Safety Recall 20S62 – Rear Suspension Toe Link Fracture – 2013-2017 Ford Explorer

October 30, 2020 NHTSA CAMPAIGN NUMBER: 20V675000

Rear Suspension Toe Link Fracture

A rear toe link fracture can result in a loss of steering control, increasing the risk of a crash.

 

NHTSA Campaign Number: 20V675

Manufacturer FordeBay logo Motor Company

Components SUSPENSION

Potential Number of Units Affected 318,381

 

Summary

FordeBay logo Motor Company (FordeBay logo) is recalling certain 2013-2017 Explorer vehicles originally sold, or currently registered in Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, and Wisconsin that were previously repaired under a prior recall numbers 16V-245 or 19V-435. The outboard section of a rear suspension toe link may fracture.

 

Remedy

FordeBay logo will notify owners, and dealers will inspect the cross-axis ball joint (CABJ) knuckle attached to the rear suspension toe link and replace it as necessary, free of charge. The recall began November 27, 2020. Owners may contact FordeBay logo customer service at 1-866-436-7332. Ford’s number for this recall is 20S62.

 

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.safercar.gov.

 

Check if your Vehicle has a Recall

 


REASON FOR THIS SAFETY RECALL

Some of the affected vehicles, sold or operated in certain traditional corrosion areas, have experienced fracture of the outboard section of the rear suspension toe link after completion of a prior recall repair. Preliminary assessment of field data indicates that the toe link ball joint (built into the knuckle) may be susceptible to seizing in certain high corrosion areas. A seized toe link ball joint can increase bending stresses in the toe link outboard of the turnbuckle. Rear toe link fracture while driving could result in unusual vehicle handling characteristics, or difficulty controlling the vehicle and may increase the risk of a crash.

 

SERVICE ACTION  

Dealers are to check both toe link ball joints integrity and, if necessary, replace the rear wheel knuckle(s), and adjust rear toe. This service must be performed on all affected vehicles at no charge to the vehicle owner.

 

OWNER NOTIFICATION AND MAILING SCHEDULE

Owners of affected vehicles were notified in two separate mailings. The first mailing occurred on November 30, 2020. Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

Owners of vehicles affected by the program expansion in Canada will receive a combined 20S62/21S32 Owner Letter the week of September 13, 2021.

 

PARTS REQUIREMENTS / ORDERING INFORMATION

Note: All parts can now be ordered through normal processes.

Part NumberDescriptionEngine AWD/ FWD Order QuantityClaim Quantity
Parts Required if Both Toe Link Ball Joints Pass
-W715419-S439Toe Link Bolt (1 bolt per side, 4 Bolts in each package)AllAll12
-W520516-S441Toe Link Nut (1 nut per side)AllAll22
*Note: If part W520516-S441 is not available then part W520215-S440 is an alternate option.
Parts Required if a Toe Link Ball Joint Fails
Part NumberDescriptionEngineAWD/ FWDOrder QuantityClaim Quantity
DB5Z-5A972-JRear Toe Link Kit – See affected Engine and AWD/FWD detail3.5L TiVCTAWD11
3.5L GTDI
3.7L DOHC
3.7L DOHCFWD
DB5Z-5A972-KRear Toe Link Kit – See affected Engine and AWD/FWD detail2.3L GTDIAWD11
2.3L GTDIFWD
2.0L GTDI
3.5L TiVCT
DB5Z-5B759-BLeft Rear KnuckleAs Required
DB5Z-5B758-BRight Rear KnuckleAs Required
-W712435-S439Wheel Hub Nut (1 nut per side)As Required
-W710681-S439Brake Caliper Bolts (2 bolts per side)As Required
-W708733-S439Brake Disk Retainer Bolt (1 bolt per side)As Required
-W520213-S440Rear Stabilizer Link Nut (1 nut per side)As Required
-W714033-S439Shock Absorber Bolt (1 bolt per side)As Required
-W715419-S439Trailing Arm Bolt (1 bolt per side)As Required
-W520516-S441Trailing Arm Nut (1 nut per side)As Required
-W715127-S439Upper Control Arm, Lower Control Arm Bolt (2 bolts per side)As Required
-W520517-S440Upper Control Arm, Lower Control Arm Nut (2 nuts per side)As Required
-W714516-S439Wheel Hub Bolts (4 bolts per side)As Required

