December 16, 2021 NHTSA CAMPAIGN NUMBER: 21V978000
Driveshaft separation can result in a loss of drive power, or unintended movement while parked if the parking brake is not engaged, increasing the risk of a crash.
NHTSA Campaign Number: 21V978
Manufacturer Ford
Motor Company
Components POWER TRAIN
Potential Number of Units Affected 4,548
Summary
Ford Motor Company (Ford) is recalling certain 2020 Transit vehicles equipped with All Wheel Drive (AWD). The bolts that attach the rear driveshaft to the transfer case may become lose or damaged, which can result in separation of the driveshaft from the transfer case.
Remedy
Dealers will inspect and replace the driveshaft bolts. If any loose bolts are found, the driveshaft, attachment hardware, transfer case flange kit, and seal will also be replaced. Repairs will be performed free of charge. Owner notification letters were mailed February 4, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 21S54.
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
September 30, 2022
Safety Recall 21S54 – Supplement # 3
Certain 2020 Model Year Transit AWD Vehicles Rear Driveshaft Bolt and Washer Replacement
AFFECTED VEHICLES
| Vehicle | Model Year | Assembly Plant | Build Dates |
| Transit AWD | 2020 | KCAP | May 1, 2019 through February 1, 2020 |
Affected vehicles are identified in OASIS and FSA VIN Lists.
REASON FOR THIS SAFETY RECALL
In some of the affected vehicles, it may be possible for the rear driveshaft to transfer case constant velocity joint (CVJ) mounting bolts to become loose, missing, or damaged. Loose, missing, or damaged driveshaft attachment bolts can lead to the separation of the driveshaft from the transfer case. This can result in an undesirable noise, secondary damage to surrounding components, including brake lines, loss of motive power while driving, or unintended vehicle movement in park without the parking brake applied.
SERVICE ACTION
The dealer is to check the torque of all 6 driveshaft bolts on the driveshaft to transfer case side for loose, missing, or damaged bolts. If bolts are found loose, missing, or damaged, the dealer is to replace the driveshaft, all driveshaft bolts, center bearing bracket bolts, driveshaft to rear axle companion flange bolts, transfer case flange kit, and transfer case seal. This includes drain and fill transfer case per technical instructions at no charge to the vehicle owner. On vehicles that do not have a loose or missing or damaged – bolt, the dealer is to replace the driveshaft bolts per WSM (Workshop Manual). Dealer will also send pictures to SSSC of loose, missing, or damaged bolts and/or damage of adjoining components.
OWNER NOTIFICATION AND MAILING SCHEDULE
Owner letters were mailed the week of January 31, 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
- Owners should contact their dealer for an appointment to have their vehicles remedied as soon as practicable.
- 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
| Part Number | Description | Order Quantity | Claim Quantity |
| LK4Z-4R602-BG | 2 PC Driveshaft (Driveshaft CVJ mounting bolts included in pkg.) | 1 | 1 |
| LK4Z-4R602-BL | 2 PC Driveshaft (Driveshaft CVJ mounting bolts included in pkg.) | 1 | 1 |
| LK4Z-4R602-BH | 3 PC Driveshaft (Driveshaft CVJ mounting bolts included in pkg.) | 1 | 1 |
| LK4Z-4R602-BK | 3 PC Driveshaft (Driveshaft CVJ mounting bolts included in pkg.) | 1 | 1 |
| LK4Z-4R602-BJ | 4 PC Driveshaft (Driveshaft CVJ mounting bolts included in pkg.) | 1 | 1 |
| W713078-S439 | 4PC Driveshaft Center Bearing Bracket Bolts (6 Bolts needed 4 in pkg) | 2 | 6 |
| W713078-S439 | 3 PC Driveshaft Center Bearing Bracket Bolts (4 bolts needed 4 in pkg) | 1 | 4 |
| W713078-S439 | 2 PC Driveshaft Center Bearing Bracket Bolts (2 bolts needed 4 in pkg) | 1 | 2 |
| MB3Z-7B215A | Transfer Case Seal | 1 | 1 |
| LK4Z-7061-A | Transfer Case Flange Kit | 1 | 1 |
| Part Number | Description | Order Quantity | Claim Quantity |
| LK4Z-4B496-B | Rear Driveshaft Mounting Bolt Kit with Captive Washer (1 in pkg 2 req for repair) | 2 | 2 |
| N800594-S100
No products found. | Driveshaft Rear Axle Companion Flange Bolts (4 bolts needed 4 in pkg) | 1 | 4 |
CERTAIN 2020 MODEL YEAR TRANSIT AWD VEHICLES – CVJ BOLT AND CAPTIVE WASHER REPLACEMENT
SERVICE PROCEDURE
1. With the vehicle in neutral and parking brake disengaged, position vehicle on a hoist. Please follow Workshop Manual (WSM) procedures in Section 100-02.
2. If equipped, remove running boards. Please follow WSM procedures in Section 501-08.
3. Using a 10mm (3/8 in) socket with a Digital or Dial Indicator Torque Wrench, loosen each of the 6 bolts and note the max breakaway torque. See Figures 1 and 2.
4. Are any of the bolts or washers missing or damaged?
No – Continue to Step 5.
Yes – Continue to Step 10.
5. Do any of the bolts show a torque less than 26 ft-lb (35 Nm)?
No – Continue to Step 6.
Yes – Continue to Step 10.
6. Remove and replace first set of 3 bolts and 1 captive washer. See Figure 3.
- Torque: 52 ft-lb (70 Nm).
7. Remove and replace second set of 3 bolts and 1 captive washer. See Figure 3.
- Torque: 52 ft-lb (70 Nm).
NOTE: Do not completely disconnect driveshaft from transfer case at any time.
8. Box and ship bolts and captive washers per the warranty return process.
9. Recall is complete.
Recommended Tools List
| Small Pry Bar | |
| Installation Tube (205-1018) | |
| Installer, Output Shaft AWD (205-1067) | |
| Holding Fixture, Drive Pinion Flange (205-126) | |
| 2 or 3 Jaw Puller (205-D027) | |
| Installer/Remover, C-Frame and Screw (205-086) |
NOTE: A new driveshaft is required, if the driveshaft is dropped.
