February 24, 2023 NHTSA CAMPAIGN NUMBER: 23V128000
Front Axle Pinion Not Heat-Treated
A fractured pinion can result in a loss of 4-wheel drive and may cause the front wheels to lock up, increasing the risk of a crash.
NHTSA Campaign Number: 23V128
Manufacturer Ford Motor Company
Components POWER TRAIN
Potential Number of Units Affected 240
Summary
Ford Motor Company (Ford) is recalling certain 2023 F-150, Expedition, and Lincoln Navigator vehicles. The front axle pinion may not have been heat-treated, which can cause it to fracture.
Remedy
Dealers will replace the front axle pinion gear set. If there is a broken front axle pinion, the entire axle assembly will be replaced. Repairs will be performed free of charge. Owner notification letters are expected to be mailed April 10, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 23S07.
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 1, 2023
NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice –
Safety Recall 23S07
Certain 2023 Model Year F-150, Expedition and Lincoln Navigator Vehicles
Equipped with 4×4 and 3.73:1 Gear Ratio Axles
Front Axle Ring and Pinion Replacement
AFFECTED VEHICLES
| Vehicle | Model Year | Assembly Plant | Build Dates |
| F-150 | 2023 | Dearborn | January 17, 2023 through January 24, 2023 |
| Kansas City | January 15, 2023 through January 23, 2023 | ||
| Expedition | Kentucky Truck | January 15, 2023 through January 26, 2023 | |
| Navigator | January 12, 2023 through January 20, 2023 |
Affected vehicles are identified in OASIS and FSA VIN Lists.
REASON FOR THIS SAFETY RECALL
In some of the affected vehicles, it’s possible the front axle pinion gear was not properly heat treated during the manufacturing process. Pinions that did not receive proper heat treatment may fracture, which may lead to the loss of the 4×4 application with the potential of the front wheels locking up, increasing the risk of a crash.
The failure mode could occur at any time in 4×4 application but is expected to occur primarily while in reverse as the pinion is subject to higher loads.
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 when parts ordering information and repair instructions are 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.
Chronology :
January – February 2023
On January 26, 2023, Ford’s Critical Concern Review Group (CCRG) opened an investigation into reports of front axle pinion fracture on three (3) 2023 model year 4×4 F150 vehicles as they were being backed onto a vehicle transporter. Ford Engineering performed a read-across and determined that, in addition to the F-150 4×4 vehicles, the pinions are also installed on 4×4 Expedition and Lincoln Navigator vehicles.
Initial investigation discovered that the fractured pinions did not go through the required heat treat (annealing) process at Ford’s axle manufacturing plant to reduce hardness and brittleness of the pinion stem threads. A team was immediately dispatched to conduct eddy current hardness checks of all available stock at affected assembly plants. Testing of axle assemblies determined this condition is limited to pinions in 3.73:1 gear ratio axles. The CCRG investigative team reviewed plant process records to determine a build population of suspect dates to derive the population of axles with pinions that may have bypassed the heat treat process.
As of February 13, 2023, Ford is not aware of any warranty, field reports or customer complaints related to this subject.
On February 17, 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.