 

CERTAIN 2013-2017 MODEL YEAR EXPLORER VEHICLES — REAR SUSPENSION TOE LINK TO WHEEL KNUCKLE BALL JOINT

 

SERVICE PROCEDURE

WARNING: Suspension fasteners are critical parts that affect performance of vital components and systems. Tighten fasteners as specified. Measure the distance from the center of the wheel hub to the lip of the fender with the vehicle in a level, static ground position (ride height) before disassembly. When securing the new toe link, it must be secured at the previously measured ride height.

WARNING: Tighten the suspension bushing fasteners with the suspension supported at ride height or with the weight of the vehicle resting on the wheels and tires, otherwise toe link and bushing damage may occur.

NOTE: This recall is to be performed on both the right rear and the left rear suspension.

1. Measure the distance from the center of the wheel hub to the lip of the fender with the vehicle in a level, static ground position (ride height) before disassembly. See Figure 1.

NOTE: The new toe link adjustment sleeve jam nuts are only finger tight. The jam nuts must be tightened to the torque specification in the Workshop Manual (WSM) even if toe adjustment is not necessary.

NOTE: The toe links must be secured at ride height during replacement. See Figure 1.

2. Position the vehicle on a hoist. Please follow the WSM procedures in Section 100-02.

3. Remove both rear tires. Please follow the WSM procedures in Section 204-04A.

4. Using a jack stand, support the rear suspension to ride height. See Figure 2.

5. Remove the toe link-to-wheel knuckle bolt and nut. See Figure 3.

6. Install the toe link to knuckle bolt and nut. Tighten the nut while holding the bolt still with a wrench. See Figure 4.

  • Torque: 111 lb.ft (150 Nm).

NOTE: When functioning properly the toe link ball joints should rotate freely. This inspection step will determine if the ability for the ball joint to rotate freely has been affected, requiring replacement.

7. Using a digital or dial type torque wrench, rotate the toe link to wheel knuckle bolt while keeping the ball joint straight. Do not allow the ball joint to twist as shown in the red picture below. Note the reading off of the torque wrench when the ball joint begins to rotate. See Figure 5.

8. Repeat steps 4 through 7 on the other side.

9. Are the readings over 11 lb. ft (15 Nm)?

For RH side:

If YES – The RH ball joint has FAILED. Proceed to step 13 for replacement instructions on this side

If NO – Proceed to Step 10 for the RH side of the vehicle.

For LH side:

If YES – The LH ball joint has FAILED. Proceed to step 13 for replacement instructions on this side.

If NO – Proceed to Step 10 for the LH side of the vehicle.

10. Install the new toe link to wheel knuckle bolt and nut with the vehicle suspension at ride height. See Figure 6.

  • Torque: 111 lb.ft (150 Nm).

11. Remove the jack stand. See Figure 7.

12. Install the wheel and tire. Please follow the WSM procedures in Section 204-04A. This completes the recall.

13. Remove and discard the toe link to subframe bolt and the toe link. See Figure 8.

14. Replace the wheel knuckle. Please follow the WSM procedures in Section 204-02.

  • Do not install the wheels and tires or perform the alignment at this time.

15. Install the new toe link. Please follow the WSM procedures in Section 204-02.

16. Perform an alignment. This completes the recall.

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.

 


Ford Media Center

FORD MOTOR COMPANY ISSUES SAFETY RECALL FORSELECT 2013-17 FORD EXPLORER VEHICLES

Nov 4, 2020 | DEARBORN, Mich.

