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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 were mailed April 21, 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
April 4, 2023
NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 23S07
Certain 2023 Model Year F-150 and Expedition Vehicles Equipped with 4×4 and 3.73:1 Gear Ratio Axles
Front Axle Pinion Gear Inspection
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 |
U.S. population of affected vehicles: 239 Affected vehicles are identified in OASIS and FSA VIN Lists.
Note: Some vehicles may be in the process of being repaired at the plant. Monitor OASIS before opening an RO and/or beginning a repair. Parts purchased for an FSA can be returned for credit, if required. See the EXCESS STOCK RETURN details in Attachment II for more information.
NOTE: All originally included Lincoln Navigator vehicles have been confirmed repaired prior to dealership delivery, therefore have been removed from this program and are no longer on demo / delivery hold.
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
Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to inspect the front axle pinion gear for hardness, following the procedure in Attachment III. If a suspect pinion is found, dealers are to replace the front axle assembly. 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
- Ford 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.
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.
- Ford 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 Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121-6251.
- 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 front axle pinion gear replacement due to breakage.
RENTAL VEHICLES
For vehicles requiring front axle assembly replacement, dealers are pre-approved for up to 5 days for a rental vehicle. Follow Extended Service Plan (ESP) guidelines for dollar amounts. Rentals will only be reimbursed for the days the vehicle is at the dealership for part replacement. Prior approval for more than 5 rental days is required from the SSSC. Contact the SSSC via the SSSC Web Contact Site for consideration and approval if appropriate.
TOWING
If towing is required, dealers are authorized to claim up to a maximum value of $250 to provide towing services 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.
PARTS REQUIREMENTS
| Part Number | Description | Order Quantity |
| ****-993-** | Front axle assembly (3.73:1 gear ratio) | 1 if required. |
NOTE: For additional required parts such as gaskets, fasteners, seals, etc. refer to the WSM procedures and Ford Ecat for additional parts requirements.
CERTAIN 2023 MODEL YEAR F-150 AND EXPEDITION VEHICLES EQUIPPED WITH 4X4 AND 3.73:1 GEAR RATIO AXLES — FRONT AXLE PINION GEAR INSPECTION
SERVICE PROCEDURE
1. If equipped remove the nut, bolts and the transmission shield. See Figure 1.
2. Index-mark the front driveshaft flange CV joint to the pinion flange cup. See Figure 2.
3. Remove the front driveshaft CV joint-to-pinion flange cup bolts and retaining straps. See Figure 3.
4. Position the front driveshaft aside. See Figure 4.
5. Using a 5/16 in (8 mm) drill bit and moderate pressure drill the drive pinion stem pilot hole for two
seconds. See Figure 5.
6. Did the 5/16 in (8 mm) drill bit remove material from the drive pinion stem pilot hole? See Figure 6.
YES – Inspection PASS. The front drive axle/differential DOES NOT need to be replaced.
Proceed to Step 7.
NO – Inspection FAIL – REPLACEMENT IS REQUIRED.
- Capture and submit clear photo(s) showing the INABILITY TO REMOVE material from the pinion with the drill test to the Special Service Support Center (SSSC) for front drive axle/differential assembly replacement approval. Install the new front drive axle/differential assembly, follow the Workshop Manual (WSM) procedures in Section 205-03.
NOTE: Prior approval and an approval code from the SSSC will be required for claim submission.
NOTE: For this procedure only new front driveshaft CV joint-to-pinion flange cup bolts and retaining straps are not required. See Step 8 for front driveshaft CV joint-to-pinion flange cup bolts and retaining straps cleaning and reuse instructions.
NOTE: For this procedure only it is not necessary to lower the sway bar or remove the front driveshaft from the transfer case.
7. Clean any debris from the drive pinion stem pilot hole.
8. Clean threads of the original driveshaft flange to pinion flange bolts with a wire brush and coat the threads with Red TA-26, Red Loctite 263 or equivalent thread locker. See Figure 7.
9. Align the index-mark on the driveshaft and pinon flange and install the front driveshaft CV joint-to-pinion flange cup retaining straps and bolts. See Figure 8.
- Torque: 41 lb.ft (55 Nm).
10. If equipped install the transmission shield and the bolts. See Figure 9.
- Torque: 71 lb.in (8 Nm).
IMPORTANT NOTE: Federal law prohibits selling motor vehicle parts or components that are under safety, compliance, or emissions recall. Unless a part is requested to be returned to Ford, all parts replaced under this FSA must be scrapped in accordance with all applicable local, state and federal environmental protection and hazardous material regulations. Refer to the Parts Retention, Return, & Scrapping section of the FSA dealer bulletin for further information.
