March 8, 2024 NHTSA CAMPAIGN NUMBER: 24E023000
Headlights Too Bright/FMVSS 108
Excessive glare or brightness to oncoming drivers increases the risk of a crash.
NHTSA Campaign Number: 24E023
Manufacturer Ford
Motor Company
Components EXTERIOR LIGHTING
Potential Number of Units Affected 1,505
Summary
Ford Motor Company (Ford) is recalling certain Ford Super Duty High Series Headlights sold as replacement parts for 2017-2019 Super Duty vehicles. Please see the recall report for the list of affected part numbers. The headlights may be too bright, exceeding the maximum light output allowed which may adversely affect the vision of drivers. As such, these headlights fails to comply with the requirements of the Federal Motor Vehicle Safety Standard (FMVSS) number 108, “Lamps, Reflective Devices, and Associated Equipment.”
Remedy
Dealers will inspect the date codes on the headlights and if necessary, replace them, free of charge. Owner notification letters are expected to be mailed April 15, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 24C04.
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 11, 2024
Equipment Recall 24C04 – Advance Notice
High Series LED service Headlamps installed on certain 2017-2019 Super Duty Vehicles
High Series LED service Headlamps – Part Number and Date Code Inspection
AFFECTED VEHICLES*
| Vehicle | Model Year | Assembly Plant | Build Dates |
| Super Duty | 2018 | Kentucky Truck | December 23, 2017 through June 29, 2018 |
| Super Duty | 2019 | Kentucky Truck | July 10, 2018 through October 22, 2019 |
US population of affected vehicles: 73. Affected vehicles are identified in OASIS and FSA VIN Lists.
* The population for this equipment recall is 1505, 73 of which are VIN-specific.
REASON FOR THIS COMPLIANCE RECALL
Some of the affected vehicles were repaired using certain service replacement headlamps that may not conform to the requirements specified by Federal Motor Vehicle Safety Standard (FMVSS) No. 108, Lamps, Reflective Devices, and Associated Equipment, Table XIX-a related to the lower beam photometry requirements.
Your dealership may have either (a) serviced an affected vehicle, or (b) sold over the counter one of the suspect replacement headlamps produced with certain date codes.
SERVICE ACTION
A complete Dealer Bulletin will be provided to dealers 2nd Quarter when it is anticipated that parts ordering information and repair instructions will be available to support this equipment 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 $27,168 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.
24C04 – CERTAIN HIGH SERIES HEADLAMPS SOLD AS SERVICE PARTS FOR 2017- 2019MY FORD SUPER DUTY
Chronology of Defect / Noncompliance Determination
Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision.
March – June 2023
On March 15, 2023, Transport Canada (TC) performed photometric testing on a 2017 model year Super Duty left-hand high series headlamp purchased from a Ford service depot to verify compliance with CMVSS No. 108. The tested headlamp showed an apparent noncompliance to CMVSS 108 for the lower beam at a single test point. On May 10, 2023, TC notified Ford of this apparent noncompliance and Ford’s Critical Concern Review Group (CCRG) opened an investigation into this issue. On June 21, 2023, Ford responded to TC requesting to re-test the same component with the Ford Super Duty headlamp test fixture.
July – November 2023
Ford obtained seventeen (17) service headlamps from service depots throughout North America for photometric testing at the Tier-1 supplier; all of these headlamps met the CMVSS 108 photometric requirements. On November 08, 2023, the retest of the same TC headlamp using the Super Duty headlamp test fixture exhibited the same apparent noncompliance. TC also conducted two tests on two different service headlamps, both of which passed.
December 2023 – January 2024
The tear down analysis of TC headlamp identified that molding of the low beam module lens within the headlamp deviated from a nominal surface design. This could cause the photometric intensity to exceed the maximum requirement at a single test point. After investigation into the molding process at the Tier-3 supplier, the team theorized that the malfunction of valve gates controlling the fill of plastic into the lens’s injection mold or variation in the cooling of the injection mold may have created the dimensional inaccuracy that could form an incorrect beam pattern.
February 2024
Ford CCRG performed a statistical analysis of the Tier-1 supplier’s quality control process data for production and service parts. This analysis confirmed that production parts supplied by the Tier-1 supplier from July 2016 through November 2019 met Ford’s statistical confidence and reliability criteria typically used to assess compliance. Additionally, the data demonstrated that the service parts built in a suspect time window between May 05, 2021, to December 30, 2021, were built out-of-process, due to a supplier quality concern during this time-period. The headlamp that TC tested with the apparent noncompliance was manufactured in September 2021 and falls within the suspect time window described above. Reviewing the warranty data, the CCRG determined that 82 vehicles in US and Canada repaired between May 2021 and March 2023 may have received service headlamps built within the suspect time window.
As of February 28, 2024, Ford is not aware of any accidents or injuries pertaining to this issue.
On March 01, 2024, Ford’s Field Review Committee reviewed the concern and approved a field action.