NOTE: Driveshafts should be supported so that each section of the driveshaft is parallel.
NOTE: Driveshafts should be supported to ensure center slip mechanism doesn’t pull out of slip boot or over articulate the joint.
NOTE: The maximum articulation of any CV-joint is 5 degrees. The maximum articulation of any U-joint is 10 degrees. If the CV or any U-joint of the driveshaft is articulated further than the maximum allowable degrees, damage may occur.
10. Note the index mark on the axle flange (yellow dot). If yellow dot is visible on driveshaft but not on the pinion flange, add corresponding mark on pinion flange. See Figure 4.
11. Remove the driveshaft flange to pinion flange bolts. See Figure 4.
NOTE: The driveshaft flange fits tightly on the flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the flange pilot. Pry only in the area shown with a suitable tool, to disconnect the driveshaft flange from the flange pilot or damage to the driveshaft flange can occur.
12. Using a small pry bar, separate the driveshaft flange from the pinion flange. See Figure 4.
13. Support the driveshaft. See Figure 4.
14. Remove and set aside the driveshaft CV-joint to transfer case flange bolts and the retaining straps/washers. See Figure 5.
NOTE: Index mark is not required at the Transfer Case CVJ interface.
NOTE: The driveshaft CV-joint fits tightly on the flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft CV-joint from the flange pilot. Pry only in the area shown with a suitable tool, to disconnect the driveshaft CV-joint from the flange pilot or damage to the driveshaft CV-joint can occur.
15. Using a small pry bar, separate the driveshaft CV-joint from the transfer case flange. See Figure 5.
16. Support the driveshaft. See Figure 5.
NOTE: The driveshaft is long and heavy with multiple U-joints. Do not over articulate the driveshaft or damage may occur.
NOTE: This step requires the aid of another technician.
17. Remove and discard the driveshaft center bearing bolts and remove the driveshaft. This will require pulling the driveshaft rearward to clear the front safety strap/hoop. For Medium Wheelbase see Figure 6. For Long Wheelbase see Figure 7.
18. Drain the transfer case. Please follow WSM procedures in Section 308-07B.
NOTE: Note the position of the component before removal.
19. Using Special Service Tool (205-126 Holding Fixture, Drive Pinion Flange), hold the flange, remove and discard the flange nut. See Figure 8.
21. Remove the seal. See Figure 10.
22. Using Special Service Tool (2 or 3 Jaw Puller), remove the outlet flange and set aside for warranty return. See Figure 11.
23. Remove the transfer case rear output shaft seal dust cover. See Figure 12.
24. Remove and discard the transfer case rear output shaft seal. See Figure 13.
25. Use Special Service Tool (205-1018 Installation Tube, 205-1067 Installer), to install the special tool to the seal. See Figure 14.
26. Using the special tool, install the transfer case rear seal. See Figure 15.
27. Install the transfer case rear output shaft seal dust cover. See Figure 16.
28. Install the new transfer case output flange. See Figure 17.
29. Install the output flange seal. See Figure 18.
30. Install the output flange spacer. See Figure 19.
31. Use Special Service Tool (205-126 Holding Fixture Drive Pinion Flange), to install the new output shaft flange nut. See Figure 20.
- Torque: 136 lb. ft (185 Nm)
NOTE: The driveshaft is long and heavy with multiple U-joints. Do not over articulate the driveshaft or damage may occur.
NOTE: This step requires the aid of another technician.
NOTE: Only tighten the bolts finger tight at this stage.
32. Install the driveshaft and the new driveshaft center bearing bolts. See Figure 21 for Medium Wheel base. See Figure 22 for Long Wheelbase.
33. Install the new driveshaft CV-joint to the transfer case flange bolts and the retaining straps/washers. See Figure 23.
- Torque: 52 lb.ft (70 Nm).
34. Align the index-mark on the driveshaft and rear drive pinion flange (yellow dot). Install the new driveshaft to the rear drive pinion flange bolts. See Figure 24.
- Torque: 76 lb.ft (103 Nm)
35. Check all center bearings alignment for bind, twist, or rub. See Figure 25.
36. Tighten the new driveshaft center bearing bolts. 2 on Medium wheel base, 4 on Long wheel base, and 6 on Extra-Long Wheelbase. See Figure 26 for Medium Wheelbase. See Figure 27 for Long Wheelbase.
37. Refill the Transfer Case. Please follow WSM procedures in section 308-07B. Recall is complete.
Submission Date: 01/14/2022
Chronology of Defect / Noncompliance Determination for Ford Motor Company Recall #21S54 – Amendment#1
Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision.
June – July 2021 On June 9, 2021, Driveline Engineering notified Ford’s Critical Concern Review Group (CCRG) of an increase in warranty reports alleging loose or missing bolts where the driveshaft connects to the transfer case constant velocity joint (CVJ) interface on certain 2020 MY Transit AWD vehicles. The AWD variant was introduced in North America for the 2020 MY. From September to October 2020, CCRG previously investigated this topic. A report received on September 14, 2020 from a fleet customer stated that four fleet vehicles had experienced loose or missing bolts at the AWD driveshaft to transfer case CVJ interface. Three of these vehicles alleged driveshaft separation. CCRG was not aware of any similar reports from other fleet or retail customers at that time. Investigation of the fleet’s reports had found no evidence of improper driveshaft flange bolt installation at Kansas City Assembly Plant (KCAP), and analysis found evidence of potential improper driveshaft removal and reinstallation by the fleet. Driveline Engineering continued to monitor this subject.
Based on the updated field data, Engineering conducted part inspections, supplier reviews and material analysis and found nothing out of specification. The KCAP team reviewed all quality and tooling records and did not identify any anomalies or special cause relating to this concern.
August – October 2021 A targeted fleet engineering study was undertaken to aid the engineering evaluation of this concern. Ford identified multiple candidate vehicles for inspection, though only one vehicle was made available based on high vehicle usage. On that vehicle, one bolt was missing, one bolt was fractured, and the remaining four bolts were loose.
