23S49 – Left Axle Shaft Failure at Flange – 2023 Ford Super Duty F-250 & F-350

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-595 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Ford Motor Company Submission Date : AUG 25, 2023 NHTSA Recall No. : 23V-595 Manufacturer Recall No. : 23S49 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 : 41,555 Estimated percentage with defect : 50 % Vehicle Information : Vehicle 1 : 2023-2023 FORD F-Super Duty: F250, F350 Vehicle Type : LIGHT VEHICLES Body Style : PICKUP TRUCK Power Train : NR Descriptive Information : Ford’s team reviewed plant records to determine the population of affected parts. Affected vehicles are equipped with single rear wheels and a 10.5-inch rear axle shaft. These vehicles are not produced in VIN order. Information as to the applicability of this action to specific vehicles can best be obtained by either calling Ford’s toll-free line (1-866-436-7332) or by contacting a local Ford or Lincoln dealer who can obtain specific information regarding the vehicles from the Ford On-line Automotive Service Information System (OASIS) database. F-250: 36,333 vehicles are affected F350: 5,222 vehicles are affected Production Dates : MAR 20, 2023 – AUG 21, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The left rear axle shaft may have been manufactured without properly completing electromagnetic induction heat treatment process. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : A broken rear axle could result in a loss of motive power and inability to hold the vehicle in park. If the parking brake is not applied, this could result in the unintended vehicle movement, increasing the risk of injury or crash. Description of the Cause : Personnel at the axle shaft supplier entered an incorrect process parameter Part 573 Safety Recall Report 23V-595 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 into one of the two machines that perform electromagnetic induction heat treatment of the subject left rear axle shafts. Identification of Any Warning that can Occur : A fractured rear axle shaft may result in rear axle noise and/or a loss of motive power in two-wheel drive operation. Involved Components : Component Name 1 : Shaft-Rear Axle Left Hand (LH) Component Description : Single Rear Wheel Axle Shaft LH 10.5 Inch Component Part Number : BC3W-4238- AC Supplier Identification : Component Manufacturer Name : Mid-West Forge Corporation Address : 17301 St Clair Ave Cleveland Ohio 44110 Country : United States Chronology : August 2023 On August 10, 2023, an issue pertaining to left rear axle shaft fractures on 2023 model year F-250 and F-350 Super Duty vehicles equipped with single rear wheels and 10.5-inch rear axles was brought to Ford’s Critical Concern Review Group for review. These failures were identified by Kentucky Truck Plant through monitoring of warranty claims. Two axle shafts returned through warranty were sent to Ford’s metallurgical lab for failure analysis. Laboratory analysis determined that the axle shafts did not meet Ford’s torsional yield and case depth design specifications in the fractured area. Each of the warranty returned parts had fractured at approximately 44 mm from the flange, indicating an area of incomplete induction heat treatment. Further supplier investigation and statistical analysis indicated that the failed parts were limited to one induction heat machine where maintenance personnel entered an incorrect offset value for the 10.5-inch left rear axle shaft. This incorrect value led to the incomplete induction heat treating process. As of August 14, 2023, there are seven warranty reports attributed to this concern. If the vehicle is equipped with four-wheel drive (4WD), a customer can place the vehicle in 4WD to regain mobility. Of the seven Part 573 Safety Recall Report 23V-595 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 warranty reports, three mention that the vehicle could move while in 4WD after the rear axle shaft fractured. On August 18, 2023, Ford’s Field Review Committee reviewed the concern and approved a field action. Ford is not aware of any reports of accident or injury related to this condition. Description of Remedy : Description of Remedy Program : Owners will be notified by mail and instructed to take their vehicle to a Ford or Lincoln dealer to have the left rear axle shaft inspected. Rear axle shafts with a suspect date code will be 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 2023. The ending date for reimbursement eligibility is estimated to be 01/31/2024. Ford will forward a copy of the notification letters to dealers to the agency when available. How Remedy Component Differs from Recalled Component : Suspect parts were built within a specified time period. The dealers will be able to identify the Julian dates stamped on the left rear axle flanges to identify axle shafts built within the suspect date window. The remedy component was produced with the correct induction heat treatment after the quality concern was identified and preventative corrective actions implemented. Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : Notification to dealers is expected to occur on August 30, 2023. Mailing of owner notification letters is expected to begin October 16, 2023 and is expected to be completed by October 20, 2023. Planned Dealer Notification Date : AUG 30, 2023 – AUG 30, 2023 Planned Owner Notification Date : OCT 16, 2023 – OCT 20, 2023 * NR – Not Reported