3 Affected Products
Vehicles
| MAKE | MODEL | YEAR |
| FORD | EXPEDITION | 2023 |
| FORD | F-150 | 2023 |
| LINCOLN | NAVIGATOR | 2023 |
5 Associated Documents
Recall 573 Report – 3/2/23
RCLRPT-23V128-8430.PDF 216.067KB
RCLRPT-23V128-8430
Recall 573 Report 3/2/23
RCLRPT-23V128-1678.PDF 216.067KB
RCLRPT-23V128-1678
Recall Acknowledgement
RCAK-23V128-2890.pdf 645.256KB
RCAK-23V128-2890
Defect Notice 573 Report
RCLRPT-23V128-6533.PDF 216.043KB
RCLRPT-23V128-6533
Manufacturer Notices(to Dealers,etc) – Advance Notice re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice – Safety Recall 23S07 Certain 2023 Model Year F-150, Expedition and Lincoln Navigator Vehicles Equipped with 4×4 and 3.73:1 Gear Ratio Axles Front Axle Ring and Pinion Replacement
RCMN-23V128-9931
Latest Recalls Documents
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V128&docType=RCL
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-128 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Ford Motor Company Submission Date : MAR 02, 2023 NHTSA Recall No. : 23V-128 Manufacturer Recall No. : 23S07 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 : 240 Estimated percentage with defect : 57 % Vehicle Information : Vehicle 1 : 2023-2023 Ford F-150 Vehicle Type : LIGHT VEHICLES Body Style : Power Train : NR Descriptive Information : Ford’s team reviewed front axle assembly manufacturing process and maintenance records to determine the population of affected parts. The Ford process is capable of tracing front axle assembly production to the vehicle in which the front axle assembly is installed. Ford is able to provide the specific VIN list – see attachment VINs. Affected vehicles are equipped with a suspect front axle pinion assembly. 227 Ford F-150 vehicles are affected. Production Dates : JAN 15, 2023 – JAN 24, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-128 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2023-2023 Ford Expedition Vehicle Type : LIGHT VEHICLES Body Style : Power Train : NR Descriptive Information : Ford’s team reviewed front axle assembly manufacturing process and maintenance records to determine the population of affected parts. The Ford process is capable of tracing front axle assembly production to the vehicle in which the front axle assembly is installed. Ford is able to provide the specific VIN list – see attachment VINs. Affected vehicles are equipped with a suspect front axle pinion assembly. 4 Ford Expedition vehicles are affected. Production Dates : JAN 15, 2023 – JAN 26, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2023-2023 Lincoln Navigator Vehicle Type : LIGHT VEHICLES Body Style : Power Train : NR Descriptive Information : Ford’s team reviewed front axle assembly manufacturing process and maintenance records to determine the population of affected parts. The Ford process is capable of tracing front axle assembly production to the vehicle in which the front axle assembly is installed. Ford is able to provide the specific VIN list – see attachment VINs. Affected vehicles are equipped with a suspect front axle pinion assembly. 9 Lincoln Navigator vehicles are affected. Production Dates : JAN 12, 2023 – JAN 20, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The front axle pinion may not have been heat-treated, which can cause it to fracture. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Pinions that did not receive proper heat treatment may fracture, which may lead to the loss of the 4×4 application with the potential of the front wheels locking up, increasing the risk of a crash. Description of the Cause : Certain front axle pinions bypassed the heat treat process at the axle manufacturing plant. Part 573 Safety Recall Report 23V-128 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Identification of Any Warning that can Occur : The driver may hear a loud noise when the pinion breaks or as the drive shaft and flange hit the frame cross member and stability bar after pinion fracture. The failure mode could occur at any time in 4×4 application but is expected to occur primarily while in reverse as the pinion is subject to higher loads. Involved Components : Component Name 1 : Gear Set Front Axle Pinion 3.73 Component Description : Front Axle Pinion Gear Set Component Part Number : CL3W-3A410-BB Supplier Identification : Component Manufacturer Name : Ford Motor Company Address : 1 American Road Dearborn Michigan 48126 Country : United States Chronology : January – February 2023 On January 26, 2023, Ford’s Critical Concern Review Group (CCRG) opened an investigation into reports of front axle pinion fracture on three (3) 2023 model year 4×4 F150 vehicles as they were being backed onto a vehicle transporter. Ford Engineering performed a read-across and determined that, in addition to the F-150 4×4 vehicles, the pinions are also installed on 4×4 Expedition and Lincoln Navigator vehicles. Initial investigation discovered that the fractured pinions did not go through the required heat treat (annealing) process at Ford’s axle manufacturing plant to reduce hardness and brittleness of the pinion stem threads. A team was immediately