Safety Recall 21S33 – Electronic Brake Booster May Leak Into ECU – 2021 Ford F-150

July 15, 2021 NHTSA CAMPAIGN NUMBER: 21V533000

Electronic Brake Booster May Leak Into ECU

Reduced braking performance can increase the risk of a crash.

 

NHTSA Campaign Number: 21V533

Manufacturer Ford Motor Company

Components SERVICE BRAKES, HYDRAULIC

Potential Number of Units Affected 51

 

Summary

Ford Motor Company (Ford) is recalling certain 2021 F-150 vehicles. The electronic brake booster may leak brake fluid into the electronic control unit, which could result in reduced braking performance.

 

Remedy

Dealers will replace the electronic brake booster assembly, free of charge. Owner notification letters were mailed on July 28, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 21S33.

 

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

 


August 23, 2021

 

Ford Motor Company (Ford) Recall No. 21S33 – Amendment #1 – Certain 2021 model year Ford F-150 vehicles built with improperly clinched electronic brake boosters

Chronology

 

On May 20, 2021, an issue pertaining to three warranty claims of electronic brake booster malfunction on 2021 model year F-150 vehicles was brought to Ford’s Critical Concern Review Group for review.  The reports related to brake fluid leaking into the ECU. The supplier analyzed the boosters and found an incomplete pressure sensor clinch that can create a leak path for brake fluid to migrate into the ECU.

 

Ford’s review of supplier records found that the supplier had identified and quarantined 169 2021 model year F-150 brake booster assemblies on December 7, 2020 because they were potentially assembled with a broken clinching tool, which is used to secure the pressure sensor to the booster housing. Further review of supplier and Ford records determined that 51 of the 169 quarantined parts were inadvertently shipped to Ford’s Dearborn Truck Plant and assembled into vehicles. All 51 of those vehicles were subsequently shipped to dealers in the U.S.

 

Engineering analysis found that a brake booster with an incomplete clinch between the pressure sensor and the brake booster housing can cause brake fluid to leak through the pressure sensor into the ECU on each mis-assembled part. This can reduce braking effectiveness of either or both brake circuits.

 

As of June 25, 2021, Ford is aware of 12 warranty claims associated with this issue.

 

On July 8, 2021, Ford’s Field Review Committee reviewed the concern and approved a field action.

 

Subsequent to the July 8th field action approval, the supplier contacted Ford indicating a warranty return part that was not part of the original population. Upon further review of their records, it was discovered that 18 additional suspect parts, not previously identified, were produced on January 18, 2021 and January 19, 2021. The supplier’s previous review did not identify this group of suspect parts because they had a more complete but still insufficient pressure sensor clinch that was not flagged in the initial data review. Five of these parts were assembled into vehicles.

 

On August 16, 2021, Ford’s Field Review Committee was informed that five vehicles will be added to the field action.

 

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

 


 


1 Affected Product

Vehicle

MAKEMODELYEAR
FORDF-1502021

 


8 Associated Documents

ISSUED Owner Notification Letter(Part 577)

RCONL-21V533-8902.pdf 50.698KB

 


Defect Notice 573 Report

RCLRPT-21V533-9119.PDF 214.586KB

 


Recall Acknowledgement

RCAK-21V533-8684.pdf 645.116KB

 


Miscellaneous Document – VIN List w/PII

RMISC-21V533-8199.pdf 6.395KB

 


ISSUED Renotification Notice

RCRN-21V533-7540.pdf 508.697KB

 


Miscellaneous Document – Amendment 1 to Chronology

RMISC-21V533-4361.pdf 195.07KB

 


Recall Quarterly Report #2, 2021-4

RCLQRT-21V533-1212.PDF 211.237KB

 


Recall Quarterly Report #1, 2021-3

RCLQRT-21V533-5131.PDF 211.134KB

 


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