes inspection. Driveshaft may be reused. Proceed to step 9.

 

9. Inspect the front Engine Coolant Temperature (ECT) sensor connectors for any damage caused by the passenger side insulator. Is there any damage? See Figure 10.

Yes – Does not pass inspection. Contact the SSSC and provide a picture of the damage for proper technical instructions and part numbers, then proceed to step 10.

No – Proceed to step 10.

 

10. Is the passenger side insulator present on the vehicle?

Yes – Proceed to step 11.

No – Proceed to step 14.

 

Remove Passenger Side Insulator

11. Carefully remove and discard the passenger side insulator from the underside of the pickup bed. See Figure 11.

NOTE: Do NOT use metal scrapers, wire brushes, power sanding or grinding discs, or any abrasive means to clean surfaces. These tools cause scratches and gouges which make leak paths.

 

Clean Sheet Metal Surface

12. Using both hands and/or a plastic scraper, remove as much of the remaining substrate material as possible. See Figure 12.

 

13. Using Mineral Spirits/Goo-Gone/3M Adhesive Remover/Brake Cleaner and lint-free rags or equivalent, clean the sheet metal surface.

 

Secure Driver Side Insulator

14 Measure and mark the one location on the driver side insulator. See Figures 13 and 14.

 

15. Use the 5.1 mm (13/64 in) drill bit for rivet part number W719880-S417 or the 6.7mm (17/64 in) drill bit for all other rivet part numbers to drill a hole through the insulator and into the floor. See Figure 15.

NOTE: Use the 13mm (1/2 in) drill stop to ensure you do not drill through the carpet.

 

16. Using a small brush, apply a layer of the anti-corrosion coating to the edges of the newly drilled hole.

17. Install the washer onto the rivet. See Figure 16.

NOTE: All approved listed rivet part numbers may not look identical to the photos in the technical instructions.

 

18. Apply a thick layer of seam sealer to the rivet, and the backside of the washer. See Figure 17.

 

19. Using a 1/4″ rivet gun, install the rivet and washer to the drilled hole. See Figure 18.

NOTE: To ensure the rivet is properly secured, apply as much force to the rivet gun as possible.

 

20. Attempt to move the washer/rivet to confirm it is properly secured.

21. Using a small brush, apply a layer of the anti-corrosion coating to the washer and rivet.

 

22. Using an air blow gun, remove any debris from threaded holes in axle flange. See Figure 19.

NOTE: Make sure that the mating faces are clean and free of foreign material.

 

23. Inspect the original driveshaft flange to pinion flange bolts for rust in the threads and replace if rusted or damaged. Clean threads of the original driveshaft flange to pinion flange bolts with a wire brush and coat the threads with LOCTITE 243 Blue Medium Strength Threadlocker or equivalent. See Figure 20.

 

24. Install the driveshaft. Please follow WSM procedures in Section 205-01.

 

CERTAIN 2021-2022 MODEL YEAR F-150 VEHICLES EQUIPPED WITH A CREW CAB, 145″ WHEELBASE, 4X4, ONE-PIECE ALUMINUM DRIVESHAFT, AND MFAL BHDAA (LESS SOUND INSULATION PACKS) – LOOSE/SAGGING UNDERBODY INSULATORS

 

SERVICE PROCEDURE

GAS ENGINES – VEHICLES MANUFACTURED AT KANSAS CITY TRUCK ASSEMBLY PLANT

Table Of Contents

Underbody Insulator Presence – 1
Check for DTCs – 3
Inspection – 3
Driveshaft – 3
Zones 1, 3 and 4 – 3
Zone 2 – 5
Secure Passenger Side Insulator – 7
Appendix A – Acceptable Photos – 11

 

Underbody Insulator Presence

1. With the vehicle in NEUTRAL, position it on a hoist. Please follow Workshop Manual (WSM)
procedures in Section 100-02.

2. Is the passenger side underbody insulator present on the vehicle? See Figure 1.

Yes – Proceed to step 3.

No – This recall is complete.

 

NOTE: If ONLY the driver side insulator is present, no action is required.

