December 14, 2022 NHTSA CAMPAIGN NUMBER: 22V925000
A fuel leak in the presence of an ignition source increases the risk of a fire.
NHTSA Campaign Number: 22V925
Manufacturer Ford Motor Company
Components FUEL SYSTEM, GASOLINE
Potential Number of Units Affected 11,074
Ford Motor Company (Ford) 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.
Dealers will inspect the fuel tank and replace, if 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 22S76.
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
|Vehicle||Model Year||Assembly Plant||Build Dates|
|F59 CHASSIS||2021||DETROIT CHASSIS||November 1, 2021 through December 28, 2021|
|2022||January 4, 2022 through March 16, 2022|
|E-Series||2022||OHIO||November 16, 2021 through February 10, 2022|
|2023||January 19, 2022 through March 1, 2022|
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.
DO NOT DEMONSTRATE OR DELIVER any new in-stock vehicles involved in this safety recall. A complete Dealer Bulletin will be provided to dealers the week of January 16, 2023, when it is anticipated that parts ordering information and repair instructions will be available to support this safety 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.
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.
Chronology of Defect / Noncompliance Determination
Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision.
On March 10, 2022, Ford’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. Ford 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.
From April-July 2022, Ford investigated the scope of the fuel tank paint peeling condition. Ford 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, Ford learned that the fuel tank supplier did not have sufficient pre- and post-paint process controls in place. Ford 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.
From August-October 2022, Ford 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.
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, Ford is not aware of any warranty claims related to this concern.
On December 07, 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.
December 14, 2022
6 Affected Products
4 Associated Documents
Defect Notice 573 ReportRCLRPT-22V925-2608
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 PaintRCMN-22V925-6409
Latest Recalls Documents
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