22S55 – Right Rear Halfshaft Inspection – 2022 Ford Mustang Mach-E

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August 26, 2022 NHTSA CAMPAIGN NUMBER: 22V646000

Rear Axle Half Shaft May Break Under Load

A broken half shaft can cause a loss of drive power, or a rollaway could occur while parked if the electronic parking brake is not engaged. Either of these scenarios can increase the risk of a crash.

 

NHTSA Campaign Number: 22V646

Manufacturer Ford Motor Company

Components POWER TRAIN

Potential Number of Units Affected 1,175

 

Summary

Ford Motor Company (Ford) is recalling certain 2022 Mustang Mach-E vehicles. The right-rear axle half shafts may have been manufactured improperly, allowing the half shaft stem to break under load.

 

Remedy

Dealers will inspect the serial number, and replace the right-rear half shaft, as necessary, free of charge. Owner notification letters were mailed September 19, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 22S55.

 

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 31, 2022

NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 22S55
Certain 2022 Model Year Mustang Mach-E Vehicles
Right Rear Halfshaft Inspection

 

AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
Mustang Mach-E 2022 Cuautitlan July 18, 2022 through July 29, 2022

 

Note: Some vehicles may be in the process of being repaired at the plant. Monitor OASIS before opening an RO and/or beginning a repair. Parts purchased for an FSA can be returned for credit, if required. See the EXCESS STOCK RETURN details in Attachment II for more information.

 

REASON FOR THIS SAFETY RECALL

In some of the affected vehicles, the right rear halfshaft may have been manufactured with a thin wall on the outer race of the inboard joint, which may break under load. A broken halfshaft will result in the loss of transmission torque to the rear wheels, which is necessary for motive power and for the transmission to hold the vehicle in park. If the electronic parking brake is not manually applied, the loss of the primary park torque will allow the vehicle to roll with the transmission in park increasing the risk of a crash.

 

SERVICE ACTION

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to inspect the right rear halfshaft and if it does not pass the inspection, replace it. Due to limited part supply, dealers must submit a part request, including a copy of the signed sales agreement for stock units, to the Special Service Support Center (SSSC). This service must be performed on all affected vehicles at no charge to the vehicle owner.

 

OWNER NOTIFICATION AND MAILING SCHEDULE

Owner letters are expected to be mailed by September 23, 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. 

 

MOBILE REPAIR RECOMMENDATIONS

  • Confirm with customer a mobile repair is feasible.
  • Check OASIS prior to going to the customer’s home or business to confirm if any other outstanding FSA needs to be completed.
  • Transportation – due to the simplicity of this repair, a specialty vehicle is not required.

 

MOBILE REPAIR ADDITIONAL INFORMATION

Please ensure the technician brings the following to the mobile repair destination:

  • Printed Technical Instructions.
  • Printed Repair/Work Order or any other necessary documentation as customer copy(s) o Documents could also be emailed to the customer.
  • Shirt/uniform and vehicle graphic with dealership or Ford logos are recommended.
  • Recommended tools and cleaning supplies:

Floor jack, jack stands, lug wrench or cordless impact, lug socket, torque wrench

 

MOBILE REPAIR QUESTIONS AND ASSISTANCE

  • For questions and assistance, contact the Special Service Support Center (SSSC) via the SSSC Web Contact Site. Work with Dealership warranty administrator to create a SSSC contact ID#.
  • Once an SSSC agent responds to the new contact ID#, you may opt to call the SSSC hotline: (800) 325-5621.

 

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 vehicle, however, should manually apply the electronic parking brake prior to exiting.
  • 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 a broken right rear halfshaft.

 

RENTAL VEHICLES

For vehicles requiring halfshaft replacement, dealers are pre-approved for up to 1 day for a rental vehicle. Follow Extended Service Plan (ESP) guidelines for dollar amounts. Rentals will only be reimbursed for the day the vehicle is at the dealership for part replacement. Prior approval for more than 1 rental day is required from the SSSC. Contact the SSSC via the SSSC Web Contact Site for consideration and approval if appropriate.

 

TOWING

If Mobile Inspection determines repairs are required, dealers are authorized to claim up to a maximum value of $250 to provide towing services for this program.