November 2021 Driveline Engineering conducted multiple assembly trials at KCAP and was unable to replicate the issue or identify a potential cause for a loss of bolt clamp load between the driveshaft and transfer case CVJ.
As of November 25, 2021, there have been 51 reports alleging loose, damaged or missing bolts at the Transit AWD driveshaft to transfer case CVJ interface with 24 alleging driveshaft separation. These reports span multiple fleets and retail customers. All reports relate to vehicles produced prior to February 1, 2020.
On December 9, 2021, Ford’s Field Review Committee reviewed the concern and approved a field action.
Ford is not aware of any reports of accident or injury related to this condition.
1 Affected Product
Vehicle
| MAKE | MODEL | YEAR |
| FORD | TRANSIT | 2020 |
15 Associated Documents
Miscellaneous Document – Chronology of Defect / Noncompliance Determination for Ford Motor Company Recall #21C25
RMISC-21V978-5760.pdf 14.489KB
Recall Acknowledgement
RCAK-21V978-3918.pdf 645.586KB
Defect Notice 573 Report
RCLRPT-21V978-5953.PDF 215.033KB
Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Safety Recall 21S54 Certain 2020 Model Year Transit AWD Vehicles Rear Driveshaft Bolt and Washer Replacement
RCMN-21V978-5022.pdf 7123.488KB
Miscellaneous Document – Chronology of Defect / Noncompliance Determination for Ford Motor Company Recall #21S54 Amendment#1
RMISC-21V978-4673.pdf 14.747KB
Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Safety Recall 21S54 – Supplement # 1 Certain 2020 Model Year Transit AWD Vehicles Rear Driveshaft Bolt and Washer Replacement
RCMN-21V978-8508.pdf 7163.858KB
Manufacturer Notices(to Dealers,etc) – Advance Notice re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Advance Notice – Safety Recall 21S54 Certain 2020 Model Year Transit AWD Vehicles Rear Driveshaft Bolt and Captive Washer Replacement
RCMN-21V978-5102.pdf 144.154KB
ISSUED Owner Notification Letter(Part 577)
Recall Quarterly Report #1, 2022-1
RCLQRT-21V978-1775.PDF 211.127KB
ISSUED Renotification Notice
Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Safety Recall 21S54 – Supplement # 2 Certain 2020 Model Year Transit AWD Vehicles Rear Driveshaft Bolt and Washer Replacement
RCMN-21V978-5297.pdf 7167.415KB
Recall Quarterly Report #2, 2022-2
RCLQRT-21V978-2399.PDF 211.232KB
Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Safety Recall 21S54 – Supplement # 3 Certain 2020 Model Year Transit AWD Vehicles Rear Driveshaft Bolt and Washer Replacement
RCMN-21V978-2184.pdf 6719.862KB
Recall 573 Report – 1/14/22
RCLRPT-21V978-4991.PDF 215.034KB
Recall Quarterly Report #3, 2022-3
RCLQRT-21V978-7639.PDF 211.32KB
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Submission Date: 12/16/2021 Chronology of Defect / Noncompliance Determination for Ford Motor Company Recall #21C25 Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision. June – July 2021 On June 9, 2021, Driveline Engineering notified Ford’s Critical Concern Review Group (CCRG) of an increase in warranty reports alleging loose or missing bolts where the driveshaft connects to the transfer case constant velocity joint (CVJ) interface on certain 2020 MY Transit AWD vehicles. The AWD variant was introduced in North America for the 2020 MY. From September to October 2020, CCRG previously investigated a report from a fleet customer of five fleet vehicles that experienced loose or missing bolts at the AWD driveshaft to transfer case CVJ interface. CCRG was not aware of any similar reports from other fleet or retail customers at that time. Investigation of the fleet’s reports had found no evidence of improper driveshaft flange bolt installation at Kansas City Assembly Plant (KCAP), and analysis found evidence of potential improper driveshaft removal and reinstallation by the fleet. Driveline Engineering continued to monitor this subject. Based on the updated field data, Engineering conducted part inspections, supplier reviews and material analysis and found nothing out of specification. The KCAP team reviewed all quality and tooling records and did not identify any anomalies or special cause relating to this concern. August – October 2021 A targeted fleet engineering study was undertaken to aid the engineering evaluation of this concern. Ford identified multiple candidate vehicles for inspection, though only one vehicle was made available based on high vehicle usage. On that vehicle, one bolt was missing, one bolt was fractured, and the remaining four bolts were loose. November 2021 Driveline Engineering conducted multiple assembly trials at KCAP and was unable to replicate the issue or identify a potential cause for a loss of bolt clamp load between the driveshaft and transfer case CVJ. As of November 25, 2021, there have been 50 reports alleging loose or missing bolts at the Transit AWD driveshaft to transfer case CVJ interface with 22 alleging driveshaft separation. These reports span multiple fleets and retail customers. All reports relate to vehicles produced prior to February 1, 2020. On December 9, 2021, Ford’s Field Review Committee reviewed the concern and approved a field action. Ford is not aware of any reports of accident or injury related to this condition. ###
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Submission Date: 01/14/2022 Chronology of Defect / Noncompliance Determination for Ford Motor Company Recall #21S54 – Amendment#1 Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision. June – July 2021 On June 9, 2021, Driveline Engineering notified Ford’s Critical Concern Review Group (CCRG) of an increase in warranty reports alleging loose or missing bolts where the driveshaft connects to the transfer case constant velocity joint (CVJ) interface on certain 2020 MY Transit AWD vehicles. The AWD variant was introduced in North America for the 2020 MY. From September to October 2020, CCRG previously investigated this topic. A report received on September 14, 2020 from a fleet customer stated that four fleet vehicles had experienced loose or missing bolts at the AWD driveshaft to transfer case CVJ interface. Three of these vehicles alleged driveshaft separation. CCRG was not aware of any similar reports from other fleet or retail customers at that time. Investigation of the fleet’s reports had found no evidence of improper driveshaft flange bolt