21S43 – Rear Toe Link Inspection/Replacement – 2011-2013 Ford Explorer

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September 22, 2021 NHTSA CAMPAIGN NUMBER: 21V746000

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: 21V746

Manufacturer FordeBay Motor Company

Components SUSPENSION

Potential Number of Units Affected 126,033

 

Summary

FordeBay Motor Company (FordeBay) is recalling certain 2011-2013 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. These vehicles may be equipped with a cross-axis ball joint (CABJ) replacement part that could seize, and result in a fracture of the outboard section of the rear suspension toe link.

 

Remedy

Dealer will inspect for the presence of a CABJ. If a CABJ of any design is found, the dealer will inspect the tightness of the CABJ, and replace the CABJ, knuckle, and/or toe link as necessary, free of charge. Interim notification letters were mailed November 10, 2021. Owner notification letters were mailed on March 17, 2022. Owners may contact FordeBay customer service at 1-866-436-7332. FordeBay’s number for this recall is 21S43.

 

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

 


2013 Ford Explorer
2013 FordeBay Explorer

 


PROGRAM TERMS

There are no mileage or time limits for this program.

Customers that complete the 21S43 repair prior to July 31, 2023 will be eligible for a one-time replacement of the wheel knuckles (if needed). The eligibility for the one-time replacement of the wheel knuckles (if needed) is for six (6) months from the Repair Order date of 21S43. Please refer to Customer Satisfaction Program 22N01 for details.

Note: It will take 3-4 business days after 21S43 claim submission for 22N01 to show as an active program in OASIS.

 

AFFECTED VEHICLES

Vehicle  Model Year Assembly Plant Build Dates
Explorer2011-2013ChicagoMay 17, 2010 through September 2, 2012

Note: In the United States this recall only affects vehicles that are registered, have ever been registered, or were sold in the following corrosion states.

 

In the United States
ConnecticutDelawareIllinoisIndianaIowa
KentuckyMaineMarylandMassachusettsMichigan
MinnesotaMissouriNew HampshireNew JerseyNew York
OhioPennsylvaniaRhode IslandVermontVirginia
West VirginiaWisconsinDistrict of Columbia

 

REASON FOR THIS SAFETY RECALL

Some of the affected vehicles that have had one (or both) rear wheel knuckle(s) replaced and were sold or operated in certain traditional corrosion areas where road salt is used extensively during winter months, may experience a seized toe link ball joint resulting in a fracture of the outboard section of the rear suspension toe link. 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 to see if any of the prior Explorer Toe Link safety recalls are open on a VIN prior to performing 21S43. Complete any of the Explorer Toe Link safety recalls prior to performing 21S43. Completing any of the prior Explorer Toe Link program after February 18, 2022 will close 21S43.

Dealers are to inspect the rear toe link bushing to see if they have been replaced. If the toe link bushing has been replaced with a ball joint, dealers are to replace both rear suspension toe links with latest level parts, check alignment, and adjust rear toe. This service must be performed on all affected vehicles at no charge to the vehicle owner.

NOTE: Some of the affected vehicles are also included in one or more of the following field service actions: 16S18, 17S11, 18S43, 19S17, or 20S62. If affected, the FordeBay system will automatically close 21S43 upon claim payment of any of the prior programs.

 

OWNER NOTIFICATION MAILING SCHEDULE

A new round of owner letters are expected to be mailed the week of March 7, 2022. 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 replacement of the rear toe links due to fracture.

 

RENTAL VEHICLES 

Rental vehicles are not approved for this program.

 

PARTS REQUIREMENTS / ORDERING INFORMATION

NOTE: The rear toe link kit part numbers have been updated. All repairs completed on or after February 18, 2022 must use the updated parts.

Part NumberDescription Engine AWD/FWD Order QuantityClaim Quantity
DB5Z-5A972-TRear Toe Link Kit – See affected Engine and AWD/FWD detail3.5L TiVCTAWD11
3.5L GTDI
3.7L DOHC
3.7L DOHCFWD
DB5Z-5A972-URear Toe Link Kit – See affected Engine and AWD/FWD detail2.3L GTDIAWD11
2.3L GTDIFWD
2.0L GTDI
3.5L TiVCT

Note: The rear toe link kits contain the parts necessary to replace the toe links on both sides of the vehicle

 


CERTAIN 2011-2013 MODEL YEAR EXPLORER VEHICLES — REAR SUSPENSION TOE LINK REPLACEMENT SERVICE PROCEDURE

 

Check to see if any of the prior Explorer Toe Link safety recalls are open on a VIN prior to performing 21S43. Complete any of the Explorer Toe Link safety recalls prior to performing 21S43. Completing any of the prior Explorer Toe Link program after February 18, 2022 will close 21S43.

 

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.

 

NOTE: It is recommended to perform this entire procedure on an alignment rack.

 

1. Position the vehicle on an alignment rack. Please follow the WSM procedures in Section 100-02.

2. Inspect the rear toe link at BOTH rear wheel knuckles to determine if the knuckle is equipped with a ball    joint or bushing. A ball joint can be identified by both a rubber moisture seal covering the connecting joint and the ball joint sleeve extending past the surface of the wheel knuckle. See Figure 1.

If either real wheel knuckle is equipped with a ball joint – Proceed to Step 3.

If both rear wheel knuckles are equipped with a bushing – This recall does not apply.

 

3. Using a jack stand, raise the rear of the vehicle by lifting the lower coil spring leaf. See Figure 2.

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

5. Remove and discard both rear toe links. See Figure 3.

1. Remove and discard the toe link-to-wheel knuckle bolts and nuts.

2. Remove and discard the toe link-to-subframe bolt and remove the toe links.

 

NOTE: Do not torque the fasteners at this time.