 

NOTE: The driver side insulator is located directly above the fuel tank.

NOTE: The passenger side insulator is located directly above the exhaust.

NOTE: Insulators are highlighted for illustration purposes only.

 

Review the video link below before starting this repair procedure:

https://bcove.video/3rdmqR0

 

Materials List

Ruler/Scale/Straight Edge 13 mm (1/2 in) Drill Stop Small Brush
Drill 6.7 mm (17/64 in) Drill Bit Marker
1/4″ Rivet Gun 5.1 mm (13/64 in) Drill Bit – Rivet W719880-S417 Tape

 

NOTE: A ¼” air over hydraulic rivet gun was used for the service trials for this program, however a pneumatic rivet gun or a manual rivet gun may also be used. However, it may not be possible to access and properly secure the rivets into the floor pan using a manual rivet gun. It is important to always confirm the rivet is properly secured to the floor pan of the vehicle.

 

Check for DTCs

3. Using the Ford Diagnostic and Repair System (FDRS), check the Powertrain Control Module (PCM) for DTCs. Are either of the following DTC’s present in the PCM, P0442 and/or P0456?

Yes – Please follow Workshop Manual (WSM) procedures for pinpoint test HX in Section 303-13, then proceed to step 4.

No – Proceed to step 4.

Inspection

4. Remove the driveshaft. Please follow WSM procedures in Section 205-01.

NOTE: Do NOT discard the driveshaft flange to pinion flange bolts.

 

Zones 1, 3 and 4

5. Inspect Zones 1, 3 and 4 of the rear driveshaft for any marks caused by the front and/or rear edges of the passenger side insulator. Are there any marks present in Zones 1, 3 or 4? See Figure 2.

Yes – Proceed to step 6.

No – Proceed to step 8.

 

6. What is the current odometer reading?

> 2,500 miles – Proceed to step 7.

< 2,500 miles – Proceed to step 8.

 

7. Place a straight edge along the driveshaft over the wear mark and attempt to fit a 0.018in (0.45mm) feeler gauge between the flat edge and the wear mark. Can the feeler gauge fit between the straight edge and anywhere along the wear mark? See Figures 3 and 4.

Yes – Does not pass inspection. Contact the SSSC and provide a picture of the driveshaft with the feeler gauge fitting between the straight edge and wear mark. Once approved, rear driveshaft replacement will be required, but do not install at this time. Proceed to step 10.

No – Passes inspection. Proceed to step 8.

 

Zone 2

8. Inspect Zone 2 (transition from larger tube diameter to smaller diameter section) of the driveshaft tube for any marks caused by the front edge of the passenger side insulator. Are there any marks present? See Figure 5.

Yes – Does not pass inspection. Proceed to step 9.

No – Passes inspection. Driveshaft may be reused. Proceed to step 10.

 

9. Inspect the marks found on Zone 2. Is the aluminum tube surface grain pattern worn off, completely smooth, or have an appearance of necking? See Figures 6 through 9.

Yes – Does not pass inspection. Contact the SSSC and provide a picture of the driveshaft with the grain pattern worn off. Be sure to show a clear image of the grain pattern missing. Once approved, rear driveshaft replacement will be required, but do not install at this time. Proceed to step 10.

No – Passes inspection. Driveshaft may be reused. Proceed to step 10.

 

Secure Passenger Side Insulator

10. Measure and mark the two locations on the passenger side insulator. See Figure 10.

 

11. Use the 5.1 mm (13/64 in) drill bit for rivet part number W719880-S417 or the 6.7mm (17/64 in) drill bit for all other rivet part numbers to drill a hole through the insulator and into the floor. See Figure 11.

NOTE: Use the 13 mm (1/2 in) drill stop to ensure you do not drill through the carpet.

 

12. Repeat step 11 for the second marked location.

13. Using a small brush, apply a layer of the anti-corrosion coating to the edges of the newly drilled holes.

14. Install the washer onto the rivet. See Figure 12.

NOTE: All approved listed rivet part numbers may not look identical to the photos in the technical instructions.