installation at Kansas City Assembly Plant (KCAP), and analysis found evidence of potential improper driveshaft removal and reinstallation by the fleet. Driveline Engineering continued to monitor this subject. Based on the updated field data, Engineering conducted part inspections, supplier reviews and material analysis and found nothing out of specification. The KCAP team reviewed all quality and tooling records and did not identify any anomalies or special cause relating to this concern. August – October 2021 A targeted fleet engineering study was undertaken to aid the engineering evaluation of this concern. Ford identified multiple candidate vehicles for inspection, though only one vehicle was made available based on high vehicle usage. On that vehicle, one bolt was missing, one bolt was fractured, and the remaining four bolts were loose. November 2021 Driveline Engineering conducted multiple assembly trials at KCAP and was unable to replicate the issue or identify a potential cause for a loss of bolt clamp load between the driveshaft and transfer case CVJ. As of November 25, 2021, there have been 51 reports alleging loose, damaged or missing bolts at the Transit AWD driveshaft to transfer case CVJ interface with 24 alleging driveshaft separation. These reports span multiple fleets and retail customers. All reports relate to vehicles produced prior to February 1, 2020. On December 9, 2021, Ford’s Field Review Committee reviewed the concern and approved a field action. Ford is not aware of any reports of accident or injury related to this condition. ###
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July, 2022 * * * IMPORTANT SAFETY RECALL REMINDER * * * According to our records, your 2020 Transit has not had necessary safety recall repairs made. We urge you to have the free repair performed at your local dealership as soon as possible. Recall Number and Description: 21S54 – AWD CV Joint Separation – Loss of Mobility What is the issue? On your vehicle, the mounting bolts that connect the rear driveshaft to the transmission transfer case may become loose. Loose mounting bolts may cause rear driveshaft separation from the transfer case. This separation will result in loss of motive power, potential damage to surrounding components, including brake lines, or unintended vehicle movement in park without the parking brake being applied, increasing the risk of a crash. If you have questions or concerns, please contact our Ford Customer Relationship Center at 1-866-436-7332. If you wish to contact us through the Internet, our address is: ford.com/support. Thank you for your attention to this very important matter. Julio de, 2022 * * * RECORDATORIO IMPORTANTE PROGRAMA DE SEGURIDAD * * * SegUR nuestros registros, no se realizaron en sur 2020 Transit las reparaciones necesarias correspondientes a la campaña de seguridad. Le solicitamos que realice esta reparación gratuita en su distribuidor local lo antes posible. Número y descripción de la campaña: 21S54 – Separación de junta CV AWD – Pérdida de movilidad ¿Cuál es el problema? Es posible que, en su vehículo, los tornillos de montaje que conectan la flecha de mando trasera a la caja de transferencia de la transmisión se aflojen. Si los tornillos de montaje están flojos podrían provocar que se separe la flecha de mando trasera de la caja de transferencia. Esta separación generará una pérdida de potencia motriz, posible daño a los componentes circundantes, incluidas las tuberías de los frenos o movimiento involuntario del vehículo en estacionamiento, sin el freno de estacionamiento aplicado, lo cual aumenta el riesgo de choque. Si tiene dudas o preguntas, comuníquese con nuestro Centro de Relación con Clientes Ford al 1-866-436-7332. Si desea ponerse en contacto con nosotros a través de Internet, nuestra dirección es: ford.com/support. Gracias por su atenciic en este asunto sumamente importante. © Copyright 2022 Ford Motor Company 1 of 2 000000000000090 / 179 / 90 SEE OTHER SIDE FOR OPENING INSTRUCTIONS SEE OTHER SIDE FOR OPENING INSTRUCTIONS REMOVE THESE SIDE EDGES FIRST Š THEN FOLD, CREASE AND TEAR THIS STUB ALONG PERFORATION Š REMOVE THESE SIDE EDGES FIRST Š THEN FOLD, CREASE AND TEAR THIS STUB ALONG PERFORATION Š P.O. BOX 1904 DEARBORN, MI 48121-1904 Presorted STD US Postage PAID R K C 0035707 A / 000000000000090 / 90 ùù
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February 2022 Ford Motor Company Ford Customer Service Division P. O. Box 1904 Dearborn, Michigan 48121 1904 * * * IMPORTANT SAFETY RECALL * * * Safety Recall Notice 21S54 / NHTSA Recall 21V978 2020 Transit Your Vehicle Identification Number (VIN): This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has decided that a defect which relates to motor vehicle safety exists in your vehicle, with the VIN shown above. We apologize for this situation and want to assure you that, with your assistance, we will correct this condition. Our commitment, together with your dealer, is to provide you with the highest level of service and support. What is the issue? On your vehicle, the mounting bolts that connect the rear driveshaft to the transmission transfer case may become loose. What is the risk? Loose mounting bolts may cause rear driveshaft separation from the transfer case. This separation will result in loss of motive power, potential damage to surrounding components, including brake lines, or unintended vehicle movement in park without the parking brake being applied, increasing the risk of a crash. What will Ford and your dealer do? Ford Motor Company has authorized your dealer to inspect the mounting bolts that connect the rear driveshaft to the transmission transfer case. If one or more bolts are loose, the dealer is to replace the driveshaft, all driveshaft bolts, center bearing bracket bolts, driveshaft to rear axle companion flange bolts, transfer case flange kit, and transfer case seal. On vehicles that do not have a loose bolt, the dealer will replace all driveshaft bolts at the transfer case interface free of charge (parts and labor). How long will it take? The time needed for this repair is less than one-half day. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time. What should you do? Please call your dealer without delay and request a service date for Recall 21S54. Provide the dealer with your VIN, which is printed near your name at the beginning of this letter. Ford has not issued instructions to stop driving your vehicle under this safety recall. You should contact your dealer for an appointment to have your vehicle remedied as soon as practicable. You can continue to safely drive your vehicle. If you do not already have a servicing dealer, you can access ford.com/support for dealer addresses, maps, and driving instructions. Ford Motor Company wants you to have this safety recall completed on your vehicle. The vehicle owner is responsible for making arrangements to have the work completed. Please note: Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. © Copyright 2022 Ford Motor Company 02164 21S54 T/DTB121S541 1 of 4 A/1/000001/1 771515928873 A/1/000001/1 JOHN A. SAMPLE 123 SAMPLE ST SAMPLE CITY, MI 12345-6789 What should you do? (continued) NOTE: You can receive information about Recalls and Customer Satisfaction Programs through our FordPass App. The app can be downloaded through the App Store or Google Play. In addition, there are other features such as reserving parking in certain locations and controlling certain functions on your vehicle (lock or unlock doors, remote start) if it is equipped to allow control. COVID-19 (CORONAVIRUS) Ford dealerships have implemented enhanced protocols to ensure both your safety and the safety of dealership employees. This includes specific procedures for cleaning and disinfecting customer vehicles before and after each vehicle is serviced. In most places, vehicle service has been deemed a critical service. Please contact your local dealer to confirm current service hours. For more information on how Ford and your local dealer are working hard to keep you on the road during these challenging times, please visit ford.com/support. What if you no longer own this vehicle? If you no longer own this vehicle, and have an address for the current owner, please forward this letter to the new owner. You received this notice because government regulations require that notification be sent to the last known owner of record. Our records are based primarily on state registration and title data, which indicate that you are the current owner. Can we assist you further? If you have difficulties getting your vehicle repaired promptly and without charge, please contact your dealership’s Service Manager for assistance. RETAIL OWNERS: If you have questions or concerns, please contact our Ford Customer Relationship Center at 1-866-436-7332 and one of our representatives will be happy to assist you. If you wish to contact us through the Internet, our address is: ford.com/support. For the hearing-impaired call 1-800-232-5952 (TDD). Representatives are available Monday through Friday: 8:00AM – 8:00PM (Eastern Time). FLEET OWNERS: If you have questions or concerns, please contact our Fleet Customer Information Center at 1-800-34-FLEET, choose Option #3, and one of our representatives will be happy to assist you. If you wish to contact us through the Internet, our address is: fleet.ford.com. Representatives are available Monday through Friday: 8:00AM – 8:00PM (Eastern Time). MOTORHOME OWNERS: If you have questions or concerns, please contact our Motorhome Customer Assistance Center toll free at 1-866-906-9811. Representatives are available 24 hours a day. If you are still having difficulty getting your vehicle repaired in a reasonable time or without charge, you may write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave. S.E., Washington, D.C. 20590 or call the toll free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153) or go to safercar.gov. Reference NHTSA Safety Recall 21V978. Thank you for your attention to this important matter. Ford Customer Service Division © Copyright 2022 Ford Motor Company 02164 21S54 T/DTB121S541 2 of 4 A/2/000001/1 * * * CAMPAÑA DE SEGURIDAD IMPORTANTE * * * Aviso de campaña de seguridad 21S54 / Campaña 21V978 de la NHTSA 2020 Transit Número de identificación del vehículo (VIN): Este aviso se le envía de acuerdo con la Ley Nacional de Seguridad y Tránsito de Vehículos de los EE. UU. Ford Motor Company ha determinado que existe un defecto relacionado con la seguridad de su vehículo, con el VIN que aparece más arriba. Lamentamos esta situación y deseamos asegurarle que, con su ayuda, corregiremos el problema. Nuestro compromiso, junto con el de su distribuidor, es ofrecerle servicio y apoyo de alto nivel. ¿Cuál es el problema? Es posible que, en su vehículo, los tornillos de montaje que conectan la flecha de mando trasera a la caja de transferencia de la transmisión se aflojen. ¿Qué riesgo existe? Si los tornillos de montaje están flojos podrían provocar que se separe la flecha de mando trasera de la caja de transferencia. Esta separación generará una pérdida de potencia motriz, posible daño a los componentes circundantes, incluidas las tuberías de los frenos o movimiento involuntario del vehículo en estacionamiento, sin el freno de estacionamiento aplicado, lo cual aumenta el riesgo de choque. ¿Qué medidas adoptarán Ford y su distribuidor? Ford Motor Company ha autorizado a su distribuidor a inspeccionar los tornillos de montaje que conectan la flecha de mando trasera a la caja de transferencia de la transmisión. Si uno o más tornillos están flojos, el distribuidor deberá reemplazar la flecha de mando, todos los tornillos de la flecha de mando, los tornillos del soporte del cojinete central, los tornillos de la brida que une la flecha de mando con el eje trasero, el kit de la brida de la caja de transferencia y el sello de la caja de transferencia. En vehículos que no tienen un tornillo flojo, el distribuidor reemplazará todos los tornillos de la flecha de mando en la interfaz de la caja de transferencia, sin costo alguno (piezas y mano de obra). ¿Cuánto tiempo tomará? El tiempo necesario para reparar será menos de medio día. Sin embargo, debido a los requisitos de planificación de servicio, es posible que su distribuidor tarde un poco más. ¿Qué debe hacer? Llame a su distribuidor lo antes posible y solicite una cita de servicio para llevar a cabo la campaña 21S54. Proporcione el VIN a su distribuidor, el cual está impreso debajo de sus datos al comienzo de esta carta. Para esta campaña de seguridad, Ford no ha emitido instrucciones de no manejar el vehículo. Deberá ponerse en contacto con su distribuidor a fin de programar una cita para solucionar este problema lo más pronto posible. Puede continuar manejando su vehículo con seguridad. Si aún no tiene un distribuidor para realizar el servicio, puede acceder a ford.com/support para conocer las direcciones de los distribuidores, ver mapas y obtener las instrucciones para llegar. Ford Motor Company le recomienda realizar esta campaña de seguridad en su vehículo. El propietario del vehículo es responsable de realizar los arreglos necesarios para llevar a cabo el trabajo. 