DEARBORN, Mich., Nov. 4, 2020 – Ford Motor Company is issuing a safety recall for select 2013-17Ford Explorer vehicles. Some affected vehicles, sold or registered in certain areas of North America states and provinces where corrosion is common, have experienced a fracture of the outboard section of the rear suspension toe link after completion of a prior safety recall repair. A fracture of a rear toe link significantly diminishes steering control, increasing the risk of a crash.
Ford is aware of 13 reports of accidents and six reports of injuries related to this condition.

This action affects approximately 350,000 vehicles in the U.S. and 25,200 in Canada. Affected vehicles were built at Chicago Assembly Plant from Sept. 4, 2012, to Jan. 25, 2017.

Dealers will complete a torque inspection of the cross-axis ball joint and replace it as necessary. The Ford reference number for this recall is 20S62.

 


Chronology of Defect / Noncompliance Determination

 

Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision.

 

Ford previously approved actions (19S17, 17G01, 16S18) to upgrade the rear toe link on Explorer vehicles based on reports of “inboard” side fractures of the original toe link design.  Analysis had found that toe link fractures inboard of the turnbuckle could occur due to reverse bending fatigue under high stress conditions during full rear suspension articulation (jounce and rebound.) The remedy for those vehicles involved replacement of the welded toe link with a new toe link that is forged on the inboard side and welded on the outboard side.

 

November 2019 – June 2020: Ford received 1 report of rear toe link fracture in the U.S. after completion of the above recall.  Ford received 5 reports of rear toe link fracture in Canada on vehicles that completed a similar recall issued in 2017. Investigation of parts removed from these vehicles indicated that aftermarket parts (bushings) had been installed in the rear suspension knuckle in place of the original CABJ. Ford advises its dealers to replace the entire knuckle if repair is needed. Our engineering analysis indicated that these aftermarket bushings had prematurely seized or had a very high torque, increasing stress on the toe link. Ford shared and discussed this information with NHTSA and Transport Canada.

 

August – September 2020: On August 27th, a new issue regarding reports of rear toe link fracture after completion of the above referenced safety recall remedy was brought to Ford’s CCRG for review.  Reports of “outboard side” fracture of the toe link after completion of the recall repair had previously been investigated and found to relate to improper use of aftermarket components. However, Ford’s ongoing monitoring and investigation of field data subsequently identified reports that appeared to involve “outboard side” fracture of a toe link that had been properly replaced.

 

Numerous efforts were undertaken to understand these reports, including retrieval and inspection of toe links and attaching hardware from complaint vehicles, laboratory analyses of select parts, and driver interviews. Ford also communicated regularly with the agency regarding reports received by the agency and the status of Ford’s investigation.

 

October 2020:  As of October 27, 2020, Ford has received 12 reports (in addition to 8 VOQs received by the agency) of “outboard side” fracture of the replacement forged toe link on 20132017 model year vehicles in the U.S., with 10 accident allegations and 4 allegations of injury. In Canada, Ford is aware of 15 reports, with 3 allegations of accident and 2 allegations of injury on the subject vehicles. Preliminary evaluation of parts obtained from these vehicles has found evidence of a corroded and seized cross-axis ball joint (CABJ). The CABJ was introduced on 2013 model year Explorer vehicles and attaches the outboard portion of the toe link to the rear knuckle.  All the reports received by Ford and the agency involve vehicles equipped with a CABJ and involve vehicles from or in traditional corrosion states. Ford is not aware of any reports of post-recall fractures in non-corrosion areas in the U.S. and Canada. Similarly, Ford is unaware of any reports occurring in areas outside the U.S. and Canada.

 

Although Ford has not concluded its investigation into this subject, Ford is undertaking this safety recall at this time to address the risk of a seized CABJ on 2013-2017 model year vehicles in North American corrosion areas that have already been remedied under prior actions. This action will provide for a torque inspection of the CABJ and replacement of the CABJ/knuckle if necessary.