 

15. Apply a thick layer of seam sealer to the rivet, and the backside of the washer. See Figure 13.

 

16. Using a 1/4″ rivet gun, install the rivet and washer to the drilled hole. See Figure 14.

NOTE: To ensure the rivet is properly secured, apply as much force to the rivet gun as possible.

 

17. Attempt to move the washer/rivet to confirm it is properly secured.

18. Using a small brush, apply a layer of the anti-corrosion coating to the washer and rivet.

19. Repeat steps 14-18 for the second drilled hole.

 

20. Using an air blow gun, remove any debris from threaded holes in axle flange. See Figure 15.

NOTE: Make sure that the mating faces are clean and free of foreign material.

 

21. Inspect the original driveshaft flange to pinion flange bolts for rust in the threads and replace if rusted or damaged. Clean threads of the original driveshaft flange to pinion flange bolts with a wire brush and coat the threads with LOCTITE 243 Blue Medium Strength Threadlocker or equivalent. See Figure 16.

 

22. Install the driveshaft. Please follow WSM procedures in Section 205-01.

 

Chronology :

May 2022
On May 26, 2022, Ford’s Critical Concern Review Group (CCRG) initiated an investigation into reports of aluminum driveshaft fracture on F-150 Crew Cab units that were not included in Ford Field Service Action (FSA) 21S56 (NHTSA Campaign Number 21V-986). The prior safety recall was approved in December 2021 to address potential aluminum driveshaft fracture resulting from underbody insulator contact on units designed and built with underbody insulators.

June – July 2022
The CCRG investigation found that underbody insulators were installed in error on certain F-150 Crew Cab vehicles that were neither designed nor intended to be built with underbody insulators. The CCRG team reviewed records from the assembly plant and product designs to understand how vehicles could be manufactured with the unintended underbody insulators. The underbody insulators, which were installed in error, may experience the same issue of inadequate adhesion to the vehicle underbody as was addressed by FSA 21S56. This can result in loosening and sagging of the insulators, which may then contact the driveshaft.

Over time, contact of the sagging underbody insulator with the rotating aluminum driveshaft may result in material reduction and fracture of the aluminum driveshaft.

As of August 3, 2022, the team is aware of four (4) warranty reports in the United States for fractured aluminum driveshafts due to apparent underbody insulator contact on vehicles not intended to be equipped with the underbody insulators. The reports were received on November 10, 2021, May 12, 2022, May 24, 2022, and June 1, 2022.

On August 5, 2022, Ford’s Field Review Committee reviewed the concern and approved a field action.

Ford is not aware of any reports of accident or injury related to this condition.

 

2 Affected Products

Vehicle

MAKE MODEL YEAR
FORD F-150 2021-2022

 

9 Associated Documents

Recall Acknowledgement

RCAK-22V623-6975.pdf 645.308KB

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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 22S53 Certain 2021-2022 Model Year F-150 Vehicles Equipped with Crew Cab, 145” Wheelbase, 4×4, One-Piece Aluminum Driveshaft, and MFAL BHDAA (Less Sound Insulation Packs)* Loose/Sagging Underbody Insulators

RCMN-22V623-8744.pdf 6137.286KB

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Defect Notice 573 Report

RCLRPT-22V623-2762.PDF 216.02KB

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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 22S53 Certain 2021-2022 Model Year F-150 Vehicles Equipped with Crew Cab, 145” Wheelbase, 4×4, One-Piece Aluminum Driveshaft, and MFAL BHDAA (Less Sound Insulation Packs)* Loose/Sagging Underbody Insulators

RCMN-22V623-0847.pdf 11207.15KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V623-8611.pdf 54.356KB

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Recall Quarterly Report #1, 2022-3

RCLQRT-22V623-3911.PDF 211.133KB

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ISSUED Renotification Notice

RCRN-22V623-2488.pdf 544.583KB

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Recall Quarterly Report #2, 2022-4

RCLQRT-22V623-2937.PDF 211.238KB

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Recall Quarterly Report #3, 2023-1

RCLQRT-22V623-6689.PDF 211.328KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V623&docType=RCL

 

 

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