dispatched to conduct eddy current hardness checks of all available stock at affected assembly plants. Testing of axle assemblies determined this condition is limited to pinions in 3.73:1 gear ratio axles. The CCRG investigative team reviewed plant process records to determine a build population of suspect dates to derive the population of axles with pinions that may have bypassed the heat treat process. As of February 13, 2023, Ford is not aware of any warranty, field reports or customer complaints related to this subject. On February 17, 2023, Ford’s Field Review Committee reviewed the concern and approved a field action. Part 573 Safety Recall Report 23V-128 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 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 the front axle pinion gear set replaced. Vehicles with a broken front axle pinion will have the entire axle assembly 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 December 31, 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 front axle pinion gear set (CL3Z-3222-D) has the required heat treatment process (annealing). 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 March 01, 2023. Mailing of owner notification letters is expected to begin April 10, 2023 and is expected to be completed by April 14, 2023. Planned Dealer Notification Date : MAR 01, 2023 – MAR 01, 2023 Planned Owner Notification Date : APR 10, 2023 – APR 14, 2023 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-128 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Ford Motor Company Submission Date : FEB 24, 2023 NHTSA Recall No. : 23V-128 Manufacturer Recall No. : 23S07 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 : 240 Estimated percentage with defect : 57 % Vehicle Information : Vehicle 1 : 2023-2023 Ford F-150 Vehicle Type : LIGHT VEHICLES Body Style : Power Train : NR Descriptive Information : Ford’s team reviewed front axle assembly manufacturing process and maintenance records to determine the population of affected parts. The Ford process is capable of tracing front axle assembly production to the vehicle in which the front axle assembly is installed. Ford is able to provide the specific VIN list – see attachment VINs. Affected vehicles are equipped with a suspect front axle pinion assembly. 227 Ford F-150 vehicles are affected. Production Dates : JAN 15, 2023 – JAN 24, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-128 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2023-2023 Ford Expedition Vehicle Type : LIGHT VEHICLES Body Style : Power Train : NR Descriptive Information : Ford’s team reviewed front axle assembly manufacturing process and maintenance records to determine the population of affected parts. The Ford process is capable of tracing front axle assembly production to the vehicle in which the front axle assembly is installed. Ford is able to provide the specific VIN list – see attachment VINs. Affected vehicles are equipped with a suspect front axle pinion assembly. 4 Ford Expedition vehicles are affected. Production Dates : JAN 15, 2023 – JAN 26, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2023-2023 Lincoln Navigator Vehicle Type : LIGHT VEHICLES Body Style : Power Train : NR Descriptive Information : Ford’s team reviewed front axle assembly manufacturing process and maintenance records to determine the population of affected parts. The Ford process is capable of tracing front axle assembly production to the vehicle in which the front axle assembly is installed. Ford is able to provide the specific VIN list – see attachment VINs. Affected vehicles are equipped with a suspect front axle pinion assembly. 9 Lincoln Navigator vehicles are affected. Production Dates : JAN 12, 2023 – JAN 20, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The front axle pinion may not have been heat-treated, which can cause it to fracture. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Pinions that did not receive proper heat treatment may fracture, which may lead to the loss of the 4×4 application with the potential of the front wheels locking up, increasing the risk of a crash. Description of the Cause : Certain front axle pinions bypassed the heat treat process at the axle manufacturing plant. Part 573 Safety Recall Report 23V-128 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Identification of Any Warning that can Occur : The driver may hear a loud noise when the pinion breaks or as the drive shaft and flange hit the frame cross member and stability bar after pinion fracture. The failure mode could occur at any time in 4×4 application but is expected to occur primarily while in reverse as the pinion is subject to higher loads. Involved Components : Component Name 1 : Gear Set Front Axle Pinion 3.73 Component Description : Front Axle Pinion Gear Set Component Part Number : CL3W-3A410-BB Supplier Identification : Component Manufacturer Name : Ford Motor Company Address : 1 American Road Dearborn Michigan 48126 Country : United States Chronology : January – February 2023 On January 26, 2023, Ford’s Critical Concern Review Group (CCRG) opened an investigation into reports of