3 of 4 A/3/000001/1 02164 21S54 T/DTB121S541 Febrero de 2022 Ford Motor Company División de Servicio al Cliente de Ford P. O. Box 1904 Dearborn, Michigan 48121 © Copyright 2022 Ford, División de Servicio al Cliente 771515928873 A/3/000001/1 JOHN A. SAMPLE 123 SAMPLE ST SAMPLE CITY, MI 12345-6789 ¿Qué debe hacer? (continuación) Tenga presente que: La ley federal exige que los arrendadores de vehículos que reciban este aviso de campaña envíen una copia del mismo al arrendatario en un plazo de diez días. NOTA: Puede recibir información sobre las campañas y los programas de satisfacción del cliente a través de la aplicación FordPass. La aplicación se puede descargar a través de App Store o Google Play. Adicionalmente, existen otras funciones como reserva de estacionamientos en determinados lugares, además de control de ciertas funciones en el vehículo (bloqueo o desbloqueo de puertas, arranque remoto) si así está equipado para permitir el control. COVID-19 (CORONAVIRUS) Los distribuidores Ford han implementado protocolos mejorados con el fin de asegurar tanto su seguridad como la de los empleados de los diferentes distribuidores. Esto incluye procedimientos específicos de limpieza y desinfección antes y después de realizar servicio en cada uno de los vehículos de nuestros clientes. En la mayoría de los lugares, la atención de vehículos se ha considerado un servicio esencial. Póngase en contacto con su distribuidor local para confirmar las horas de servicio actuales. Para obtener más información sobre cómo Ford y su distribuidor local están trabajando arduamente para mantenerlo en las calles durante estos tiempos difíciles, visite ford.com/support. ¿Qué pasa si usted ya no es el propietario del vehículo? Si usted ya no es el propietario del vehículo y tiene la dirección del propietario actual, le solicitamos que le reenvíe esta carta. Usted recibió este aviso porque las regulaciones del gobierno exigen el envío de notificaciones al propietario conocido más reciente del registro. Nuestros registros se basan principalmente en datos estatales y de propiedad, que indican que usted es el propietario actual del vehículo. ¿Podemos hacer algo más por usted? Si tiene problemas para reparar de inmediato su vehículo y sin costo alguno, comuníquese con el Gerente de Servicio de su distribuidor para solicitar ayuda. PROPIETARIOS MINORISTAS: Si tiene dudas o preguntas, comuníquese con nuestro Centro de Relación con Clientes Ford al 1-866-436-7332 y uno de nuestros representantes con gusto lo atenderá. Si desea comunicarse con nosotros a través de Internet, nuestra dirección es: ford.com/support. Las personas con problemas de audición pueden llamar al 1-800-232-5952 (TDD). Los representantes atienden de lunes a viernes, de 8:00 a.m. a 8:00 p.m. (hora del este). PROPIETARIOS DE FLOTAS: Si tiene dudas o preguntas, comuníquese con nuestro Centro de Información a Clientes de flotas al 1-800-34-FLEET, elija la opción n.° 3 y uno de nuestros representantes con gusto lo atenderá. Si desea comunicarse con nosotros a través de Internet, nuestra dirección es: fleet.ford.com. Los representantes atienden de lunes a viernes, de 8:00 a.m. a 8:00 p.m. (hora del este). PROPIETARIOS DE CASAS RODANTES: Si tiene dudas o preguntas, comuníquese con nuestro Centro de Asistencia a Clientes de Casas Rodantes sin cargo al 1-866-906-9811. Los representantes se encuentran disponibles las 24 horas del día. Si aun así tiene problemas para reparar su vehículo en un periodo de tiempo razonable o sin costo, puede escribir al Administrador de National Highway Traffic Safety Administration, 1200 New Jersey Ave. S.E., Washington, D.C. 20590, llamar a la Línea directa de seguridad vehicular al 1-888-327-4236 (TTY: 1-800-424-9153) o visitar safercar.gov. Referencia: Campaña de seguridad 21V978 de la NHTSA. Gracias por su atención en este asunto sumamente importante. Ford, División de Servicio al Cliente 4 of 4 A/4/000001/1 02164 21S54 T/DTB121S541 © Copyright 2022 Ford, División de Servicio al Cliente
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© Copyright 2022 Ford Motor Company David J. Johnson Ford Motor Company Director P. O. Box 1904 Service Engineering Operations Dearborn, Michigan 48121 Ford Customer Service Division September 30, 2022 TO: All U.S. Ford and Lincoln Dealers SUBJECT: REF: NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Safety Recall 21S54 – Supplement # 3 Certain 2020 Model Year Transit AWD Vehicles Rear Driveshaft Bolt and Washer Replacement Advance Notice – Safety Recall 21S54 – Supplement # 1 Certain 2020 Model Year Transit AWD Vehicles Rear Driveshaft Bolt and Captive Washer Replacement New! REASON FOR THIS SUPPLEMENT Attachment III: Technical Information, Parts return no longer required. AFFECTED VEHICLES Vehicle Model Year Assembly Plant Build Dates Transit AWD 2020 KCAP May 1, 2019 through February 1, 2020 Affected vehicles are identified in OASIS and FSA VIN Lists. REASON FOR THIS SAFETY RECALL In some of the affected vehicles, it may be possible for the rear driveshaft to transfer case constant velocity joint (CVJ) mounting bolts to become loose, missing, or damaged. Loose, missing, or damaged driveshaft attachment bolts can lead to the separation of the driveshaft from the transfer case. This can result in an undesirable noise, secondary damage to surrounding components, including brake lines, loss of motive power while driving, or unintended vehicle movement in park without the parking brake applied. SERVICE ACTION The dealer is to check the torque of all 6 driveshaft bolts on the driveshaft to transfer case side for loose, missing, or damaged bolts. If bolts are found loose, missing, or damaged, the dealer is to replace the driveshaft, all driveshaft bolts, center bearing bracket bolts, driveshaft to rear axle companion flange bolts, transfer