September 14, 2022 NHTSA CAMPAIGN NUMBER: 22V684000
NHTSA Campaign Number: 22V684
Manufacturer Ford Motor Company
Components AIR BAGS
Potential Number of Units Affected 74
Ford Motor Company (Ford) is recalling certain 2022 F-150 vehicles. The right-side instrument panel cover may have been manufactured incorrectly, which can cause the air bag to not deploy as intended. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 208, “Occupant Crash Protection.”
Dealers will replace the right-side instrument panel cover, free of charge. Owner notification letters are expected to be mailed October 17, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 22C23.
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.
|Vehicle||Model Year||Assembly Plant||Build Dates|
|F-150 Limited||2022||Dearborn||June 16, 2022 through July 17, 2022|
|F-150 Lariat Sport||June 22, 2022 through June 26, 2022|
REASON FOR THIS COMPLIANCE RECALL
Some of the affected vehicles may not conform to the requirements specified by Federal Motor Vehicle Safety Standard (FMVSS) No. 208 Occupant Crash Protection. These vehicles may have been built with a passenger side instrument panel (IP) cover with an injection molded substrate that was either manufactured with thermally degraded resin material or laser etched with an improper and inconsistent tear seam depth.
In the event of a crash necessitating deployment of the passenger airbag, the airbag may not deploy as intended, increasing the risk of injury. The IP cover on these vehicles may also fragment during deployment and project fragments toward the occupant, increasing the risk of injury.
DO NOT DEMONSTRATE OR DELIVER any new in-stock vehicles involved in this compliance recall. A complete Dealer Bulletin will be provided to dealers the week of October 11, 2022 when it is anticipated that parts ordering information and repair instructions will be available to support this compliance recall.
IMPORTANT: Dealers should open a Repair Order (RO) only when a full dealer bulletin is published. Opening an RO against an Awareness or Advance Notice will result in warranty rejections against a recall.
Owners of record will be notified via first-class mail after repair instructions and parts ordering information have been provided to dealers.
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 prior to delivery.
On June 30, 2022, an issue pertaining to a failed passenger airbag (PAB) door tear seam lot acceptance test (LAT) by the airbag supplier was brought to Ford’s Critical Concern Review Group for review. Ford’s Supplier Technical Assistance (STA) group indicated this concern resulted from an improper laser etching process used to form the airbag tear seam on the instrument panel (IP) topper. As of June 24, 2022, all affected vehicle/components were believed to be within Ford’s possession and contained.
July – August 2022
On July 21, 2022, a failed IP topper chute weld LAT by the airbag supplier was reported to Ford’s CCRG. Ford’s Supplier Technical Assistance (STA) group indicated this concern resulted from IP substrate delamination on an injection molded substrate batch produced at the tier 3 supplier. Based on component traceability to VIN all affected vehicles/components were believed to be contained as of July 18, 2022. Ongoing monitoring of vehicle containment found some vehicles escaped containment and were delivered to dealers.
CCRG requested an assessment whether component testing could be conducted to evaluate potential effect on airbag performance. Ford Engineering subsequently determined that physical testing to evaluate potential effects, including risk of material fragmentation on the non-conforming parts, was not feasible. Based on engineering judgement, suspect IP toppers may alter the intended passenger airbag cushion opening and inflation characteristics and potentially project fragments toward the occupant. Based on this assessment, the suspect vehicles may not meet a F/CMVSS No. 208 compliance test if they were to be tested.
On September 7, 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
3 Associated Documents
Noncompliance Notice 573 Report
Manufacturer Notices(to Dealers,etc) – Advance Dealer Notice re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice – Compliance Recall 22C23 Certain 2022 Model Year F-150 Limited and Lariat Sport Package Vehicles Passenger Side Instrument Panel Cover ReplacementRCMN-22V684-4717
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