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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
11 Associated Documents
Recall 573 Report – 3/2/23
RCLRPT-23V128-8430.PDF 216.067KB
Recall 573 Report 3/2/23
RCLRPT-23V128-1678.PDF 216.067KB
Recall Acknowledgement
RCAK-23V128-2890.pdf 645.256KB
Defect Notice 573 Report
RCLRPT-23V128-6533.PDF 216.043KB
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
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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 23S07 Certain 2023 Model Year F-150 and Expedition Vehicles Equipped with 4×4 and 3.73:1 Gear Ratio Axles Front Axle Pinion Gear Inspection
RCMN-23V128-5742.pdf 4651.633KB
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Recall 573 Report – 4/12/23
RCLRPT-23V128-4239.PDF 216.069KB
ISSUED Owner Notification Letter(Part 577)
RCONL-23V128-2607.pdf 53.341KB
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Recall Quarterly Report #1, 2023-2
RCLQRT-23V128-5191.PDF 211.125KB
Recall Quarterly Report #2, 2023-3
RCLQRT-23V128-8800.PDF 211.364KB
Recall Quarterly Report #3, 2023-4
RCLQRT-23V128-3134.PDF 211.451KB
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SEOCONTENT-START
April 2023
Ford Motor Company
Ford Customer Service Division
P. O. Box 1904
Dearborn, Michigan 48121 1904
* * * IMPORTANT SAFETY RECALL * * *
Safety Recall Notice 23S07 / NHTSA Recall 23V128
2023 F-150 Truck
Your Vehicle Identification Number (VIN):
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
Ford Motor Company has decided that a defect that relates to motor vehicle safety exists in your
vehicle, with the VIN shown above.
We apologize for this situation and want to assure you that, with your assistance, we will correct this
condition. Our commitment, together with your dealer, is to provide you with the highest level of service
and support.
What is the issue? On your vehicle, it may be possible the front axle pinion was not properly heat
treated during the manufacturing process.
What is the risk? A front axle pinion that was not properly heat treated 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.
What will Ford and
your dealer do?
Ford Motor Company has authorized your dealer to inspect and test your
vehicle’s front axle pinion for hardness. If found defective, your dealer will
replace the front axle assembly, free of charge (parts and labor).
How long will it take? The time needed for this repair is less than one day. However, due to service
scheduling requirements, your dealer may need your vehicle for a longer
period of time. In addition, your vehicle will require an inspection to determine
if parts need to be ordered.
What should you do? Please call your dealer without delay and request a service date for Recall
23S07. Provide the dealer with your VIN, which is printed near your name at
the beginning of this letter.
Ford has not issued instructions to stop driving your vehicle under this safety
recall. You should contact your dealer for an appointment to have your
vehicle remedied as soon as practicable.
If you do not already have a servicing dealer, you can access
ford.com/support for dealer addresses, maps, and driving instructions.
Ford Motor Company wants you to have this safety recall completed on your
vehicle. The vehicle owner is responsible for making arrangements to have
the work completed. Ford Motor Company can deny coverage for any vehicle
damage that may result from the failure to have this recall performed on a
timely basis. Therefore, please have this recall performed as soon as
possible.
Please note: Federal law requires that any vehicle lessor receiving this
recall notice must forward a copy of this notice to the lessee within ten
days.
© Copyright 2023 Ford Motor Company
01114
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1 of 4
A/1/000001/1
771809453687 A/1/000001/1
JOHN A. SAMPLE
123 SAMPLE ST
SAMPLE CITY, MI 12345-6789
What should you do?
(continued)
NOTE: You can receive information about Recalls and Customer Satisfaction
Programs through our FordPass App. The app can be downloaded through
the App Store or Google Play. In addition, there are other features such as
reserving parking in certain locations and controlling certain functions on your
vehicle (lock or unlock doors, remote start) if it is equipped to allow control.
Do you need a rental
vehicle?
If your dealer determines that front axle replacement is required and needs
your vehicle overnight, your dealer is authorized to provide a rental vehicle for
your personal transportation at no charge (except for fuel and insurance)
while your vehicle is at the dealership for repairs. Please see your dealer for
guidelines and limitations.
Have you previously
paid for this repair?
If you have previously paid for a repair that addresses the issue described in
this letter, you still need to have this recall performed to ensure the correct
parts and procedures were used.
You may be eligible for a refund of previously paid repairs. Refunds will only
be provided for service related to front axle pinion failure. To verify eligibility
and expedite reimbursement, give your paid original receipt to your dealer.
Refund requests may also be sent directly to Ford Motor Company. To
request your refund from Ford, send the refund request with all required
documentation, including your original repair receipt (no photocopies), to Ford
Motor Company at P.O. Box 6251, Dearborn, Michigan 48121-6251. Refund
requests mailed to this address may take up to 60 days to process. Your
original receipt will be returned to you.