###
March 08, 2024
1 Affected Product
Equipment
4 Associated Documents
Chronology of Defect / Noncompliance Determination
RMISC-24E023-9076.pdf 74.048KB
Noncompliance Notice 573 Report
RCLRPT-24E023-5231.PDF 218.367KB
Manufacturer Notices(to Dealers,etc)
Recall Acknowledgement
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SEOCONTENT-START
Ó Copyright 2024 Ford Motor Company
Stacy L. Balzer Ford Motor Company
Director PO Box 1904
Service Engineering Operations Dearborn, Michigan 48121
Ford Customer Service Division
March 11, 2024
TO: All U.S. Ford and Lincoln Dealers
SUBJECT: Equipment Recall 24C04 – Advance Notice
High Series LED service Headlamps installed on certain 2017-2019 Super Duty
Vehicles
High Series LED service Headlamps – Part Number and Date Code Inspection
AFFECTED VEHICLES*
Vehicle Model Year Assembly Plant Build Dates
Super Duty 2018 Kentucky Truck December 23, 2017 through June 29, 2018
Super Duty 2019 Kentucky Truck July 10, 2018 through October 22, 2019
US population of affected vehicles: 73. Affected vehicles are identified in OASIS and FSA VIN Lists.
* The population for this equipment recall is 1505, 73 of which are VIN-specific.
REASON FOR THIS COMPLIANCE RECALL
Some of the affected vehicles were repaired using certain service replacement headlamps that may
not conform to the requirements specified by Federal Motor Vehicle Safety Standard (FMVSS) No.
108, Lamps, Reflective Devices, and Associated Equipment, Table XIX-a related to the lower beam
photometry requirements.
Your dealership may have either (a) serviced an affected vehicle, or (b) sold over the counter one of
the suspect replacement headlamps produced with certain date codes.
SERVICE ACTION
A complete Dealer Bulletin will be provided to dealers 2nd Quarter when it is anticipated that parts
ordering information and repair instructions will be available to support this equipment 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 $27,168 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.
Ó Copyright 2024 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
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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24E-023
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Ford Motor Company MAR 08, 2024 NHTSA Recall No. : 24E-023 Manufacturer Recall No. : 24C04 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 : 1,505 Estimated percentage with defect : 13 %
Equipment Information : Brand / Trade 1 :
Model : Ford Service Parts
Ford Super Duty High Series Headlamp Part No. : HC3Z-13008-N Size : N/A Function : N/A
Descriptive Information : Ford’s team reviewed supplier process and test records to determine the population of affected service parts. 1,505 service headlamps built from 05/05/2021 to 12/30/2021 for 2017-2019 model year Super Duty vehicles have been included in the recall population. Affected service headlamps may not meet the lower beam photometric requirements of FMVSS 108. Through Ford warranty records, Ford identified 73 vehicles in the US that may have the affected service headlamps installed on the vehicle. The remaining headlamps were sold as replacement parts and Ford does not have traceability to a specific vehicle. Production Dates : MAY 05, 2021 – DEC 30, 2021 Part 573 Safety Recall Report 24E-023 Page 2 Brand / Trade 2 :
Model : Ford Service Parts
Ford Super Duty High Series Headlamp Part No. : HC3Z-13008-P Size : N/A Function : N/A
Descriptive Information : Ford’s team reviewed supplier process and test records to determine the population of affected service parts. 1,505 service headlamps built from 05/05/2021 to 12/30/2021 for 2017-2019 model year Super Duty vehicles have been included in the recall population. Affected service headlamps may not meet the lower beam photometric requirements of FMVSS 108. Through Ford warranty records, Ford identified 73 vehicles in the US that may have the affected service headlamps installed on the vehicle. The remaining headlamps were sold as replacement parts and Ford does not have traceability to a specific vehicle.
Production Dates : MAY 05, 2021 – DEC 30, 2021 Brand / Trade 3 :
Model : Ford Service Parts
Ford Super Duty High Series Headlamp Part No. : HC3Z-13008-PCP Size : N/A Function : N/A
Descriptive Information : Ford’s team reviewed supplier process and test records to determine the population of affected service parts. 1,505 service headlamps built from 05/05/2021 to 12/30/2021 for 2017-2019 model year Super Duty vehicles have been included in the recall population. Affected service headlamps may not meet the lower beam photometric requirements of FMVSS 108. Through Ford warranty records, Ford identified 73 vehicles in the US that may have the affected service headlamps installed on the vehicle. The remaining headlamps were sold as replacement parts and Ford does not have traceability to a specific vehicle.
Production Dates : MAY 05, 2021 – DEC 30, 2021 The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24E-023 Page 3 Brand / Trade 4 :
Model : Ford Service Parts
Ford Super Duty High Series Headlamp Part No. : KC3Z-13008-A Size : N/A Function : N/A
Descriptive Information : Ford’s team reviewed supplier process and test records to determine the population of affected service parts. 1,505 service headlamps built from 05/05/2021 to 12/30/2021 for 2017-2019 model year Super Duty vehicles have been included in the recall population. Affected service headlamps may not meet the lower beam photometric requirements of FMVSS 108. Through Ford warranty records, Ford identified 73 vehicles in the US that may have the affected service headlamps installed on the vehicle. The remaining headlamps were sold as replacement parts and Ford does not have traceability to a specific vehicle.
