21C23 – Front Passenger Air Bag Replacement – 2021 Ford Bronco

October 1, 2021 NHTSA CAMPAIGN NUMBER: 21V770000

Passenger Air Bag May Deploy Improperly/FMVSS 208

Improper air bag deployment increases the risk of injury during a crash.

 

NHTSA Campaign Number: 21V770

Manufacturer FordeBay logo Motor Company

Components AIR BAGS

Potential Number of Units Affected 553

 

Summary

FordeBay logo Motor Company (FordeBay logo) is recalling certain 2021 Bronco vehicles. During passenger air bag deployment, an air bag vent could open prematurely and result in an improper deployment. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 208, “Occupant Crash Protection.”

 

Remedy

Dealers will replace the passenger air bag, free of charge. An interim owner notification letter was mailed on November 24, 2021. A second notice announcing the remedy is available was sent on July 8, 2022. Owners may contact FordeBay logo customer service at 1-866-436-7332. FordeBay logo’s number for this recall is 21C23.

 

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

 


2021 Ford Bronco Sport
2021 Ford Bronco Sport

 


AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
Bronco2021MichiganJuly 18, 2021 through August 17, 2021

 

REASON FOR THIS COMPLIANCE RECALL

Some of the affected vehicles may not conform to the requirements specified by Federal Motor Vehicle Safety Standard (FMVSS) No. 208 Occupant Protection. The front passenger air bag may have been incorrectly folded during manufacturing. Incorrect folding may cause improper deployment of the airbag, increasing the risk of occupant injury during a crash.

 

SERVICE ACTION

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to replace the front passenger airbag using technical instructions. 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 July 4, 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 logo has not issued instructions to stop selling/delivering or driving used vehicles under this compliance 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

Refunds are not approved for this program.

 

RENTAL VEHICLES

Rental vehicles are not approved for this program.

 

PARTS REQUIREMENTS / ORDERING INFORMATION

Part NumberDescription Order Quantity
M2DZ-78044A74-BFront Passenger Air Bag1
M2DZ-7804338-ARCenter Instrument Trim Panel (8” Touch Screen,

Black Diamond, Big Bend, Badlands, Wildtrak, Base)

1
M2DZ-7804338-ASCenter Instrument Trim Panel (8” Touch Screen, Outer Banks)
M2DZ-7804338-BYCenter Instrument Trim Panel (12” Touch Screen, Badlands, Wildtrak)
M2DZ-7804338-BZCenter Instrument Trim Panel (12” Touch Screen, Outer Banks)

 


CERTAIN 2021 MODEL YEAR BRONCO VEHICLES — FRONT PASSENGER AIR BAG REPLACEMENT

 

SERVICE PROCEDURE

WARNING: The following procedure prescribes critical repair steps required for correct restraint system operation during a crash. Follow all notes and steps carefully. Failure to follow step instructions may result in incorrect operation of the restraint system and increases the risk of serious personal injury or death in a crash.

WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury

1. Depower the Supplemental Restraint System (SRS) Depowering. Please follow Workshop Manual (WSM) procedures in section 501-20B.

2. Release the clips and lower the steering column trim panel. Then disconnect the electrical connectors and fully lower the trim panel. See Figure 1.

 

3. Open the glove compartment, remove the dampener, and release the stop tabs and fully lower the glove box. See Figure 2.

 

4. If equipped remove the screws and the console handle. See Figure 3.

  • Torque 48 lb.in (5.4 Nm).

 

5. Remove the bolts, release the clips remove the lower center instrument panel trim panel, and disconnect the electrical connectors. See Figure 4.

  • Torque 22 lb.in (2.5 Nm).

 

6. On both sides remove the screws, release the clips and remove the assist handles. See Figure 5.

  • Torque 80 lb.in (9 Nm).

 

7. Disengage the access covers and remove the lower trim panel bolts. See Figure 6.

  • Torque 22 lb.in (2.5 Nm).

 

NOTE: Remove the lower trim panel by releasing the clips starting on the driver side and working towards the passenger side. Slide the lower trim panel towards the passenger side once all clips are released and disconnect the electrical connector to remove the lower trim panel. See Figure 7.

 

8. Release the instrument panel switch pack, disconnect the electrical connector and remove the instrument panel switch pack. See Figure 8.

