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December 22, 2023 NHTSA CAMPAIGN NUMBER: 23V896000
Damaged axle hub splines can result in a vehicle roll away when the vehicle is in park without the parking brake applied, or cause a loss of drive power. Both of these conditions can increase the risk of a crash.
NHTSA Campaign Number: 23V896
Manufacturer Ford
Motor Company
Components POWER TRAIN
Potential Number of Units Affected 112,965
Summary
Ford Motor Company (Ford) is recalling certain 2021-2023 F-150 vehicles equipped with the Trailer Tow Max Duty package and a 9.75-inch heavy duty axle with a 3/4 float axle design. The rear axle hub bolt may fatigue and break, which can result in damage to the axle hub splines.
Remedy
The remedy is currently under development. Owners will be instructed to take their vehicle to a dealer for an interim repair if they experience symptoms related to rear axle bolt breakage, such as a clicking or rattling noise. Owner notification letters are expected to be mailed January 29, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 23S65.
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
Ford Motor Company (Ford) Recall No. 23S65 Chronology
CERTAIN 2021-2023 MODEL YEAR FORD F-150 VEHICLES EQUIPPED WITH A 9.75-INCHHEAVY DUTY ¾ FLOAT AXLE – STRIPPED HUB SPLINES
Date of Submission: December 22, 2023
Chronology of Defect / Noncompliance Determination
Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision.
On June 6, 2022, NHTSA contacted Ford regarding three Vehicle Owner’s Questionnaire reports of broken rear axle hub bolts on 2021-2022 model year F-150 vehicles equipped with the 9.75-inch HD ¾ float axle. Ford had online meetings with NHTSA on June 15 and June 22, 2022 to discuss the VOQs and to provide responses to NHTSA’s requests for information.
On September 23, 2022, Ford’s Field Review Committee (FRC) approved Customer Satisfaction Field Service Actions to address loose or broken rear axle hub bolts on certain 2021-2022 model year F-150 vehicles equipped with the 9.75-inch HD ¾ float axle. The FRC’s approval came at the end of a Ford Critical Concern Review Group (CCRG) investigation that opened in February, 2022. At the time of the FRC approval of the Customer Satisfaction programs, warranty data indicated that the noise of a loose or broken bolt inside the wheel cap was apparent to most customers, who then sought service. In other instances, dealer technicians identified the broken axle hub bolt during routine maintenance that typically occurs within the warranty period (i.e. oil change or tire rotation). In nearly all of the claims at the time, either the noise from the rattling bolt or vehicle maintenance identified the broken bolt. At the time, Ford understood that it was possible for an unrepaired broken bolt to lead to spline fretting; however, Ford believed that broken bolts would be detectable and approved a one-time repair program for a five-month production window that was the source of most of the claims.
On November 17, 2022, NHTSA contacted Ford regarding Vehicle Owner’s Questionnaire reports indicating that Ford dealer technicians were telling customers that the wheel end may detach from the vehicle in the event of a rear axle hub bolt fracture. There is no potential for the wheel to separate from the vehicle due to this condition because there are four (4) bolts that retain the rear axle wheel end hub and bearing assembly to the brake bracket, which is welded to the axle tube. November 22, 2022, Ford reviewed the axle system design and the effect on vehicle of a broken rear axle hub bolt with NHTSA, describing that bolt head fracture would not result in wheel separation from a vehicle. Ford published a dealer communication on February 14, 2023, specifying that if the rear axle hub bolt breaks, the wheel hub will remain attached and will not separate from the rear axle shaft.
On August 31, 2023, the CCRG opened an investigation into reports of broken rear axle hub bolts that had progressed to stripped wheel-end hub splines on 2021-2022 model year F-150 vehicles equipped with the 9.75-inch HD ¾ float axle. The CCRG reviewed warranty reports related to the topic and identified reports of loss of motive power and unintended vehicle movement while in park for vehicles with stripped wheel-end hub splines.
As part the CCRG investigation, Ford obtained field-returned parts for analysis. Ford Engineering performed fracture mechanics analysis and metallurgical analysis on the field-returned parts to understand the failure mechanism. Additionally, the engineering team designed and built a fixture to replicate the failure mode. Concurrent to these workstreams, engineering conducted a vehicle durability test which ultimately did not recreate the stripped spline condition. These activities took place from September through mid-December 2023.