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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 August 30, 2023 TO: All U.S. Ford and Lincoln Dealers SUBJECT: NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Safety Recall 23S49 Certain 2023 Model Year F250-F350 with 10.5” Axle Shaft Left Axle Shaft Failure at Flange AFFECTED VEHICLES Vehicle Model Year Assembly Plant Build Dates F250-F350 2023 Kentucky Truck March 20, 2023 through August 21, 2023 US population of affected vehicles: 41,477. Affected vehicles are identified in OASIS and FSA VIN Lists. REASON FOR THIS SAFETY RECALL In some of the affected vehicles, the left rear axle shaft was manufactured without proper completion of a heat treatment process which may cause the left rear axle shaft to break. A broken rear axle shaft could result in a loss of motive power and the inability to hold the vehicle in park. If the parking brake is not applied, this could result in unintended vehicle movement, increasing the risk of injury or crash. SERVICE ACTION Dealers are to locate the pin stamp on the left rear axle flange. If the first digit of the pin stamp is 1 or 2, replace the left rear axle flange when parts are available, 1st quarter, 2024. If the first digit of the pin stamp is not 1 or 2, the axle passed the inspection. 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 October 16, 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 • Administrative Information • Labor Allowances and Parts Ordering Information • Technical Instructions • Mobile Service Repair Assessment • Mobile Repair/Vehicle Pickup and Delivery Record • Owner Notification Letter 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 Administrative Information Page 1 of 3 Safety Recall 23S49 MOBILE SERVICE REPAIR ASSESSMENT LEVEL • All repairs in this program have the following assessment level. – Not a Mobile Service Repair OASIS ACTIVATION OASIS will be activated on August 30, 2023. FSA VIN LISTS ACTIVATION FSA VIN Lists will be available through https://web.fsavinlists.dealerconnection.com on August 30, 2023. Owner names and addresses will be available by October 30, 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. BRANDED / SALVAGED TITLE VEHICLES Affected branded / salvaged title 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. Ó Copyright 2023 Ford Motor Company Administrative Information Page 2 of 3 Safety Recall 23S49 • 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 left rear axle failure at the flange. RENTAL VEHICLES Rental vehicles are not approved for this program. PICK-UP AND DELIVERY- Participating Dealers Dealers participating in the Remote Experience Program: • Refer to EFC12071, 2023 Remote Experience Program, Pickup & Delivery (PDL) Offset section for additional details. PICK-UP AND DELIVERY- Non-participating Dealers Dealers not participating in the 2023 Remote Experience Program for Pick-up & Delivery are authorized to claim unique services for completing this program. • Dealers are authorized to claim one-half labor hour per repair for vehicle pick-up & delivery services. Refer to Labor Allowances for details. • Dealers must retain a Vehicle Pick-up & Delivery Record with the repair order documentation. 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. Ó Copyright 2023 Ford Motor Company Administrative Information Page 3 of 3 Safety Recall 23S49 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 (23S49) 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. • Pickup & Delivery: o Dealers participating in the Remote Experience Program –  Refer to EFC12071, 2023 Remote Experience Program, Pickup & Delivery (PDL) Offset section for additional details. o Dealers NOT participating in the Remote Experience Program –  Dealers are authorized to claim one-half labor hour per repair for vehicle pickup and delivery services.  Dealers must retain a Vehicle Pick-up and Delivery Record with the repair order documentation. Ó Copyright 2023 Ford Motor Company Labor Allowances and Parts Ordering Information Page 1 of 1 Safety Recall 23S49 LABOR ALLOWANCES Description Labor Operation Labor Time Inspect Left Rear Axle Flange – PASS 23S49B 0.3 Hours Inspect Left Rear Axle Flange – DOES NOT PASS 23S49BB 0.3 Hours Vehicle Pick-up and Delivery Allowance: This allowance is only for non-eligible 2023 Remote Experience Program Dealers. NOTE: This allowance is for dealer-performed vehicle pickup/ delivery for dealership repairs only. Can only be claimed once, regardless of outstanding FSAs repaired. 