 

PICKUP AND DELIVERY

All customers affected by this recall have the option of complimentary Vehicle Pick-Up & Delivery service (at participating dealers). Pick-Up and Delivery may also be combined with a rental vehicle for one day. Claim any additional rental days approved by the SSSC as instructed.

Dealers are authorized to claim unique services for completing this program, including:

  • Dealers are authorized to claim one-half labor hour per repair for vehicle pick-up and delivery services.
  • Dealers must retain a Vehicle Pick-Up and Delivery Record with the repair order documentation. Refer to the Claims Preparation and Submission section and Attachment IV for details.

 

PARTS REQUIREMENTS / ORDERING INFORMATION

Part Number Description Order Quantity Claim Quantity
LJ9Z-4K138-A Halfshaft (right rear) 1 1
W720792-S439 Caliper anchor plate bolts (2 req/pkg of 4) 1 2
W714333-S439 Hub bearing bolts (4 req/pkg of 4) 1 4

 

Part Number Description Order Quantity Claim Quantity
CCPZ-3B477-B 22S55 - Right Rear Halfshaft Inspection - 2022 Ford Mustang Mach-E | small light Halfshaft retainer nut 1 1

 


CERTAIN 2022 MODEL YEAR MUSTANG MACH-E VEHICLES — RIGHT REAR HALFSHAFT INSPECTION

 

SERVICE PROCEDURE

MOBILE REPAIR INSPECTION INSTRUCTIONS

WARNING: When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the parking brake if the rear wheels will remain on the ground. These actions help prevent unintended vehicle movement. Failure to follow these instructions may result in serious personal injury.

WARNING: Never get underneath a vehicle that is supported only by a jack. The jack could unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions may result in serious personal injury.

WARNING: Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand. Failure to follow this instruction may result in serious personal injury.

WARNING: Turn off (disable) the power running boards (if equipped) before jacking, lifting or placing any object under the vehicle. Never place your hand between the power running board and the vehicle. Extended power running boards will retract when doors are closed. Failure to follow these instructions may result in serious personal injury.

NOTICE: When raising a vehicle on a hoist, use care when positioning the hoist adapters prior to lifting the vehicle so that hoist arms do not interfere with the surrounding suspension or steering linkage components.

NOTE: If you suspect that you will not have Internet access at the vehicle’s mobile repair location then, you should print a copy of these instructions (including any required Workshop Manual references) for reference during the mobile repair.

1. Is the inspection of the right rear halfshaft taking place at the dealership?

Yes – Proceed to step 2.

No – Print and take the Mobile Repair Inspection documentation to the inspection site. Proceed to step 3.

2. Position the vehicle on a hoist, then proceed to step 4. Please follow Workshop Manual (WSM) Procedures in Section 100-00.

3. Remove the right rear tire. Please follow Workshop Manual (WSM) Procedures in Section 204-04A.

4. Does the middle section of the vehicle’s right rear halfshaft have a black painted finish, as shown in Figure 2?

No – Proceed to step 5.

Yes – Proceed to step 7.

5. Locate the white label containing a large font part number on the halfshaft. See Figure 1.

 

6. Capture a photo of the halfshaft with the label and submit it via Concern Reports using the “Report a Vehicle Concern” process. Concern Reports may be submitted via Web Based PTS or through Mobile PTS using any mobile device (e.g., tablets, smart phones). Recall is complete.

NOTE: Photos taken must also include the middle section of the halfshaft showing the unpainted finish, similar to Figure 1.

 

7. Locate the white label containing 3 QR codes on the halfshaft. See Figure 2.

 

8. Locate and capture a photo of the serial number that begins with a number and NOT a letter. If needed, use a small dry rag to clean it off. To prevent removal of ink, do not use brake cleaner to clean off the serial number. See Figure 3.

9. Verify if the recorded serial number is listed in the suspect serial numbers in Attachment IV. Is the recorded serial number on the suspect serial numbers list in Attachment IV?

CAUTION: WHEN COMPARING THE SERIAL NUMBER ON THE LABEL TO THE LIST, YOU WILL NEED TO IGNORE THE VERY LAST CHARACTER ONLY IF IT IS A LETTER. SEE FIGURE 4. OTHERWISE, IT WILL NEED TO MATCH EXACTLY AS SHOWN ON THE LABEL.