case flange kit, and transfer case seal. This includes drain and fill transfer case per technical instructions at no charge to the vehicle owner. On vehicles that do not have a loose or missing or damaged – bolt, the dealer is to replace the driveshaft bolts per WSM (Workshop Manual). Dealer will also send pictures to SSSC of loose, missing, or damaged bolts and/or damage of adjoining components. © Copyright 2022 Ford Motor Company OWNER NOTIFICATION MAILING SCHEDULE Owner letters were mailed the week of January 31, 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. ATTACHMENTS Attachment I: Administrative Information Attachment II: Labor Allowances and Parts Ordering Information Attachment III: Technical Information Owner Notification Letters QUESTIONS & ASSISTANCE For questions and assistance, contact the Special Service Support Center (SSSC) via the SSSC Web Contact Site. The SSSC Web Contact Site can be accessed through the Professional Technician System (PTS) website using the SSSC link listed at the bottom of the OASIS VIN report screen or listed under the SSSC tab. Sincerely, David J. Johnson © Copyright 2022 Ford Motor Company ATTACHMENT I Page 1 of 2 NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Safety Recall 21S54 – Supplement # 3 Certain 2020 Model Year Transit AWD Vehicles Rear Driveshaft Bolt and Washer Replacement OASIS ACTIVATION OASIS was activated on December 18, 2021. FSA VIN LISTS ACTIVATION FSA VIN Lists was made available through https://web.fsavinlists.dealerconnection.com on December 18, 2021. Owner names and addresses were made available the week of January 31, 2022. NOTE: Your FSA VIN Lists may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall. SOLD VEHICLES • Owners should contact their dealer for an appointment to have their vehicles remedied as soon as practicable. • 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. © Copyright 2022 Ford Motor Company ATTACHMENT I Page 2 of 2 NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Safety Recall 21S54 – Supplement # 3 Certain 2020 Model Year Transit AWD Vehicles Rear Driveshaft Bolt and Washer Replacement ADDITIONAL REPAIR (LABOR TIME AND/OR PARTS) Additional repairs identified as necessary to complete the FSA should be managed as follows: • For related damage and access time requirements, refer to the Warranty and Policy Manual / Section 6 – Ford & Lincoln Program Policies / General Information & Special Circumstances for FSA’s / Related Damage. • For vehicles within new vehicle bumper-to-bumper warranty coverage, no SSSC approval is required, although related damage must be on a separate repair line with the “Related Damage” radio button checked. o Ford vehicles – 3 years or 36,000 miles For vehicles outside new vehicle bumper-to-bumper warranty coverage, submit an Approval Request to the SSSC Web Contact Site prior to completing the repair. CLAIMS PREPARATION AND SUBMISSION • Claim Entry: Enter claims using Dealer Management System (DMS) or One Warranty Solution (OWS) online. o When entering claims, select claim type 31: Field Service Action. The FSA number (21S54) is the subcode. o For additional claims preparation and submission information, refer to the Recall and Customer Satisfaction Program (CSP) Repairs in the OWS User Guide. • Related Damage/Additional labor and/or parts: Must be claimed as Related Damage on a separate repair line from the FSA with same claim type and subcode as described in Claim Entry above. IMPORTANT: Click the Related Damage Indicator radio button. © Copyright 2022 Ford Motor Company ATTACHMENT II Page 1 of 4 NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Safety Recall 21S54 – Supplement # 3 Certain 2020 Model Year Transit AWD Vehicles Rear Driveshaft Bolt and Washer Replacement LABOR ALLOWANCES Description Labor Operation Labor Time Inspection / Replacement: Check torque of rear driveshaft to transfer case bolts for damage, missing or looseness, Pass inspection. Replace Driveshaft bolts and Captive washer. (Only E can be used with this labor operation if required) 21S54B 0.4 Pictures: Submit Pictures if Driveshaft Bolts are Found damaged, missing, or loose. (Can only be used with C or D, E, and F) 21S54ZZ 0.2 2-piece Driveshaft: Check torque of rear driveshaft to transfer case bolts for damage, missing or looseness, fail – replace driveshaft/bolts, transfer case flange and seals (Includes drain and fill transfer case and prep driveshaft for return) (Only E and/or ZZ can be used with this labor operation if required) 21S54C 1.3 3-piece Driveshaft: Check torque of rear driveshaft to transfer case bolts for damage, missing or looseness, fail – replace driveshaft/bolts, transfer case flange and seals (Includes drain and fill transfer case and prep driveshaft for return) (Only E and/or ZZ can be used with this labor operation if required) 21S54D 1.6 4-piece Driveshaft: Check torque of rear driveshaft to transfer case bolts for damage, missing or looseness, failreplace driveshaft/bolts, transfer case. (Only E and/or ZZ can be used with this labor operation if required) 21S54F 1.7 Extra Time: Remove Running Boards if Equipped. 21S54E 0.3 © Copyright 2022 Ford Motor Company ATTACHMENT II Page 2 of 4 NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Safety Recall 21S54 – Supplement # 3 Certain 2020 Model Year Transit AWD Vehicles Rear Driveshaft Bolt and Washer Replacement PARTS REQUIREMENTS / ORDERING INFORMATION SSSC Web Contact Site: To place an order for parts listed below submit a VIN-specific Part Order contact via the SSSC Web Contact Site. There are limited parts to perform this recall and may initially go on backorder. Part Number Description Order Quantity Claim Quantity LK4Z-4R602-BG 2 PC Driveshaft (Driveshaft CVJ mounting bolts included in pkg.) 1 1 LK4Z-4R602-BL 2 PC Driveshaft (Driveshaft CVJ mounting bolts included in pkg.) 1 1 LK4Z-4R602-BH 3 PC Driveshaft (Driveshaft CVJ mounting bolts included in pkg.) 1 1 LK4Z-4R602-BK 3 PC Driveshaft (Driveshaft CVJ mounting bolts included in pkg.) 1 1 LK4Z-4R602-BJ 4 PC Driveshaft (Driveshaft CVJ mounting bolts included in pkg.) 1 1 W713078-S439 4PC Driveshaft Center Bearing Bracket Bolts (6 Bolts needed 4 in pkg) 2 6 W713078-S439 3 PC Driveshaft Center Bearing Bracket Bolts (4 bolts needed 4 in pkg) 1 4 W713078-S439 2 PC Driveshaft Center Bearing Bracket