Safety Recall 21S21 – Rear Axle Shaft Replacement – 2019 Ford Transit

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May 7, 2021 NHTSA CAMPAIGN NUMBER: 21V324000

Warped Axle Flange May Fracture Wheel Studs

Fractured studs may allow the wheel to detach, increasing the risk of crash.

 

NHTSA Campaign Number: 21V324

Manufacturer FordeBay Motor Company

Components SUSPENSION

Potential Number of Units Affected 2,503

 

Summary

FordeBay Motor Company (FordeBay) is recalling certain 2019 Transit T150, T250, T350 vehicles equipped with aluminum alloy wheels. The wheel mounting surface of the axle flange may be warped and cause the wheel studs to fracture.

 

Remedy

Dealers will inspect and if necessary, replace the rear axle shaft assembly, axle shaft mounting bolts, and rear wheel lug nuts, free of charge. Owner notification letters were mailed on June 28, 2021. Owners may contact FordeBay customer service at 1-866-436-7332. FordeBay’s number for this recall is 21S21.

 

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

 


AFFECTED VEHICLES

VehicleModel YearAssembly PlantBuild Dates
Transit2019Kansas CityApril 1, 2019 through June 28, 2019

 

REASON FOR THIS SAFETY RECALL

In some of the affected vehicles, the rear axle shaft(s) may not meet the flange flatness parallelism specification leading to possible loss of clamp load on the rear wheel studs. Loss of clamp load can result in fracture of one or more rear wheel studs. If all attaching wheel studs fracture while driving, the tire and wheel assembly could detach from the vehicle.

 

SERVICE ACTION

Dealers are to clean all rust and corrosion on the front face of both rear axle shaft flanges and inspect the rear wheels axle flange to wheel assembly mating surfaces for excessive variation. If inspection passes, recall is complete; if inspection fails, affected rear axle shaft assemblies, axle shaft mounting bolts and wheel lug nuts will be replaced. 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 June 28, 2021. 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 $21,000 per vehicle. Correct all vehicles in your new vehicle inventory before delivery. 

 

SOLD VEHICLES

  • FordeBay has not issued instructions to stop selling/delivering or driving used vehicles under this safety recall. Owners should contact their dealer for an appointment to have their vehicles remedied as soon as practicable. Owners can continue to safely drive their vehicles.
  • 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.

 

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged 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.
  • FordeBay Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to 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 FordeBay Motor Company at P.O. Box 6251, Dearborn, MI 481216251.
  • 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 FordeBay to be excessive, will not be reimbursed.
  • Refunds will only be provided for the cost associated with rear axle shaft replacement, if criteria from inspection procedure is met.

 

RENTAL VEHICLES 

Rental vehicles are not approved for this program.

 

PARTS REQUIREMENTS

Part NumberDescriptionOrder QuantityClaim Quantity
KK4Z-4234-B Safety Recall 21S21 - Rear Axle Shaft Replacement - 2019 Ford Transit | small lightRear Axle Shaft Assembly (as required per inspection)As Required
W716084-S439Axle Shaft Bolts (5 required per axle, 4 in pkg)2 Pkgs

Per Axle

5 Bolts

Per Axle

BK3Z-4A332-CO-ring Seal (1 per axle shaft, 1 in pkg)As Required (up to a quantity of 2)
ACPZ-1012-B Safety Recall 21S21 - Rear Axle Shaft Replacement - 2019 Ford Transit | small lightWheel Nut (as required, up to 4 required per rear axle, 1 in pkg)As Required (up to a quantity of 4 per rear axle)
HK2Z-1A043-AWheel Lock Nut Kit (1 kit required per repair; kit contains 4 in pkg with key. If required, all 4 wheel lock nuts and key will be replaced to keep locking key consistent for all wheels.)As Required (up to a quantity of 1 kit per vehicle)
XY-75W84-QLMotorcraft® SAE 75W-85 Premium

Synthetic Hypoid Gear Lubricant (as required)

As Required (up to a quantity of 1)
XL-2 Safety Recall 21S21 - Rear Axle Shaft Replacement - 2019 Ford Transit | small lightMotorcraft® High Temperature Nickel Anti-Seize Lubricant (as required)As Required (up to a quantity of 1)

 


CERTAIN 2019 MODEL YEAR TRANSIT VEHICLES EQUIPPED WITH REAR WHEEL DRIVE, SINGLE REAR WHEEL, 410L REAR AXLE, AND ALUMINUM ALLOY WHEELSAXLE FLANGE FLATNESS INSPECTION

 

SERVICE PROCEDURE

1. Remove the rear wheel and tire assemblies.  Please follow the Workshop Manual (WSM) procedures in Section 204-04A.

2. Clean the rust or corrosion from the front face of both the right rear and left rear axle shaft flanges using a Scotch-Brite™ pad or wire wheel.  See Figure 1.