Detailed information regarding eligibility for Ford’s reimbursement program
and documentation requirements may be obtained by contacting the Ford
Customer Relationship Center at 1-866-436-7332.
What if you no longer
own this vehicle?
If you no longer own this vehicle and have an address for the current owner,
please forward this letter to the new owner.
You received this notice because government regulations require that
notification be sent to the last known owner of record. Our records are based
primarily on state registration and title data, which indicate that you are the
current owner.
Can we assist you
further?
If you have difficulties getting your vehicle repaired promptly and without
charge, please contact your dealership’s Service Manager for assistance.
RETAIL OWNERS: If you have questions or concerns, please contact our
Ford Customer Relationship Center at 1-866-436-7332 and one of our
representatives will be happy to assist you. If you wish to contact us through
the Internet, our address is ford.com/support.
For the hearing impaired call 1-800-232-5952 (TDD). Representatives are
available Monday through Friday: 8:00 AM – 8:00 PM (Eastern Time).
FLEET OWNERS: If you have questions or concerns, please contact our
Ford Pro Contact Center at 1-800-34-FLEET, choose Option #1, and one of
our representatives will be happy to assist you. If you wish to contact us
through the Internet, our address is fleet.ford.com.
Representatives are available Monday through Friday: 7:00 AM – 11:00 PM
and Saturday 7:00 AM – 5:00 PM (Eastern Time).
If you are still having difficulty getting your vehicle repaired in a reasonable
time or without charge, you may write the Administrator, National Highway
Traffic Safety Administration, 1200 New Jersey Ave. S.E., Washington, D.C.
20590 or call the toll-free Vehicle Safety Hotline at 1-888-327-4236
(TTY: 1-800-424-9153) or go to NHTSA.gov. Reference NHTSA Safety Recall
23V128.
Thank you for your attention to this important matter.
Ford Customer Service Division
© Copyright 2023 Ford Motor Company
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A/2/000001/1
* * * CAMPAÑA DE SEGURIDAD IMPORTANTE * * *
Aviso de Campaña de seguridad 23S07 / Campaña 23V128 de la NHTSA
2023 F-150 Truck
Número de identificación del vehículo (VIN):
Este aviso se le envía de acuerdo con la Ley Nacional de Seguridad de Tránsito y Vehículos
Motorizados de los EE. UU.
Ford Motor Company ha determinado que existe un defecto relacionado con la seguridad de su
vehículo, con el VIN que aparece más arriba.
Lamentamos esta situación y deseamos asegurarle que, con su ayuda, corregiremos el problema.
Nuestro compromiso, junto con el de su distribuidor, es ofrecerle servicio y apoyo de alto nivel.
¿Cuál es el
problema?
Es posible que el piñón del eje delantero de su vehículo no haya sido
termotratado correctamente durante el proceso de manufactura.
¿Qué riesgo existe? Si un piñón del eje delantero no es correctamente termotratado se podría
fracturar y ocasionar la pérdida de la aplicación 4×4 con la posibilidad de que
se bloqueen las ruedas delanteras, lo que aumenta el riesgo de choque.
El modo de falla podría ocurrir en cualquier momento durante la aplicación
4×4, pero es esperable que ocurra principalmente mientras está en reversa, ya
que el piñón está sujeto a cargas mayores.
¿Qué medidas
adoptarán Ford y su
distribuidor?
Ford Motor Company ha autorizado a su distribuidor a inspeccionar y probar la
rigidez del piñón del eje delantero de su vehículo. Si se determina que
presenta defectos, su distribuidor reemplazará el ensamble del eje delantero,
sin costo alguno (piezas y mano de obra).
¿Cuánto tiempo
tomará?
El tiempo necesario para esta reparación es de menos de un día. Sin
embargo, debido a los requisitos de planificación de servicio, es posible que su
distribuidor tarde un poco más. Además, se realizará una inspección del
vehículo para determinar si se deben solicitar piezas.
¿Qué debe hacer? Llame de inmediato a su distribuidor y solicite una cita de servicio para realizar
la Campaña 23S07. Proporcione el VIN a su distribuidor, el cual está impreso
debajo de sus datos al comienzo de esta carta.
Para esta campaña de seguridad, Ford no ha emitido instrucciones de dejar
manejar el vehículo. Deberá ponerse en contacto con su distribuidor a fin de
programar una cita para solucionar este problema lo más pronto posible.
Si aún no tiene un distribuidor para realizar el servicio, puede acceder a
ford.com/support para conocer las direcciones de los distribuidores, ver mapas
y obtener las instrucciones para llegar.