Production Dates : MAY 05, 2021 – DEC 30, 2021 Brand / Trade 5 :
Model : Ford Service Parts
Ford Super Duty High Series Headlamp Part No. : KC3Z-13008-B Size : N/A Function : N/A
Descriptive Information : Ford’s team reviewed supplier process and test records to determine the population of affected service parts. 1,505 service headlamps built from 05/05/2021 to 12/30/2021 for 2017-2019 model year Super Duty vehicles have been included in the recall population. Affected service headlamps may not meet the lower beam photometric requirements of FMVSS 108. Through Ford warranty records, Ford identified 73 vehicles in the US that may have the affected service headlamps installed on the vehicle. The remaining headlamps were sold as replacement parts and Ford does not have traceability to a specific vehicle.
Production Dates : MAY 05, 2021 – DEC 30, 2021 Description of Noncompliance : Description of the Noncompliance : On the affected service headlamps, the lower beam fails to conform, in part, to S10.18.9.5 of Federal Motor Vehicle Safety Standard (FMVSS) No. 108, “Lamps, reflective devices and associated equipment.” When tested, the light emitted within the boundary of 10U to 90U and 90L to 90R may exceed the maximum photometric requirement specified in Table XIX-a of FMVSS 108. FMVSS 1 : 108 – Lamps, reflective devices, and assoc. Equipment FMVSS 2 : NR The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24E-023 Page 4 Description of the Safety Risk : Headlamps built between May 05, 2021, through December 30, 2021, may not comply with the lower beam photometric requirements specified in Table
XIX-a of FMVSS 108.
Description of the Cause : The molding of the low beam module lens within the headlamp deviated from the nominal surface design which could cause the photometric intensity to exceed the maximum requirement within the boundary of 10U to 90U and 90L to 90R. The malfunction of valve gates controlling the fill of plastic into the lens’s injection mold or variation in the cooling of the injection mold may have created the dimensional inaccuracy that could form an incorrect beam pattern. Identification of Any Warning
that can Occur : None. Involved Components : Component Name : RH High Series Headlamp
Component Description : RH High Series Headlamp for Super Duty with metallic marker – service part Component Part Number : HC3Z-13008-N Component Name : LH High Series Headlamp
Component Description : LH High Series Headlamp for Super Duty with metallic marker – service part Component Part Number : HC3Z-13008-P Component Name : LH High Series Headlamp
Component Description : LH High Series Headlamp for Super Duty with metallic marker – service part Component Part Number : HC3Z-13008-PCP Component Name : LH High Series Headlamp
Component Description : LH High Series Headlamp for Super Duty with non-metallic marker – service part Component Part Number : KC3Z-13008-A Component Name : RH High Series Headlamp
Component Description : RH High Series Headlamp for Super Duty with non-metallic marker – service part Component Part Number : KC3Z-13008-B The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24E-023 Page 5 Supplier Identification : Component Manufacturer
Name : Ventra Sandusky LLC Address : 3020 Tiffin Avenue
Sandusky Ohio 44870-5352
Country : United States Chronology :
Chronology added as a separate attachment. Description of Remedy :
Description of Remedy Program : Letters will be sent to the dealer principals of the dealerships that ordered
the suspect parts for which there is no traceability. The dealerships will be instructed to inspect their service part stock for high series headlamps containing date codes and to purge those parts if found. Dealer will provide evidence that the parts have been scrapped/destroyed.
Dealerships will be instructed to contact customers that purchased the high series headlamp and request that the customer bring their vehicle to the dealership to have the date code inspected on the headlamp and if found within the suspect time window, to replace the headlamp. There will be no charge for this service.
Additionally, owners of vehicles identified through warranty data will be notified by mail and instructed to take their vehicle to a Ford or Lincoln dealer to have the headlamps inspected for date codes and if found within the suspect time window, to replace them. 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 May 06, 2024. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production : The supplier conducted 100% photometric inspection of the remedy replacement headlamps.
Not required per 49 Part 573. Recall Schedule : Description of Recall Schedule : Notification to dealers is expected to occur on March 11, 2024. Mailing of The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24E-023
Page 6
The information contained in this report was submitted pursuant to 49 CFR §573
owner notification letters is expected to begin April 15, 2024 and is expected to be completed by April 19, 2024.
Planned Dealer Notification Date : MAR 11, 2024 – MAR 11, 2024
Planned Owner Notification Date : APR 15, 2024 – APR 19, 2024 Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or installation in new motor vehicles or new items of motor vehicle equipment:
Name : NR Address : NR
NR Country : NR Company Phone : NR
* NR – Not Reported
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SEOCONTENT-END
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