Safety Recall 23S04 Fuel Tank Replacement – 2023 Ford Transit

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Ó Copyright 2023 Ford Motor Company Stacy L. Balzer Ford Motor Company Operating Director P. O. Box 1904 Service Engineering Operations Dearborn, Michigan 48121 Ford Customer Service Division February 13, 2023 TO: All U.S. Ford and Lincoln Dealers SUBJECT: NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice – Safety Recall 23S04 Certain 2023 Model Year Transit Vehicles Equipped with 95L Fuel Tanks Fuel Tank Replacement AFFECTED VEHICLES Vehicle Model Year Assembly Plant Build Dates Transit 2023 Kansas City November 3, 2022 through November 10, 2022 Affected vehicles are identified in OASIS and FSA VIN Lists. REASON FOR THIS SAFETY RECALL In some of the affected vehicles, a Grade Vent Valve (GVV) may not be properly welded to the fuel tank shell. Over time, the weld between the GVV and the fuel tank shell may separate, which may lead to a fuel vapor leak or liquid fuel leak. An inadequate weld between the GVV and the fuel tank shell may be insufficient to prevent a fuel leak during a crash. A fuel leak in the presence of an ignition source increases the risk of a fire. SERVICE ACTION 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 month of March 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. CUSTOMER NOTIFICATION Owners of record will be notified via first-class mail after repair instructions and parts ordering information have been provided to dealers. 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 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. Ó Copyright 2023 Ford Motor Company QUESTIONS & ASSISTANCE For questions and assistance, contact the Special Service Support Center (SSSC) via the SSSC Web Contact Site. The SSSC Web Contact Site can be accessed through the Professional Technician System (PTS) website using the SSSC link listed at the bottom of the OASIS VIN report screen or listed under the SSSC tab. Sincerely, Stacy L. Balzer

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-071 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Ford Motor Company Submission Date : FEB 10, 2023 NHTSA Recall No. : 23V-071 Manufacturer Recall No. : 23S04 Manufacturer Information : Manufacturer Name : Ford Motor Company Address : 330 Town Center Drive Suite 500 Dearborn MI 48126-2738 Company phone : 1-866-436-7332 Population : Number of potentially involved : 1,159 Estimated percentage with defect : 85 % Vehicle Information : Vehicle 1 : 2023-2023 Ford Transit Vehicle Type : LIGHT VEHICLES Body Style : ALL Power Train : GAS Descriptive Information : Ford’s team reviewed supplier process and maintenance records to determine the population of affected parts. The Ford process is capable of tracing fuel tank production to the vehicle in which the fuel tank is installed. Affected vehicles are equipped with suspect 95L fuel tanks. These vehicles are not produced in VIN order. Information as to the applicability of this action to specific vehicles can best be obtained by either calling Ford’s toll-free line (1-866-436-7332) or by contacting a local Ford or Lincoln dealer who can obtain specific information regarding the vehicles from the Ford On-line Automotive Service Information System (OASIS) database. Production Dates : NOV 03, 2022 – NOV 10, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The fuel tank grade vent valve may not be properly welded to the fuel tank shell. Over time, the weld between the grade vent valve and the fuel tank shell may separate, which may ultimately lead to a fuel vapor leak or liquid fuel leak. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : An inadequate weld between the grade vent valve and the fuel tank shell may be insufficient to prevent a fuel leak during a crash. A fuel leak in the presence of an ignition source increases the risk of a fire. Description of the Cause : The fuel tank supplier incorrectly installed a thermocouple on the fuel tank Part 573 Safety Recall Report 23V-071 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 welding equipment causing the welder platen to overheat, resulting in an inadequate weld. Identification of Any Warning that can Occur : If the grade vent valve weld were to separate over time, a check engine light for detection of a vapor leak may illuminate. The customer may also observe a fuel odor or liquid fuel leak. Involved Components : Component Name 1 : Fuel Tank Assembly Component Description : Fuel Tank Assembly Component Part Number : LK41-9K007-AG/AH Component Name 2 : Fuel Tank Assembly Component Description : Fuel Tank Assembly Component Part Number : LK41-9K007-BG/BH Component Name 3 : Fuel Tank Assembly Component Description : Fuel Tank Assembly Component Part Number : LK41-9K007-EG/EH Supplier Identification : Component Manufacturer Name : Plastic Omnium Auto Inergy (LLC) Address : 2710 Bellingham Dr. Suite 400 Troy Michigan 48083 Country : United States Chronology : November 2022 On November 17, 2022, Ford’s Critical Concern Review Group (CCRG) initiated an investigation into the quality of the weld between the fuel tank shell and the grade vent valve on 2023 model year Transit vehicles equipped with 95L fuel tanks. On November 9, 2022, the supplier discovered an issue with weld quality after there was a Part 573 Safety Recall Report 23V-071 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 quality check test failure. The supplier discovered that the thermocouple on the welder hot plate was incorrectly installed after an October 30, 2022 maintenance event, causing the hot plate temperature to intermittently exceed the specified set point. This can result in improper material adhesion. Ford began collecting samples from the suspect population for analysis to better understand the weld integrity of the grade vent valve. December 2022 – January 2023 Ford’s CCRG continued to investigate the scope of the weld quality issue and impact to vehicle operation. Ford Engineering conducted a series of tests to quantify the quality of the weld between the grade vent valve and the fuel tank shell on suspect parts. The CCRG evaluation found that approximately 85% of the fuel tanks tested had an inadequate weld between the tank shell and the grade vent valve when tested to an industry-standard weld integrity test. Based on these test results, CCRG concluded that the lack of weld strength in this location would make it prone to fuel leaks, including those that occur in a crash. Ford is not aware of any warranty or field reports related to this condition. On February 3, 2023, 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. Description of Remedy : Description of Remedy Program : Owners will be notified by mail and instructed to take their vehicle to a Ford or Lincoln dealer to have their fuel tank replaced. There will be no charge for this service. Ford provided the general reimbursement plan for the cost of remedies paid for by vehicle owners prior to notification of a safety recall in May 2021. The ending date for reimbursement eligibility is estimated to be April 14, 2023. Ford will forward a copy of the notification letters to dealers to the agency when available. How Remedy Component Differs from Recalled Component : The replacement fuel tank shell (LK4Z-9002-T and LK4Z-9002-X) contains a grade vent valve properly welded to the fuel tank shell. Identify How/When Recall Condition was Corrected in Production : Not required per 49 Part 573. Recall Schedule : Description of Recall Schedule : Notification to dealers is expected to occur on February 13, 2023. Part 573 Safety Recall Report 23V-071 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Mailing of owner notification letters is expected to begin March 27, 2023 and is expected to be completed by March 31, 2023. Planned Dealer Notification Date : FEB 13, 2023 – FEB 13, 2023 Planned Owner Notification Date : MAR 27, 2023 – MAR 31, 2023 * NR – Not Reported

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