Ford Motor Company le recomienda realizar esta campaña de seguridad en su
vehículo. El propietario del vehículo es responsable de efectuar los arreglos
necesarios para llevar a cabo el trabajo. Ford Motor Company puede negar la
cobertura en caso de que el vehículo hubiese sufrido daños por no haber
realizado la campaña de manera oportuna. Por lo tanto, le solicitamos que
realice esta campaña lo antes posible.
Tenga presente que: La ley federal exige que los arrendadores de
vehículos que reciban este aviso de campaña envíen una copia del
mismo al arrendatario en un plazo de diez días.
3 of 4
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Abril de 2023
Ford Motor Company
División de Servicio al Cliente de Ford
P. O. Box 1904
Dearborn, Michigan 48121
©
Copyright 2023 Ford, División de Servicio al Cliente
771809453687 A/3/000001/1
JOHN A. SAMPLE
123 SAMPLE ST
SAMPLE CITY, MI 12345-6789
¿Qué debe hacer?
(continuación)
NOTA: Puede recibir información sobre las campañas y los programas de
satisfacción del cliente a través de la aplicación FordPass. La aplicación se
puede descargar a través de App Store o Google Play. Adicionalmente,
existen otras funciones como reserva de estacionamientos en determinados
lugares, además de control de ciertas funciones en el vehículo (bloqueo o
desbloqueo de puertas, arranque remoto) si así está equipado para permitir el
control.
¿Necesita un
vehículo de alquiler?
Si su distribuidor determina que es necesario efectuar el reemplazo del eje
delantero y el vehículo debe permanecer en las instalaciones durante la
noche, el distribuidor está autorizado a ofrecerle un vehículo de alquiler para
su transporte personal sin costo (excepto combustible y seguro) mientras su
vehículo se encuentre en reparación. Comuníquese con su distribuidor para
conocer las pautas y limitaciones.
¿Ha pagado
anteriormente por
esta reparación?
Si usted ha pagado previamente por una reparación que aborda el problema
descrito en esta carta, igualmente se le recomienda realizar esta campaña
para garantizar que se hayan utilizado las piezas y los procedimientos
correctos.
Es posible que cumpla con los requisitos para recibir un reembolso por las
reparaciones pagadas previamente. Solo se otorgarán reembolsos por
servicios relacionados con fallas del piñón del eje delantero. Para comprobar
si cumple con los requisitos y agilizar el reembolso, proporcione el recibo de
pago original a su distribuidor.
También puede enviar las solicitudes de reembolso directamente a Ford Motor
Company. Para solicitar un reembolso a Ford, envíe la solicitud con toda la
documentación requerida, incluido el recibo original de la reparación (no envíe
fotocopias), a Ford Motor Company, P.O. Box 6251, Dearborn, Michigan
48121-6251. El procesamiento de las solicitudes de reembolso enviadas a
esta dirección puede tardar hasta 60 días. Su recibo original le será regresado.
Comuníquese con el Centro de Relación con Clientes al 1-866-436-7332 para
obtener información detallada relacionada con el programa de reembolso de
Ford y los requisitos de documentación.
¿Qué pasa si usted
ya no es el
propietario del
vehículo?
Si usted ya no es el propietario del vehículo y tiene la dirección del propietario
actual, le solicitamos que le reenvíe esta carta.
Usted recibió este aviso porque las regulaciones del gobierno exigen el envío
de notificaciones al propietario conocido más reciente del registro. Nuestros
registros se basan principalmente en datos estatales y de propiedad, que
indican que usted es el propietario actual del vehículo.
¿Podemos hacer
algo más por usted?
Si tiene problemas para reparar de inmediato su vehículo y sin costo alguno,
comuníquese con el Gerente de Servicio de su distribuidor para solicitar
ayuda.
PROPIETARIOS MINORISTAS: Si tiene dudas o preguntas, comuníquese con
nuestro Centro de Relación con Clientes Ford al 1-866-436-7332 y uno de
nuestros representantes con gusto lo atenderá. Si desea comunicarse con
nosotros a través de Internet, nuestra dirección es ford.com/support.
Las personas con problemas de audición pueden llamar al 1-800-232-5952
(TDD). Los representantes atienden de lunes a viernes, de 8:00 a.m. a
8:00 p.m. (hora del este).
PROPIETARIOS DE FLOTAS: Si tiene dudas o preguntas, comuníquese con
nuestro Centro de contacto de Ford Pro al 1-800-34-FLEET, elija la opción
n.° 1 y uno de nuestros representantes con gusto lo atenderá. Si desea
comunicarse con nosotros a través de Internet, nuestra dirección es
fleet.ford.com.
