23S07 Front Axle Ring and Pinion Replacement – 2023 Ford F-150, Expedition, & Lincoln Navigator

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.pdf 43.363KB

RCMN-23V128-9931

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V128&docType=RCL

 


 

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