22C23 – Passenger Side Instrument Panel Cover Replacement – 2022 Ford F-150

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September 14, 2022 NHTSA CAMPAIGN NUMBER: 22V684000

Improper Air Bag Deployment/FMVSS 208

During air bag deployment, the air bag cover my break and project fragments into the vehicle, or the air bag may deploy improperly, increasing the risk of occupant injury.

 

NHTSA Campaign Number: 22V684

Manufacturer Ford Motor Company

Components AIR BAGS

Potential Number of Units Affected 74

 

Summary

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.”

 

Remedy

Dealers will replace the right-side instrument panel cover, free of charge. Owner notification letters were mailed October 26, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 22C23.

 

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

 


October 17, 2022

NEW VEHICLE DEMONSTRATION / DELIVERY HOLD –  Compliance Recall 22C23
Certain 2022 Model Year F-150 Limited and Lariat Sport Package Vehicles

Passenger Side Instrument Panel Cover Replacement

 

AFFECTED VEHICLES

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

Affected vehicles are identified in OASIS and FSA VIN Lists.

 

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.

 

SERVICE ACTION

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to replace the passenger instrument panel cover. 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 the week of October 17, 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 compliance 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 481216251.
  • 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 passenger side instrument panel cover replacement.

 

RENTAL VEHICLES 

Rental vehicles are not approved for this program.

 

PARTS

Part Number  Description (note: order only one IP cover) Order Quantity
ML3Z-15044F58-CB Passenger IP Cover – F-150 Lariat Sport ONLY 1
ML3Z-15044F58-GB Passenger IP Cover – F-150 Limited ONLY

 


CERTAIN 2022 MODEL YEAR F-150 LIMITED AND LARIAT SPORT PACKAGE VEHICLES — PASSENGER SIDE INSTRUMENT PANEL COVER REPLACEMENT

 

SERVICE PROCEDURE

NOTE: For this procedure only it is not necessary to remove the instrument panel.

NOTE: Retaining clip/bolt quantities may vary from what is shown throughout this procedure.

1. Depower the Supplemental Restraint System (SRS). Please follow the Workshop Manual (WSM) procedures in Section 501-20B.

2. Remove the A-pillar trim panels. Please follow the WSM procedures in  Section 501-05.

3. Release the clips and remove the Right Hand (RH) instrument panel trim panel. See Figure 1.

 

4. Release the clips and remove the defrost grille trim panel. See Figure 2.

 

5. Release the clips and remove the trim panel. See Figure 3.

 

6. Release the clips, disconnect the electrical connector and remove the center finish trim. See Figure 4.

 

7. Release the clips and remove the floor console lower RH trim panel. See Figure 5.

 

8. Release the clips and remove the floor console upper RH trim panel. See Figure 6.

 

9. Remove the bolt, release the clips and remove the floor console lower Left Hand (LH) trim panel. See Figure 7.

  • Torque 22 lb.in (2.5 Nm).

 

10. Release the clips and remove the floor console upper LH trim panel. See Figure 8.

 

11. Remove the bolts, disconnect the electrical connectors and remove the Front Controls Interface Module (FCIM). See Figure 9.

  • Torque 22 lb.in (2.5 Nm).

NOTE: Instrument panel removed for clarity.

 

12. Release the clips and remove the speaker grille. See Figure 10.

 

NOTE: If equipped remove the rubber pad. See Figure 11.

 

13. Remove the bolts, disconnect the electrical connector and remove and the upper instrument panel storage tray. See Figure 12.

  • Torque 22 lb.in (2.5 Nm).

14. Remove the bolts. See Figure 13.

  • Torque 42.48 lb.in (4.8 Nm).

 

15. Release the retainers, remove and discard the push pin and remove the LH register bezel. See Figure 14.

NOTE: The push pin must be replaced each time the bezel is removed.

NOTE: Instrument panel removed for clarity.

 

16. Remove the bolts, separate the gap hider from the upper steering column shroud, release the 7 clips and remove the IPC bezel. See Figure 15.

  • Torque 36 lb.in (4.1 Nm).

NOTE: Instrument panel removed for clarity.

 

17. Remove the bolts, disconnect the electrical connectors and remove the display unit. See Figure 16.

  • Torque 22 lb.in (2.5 Nm).

NOTE: Instrument panel removed for clarity.

 

18. Release the retainers and, remove and discard the push pin remove the RH register bezel. See Figure 17.

NOTE: The push pin must be replaced each time the bezel is removed.

NOTE: Instrument panel removed for clarity.

 

19. Remove the bolt and the RH register. See Figure 18.

  • Torque 22 lb.in (2.5 Nm).

NOTE: Instrument panel removed for clarity.

 

20. Remove the bolts and remove the upper storage compartment. See Figure 19.

  • Torque 22 lb.in (2.5 Nm).

NOTE: Instrument panel removed for clarity.

 

21. Remove the screws through the upper stowage bin opening. See Figure 20.

  • Torque 11.5 lb.in (1.3 Nm).

 

22. Remove the bolts. See Figure 21.

  • Torque 93 lb.in (10.5 Nm).

 

23. Disconnect the passenger airbag electrical connector. See Figure 22.

 

24. Remove the RH instrument panel upper section bolts. See Figure 23.

  • Torque 22 lb.in (2.5 Nm).

NOTE: Instrument panel removed for clarity.

 

25. Remove the RH instrument panel upper section by lifting upwards to release the clips. See Figure 24.

NOTE: Instrument panel removed for clarity.

 

26. Transfer the passenger airbag to the new passenger side instrument panel upper section. Please follow the WSM procedures in Section 501-20B.

27.  Install the new passenger side instrument panel upper section, by reversing the removal procedure, starting at Step 25.

IMPORTANT NOTE: Federal law prohibits selling motor vehicle parts or components that are under safety, compliance, or emissions recall. Unless a part is requested to be returned to Ford, all parts replaced under this FSA must be scrapped in accordance with all applicable local, state and federal environmental protection and hazardous material regulations. Refer to the Parts Retention, Return, & Scrapping section of the FSA dealer bulletin for further information.

 


Chronology :

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

Vehicle

MAKE MODEL YEAR
FORD F-150 2022

 


8 Associated Documents

Noncompliance Notice 573 Report

RCLRPT-22V684-3226.PDF 243.967KB

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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 Replacement

RCMN-22V684-4717.pdf 145.082KB

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Recall Acknowledgement

RCAK-22V684-1477.pdf 645.148KB

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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Compliance Recall 22C23 Certain 2022 Model Year F-150 Limited and Lariat Sport Package Vehicles Passenger Side Instrument Panel Cover Replacement

RCMN-22V684-3687.pdf 7743.264KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V684-0876.pdf 52.377KB

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Recall Quarterly Report #1, 2022-4

RCLQRT-22V684-0334.PDF 211.13KB

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ISSUED Renotification Notice

RCRN-22V684-3703.pdf 544.885KB

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Recall Quarterly Report #2, 2023-1

RCLQRT-22V684-3089.PDF 211.23KB

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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=22V684&docType=RCL

 


 

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