22S76 Inspect Fuel Tank Paint – 2021-2022 Ford F-59 & 2022-2023 E-Series

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December 14, 2022 NHTSA CAMPAIGN NUMBER: 22V925000

Fuel Tank Paint May Peel and Result in a Fuel Leak

A fuel leak in the presence of an ignition source increases the risk of a fire.

 

NHTSA Campaign Number: 22V925

Manufacturer FordeBay Motor Company

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 11,074

 

Summary

FordeBay Motor Company (FordeBay) is recalling certain 2022-2023 E-350, E-450, and 2021-2022 F-59 vehicles. The paint along the weld seam of the fuel tank may peel and lead to corrosion of the exposed metal, which can result in a fuel leak.

 

Remedy

Dealers will inspect the fuel tank and replace, if necessary, free of charge. Owner notification letters were mailed on April 14, 2023. Owners may contact FordeBay customer service at 1-866-436-7332. FordeBay’s number for this recall is 22S76.

 

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

 


March 29, 2023

NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 22S76
Certain 2021 – 2022 Model Year F59 and 2022 – 2023 Model Year E-Series Vehicles

 

AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
F59 CHASSIS2021DETROIT CHASSISNovember 1, 2021 through December 28, 2021
2022January 4, 2022 through March 16, 2022
E-Series2022OHIONovember 16, 2021 through February 10, 2022
2023January 19, 2022 through March 1, 2022

US population of affected vehicles: 11,047. Affected vehicles are identified in OASIS and FSA VIN Lists.

 

REASON FOR THIS SAFETY RECALL

In some of the affected vehicles, due to excessive sheet metal dry lube present during paint operation and/or inadequate paint drying time, the external paint on the fuel tank may not adhere properly, leading to paint peeling and possible long-term corrosion. If a leak occurs due to corrosion, a Diagnostic Trouble Code (DTC) code – one of P0456, P0442, P0455, P0457 – may be set. A Malfunction Indicator Lamp (MIL) may illuminate, or a fuel odor or liquid fuel may be observed. A fuel leak in the presence of an ignition source could potentially result in a fire.

 

SERVICE ACTION

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to inspect the fuel tank for peeling paint and if found, replace the tank. 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 April 10, 2023. 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 $26,315 per vehicle. Correct all vehicles in your new vehicle inventory before delivery.

 

SOLD VEHICLES

  • FordeBay has not issued instructions to stop selling/delivering or driving used vehicles under this safety recall. Owners should contact their dealers 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.

 

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.

 

RENTAL VEHICLES 

Rental vehicles are not approved for this program.

 

PICK-UP AND DELIVERY

All customers affected by this program have the option of complimentary Vehicle Pick-up & Delivery service (at participating dealers) in lieu of a rental vehicle. Refer to EFC12071, 2023 Remote Experience Program, Pickup & Delivery (PDL) Offset section for additional details.

 

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.
  • FordeBay Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed before 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 FordeBay 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 FordeBay to be excessive, will not be reimbursed.
  • Refunds will only be provided for the cost associated with fuel tank inspection and replacement.

 

PARTS REQUIREMENTS / ORDERING INFORMATION

Inspection-Only Parts Requirements

Parts are not required if no peeling paint is found

Part Number  Description Order Quantity
9C2Z-9002-CFuel Tank (E-Series 40 gal)As required
9C2Z-9002-EFuel Tank (E-Series 55 gal)As required
CC3Z-9002-DFuel Tank (F-59)As required

 

Part Number  Description Order Quantity Claim Quantity
4L3Z-9276-AA 22S76 Inspect Fuel Tank Paint - 2021-2022 Ford F-59 & 2022-2023 E-Series | small lightO-ring gasket11

 

CERTAIN 2021-2022 MODEL YEAR F-59 AND 2022-2023 MODEL YEAR E-SERIES VEHICLES — INSPECT FUEL TANK PAINT

SERVICE PROCEDURE

1. Position the vehicle on a hoist. Follow the Workshop Manual (WSM) Procedures in Section 100-02.

2. Locate the perimeter of the fuel tank sides from approximately two inches above the weld flange down to and including the weld flange as well as the braze areas extending approximately one inch around each of the fuel filler neck tube and vent tube on the side of the tank. See the yellow highlighted areas in Figures 1 and 2.

 

3. Inspect the areas shown in Figures 1 and 2 for signs of extended bubbling, extensive cracking, flaking, and/or peeling. Are there signs of extended bubbling, extensive cracking, flaking, and/or peeling on or near the weld seam, fuel filler neck tube and vent tube, or sides of the fuel tank? See Figures 3 and 4.