5. Install the new toe links by reversing the removal procedure. See Figure 3.

  • Only hand tighten the inboard fastener and snug the outboard retainer at this time.

6. Install both rear tires. Please follow the WSM procedures in Section 204-04A.

7. Lower the vehicle onto the alignment rack with the rear adjustment rack slip plates loose.

8. Tighten the inboard rear toe link bolts on both sides.

  • Torque: 111 lb.ft (150 Nm)

 

9. Set the tire pressure and perform an alignment and tighten the outboard bolt and nut on both sides. This completes the recall.

  • Torque: 111 lb.ft (150 Nm)

 

NOTE: the frame side of the new toe link has a slot that is used for the alignment process. See Figure 4.

 

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 FordeBay, 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.

 


Recommended Repair:

If 2011-2019 FordeBay Explorers or PIU vehicles require service of the rear wheel knuckle and/or rear wheel knuckle bushings, the recommended repair is to replace the affected rear wheel knuckle (5B758/9) as an assembly only. Refer to WSM, Section 204-02, and the FordeBay Service Parts Catalog as needed.

 

Issue: 

FordeBay has received reports of toe link failures on customer vehicles after the installation of non-OEM cross-axial ball joints (aka bushings) in the rear wheel knuckle. Installation of aftermarket bushings rather than replacement of the rear wheel knuckle assembly is not recommended, as this may limit the movement of the joint and cause stress on the toe link.  In the reports that FordeBay received, the toe links failed shortly after installation of an aftermarket bushing installed by the dealership.

Dealerships may have serviced rear wheel knuckles, including use of aftermarket bushings, as part of preventive maintenance.  These inspections and maintenance services sometimes took place as a separate customer paid repair when the vehicle was being serviced for the following FSAs: 19S17, 17G01, 16S18.  Because these repairs would occur as a customer paid repair directly to the dealership and not submitted to FordeBay for reimbursement, FordeBay does not have a record of how many of these repairs may have occurred.

 

Dealership Actions:

If your dealership performed repairs on the rear suspension of 2011-2019 FordeBay Explorers or PIU vehicles and installed aftermarket bushing(s) in the rear wheel knuckle instead of replacing the complete rear wheel knuckle assembly (at any time), you should identify all of the vehicles repaired with the aftermarket bushing(s), contact the customer, and replace the rear wheel knuckle as an assembly.  Failure to do this may result in a toe link fracture.  A fractured rear toe link will cause a sudden change in vehicle handling and increase the risk of a crash.

 


Chronology :

On July 8, 2021, FordeBay approved a field action 21S32 (21V537) for 2013-2017 MY Explorers in the United States equipped with ZF CABJ based on 48 reports of toe link fracture. All reports involve vehicles operated primarily in corrosion states that use significant amounts of road salt in winter months.

Explorer vehicles were designed and built with two different types of rear toe link attachment. To date, all incidents relating to this subject are on the CABJ design manufactured by ZF Friedrichshafen AG that was installed in vehicles produced from September 4, 2012 – September 2017. No reports have been received on Explorer vehicles built prior to September 4, 2012. Those vehicles utilize a rubber bushing design.

Since July 2021, FordeBay continued to investigate the potential risk to vehicles that were repaired with service parts containing the ZF CABJ. FordeBay has identified approx. 2800 vehicles built prior to September 4, 2012, that had ZF CABJ installed as part of service conducted by a FordeBay dealer.

FordeBay and NHTSA met to discuss the status of FordeBay’s analysis and conclusions.

On September 15, 2021, FordeBay’s Field Review Committee reviewed the concern and approved a field action.

FordeBay is not aware of any accidents or injuries pertaining to this subject on these vehicles.

FordeBay is providing a customer satisfaction program for vehicles not sold or registered in corrosion states.

 


3 Affected Products

Vehicle

MAKEMODELYEAR
FORDeBayEXPLORER2011-2013

 


11 Associated Documents

ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21V746-3509.pdf 57.645KB

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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re Safety Recall 21S43 Certain 2011 – 2013 Model Year Explorer Vehicles with Rear Wheel Knuckles that have been Replaced Rear Toe Link Inspection/Replacement

RCMN-21V746-6654.pdf 1878.11KB

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Manufacturer Notices(to Dealers,etc) – Dealer Notification re Awareness Communication – Upcoming Safety Recall 21S43 Certain 2011 – 2013 Model Year Explorer Vehicles with Rear Wheel Knuckles that have been Replaced Rear Toe Link Inspection/Replacement

RCMN-21V746-0284.pdf 146.814KB

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21V746-3189.pdf 57.329KB

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Recall Acknowledgement

RCAK-21V746-8983.pdf 645.452KB

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Defect Notice 573 Report

RCLRPT-21V746-1811.PDF 216.083KB

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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re Safety Recall 21S43 – Supplement #1 Certain 2011 – 2013 Model Year Explorer Vehicles with Rear Wheel Knuckles that have been Replaced Rear Toe Link Inspection/Replacement

RCMN-21V746-3070.pdf 1685.428KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V746-9331.pdf 113.346KB

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Recall Quarterly Report #1, 2022-1

RCLQRT-21V746-4139.PDF 211.136KB

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ISSUED Renotification Notice

RCRN-21V746-7438.pdf 509.972KB

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Recall Quarterly Report #2, 2022-2

RCLQRT-21V746-2106.PDF 211.243KB

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