Yes – Does not pass inspection. Submit the photograph of the serial number to SSSC for determination as to whether or not the right rear halfshaft needs to be replaced. SSSC will release halfshaft order based on need. Advise customer that their vehicle will be towed to the dealership to determine if a repair is required. Arrangements will be made for a loaner vehicle.

No – Dealers must submit their photo(s) via Concern Reports using the “Report a Vehicle Concern” process. Concern Reports may be submitted via Web Based PTS or through Mobile PTS using any mobile device (e.g., tablets, smart phones). Recall is complete.

 

10. Did SSSC determine that a new right rear halfshaft is needed?

NOTE: If replacing the right rear halfshaft, it is not necessary to check and top off the rear electric drive assembly oil level.

Yes – Replace the right rear halfshaft. Follow Workshop Manual (WSM) procedures in Section 205-05

No – Right rear halfshaft replacement is not required. Recall is complete.

 


22S55 – CERTAIN 2022 FORD MUSTANG MACH-E VEHICLES – REAR RIGHT HALFSHAFT

Date of submission: 8/26/2022
Manufacturer’s identification code for this recall: FSA 22S55

 

Chronology of Defect / Noncompliance Determination

On July 29th, 2022, an issue pertaining to broken Mach-E rear right halfshafts was brought to Ford’s Critical Concern Review Group by product engineering for review. It was reported that on July 27th, 2022, Cuautitlan Assembly Plant identified 2 VINs with broken rear right halfshafts.   One broken halfshaft was identified during squeak and rattle validation, and a second just before loading transport. Production records show Neapco Rear right half shafts where first introduced to production on July 18th, 2022.

 

On August 3rd, 2022, Tier 1 Supplier Neapco informed Ford Motor Company that inspection records show that between 2/14/2022 and 2/25/2022, Yecheng (tier 2 supplier for the green turning operation) suspended its 100% inspection of the bottom wall thickness of the rear right halfshaft outer race production line due to labor shortages caused by the Chinese New Year. This allowed non-compliant parts to pass through into finished rear right halfshaft assemblies. Metallurgical analysis of the two broken parts showed that failure was due to a thin wall on the outer race allowing the halfshaft stem to break under load. Improper placement (not fully seated) during the green turning in the lathe caused too much material to be removed, exceeding the specified minimum wall thickness of 9.1mm.

 

On August 8th, 2022, Tier 1 Supplier Neapco confirmed 4,608 parts were produced as part of the two suspect lots. Shipping records show a total of 504 halfshafts from the suspect lots were delivered to Ford CSAP and the rest were contained at Neapco’s Facilities.

 

On August 15th, 2022, Tier 1 Supplier Neapco informed Ford Motor Company all rear right halfshafts at its Saltillo facility had been sorted, finding a total of 7 non-compliant parts, all confirmed to be from the affected lots.

 

No warranty or field reports have been found related to this concern. Ford is not aware of any VOQs related to this concern.

 

On August 19, 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.

 


1 Affected Product

Vehicle

MAKE MODEL YEAR
FORD MUSTANG MACH E 2022

 


10 Associated Documents

Recall Acknowledgement

RCAK-22V646-4102.pdf 645.298KB

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Miscellaneous Document – Chronology re 22S55 – CERTAIN 2022 FORD MUSTANG MACH-E VEHICLES – REAR RIGHT HALFSHAFT

RMISC-22V646-2999.pdf 113.397KB

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Defect Notice 573 Report

RCLRPT-22V646-5647.PDF 214.386KB

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Manufacturer Notices(to Dealers,etc) – August 31, 2022 SUBJECT: NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 22S55 Certain 2022 Model Year Mustang Mach-E Vehicles Right Rear Halfshaft Inspection

RCMN-22V646-7194.pdf 1412.018KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V646-6839.pdf 53.824KB

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Recall 573 Report – 8/26/22

RCLRPT-22V646-1008.PDF 214.386KB

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Recall Quarterly Report #1, 2022-3

RCLQRT-22V646-5455.PDF 211.139KB

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ISSUED Renotification Notice

RCRN-22V646-2015.pdf 544.33KB

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Recall Quarterly Report #2, 2022-4

RCLQRT-22V646-5120.PDF 211.239KB

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Recall Quarterly Report #3, 2023-1

RCLQRT-22V646-5355.PDF 211.327KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V646&docType=RCL

 


 

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