December 14, 2022 NHTSA CAMPAIGN NUMBER: 22V928000
An improperly secured side impact sensor may cause the air bags to unintentionally deploy, or not to deploy as intended, increasing the risk of injury in a crash.
NHTSA Campaign Number: 22V928
Manufacturer Ford Motor Company
Components AIR BAGS
Potential Number of Units Affected 1,226
Dealers will inspect the side impact sensor attachments and repair, as necessary, free of charge. Owner notification letters are expected to be mailed January 23, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 22S77.
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.
December 15, 2022
NEW VEHICLE DEMONSTRATION/DELIVERY HOLD – Safety Recall 22S77
Certain 2021-2022 Model Year Bronco Vehicles
Side Impact Sensor Retaining Stud and Nut Inspection
|Vehicle||Model Year||Assembly Plant||Build Dates|
|Bronco||2021||Michigan Assembly||February 19, 2021 through September 16, 2021|
|Bronco||2022||Michigan Assembly||September 1, 2021 through September 3, 2021|
Affected vehicles are identified in OASIS and FSA VIN Lists.
REASON FOR THIS SAFETY RECALL
In some of the affected vehicles, the side impact sensors may not have been properly installed. A side impact sensor that is not installed properly may not detect certain side impact events. The incorrect side impact sensor readings could cause the affected air bags to unintentionally deploy or to not deploy when intended, increasing the risk of injury in a crash.
Dealers are to inspect for a missing B-pillar crash sensor mounting stud, missing retainer nut and/or loose mounting stud. If nut is missing a nut must be installed. If the stud is missing or loose, the dealer will follow the repair procedure to weld a new stud in place and apply a corrosion resistant coating. The dealers will be instructed to contact the Special Service Support Center (SSSC) to obtain a stud until service parts are available through the depots. 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 January 23, 2023. Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.
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.
- Ford has not issued instructions to stop selling/delivering or driving used vehicles under this safety Owners should contact their dealer for an appointment to have their vehicles remedied as soon as practicable.
- 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.
- 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.
- 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 Side Impact Sensor Retaining Stud and Nut Inspection..
Rental vehicles are not approved for this program.
PARTS REQUIREMENTS / ORDERING INFORMATION Special Program Part Ordering:
To place an order for Side Impact Sensor Retaining Stud submit a VIN-specific Part Order contact via the SSSC Web Contact Site.
|Part Number||Description||Order Quantity||Claim Quantity|
|W703951-S300||Side Impact Sensor Retaining Stud||Only after failed inspection||As required|
|Part Number||Description||Order Quantity||Claim Quantity|
|W520101-S437||Side Impact Sensor Nut||Only after failed inspection||As required|
CERTAIN 2021-2022 MODEL YEAR BRONCO VEHICLES — SIDE IMPACT SENSOR RETAINING STUD AND NUT INSPECTION
Side Impact Sensor Retaining Stud and Nut Inspection
1. On both sides, remove the lower B-pillar trim panel to gain access to the side impact sensor.
NOTE: The upper B-pillar trim panels do NOT need to be removed for this FSA.
2. Inspect for the presence of the side impact sensor retaining stud and nut on both sides.
See Figures 2 and 3. Is the side impact sensor retaining stud and/or nut missing on either side?
No – Passes inspection. Reinstall the lower B-pillar trim panels per WSM Section 501-05.
This recall is complete.
Yes – Does not pass inspection.
- Nut ONLY Missing – Order a retaining nut through the normal part ordering process, refer to the dealer bulletin. Proceed to step 3.
- Nut AND Stud Missing – Order a new side impact sensor stud and retaining nut through the normal part ordering process, refer to the dealer bulletin.
Proceed to step 5.
3. Install the new retaining nut. See Figure 4.
4. Reinstall the lower B-pillar trim panels per WSM Section 501-05.
Side Impact Sensor Retaining Stud and Nut Installation
NOTE: Perform this procedure ONLY on the side(s) where the retaining stud is missing.