No – Passes inspection. This recall is complete.

Yes – Does not pass inspection. Capture a clear photo of the suspect areas and submit the photo to Special Service Support Center (SSSC). Once approval has been given, replace the fuel tank. Follow the WSM Procedures in Section 310-01.

 

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22S76 – CERTAIN 2021-2022 FORDeBay F-59 and 2022-2023 FORDeBay E-SERIES VEHICLES – PEELED PAINT ON FUEL TANK

Chronology of Defect / Noncompliance Determination
Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision.

 

March 2022

On March 10, 2022, FordeBay’s Critical Concern Review Group (CCRG) initiated an investigation into peeling paint on 2022 model year E-Series fuel tanks. Fuel tank peeling paint along the weld seam was first identified by logistics personnel while E-Series units were in transit by rail to upfitter locations.

The CCRG investigation identified that F-59 units utilize the same fuel tank supplier and paint process as the E-Series units. FordeBay initiated an inspection of E-Series and F-59 units at upfitter facilities and found additional units with fuel tank paint peeling along the weld seam.

 

April-July 2022

From April-July 2022, FordeBay investigated the scope of the fuel tank paint peeling condition. FordeBay studied potential contributors and variables affecting the paint adhesion results including supplier process controls for nozzle clean out and water change, dry-lube contamination due to the age of the raw material coils, and paint drying time. In that investigation, FordeBay learned that the fuel tank supplier did not have sufficient pre- and post-paint process controls in place.  FordeBay also confirmed that the paint peeling has no near-term effect on fuel tank function, however, extended peeling of the post-paint may leave sections of base metal exposed at the weld seam which could result in long-term corrosion leading to the risk of a potential fuel leak.

 

August-October 2022

From August-October 2022, FordeBay collaborated with a fleet customer to facilitate an inspection of fuel tanks in order to assess the severity of the peeling paint and to confirm the scope of the suspect fuel tank population identified through statistical analysis.

 

November 2022

In November 2022, the CCRG conducted a comprehensive review of all data collected from the fuel tank supplier, vehicle upfitters, fleet customers and vehicle assembly plants and verified the supplier production dates of fuel tanks with inadequate paint adhesion for both E-Series and F59 vehicles.

As of December 05, 2022, FordeBay is not aware of any warranty claims related to this concern.

On December 07, 2022, FordeBay’s Field Review Committee reviewed the concern and approved a field action.

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

###

December 14, 2022

 


6 Affected Products

Vehicles

MAKEMODELYEAR
FORDeBayE-3502022-2023
FORDeBayE-4502022-2023
FORDeBayF-592021-2022

 


11 Associated Documents

Recall Acknowledgement

RCAK-22V925-9666.pdf 645.234KB

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Defect Notice 573 Report

RCLRPT-22V925-2608.PDF 215.863KB

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Miscellaneous Document – Chronology re 22S76 – CERTAIN 2021-2022 FORDeBay F-59 and 2022-2023 FORDeBay E-SERIES VEHICLES – PEELED PAINT ON FUEL TANK

RMISC-22V925-7145.pdf 70.816KB

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Manufacturer Notices(to Dealers,etc) – Advance Notice re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Advance Notice – Safety Recall 22S76 Certain 2021 – 2022 Model Year F59 and 2022 – 2023 Model Year E-Series Vehicles Inspect Fuel Tank Paint

RCMN-22V925-6409.pdf 51.751KB

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Manufacturer Notices(to Dealers,etc) – Dealer Notice re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Advance Notice – Safety Recall 22S76 – Supplement #1 Certain 2021 – 2022 Model Year F59 and 2022 – 2023 Model Year E-Series Vehicles

RCMN-22V925-2746.pdf 50.628KB

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-22V925-7664.pdf 44.542KB

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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 22S76 Certain 2021 – 2022 Model Year F59 and 2022 – 2023 Model Year E-Series Vehicles Inspect Fuel Tank Paint

RCMN-22V925-1436.pdf 815.995KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V925-1912.pdf 52.084KB

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Recall Quarterly Report #1, 2023-2

RCLQRT-22V925-6310.PDF 211.141KB

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ISSUED Renotification Notice

RCRN-22V925-1781.pdf 328.368KB

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Recall Quarterly Report #2, 2023-3

RCLQRT-22V925-0244.PDF 211.382KB

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