23S49PP 0.5 Hours PARTS REQUIREMENTS / ORDERING INFORMATION Parts are not required to complete this inspection. TECHNICAL INSTRUCTIONS PAGE 1 OF 2 SAFETY RECALL 23S49 CPR © 2023 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 08/2023 CERTAIN 2023 MODEL YEAR SUPERDUTY VEHICLES EQUIPPED WITH A SINGLE REAR WHEEL (SRW) 10.5 AXLE — LEFT AXLE SHAFT FLANGE INSPECTION SERVICE PROCEDURE This procedure is different from the Workshop Manual (WSM). Follow Technical Instructions carefully. 1. Remove the Left Hand (LH) rear wheel. Follow the WSM procedures in Section 204-04A. NOTICE: DO NOT use sand paper or aggressive pressure as the pin stamp could be removed. 2. Using a right angle grinder with a scotch brite pad, apply light pressure and remove the black coating on the LH rear axle flange to expose the bare metal. See Figure 1. FIGURE 1 STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 23565B RIGHT ANGLE GRINDER WITHSCOTCH BRITE PAD LH REAR AXLE FLANGE BARE METAL BLACK COATING TECHNICAL INSTRUCTIONS PAGE 2 OF 2 SAFETY RECALL 23S49 CPR © 2023 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 08/2023 3. Locate the pin stamp on the LH rear axle flange. See Figure 2. Was the first digit on the pin stamp a 1 or 2? YES – The axle DOES NOT PASS inspection; axle shaft must be replaced when parts are available. Install the LH rear wheel. Follow the WSM procedures in Section 204-04A. NO – The axle PASSED inspection. Install the LH rear wheel. Follow the WSM procedures in Section 204-04A. This completes the FSA. FIGURE 2 PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 23565C PIN STAMP FIRST DIGIT LH REAR AXLE PIN STAMP Mobile Service Repair Assessment Page 1 of 2 Recall 23S49 Mobile Service Repair Assessment Assessment levels have been identified to help determine the ease of performing eligible mobile service repairs for a Field Service Action (FSA) outside of the dealership service facility. Dealer Bulletin Within Attachment I of the dealer bulletin a mobile service repair assessment level(s) will be provided. These assessment levels have been determined using the amount of time, equipment and labor identified to perform the intended service action. Assessment Levels – Mobile Reprogramming – Light Mobile Service – Enhanced Mobile Service – Advanced Mobile Service – Wheel and Tire Mobile Service – Not a Mobile Service Repair Description of each level that is used to determine the overall assessment. – Mobile Reprogramming • Module Programming or similar type services • Minimum tools maybe required other than an IDS/FDRS setup • FDRS programming that requires internet connection (wi-fi or mobile hotspot) • Make sure vehicle has a charge port to ensure battery voltage is maintained during flashing of the module(s) • Repairs not greater than 1 hour in length (including time to wait for programming) Note: The location will need a charging station or wall box to maintain the 12-volt battery. – Light Mobile Service • Interior repair procedures that do not require seat, dash, or headliner removal • Under hood repairs that do not require large component removal • Exterior repairs that do not require large component/panel removal • Repairs may require standard hand tools (Access to a Technician starter kit or similar) Mobile Service Repair Assessment Page 2 of 2 Recall 23S49 – Enhanced Mobile Service • A two-person process is required anytime a procedure requires work under the vehicle • Brake Inspection and Brake Repair/Replacement • Limited Suspension Component replacement (no alignment) • Under Vehicle access for limited repairs (no large component removal) • Vehicle Check Up – VCU • Pre-Delivery Inspection – PDI • Used Car Inspection/Presale Inspection • May require floor jack, jack stands, and impact tools Note: Wheel lock may be required. – Advanced Mobile Service • Fluid Exchange/Oil Change • Light Repairs • Brake Hydraulic Repairs – Wheel and Tire Mobile Service • Tire Removal from Wheel • Tire Balancing • Tire Repair Note: Specialized Mobile Service unit and equipment including Tire balancer and Tire Changer required. – Not a Mobile Service Repair • Large component removal • BEV Battery Replacement • Requires a vehicle hoist – to complete the repair (more than inspection) • Required vehicle alignment • Requires significant vehicle disassembly • Repairs greater than 2-3 hours • Any repairs that require M-Time • Includes a service procedure where the vehicle owner may be distressed about the state of their vehicle Mobile or Pick-Up and Delivery Repair Record Page 1 of 1 23S49 MOBILE REPAIR / VEHICLE PICK-UP AND DELIVERY RECORD VIN ____________________________ received (check one): ☐ Mobile Repair ☐ Pick-up and/or delivery service As outlined below for the 23S49 Field Service Action program. ☐ Mobile Repair – Date: _______________ OR ☐ Pick-up – Date: _______________ ☐ Delivery – Date: _______________ Repair Order # Repair Order Date Service Manager Signature Date

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