7. WARNING: Before beginning any further service repair, refer to welding precautions in Section 501-25 General Procedures. Failure to follow this instruction may result in serious personal injury.
8. Use a welding blanket to cover and protect the repair area.
9. Using an angle sander with a 36-grit disc, remove the paint from the area the new stud is to be installed at.
10. Using a die grinder, cut off the head of the new retaining stud. See Figure 5.
11. Place the welder’s ground clamp on the rear door striker. See Figure 6.
NOTE: Make sure there is a solid mechanical connection that will not slip or fall off.
12. Using a pair of pliers, position the new retaining stud in place and tack weld it to the inner B-pillar. See Figure 7.
13. Allow surface to cool down to ambient temperature.
14. Position the side impact sensor onto the stud to ensure that the alignment pin and sensor fit correctly. See Figure 8.
15. Solid weld the new stud to the inner B-pillar.
16. Allow surface to cool down to ambient temperature prior to applying any corrosion repair.
17. After all weld repair is complete, use a wire brush to clean the affected area of all surface contamination.
18. Apply one layer of corrosion protection to the repaired surface area.
19. Remove the welding blanket and the ground clamp from the vehicle.
20. Reposition the side impact sensor onto the newly installed retaining stud. See Figure 9.
21. Install the new retaining nut. See Figure 10.
- Torque: 93 lb.in (10.5 Nm)
22. Lightly pull/wiggle the side impact sensor electrical connector to confirm it is properly secured.
23. Reinstall the lower B-pillar trim panels per WSM Section 501-05.
26. Use the dealer scan tool to check and clear DTC’s.
Chronology of Defect Determination – 22S77
On May 19, 2022, Ford’s Critical Concern Review Group (CCRG) initiated an investigation into a single report of a left-hand side impact sensor that was not properly attached on a 2021 model year Bronco vehicle that presented for service at a dealership for an unrelated reason. Dealership personnel identified that the left-hand side impact sensor mounting stud was missing.
Ford’s assembly plant quality records show that the suspect vehicle was identified as having an improper side impact sensor assembly through error-proofing processes during vehicle production. The CCRG investigation determined that the vehicle concern appeared to have been closed by plant personnel without completing the inspection and repair for a missing side impact sensor stud. At the time, there were no other known occurrences in the field.
The CCRG recommended inspecting a sampling of the vehicles identified through assembly plant error-proofing process records to evaluate the quality of the side impact sensor mounting. The CCRG reviewed the proposal to conduct an inspection study (Harvest Program) with NHTSA on August 4, 2022. The harvest program information would be provided to NHTSA as part of Ford’s monthly Part 579 regulatory filings.
On August 19, 2022, Ford’s Field Review Committee reviewed and approved a Harvest Program (22H05) to sample these vehicles to evaluate the quality of the side impact sensor mounting.
Ford reviewed the status of inspection program (22H05) with NHTSA on October 26, 2022.
As of October 21, 2022, twenty-nine (29) vehicle inspections had occurred. All of the twentynine (29) vehicles passed inspection with no occurrences found related to improper side impact sensor attachment.
The CCRG continued to monitor the status of the 22H05 inspection program.
As of December 5, 2022, ninety-two (92) U.S. vehicles have been inspected for 22H05 and dealerships have identified two (2) vehicles with a missing side impact sensor stud (November 16, 2022, and December 5, 2022).
On December 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.
2 Affected Products
5 Associated Documents
Defect Notice 573 ReportRCLRPT-22V928-3803
Miscellaneous Document – Chronology of Defect Determination – 22S77
Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION/DELIVERY HOLD – Safety Recall 22S77 Certain 2021-2022 Model Year Bronco Vehicles Side Impact Sensor Retaining Stud and Nut InspectionRCMN-22V928-6281
Recall 573 Report – 12/20/22
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