Los representantes atienden de lunes a viernes de 7:00 a.m. a 11:00 p.m. y
sábado de 7:00 a.m. a 5:00 p.m. (hora del este).
Si continúa con dificultades para reparar su vehículo en un tiempo razonable o
sin cargo, le sugerimos que escriba al Administrador, National Highway Traffic
Safety Administration, 1200 New Jersey Ave. S.E., Washington, D.C. 20590 o
bien que llame sin cargo a la línea directa de seguridad vehicular al
1-888-327-4236 (TTY: 1-800-424-9153) o visite NHTSA.gov. Referencia:
Campaña de seguridad 23V128 de la NHTSA.
Gracias por su atención en este asunto sumamente importante.
Ford, División de Servicio al Cliente
4 of 4
A/4/000001/1
01114
23S07 NI/DTB123S071
© Copyright 2023 Ford, División de Servicio al Cliente
**************************************************************************************************************
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
**************************************************************************************************************
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
April 4, 2023
TO: All U.S. Ford and Lincoln Dealers
SUBJECT: NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 23S07
Certain 2023 Model Year F-150 and Expedition Vehicles Equipped with 4×4 and 3.73:1
Gear Ratio Axles
Front Axle Pinion Gear Inspection
REF: 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
Dated: March 1, 2023
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
U.S. population of affected vehicles: 239 Affected vehicles are identified in OASIS and FSA VIN Lists.
Note: Some vehicles may be in the process of being repaired at the plant. Monitor OASIS before
opening an RO and/or beginning a repair. Parts purchased for an FSA can be returned for credit, if
required. See the EXCESS STOCK RETURN details in Attachment II for more information.
NOTE: All originally included Lincoln Navigator vehicles have been confirmed repaired prior to
dealership delivery, therefore have been removed from this program and are no longer on demo /
delivery hold.
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
Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to
inspect the front axle pinion gear for hardness, following the procedure in Attachment III. If a suspect
pinion is found, dealers are to replace the front axle assembly. This service must be performed on all
affected vehicles at no charge to the vehicle owner.
OWNER NOTIFICATION 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.
ATTACHMENTS
Attachment I: Administrative Information
Attachment II: Labor Allowances and Parts Ordering Information
Attachment III: Technical Information
Owner Notification Letters
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
Ó Copyright 2023 Ford Motor Company
ATTACHMENT I
Page 1 of 2
NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 23S07
Certain 2023 Model Year F-150 and Expedition Vehicles Equipped with 4×4 and 3.73:1 Gear Ratio Axles
Front Axle Pinion Gear Inspection
OASIS ACTIVATION
OASIS was activated on March 1, 2023.
FSA VIN LISTS ACTIVATION
FSA VIN Lists were available through https://web.fsavinlists.dealerconnection.com on March 1, 2023.
Owner names and addresses will be available by April 28, 2023.
NOTE: Your FSA VIN Lists may contain owner names and addresses obtained from motor vehicle
registration records. The use of such motor vehicle registration data for any purpose other than in
connection with this recall is a violation of law in several states, provinces, and countries. Accordingly,
you must limit the use of this listing to the follow-up necessary to complete this recall.
SOLD VEHICLES
• Ford 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.
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.
• Ford 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 Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121-6251.
• 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 front axle pinion gear replacement due
to breakage.
RENTAL VEHICLES
For vehicles requiring front axle assembly replacement, dealers are pre-approved for up to 5 days for a
rental vehicle. Follow Extended Service Plan (ESP) guidelines for dollar amounts. Rentals will only be
reimbursed for the days the vehicle is at the dealership for part replacement. Prior approval for more than
5 rental days is required from the SSSC. Contact the SSSC via the SSSC Web Contact Site for
consideration and approval if appropriate.
TOWING
If towing is required, dealers are authorized to claim up to a maximum value of $250 to provide towing
services 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.
Ó Copyright 2023 Ford Motor Company
ATTACHMENT I
Page 2 of 2
NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 23S07
Certain 2023 Model Year F-150 and Expedition Vehicles Equipped with 4×4 and 3.73:1 Gear Ratio Axles
Front Axle Pinion Gear Inspection
REPAIR PHOTO SUBMISSION
Ford has requested photo evidence of the pinion shaft failed inspection, when axle assembly
replacement is required. For claim reimbursement please submit photos that clearly show the vehicle
VIN, along with the pinion shaft post inspection clearly showing metal not removed after drilling.
• Photos can be attached using the Mobile PTS “Report a Vehicle Concern”. You can access
Mobile PTS using your mobile device at: https://m.fordtechservice.dealerconnection.com/.