Based on the investigation, the CCRG believes that after the rear axle bolt fractures, spline fretting can occur over time due to micro-movements between the hub splines and the axle splines, with corrosion playing a significant factor. Because spline fretting is an issue that occurs over time with corrosion, early reports were only related to the bolt breakage.
As of December 02, 2023, there were 376 warranty reports related to rear axle bolt breakage and stripped hub splines resulting in loss of motive power and/or loss of park, received from January 8, 2022, through November 27, 2023.
On December 15, 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
Vehicle
| MAKE | MODEL | YEAR |
| FORD | F-150 | 2021-2023 |
3 Associated Documents
Recall Acknowledgement
RCAK-23V896-5442.pdf 645.711KB
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Chronology
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Defect Notice 573 Report
RCLRPT-23V896-5481.PDF 214.528KB
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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-896
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Ford Motor Company DEC 22, 2023 NHTSA Recall No. : 23V-896 Manufacturer Recall No. : 23S65 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 : 112,965 Estimated percentage with defect : 2 %
Vehicle Information : Vehicle 1 : 2021-2023 Ford F-150 Vehicle Type : LIGHT VEHICLES
Body Style :
Power Train : NR
Descriptive Information : Affected vehicles are equipped with the Trailer Tow Max Duty package and a 9.75- inch heavy duty (HD) axle with a ¾ float axle design and were built between January 28, 2020 and December 25, 2022.
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.
54,509 2021 model year F-150 vehicles are affected. 47,886 2022 model year F-150 vehicles are affected. 10,570 2023 model year F-150 vehicles are affected.
Production Dates : JAN 28, 2020 – DEC 25, 2022 VIN Range 1 : Begin : NR End : NR Not sequential
Description of Defect :
Description of the Defect : The rear axle hub bolt may break due to fatigue and will no longer prevent micro-movement between the hub splines and the axle shaft splines. Over time, in a corrosive environment, corrosion and the micro-movement may result in wearing of the hub splines which can lead to loss of torque transfer to the wheel end. FMVSS 1 : NR Part 573 Safety Recall Report 23V-896 Page 2 FMVSS 2 : NR
Description of the Safety Risk : Stripped rear axle hub splines may result in unintended vehicle movement
while the vehicle is in Park if the Electric Parking Brake (EPB) is not applied, increasing the risk of injury or crash. There are some conditions in which the EPB will automatically apply and the EPB can also be applied manually.
Stripped rear axle hub splines may also result in loss of motive power in 4X2 operation (vehicle will move in 4X4, if equipped).
Description of the Cause : Micro-movement between the hub splines and the axle shaft splines leads to fretting, which creates wear from displaced particles of the splines. The fretting particles may corrode, expand, and accelerate the fretting wear, leading to eventual wear-out (stripping) of the hub splines. Identification of Any Warning
that can Occur : As the rear axle hub bolt becomes loose, customers may report a clicking noise. If the bolt breaks, customers may report a rattle noise (the bolt head will be contained within the wheel center cap). Involved Components : Component Name 1 : Rear Axle Shaft Assembly
Component Description : Rear Axle Shaft Assembly (Left-hand side) Component Part Number : ML3W-4725-C Component Name 2 : Rear Axle Shaft Assembly
Component Description : Rear Axle Shaft Assembly (Right-hand side) Component Part Number : ML3W-4234-C Supplier Identification : Component Manufacturer
Name : Sterling Axle Plant Address : 39000 Mound Road
Sterling Heights Michigan 48310
Country : United States Chronology : The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-896
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Chronology is provided as an attachment.
Description of Remedy :
Description of Remedy Program : Owners will be notified by mail and informed that Ford’s investigation is
ongoing and that they will be contacted when further information is available. Customers will be instructed to take their vehicle to a Ford or Lincoln dealer for an interim repair if they experience symptoms related to rear axle bolt fracture prior to availability of the final remedy. 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 February 23, 2024. 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 service remedy will be defined at a later date. NR Recall Schedule :
Description of Recall Schedule : Notification to dealers is expected to occur on January 16, 2024. Mailing
of owner notification letters is expected to begin January 29, 2024 and is expected to be completed by February 2, 2024.
Planned Dealer Notification Date : JAN 16, 2024 – JAN 16, 2024
Planned Owner Notification Date : JAN 29, 2024 – FEB 02, 2024
* NR – Not Reported
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