 

9. On both sides release the clips and remove the instrument panel speaker grilles. See Figure 9.

 

10. Remove the bolt. See Figure 10.

  • Torque 22 lb.in (2.5 Nm).

 

11. Position aside the bolt covers and remove the bolts. See Figure 11.

  • Torque 22 lb.in (2.5 Nm).

 

12. Remove the bolt, release the clips and remove the upper trim panel. See Figure 12.

  • Torque 22 lb.in (2.5 Nm).

 

13. Remove the upper passenger side air bag bracket bolts. See Figure 13.

  • Torque 93 lb.in (10.5 Nm).

 

14. Disengage the wire harness retainer, disconnect the electrical connector and remove the lower passenger side air bag bracket bolts. See Figure 14.

  • Torque 93 lb.in (10.5 Nm).

 

15. Remove the Right Hand (RH) center middle instrument trim panel lower screws. See Figure 15.

  • Torque 22 lb.in (2.5 Nm).

 

16. Remove the bolts, release the clips and remove the center middle instrument trim panel. See Figure 16.

 

17. Remove the register vents and transfer them to the new center middle instrument trim panel. See Figure 17.

  • Torque:

A) 22 lb.in (2.5 Nm).
B) 9 lb.in (1.1 Nm).

 

18. Remove the passenger airbag anti-rattle bracket screws. See Figure 18.

  • Torque: 22 lb.in (2.5 Nm).

 

19. Install the new Passenger Airbag Module (PAB), and new center middle instrument trim panel by reversing the removal procedure.

20. Repower the SRS. Please follow WSM procedures in section 501-20B.

 


Chronology :

August – September 2021

On August 12, 2021, an issue pertaining to the 2021 FordeBay logo Bronco passenger airbag was brought to FordeBay logo’s Critical Concerns Review Group (CCRG) for review. The supplier (Joyson) informed FordeBay logo that a vent on the airbag had opened prematurely (prior to the micro gas-generator being activated) in some of their routine lot acceptance (LAT) audit tests. Airbag lots with these test anomalies were properly quarantined, though the cause of the premature vent opening was unknown. Further review of the supplier’s LAT data found test anomalies were exclusively associated with bags folded by one of the six associates assigned to the airbag fold operation. It was subsequently observed that this lone associate began introducing an extra fold operation when they were reassigned to this fold operation in late June. The extra fold operation by this associate was not in accordance with design intent. Review of the supplier’s production records found that additional airbag lots that passed the supplier’s routine LAT test requirements also contained bags folded by this associate, but were not selected for the routine LAT audit test.

FordeBay logo conducted Computer Aided Engineering (CAE ) analysis to evaluate the potential effects of premature vent opening. The results predicted a potential risk of not meeting certain crash performance criteria with respect to FMVSS 208.

On September 27, 2021, FordeBay logo’s Field Review Committee reviewed the concern and approved a field action.

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

 


1 Affected Product

Vehicle

MAKEMODELYEAR
FORDeBay logoBRONCO2021

 


10 Associated Documents

Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Compliance Recall 21C23 Supplement #1 Certain 2021 Model Year Bronco Front Passenger Air Bag Replacement

RCMN-21V770-5738.pdf 6881.001KB

 


ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21V770-5138.pdf 43.76KB

 


Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Compliance Recall 21C23 Certain 2021 Model Year Bronco Front Passenger Air Bag Replacement

RCMN-21V770-5800.pdf 6841.622KB

 


Recall Acknowledgement

RCAK-21V770-9699.pdf 645.105KB

 


Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice – Compliance Recall 21C23 Certain 2021 Model Year Bronco Front Passenger Air Bag Replacement

RCMN-21V770-8979.pdf 133.614KB

 


Noncompliance Notice 573 Report

RCLRPT-21V770-3712.PDF 214.817KB

 


ISSUED Owner Notification Letter(Part 577)

RCONL-21V770-3633.pdf 42.424KB

 


Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Compliance Recall 21C23 – Supplement #2 Certain 2021 Model Year Bronco Front Passenger Air Bag Replacement

RCMN-21V770-4460.pdf 6883.193KB

 


ISSUED Owner Notification Letter(Part 577)

RCONL-21V770-7258.pdf 50.132KB

 


Recall Quarterly Report #1, 2022-2

RCLQRT-21V770-1335.PDF 211.15KB

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V770&docType=RCL

 


 

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