Note: If you have never used the Web-Based report a vehicle concern- you will need to
create your User Profile before accessing “Report a Vehicle Concern” on Mobile PTS.
Instructions on how to create a user profile and submit photos can be found in EFC08860.
Note: Ensure that your “User Profile” is added/updated to include your STARS ID. This can
be done by accessing your User Profile directly at:
https://www.gcr.dealerconnection.com/asp/DealerProfile.asp.
• After completing the report entry form you can upload a maximum of 5 attachments at once.
o If submitting more than one attachment (photo), the files must be saved to the mobile
device you’re using, before submitting the report.
o If submitting one attachment (photo), you can capture the photo during the report
submission when asked to add the attachment.
ADDITIONAL REPAIR (LABOR TIME AND/OR PARTS)
Additional repairs identified as necessary to complete the FSA should be managed as follows:
• For related damage and access time requirements, refer to the Warranty and Policy Manual /
Section 6 – Ford & Lincoln Program Policies / General Information & Special Circumstances for
FSAs / Related Damage.
• For vehicles within new vehicle bumper-to-bumper warranty coverage, no SSSC approval is
required, although related damage must be on a separate repair line with the “Related Damage”
radio button checked.
o Ford vehicles – 3 years or 36,000 miles
• For vehicles outside new vehicle bumper-to-bumper warranty coverage, submit an Approval
Request to the SSSC Web Contact Site before completing the repair.
CLAIMS PREPARATION AND SUBMISSION
• Claim Entry: Enter claims using Dealer Management System (DMS) or One Warranty Solution
(OWS) online.
o When entering claims, select claim type 31: Field Service Action. The FSA number 23S07
is the subcode.
o For additional claims preparation and submission information, refer to the Recall and
Customer Satisfaction Program (CSP) Repairs in the OWS User Guide.
• Related Damage/Additional labor and/or parts: Must be claimed as Related Damage on a
separate repair line from the FSA with the same claim type and subcode as described in Claim
Entry above.
IMPORTANT: Click the Related Damage Indicator radio button.
• Rentals: For rental vehicle claiming, follow Extended Service Plan (ESP) guidelines for dollar
amounts. Enter the total amount of the rental expense under the Miscellaneous Expense code
RENTAL.
• Refunds: Submit refunds on a separate repair line.
– Program Code: 23S07 – Misc. Expense: ADMIN
– Misc. Expense: REFUND – Misc. Expense: 0.2 Hrs.
o Multiple refunds should be submitted on one repair line and the invoice details for each
repair should be detailed in the comments section of the claim.
Pickup & Delivery: Refer to EFC12071, 2023 Remote Experience Program, Pickup & Delivery (PDL)
Offset section for additional details.
• Provision for Towing: Dealers are authorized to claim up to a maximum value of $250 to
provide towing services for completing this program if the front tires have seized due to suspected
front axle pinion shaft failure. Submit on the same line as the repair.
o Program Code: 23S07
o Misc. Expense: OTHER
o Misc. Expense: Claim up to $250.00
Ó Copyright 2023 Ford Motor Company
ATTACHMENT II
Page 1 of 2
NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 23S07
Certain 2023 Model Year F-150 and Expedition Vehicles Equipped with 4×4 and 3.73:1 Gear Ratio Axles
Front Axle Pinion Gear Inspection
LABOR ALLOWANCES
Description Labor Operation Labor Time
Inspect front axle pinion shaft, drill test – PASS 23S07A 0.8 Hour
Inspect front axle pinion shaft, drill test – FAIL
Replace the front axle assembly.
23S07B 3.7 Hours
Time allowed to submit photos of the front axle pinion shaft if
fails inspection.
Only to be used with B labor operation.
NOTE: If any aftermarket equipment is on the vehicle that
requires additional labor time, add pics and information to
this SSSC request for consideration for extra labor time.
23S07ZZ 0.2 Hours
PARTS REQUIREMENTS / ORDERING INFORMATION (SSSC Approval Required)
Part Number Description Order Quantity Claim Quantity
****-993-** Front axle assembly (3.73:1 gear ratio) 1 if required.
NOTE: For additional required parts such as gaskets, fasteners, seals, etc. refer to the WSM procedures
and Ford Ecat for additional parts requirements.
To place an order for a front axle assembly, photo submission for prior approval must be submitted in a
VIN-specific Approval Request via the SSSC Web Contact Site. Ensure to include a photo of the VIN tag,
along with at least one photo clearly showing the failed inspection drill test to the front axle pinion. An
approval code will be provided for claiming the axle assembly and associated parts upon review.
DEALER PRICE
For the latest prices, refer to DOES II.