 

For any 2013-2017 MY vehicles not yet remedied under the prior actions, the repair procedure for those actions will be updated to include the CABJ torque inspection.

 

Ford’s investigation will continue for this subject.

 

On October 23, 2020, Ford’s Field Review Committee reviewed the concern and approved a field action.

 

Ford is aware of 10 allegations of accident and 4 allegations of injury on vehicles in the U.S..

 

March 12, 2021: Ford revised the number of vehicles potentially affected according to the latest registration information.

 

March 22, 2021: Ford revised the descriptive information to include the list of corrosion states.

 


 


5 Affected Products

Vehicle

MAKEMODELYEAR
FORDEXPLORER2013-2017

 


18 Associated Documents

Owner Notification Letter(Part 577)

RCONL-20V675-5120.pdf 55.875KB

 


Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re Safety Recall 20S62 – Supplement #2 Certain 2013 through 2017 Model Year Explorer and Police Interceptor Utility Vehicles that are Registered or Sold in High Corrosion States/Provinces Rear Toe Link Ball Joint Inspection

RCMN-20V675-8234.pdf 1620.33KB

 


ISSUED Renotification Notice

RCRN-20V675-4712.pdf 55.65KB

 


Renotification Notice

RCRN-20V675-5204.pdf 42.319KB

 


Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re Safety Recall 20S62 – Supplement #1 Certain 2013 through 2017 Model Year Explorer and Police Interceptor Utility Vehicles that are Registered or Sold in High Corrosion States/Provinces Rear Toe Link Ball Joint Inspection

RCMN-20V675-0267.pdf 1637.278KB

 


Miscellaneous Document – Chronology of Defect / Noncompliance Determination

RMISC-20V675-5374.pdf 16.894KB

 


ISSUED Renotification Notice

RCRN-20V675-8728.pdf 567.183KB

 


Manufacturer Notices(to Dealers,etc) – Dealer Notification re Awareness Communication – Upcoming SAFETY Recall 20S62 Certain 2013 through 2017 Model Year Explorer and Police Interceptor Utility Vehicles that are Registered or Sold in High Corrosion States/Provinces Rear Toe Link Ball Joint Inspection

RCMN-20V675-5278.pdf 146.047KB

 


Miscellaneous Document – Media Release re Ford Motor Company Issues Safety Recall For Select 201-17 Ford Explorer Vehicles

RMISC-20V675-0070.pdf 57.904KB

 


Recall Quarterly Report #2, 2021-1

RCLQRT-20V675-3930.PDF 211.244KB

 


Defect Notice 573 Report

RCLRPT-20V675-1963.PDF 213.933KB

 


Recall Acknowledgement

RCAK-20V675-5453.pdf 333.609KB

 


Chronology

RMISC-20V675-0657.pdf 17.598KB

 


Recall Quarterly Report #1, 2020-4

RCLQRT-20V675-0068.PDF 211.138KB

 


Manufacturer Notices(to Dealers,etc) – Dealer Notification re Safety Recall 20S62 Certain 2013 through 2017 Model Year Explorer and Police Interceptor Utility Vehicles that are Registered or Sold in High Corrosion States/Provinces Rear Toe Link Ball Joint Inspection

RCMN-20V675-3269.pdf 1598.988KB

 


Manufacturer Notices(to Dealers,etc) – Dealer Memo re Safety Recall 20S62 – Supplement #3 Certain 2013 through 2017 Model Year Explorer and Police Interceptor Utility Vehicles that are Registered or Sold in High Corrosion States/Provinces Rear Toe Link Ball Joint Inspection

RCMN-20V675-0323.pdf 1606.217KB

 


Recall Quarterly Report #3, 2021-2

RCLQRT-20V675-3171.PDF 211.339KB

 


Recall Quarterly Report #4, 2021-3

RCLQRT-20V675-1798.PDF 211.457KB

 


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