front axle pinion fracture on three (3) 2023 model year 4×4 F150 vehicles as they were being backed onto a vehicle transporter. Ford Engineering performed a read-across and determined that, in addition to the ford.oemdtc.com/product/k-B0140MWC04/US/fordoemdtc-20">F-150 4×4 vehicles, the pinions are also installed on 4×4 Expedition and Lincoln Navigator vehicles. Initial investigation discovered that the fractured pinions did not go through the required heat treat (annealing) process at Ford’s axle manufacturing plant to reduce hardness and brittleness of the pinion stem threads. A team was immediately dispatched to conduct eddy current hardness checks of all available stock at affected assembly plants. Testing of axle assemblies determined this condition is limited to pinions in 3.73:1 gear ratio axles. The CCRG investigative team reviewed plant process records to determine a build population of suspect dates to derive the population of axles with pinions that may have bypassed the heat treat process. As of February 13, 2023, Ford is not aware of any warranty, field reports or customer complaints related to this subject. On February 17, 2023, Ford’s Field Review Committee reviewed the concern and approved a field action. Part 573 Safety Recall Report 23V-128 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 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 the front axle pinion gear set replaced. Vehicles with a broken front axle pinion will have the entire axle assembly 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 December 31, 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 front axle pinion gear set (CL3Z-3222-D) has the required heat treatment process (annealing). 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 March 01, 2023. Mailing of owner notification letters is expected to begin March 20, 2023 and is expected to be completed by March 24, 2023. Planned Dealer Notification Date : MAR 01, 2023 – MAR 01, 2023 Planned Owner Notification Date : MAR 20, 2023 – MAR 24, 2023 * NR – Not Reported
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Advance Notice Not From NHTSA
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 March 1, 2023 TO: All U.S. Ford and Lincoln Dealers SUBJECT: NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice – Safety Recall 23S07 Certain 2023 Model Year F-150, Expedition and Lincoln Navigator Vehicles Equipped with 4×4 and 3.73:1 Gear Ratio Axles Front Axle Ring and Pinion Replacement AFFECTED VEHICLES Vehicle Model Year Assembly Plant Build Dates F-150 2023 Dearborn January 17, 2023 through January 24, 2023 Kansas City January 15, 2023 through January 23, 2023 Expedition Kentucky Truck January 15, 2023 through January 26, 2023 Navigator January 12, 2023 through January 20, 2023 Affected vehicles are identified in OASIS and FSA VIN Lists. REASON FOR THIS SAFETY RECALL In some of the affected vehicles, it’s possible the front axle pinion gear was not properly heat treated during the manufacturing process. Pinions that did not receive proper heat treatment may fracture, which may lead to the loss of the 4×4 application with the potential of the front wheels locking up, increasing the risk of a crash. The failure mode could occur at any time in 4×4 application but is expected to occur primarily while in reverse as the pinion is subject to higher loads. 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 when parts ordering information and repair instructions are 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. 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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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 March 1, 2023 TO: All U.S. Ford and Lincoln Dealers SUBJECT: NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice – Safety Recall 23S07 Certain 2023 Model Year F-150, Expedition and Lincoln Navigator Vehicles Equipped with 4×4 and 3.73:1 Gear Ratio Axles Front Axle Ring and Pinion Replacement AFFECTED VEHICLES Vehicle Model Year Assembly Plant Build Dates F-150 2023 Dearborn January 17, 2023 through January 24, 2023 Kansas City January 15, 2023 through January 23, 2023 Expedition Kentucky Truck January 15, 2023 through January 26, 2023 Navigator January 12, 2023 through January 20, 2023 Affected vehicles are identified in OASIS and FSA VIN Lists. REASON FOR THIS SAFETY RECALL In some of the affected vehicles, it’s possible the front axle pinion gear was not properly heat treated during the manufacturing process. Pinions that did not receive proper heat treatment may fracture, which may lead to the loss of the 4×4 application with the potential of the front wheels locking up, increasing the risk of a crash. The failure mode could occur at any time in 4×4 application but is expected to occur primarily while in reverse as the pinion is subject to higher loads. 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 when parts ordering information and repair instructions are 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. 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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