PARTS RETENTION, RETURN, & SCRAPPING
Follow the provisions of the Warranty and Policy Manual, Section 1 – WARRANTY PARTS RETENTION
AND RETURN POLICIES. If a replaced part receives a scrap disposition, the part must be scrapped by
all applicable local, state, and federal environmental protection and hazardous material regulations.
Federal law prohibits selling motor vehicle parts or components that are under safety, compliance, or
emissions recall.
EXCESS STOCK RETURN
The excess stock returned for credit must have been purchased from Ford Customer Service Division by
Policy Procedure Bulletin 4000.
REPLACED FSA PARTS INSPECTION AND SIGN OFF
Effective March 1st, 2021, all parts replaced as part of an FSA repair with a repair order open date of
March 1st, 2021, or later must be inspected and signed off on the repair order by a member of your dealer
fixed operations management team or an employee of the task has been delegated to. If the task is to be
delegated to a non-management employee, the employee needs to be someone other than the
technician who completed the repair and needs to understand the importance of completing this task
consistently and accurately.
• All parts replaced as part of an FSA repair should be returned to the parts department following
the Warranty Parts Retention and Return Policies.
• Inspect the replaced parts to verify the FSA repair was completed.
• If the FSA repair is found to be complete, the designated employee signs the repair order line or
parts return stamp area (electronic or hand signed) for the FSA repair indicating the parts were
inspected and validated to have been replaced.
• After the parts have been inspected, they should be handled based on the guidance in the parts
status report in the Online Warranty System (Hold, Return, CORE, Scrap, etc.).
• This process is subject to review during warranty audits for FSA repairs with a repair order open
date of March 1st, 2021, or later. Any eligible FSA claims requiring parts replacement found not to
have been inspected and signed off during a warranty audit will be subject to chargeback and
consideration for enrollment into the Dealer Incomplete Recall Repair Process.
Ó Copyright 2023 Ford Motor Company
ATTACHMENT II
Page 2 of 2
NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 23S07
Certain 2023 Model Year F-150 and Expedition Vehicles Equipped with 4×4 and 3.73:1 Gear Ratio Axles
Front Axle Pinion Gear Inspection
REPLACED FSA PARTS INSPECTION AND SIGN OFF (continued)
Note: Other approvals (electronic or handwritten) for add-on repair lines, dealer-owned vehicle repairs,
and repeat repairs do not qualify as FSA parts inspection approvals. The post-repair FSA parts
inspection process (electronic or handwritten) is independent of other warranty approval requirements.
The approval by the designated employee implies that the FSA parts were found to be replaced and
must be able to be identified on the Repair Order. If multiple FSAs require approval on a single Repair
Order, each applicable occurrence will require individual post-repair approval by the designated
employee.
ATTACHMENT III
PAGE 1 OF 6
SAFETY RECALL 23S07
CPR © 2023 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
04/2023
CERTAIN 2023 MODEL YEAR F-150 AND EXPEDITION VEHICLES EQUIPPED
WITH 4X4 AND 3.73:1 GEAR RATIO AXLES — FRONT AXLE PINION GEAR
INSPECTION
SERVICE PROCEDURE
1. If equipped remove the nut, bolts and the transmission shield. See Figure 1.
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
x4
23064A
x1
FIGURE 1
2. Index-mark the front driveshaft flange CV joint to the pinion flange cup. See Figure 2.
22064B
FIGURE 2
ATTACHMENT III
PAGE 2 OF 6
SAFETY RECALL 23S07
CPR © 2023 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
04/2023
3. Remove the front driveshaft CV joint-to-pinion flange cup bolts and retaining straps. See Figure 3.
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
x6
x2
22064C
FIGURE 3
4. Position the front driveshaft aside. See Figure 4.
STUD FOR
MISSING NUT
STUD FOR
STUD FOR
MISSING NUT
22064D
FIGURE 4
ATTACHMENT III
PAGE 3 OF 6
SAFETY RECALL 23S07
CPR © 2023 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
04/2023
5. Using a 5/16 in (8 mm) drill bit and moderate pressure drill the drive pinion stem pilot hole for two
seconds. See Figure 5.
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
22064E
DRIVE PINION STEM
PILOT HOLE
5/16 IN (8 MM)
DRILL BIT
FIGURE 5
ATTACHMENT III
PAGE 4 OF 6
SAFETY RECALL 23S07
CPR © 2023 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
04/2023
6. Did the 5/16 in (8 mm) drill bit remove material from the drive pinion stem pilot hole? See Figure 6.
YES – Inspection PASS. The front drive axle/differential DOES NOT need to be replaced.
Proceed to Step 7.
NO – Inspection FAIL – REPLACEMENT IS REQUIRED.