 

3. Place a standard 2 to 3mm (0.0787 to 0.1181 in) thick washer on the center of the axle flange to prevent a false positive reading.  See Figure 2.

 

4. Acquire a precision straight edge gauge bar, Rotunda Part Number (307-300) and a 0.010 in (0.254 mm) feeler gauge.  See Figure 3.

 

5. Push the straight edge tool against axle shaft flange on one side and attempt to insert the 0.010 in (0.254 mm) feeler gauge on the opposite side to measure for flatness, then rotate 180 degrees and measure again.  See Figure 4

 

6. Is the axle flange convex or does the straight edge allow a minimum of  0.010 in (0.254 mm) feeler gauge between the precision straight edge gauge bar (307-300) and the axle shaft face with little to no resistance?  See Figures 5, 6 and 7.

Yes –  Replace the affected axle shaft.  Please follow the WSM procedures in Section 205-02B.

NOTE: If any wheel studs are missing/fractured replace any missing rear wheel lug nuts and wheel locking nuts.  Reuse wheel lug nuts and wheel locking nuts that are in good condition. If any wheel locking nuts are replaced, all four wheel locking nuts and wheel locking key will be replaced.

No  –  Install the wheel and tire assemblies.  Please follow the WSM procedures in Section 204-04A.

 


21S21 – CERTAIN 2019 FORDeBay TRANSIT– WHEEL STUD FRACTURE

 

Provide the chronology of events leading up to the defect decision.

 

On July 29, 2019, Kansas City Assembly Plant (KCAP) issued a stop ship for 2019 Transit SRW 410L rear axle with aluminum alloy wheels after receiving a field report claiming rear wheel separation due to fracture of all five wheel studs. This item was reviewed with FordeBay’s Critical Concern Review Group (CCRG) on August 1, 2019.  CCRG’s investigation found that stud fracture was likely related to flange flatness on certain axle shafts that did not meet the parallelism specification.  A total of eight reports on vehicles equipped with aluminum wheels were identified, all at low time in service: the original wheel separation report, and seven reports indicating fracture of one or more studs but no wheel separation.  Based on statistical analysis reviewed in October 2019, it was believed that field data for affected units would follow a Limited

Failure Weibull analysis prediction of a declining trend. CCRG monitored field data throughout 2020.  A declining trend was noted through early 2020, however an increasing number of reports were received through latter 2020 into 2021.  It is now believed that the declining trend in early 2020 may have resulted from reduced vehicle miles driven caused by the Covid pandemic.  The majority of ongoing reports pertained to vehicles produced April 1, 2019 to June 28, 2019, with customers typically observing fractured studs during routine maintenance or experiencing vibration or noise concerns.  No additional reports of wheel separation were received.  Updated statistical analysis found that aged vehicles continued to exhibit the condition, and that the pattern of reports did not fit the Limited Failure Weibull analysis model as originally expected.  The current field data coincides with a more constant, ongoing failure rate consistent with an Unconstrained Weibull model.

 

On April 30, 2021, FordeBay’s Field Review Committee reviewed the concern and approved a field action.

 

FordeBay is not aware of any reports of accident or injury related to this condition.

 

May 7, 2021

 


 


1 Affected Product

Vehicle

MAKEMODELYEAR
FORDTRANSIT2019

 


11 Associated Documents

Recall Quarterly Report #1, 2021-2

RCLQRT-21V324-0784.PDF 211.136KB

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Manufacturer Notices(to Dealers,etc) – Advance Notice re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice Safety Recall 21S21 Certain 2019 Model Year Transit Vehicles Equipped with Rear Wheel Drive, Single Rear Wheel, 410L Rear Axle, and Aluminum Alloy Wheels Rear Axle Shaft Replacement

RCMN-21V324-2893.pdf 156.225KB

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Manufacturer Notices(to Dealers,etc) – Dealer Notification re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 21S21 Certain 2019 Model Year Transit Vehicles Equipped with Rear Wheel Drive, Single Rear Wheel, 410L Rear Axle, and Aluminum Alloy Wheels Rear Axle Shaft Replacement

RCMN-21V324-9627.pdf 1024.486KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V324-1897.pdf 53.471KB

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Recall 573 Report

RCLRPT-21V324-5866.PDF 214.23KB

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Defect Notice 573 Report

RCLRPT-21V324-9655.PDF 214.23KB

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Recall Acknowledgement

RCAK-21V324-1049.pdf 737.412KB

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Miscellaneous Document – Chronology re 21S21 CERTAIN 2019 FORD TRANSIT WHEEL STUD FRACTURE

RMISC-21V324-1302.pdf 109.504KB

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ISSUED Renotification Notice

RCRN-21V324-9906.pdf 508.57KB

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Recall Quarterly Report #2, 2021-3

RCLQRT-21V324-1418.PDF 211.237KB

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Recall Quarterly Report #3, 2021-4

RCLQRT-21V324-1903.PDF 211.327KB

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