• Capture and submit clear photo(s) showing the INABILITY TO REMOVE material from the pinion
with the drill test to the Special Service Support Center (SSSC) for front drive axle/differential
assembly replacement approval. Install the new front drive axle/differential assembly, follow the
Workshop Manual (WSM) procedures in Section 205-03.
NOTE: Prior approval and an approval code from the SSSC will be required for claim submission.
NOTE: For this procedure only new front driveshaft CV joint-to-pinion flange cup bolts and retaining
straps are not required. See Step 8 for front driveshaft CV joint-to-pinion flange cup bolts and
retaining straps cleaning and reuse instructions.
NOTE: For this procedure only it is not necessary to lower the sway bar or remove the front driveshaft
from the transfer case.
STUD FOR
MISSING NUT
STUD FOR
STUD FOR
MISSING NUT
DRIVE PINION STEM
PILOT HOLE
PASS FFAAIILL
23064F
DRIVE PINION STEM
PILOT HOLE
MATERIAL REMOVED
BY DRILL BIT MATERIAL NOT
REMOVED BY DRILL BIT
FIGURE 6
ATTACHMENT III
PAGE 5 OF 6
SAFETY RECALL 23S07
CPR © 2023 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
04/2023
7. Clean any debris from the drive pinion stem pilot hole.
8. Clean threads of the original driveshaft flange to pinion flange bolts with a wire brush
and coat the threads with Red TA-26, Red Loctite 263 or equivalent thread locker. See Figure 7.
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
23064G
COATED
AREA
COATED
AREA
LEAD IN END
OF BOLTS
1-2 THREADS
LEAD IN END
OF BOLTS
1-2 THREADS
0.41 – 0.55 IN (10.5 – 14 mm)
THREAD LENGTH
TO BE COATED
0.41 – 0.55 IN (10.5 – 14 mm)
THREAD LENGTH
TO BE COATED
FIGURE 7
9. Align the index-mark on the driveshaft and pinon flange and install the front driveshaft CV joint-topinion
flange cup retaining straps and bolts. See Figure 8.
• Torque: 41 lb.ft (55 Nm).
STUD FOR
23064H
x6
x2
FIGURE 8
ATTACHMENT III
PAGE 6 OF 6
SAFETY RECALL 23S07
CPR © 2023 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
04/2023
10. If equipped install the transmission shield and the bolts. See Figure 9.
• Torque: 71 lb.in (8 Nm).
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
x4
23064A
x1
FIGURE 9
IMPORTANT NOTE: Federal law prohibits selling motor vehicle parts or components that are
under safety, compliance, or emissions recall. Unless a part is requested to be
returned to Ford, all parts replaced under this FSA must be scrapped in
accordance with all applicable local, state and federal environmental
protection and hazardous material regulations. Refer to the Parts Retention,
Return, & Scrapping section of the FSA dealer bulletin for further information.
**************************************************************************************************************
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 : Submission Date :
Ford Motor Company 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 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. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-128 Page 3 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. The information contained in this report was submitted pursuant to 49 CFR §573 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 :
Identify How/When Recall Condition was Corrected in Production :
The replacement front axle pinion gear set (CL3Z-3222-D) has the required heat treatment process (annealing).
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
**************************************************************************************************************
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 : Submission Date :
Ford Motor Company 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 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. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-128 Page 3 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. The information contained in this report was submitted pursuant to 49 CFR §573 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 :
Identify How/When Recall Condition was Corrected in Production :
The replacement front axle pinion gear set (CL3Z-3222-D) has the required heat treatment process (annealing).
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
**************************************************************************************************************
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 : Submission Date :
Ford Motor Company APR 12, 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 Vehicle 2 : 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 Vehicle 3 : 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 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. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-128 Page 3 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. The information contained in this report was submitted pursuant to 49 CFR §573 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 inspected and tested for hardness. The front axle assembly will be replaced if the pinion does not pass the hardness test. 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 :
Identify How/When Recall Condition was Corrected in Production :
The replacement front axle pinion gear set (CL3Z-3222-D) has the required heat treatment process (annealing).
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 17, 2023 and is expected to be completed by April 21, 2023.
Planned Dealer Notification Date : MAR 01, 2023 – MAR 01, 2023
Planned Owner Notification Date : APR 17, 2023 – APR 21, 2023
* NR – Not Reported
**************************************************************************************************************
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 : Submission Date :
Ford Motor Company 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 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. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-128 Page 3 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. The information contained in this report was submitted pursuant to 49 CFR §573 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 :
Identify How/When Recall Condition was Corrected in Production :
The replacement front axle pinion gear set (CL3Z-3222-D) has the required heat treatment process (annealing).
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
SEOCONTENT-END
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