Bolts (2 bolts needed 4 in pkg) 1 2 MB3Z-7B215A Transfer Case Seal 1 1 LK4Z-7061-A Transfer Case Flange Kit 1 1 Dealers will be notified via a DOES II communication if circumstances warrant a change in part supply strategy and when open ordering resumes. © Copyright 2022 Ford Motor Company ATTACHMENT II Page 3 of 4 NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Safety Recall 21S54 – Supplement # 3 Certain 2020 Model Year Transit AWD Vehicles Rear Driveshaft Bolt and Washer Replacement Order the parts below through normal order processing channels: Part Number Description Order Quantity Claim Quantity LK4Z-4B496-B Rear Driveshaft Mounting Bolt Kit with Captive Washer (1 in pkg 2 req for repair) 2 2 N800594-S100 Driveshaft Rear Axle Companion Flange Bolts (4 bolts needed 4 in pkg) 1 4 DEALER PRICE For latest prices, refer to DOES II. © Copyright 2022 Ford Motor Company ATTACHMENT II Page 4 of 4 NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Safety Recall 21S54 – Supplement # 3 Certain 2020 Model Year Transit AWD Vehicles Rear Driveshaft Bolt and Washer Replacement PARTS RETENTION, RETURN, & SCRAPPING Follow the provisions of the Warranty and Policy Manual, Section 1 – WARRANTY PARTS RETENTION AND RETURN POLICIES. If a replaced part receives a scrap disposition, the part must be scrapped in accordance with all applicable local, state and federal environmental protection and hazardous material regulations. Federal law prohibits selling motor vehicle parts or components that are under safety, compliance, or emissions recall. REPLACED FSA PARTS INSPECTION AND SIGN OFF Effective March 1st, 2021 all parts replaced as part of an FSA repair with a repair order open date of March 1st, 2021 or later must be inspected and signed off on the repair order by a member of your dealers fixed operations management team or an employee the task has been delegated to. If the task is to be delegated to a non-management employee, the employee needs to be someone other than the technician who completed the repair and needs to understand the importance of completing this task consistently and accurately. • All parts replaced as part of an FSA repair should be returned to the parts department following the Warranty Parts Retention and Return Policies. • Inspect the replaced parts to verify the FSA repair was completed. • If the FSA repair is found to be complete, the designated employee signs the repair order line or parts return stamp area (electronic or hand signed) for the FSA repair indicating the parts were inspected and validated to have been replaced. • After the parts have been inspected, they should be handled based on the guidance in the parts status report in the Online Warranty System (Hold, Return, CORE, Scrap, etc.). • This process is subject to review during warranty audits for FSA repairs with a repair order open date of March 1st, 2021 or later. Any eligible FSA claims requiring parts replacement, found not to have been inspected and signed off during a warranty audit will be subject to chargeback and consideration for enrollment into the Dealer Incomplete Recall Repair Process. Note: Other approvals (electronic or handwritten) for add-on repair lines, dealer owned vehicle repairs, and repeat repairs do not qualify as FSA parts inspection approvals. The post repair FSA parts inspection process (electronic or handwritten) is independent from other warranty approval requirements. The approval by the designated employee implies that the FSA parts were found to be replaced and must be able to be clearly identified on the Repair Order. If multiple FSA’s require approval on a single Repair Order, each applicable occurrence will require individual post repair approval by the designated employee. ATTACHMENT III PAGE 1 OF 17 SAFETY RECALL 21S54-S3 CPR © 2021 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 09/2022 CERTAIN 2020 MODEL YEAR TRANSIT AWD VEHICLES – CVJ BOLT AND CAPTIVE WASHER REPLACEMENT SERVICE PROCEDURE 1. With the vehicle in neutral and parking brake disengaged, position vehicle on a hoist. Please follow Workshop Manual (WSM) procedures in Section 100-02. 2. If equipped, remove running boards. Please follow WSM procedures in Section 501-08. 3. Using a 10mm (3/8 in) socket with a Digital or Dial Indicator Torque Wrench, loosen each of the 6 bolts and note the max breakaway torque. See Figures 1 and 2. 21334A PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT FIGURE 1 21334B x6 x2 FIGURE 2 ATTACHMENT III PAGE 2 OF 17 SAFETY RECALL 21S54-S3 CPR © 2021 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 09/2022 FIGURE 3 4. Are any of the bolts or washers missing or damaged? No – Continue to Step 5. Yes – Continue to Step 10. 5. Do any of the bolts show a torque less than 26 ft-lb (35 Nm)? No – Continue to Step 6. Yes – Continue to Step 10. 6. Remove and replace first set of 3 bolts and 1 captive washer. See Figure 3. •Torque: 52 ft-lb (70 Nm). 7. Remove and replace second set of 3 bolts and 1 captive washer. See Figure 3. •Torque: 52 ft-lb (70 Nm). NOTE: Do not completely disconnect driveshaft from transfer case at any time. PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 21334C x6 x2 8. Box and ship bolts and captive washers per the warranty return process. 9. Recall is complete. ATTACHMENT III PAGE 3 OF 17 SAFETY RECALL 21S54-S3 CPR © 2021 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 09/2022 Small Pry Bar Installation Tube (205-1018) Installer, Output Shaft AWD (205-1067) Holding Fixture, Drive Pinion Flange (205-126) 2 or 3 Jaw Puller (205-D027) Installer/Remover, C-Frame and Screw (205-086) Recommended Tools List ATTACHMENT III PAGE 4 OF 17 SAFETY RECALL 21S54-S3 CPR © 2021 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 09/2022 NOTE: A new driveshaft is required, if the driveshaft is dropped. NOTE: Driveshafts should be supported so that each section of the driveshaft is parallel. NOTE: Driveshafts should be supported to ensure center slip mechanism doesn’t pull out of slip boot or over articulate the joint. NOTE: The maximum articulation of any CV-joint is 5 degrees. The maximum articulation of any U-joint is 10 degrees. If the CV or any U-joint of the driveshaft is articulated further than the maximum allowable degrees, damage may occur. 10. Note the index mark on the axle flange (yellow dot). If yellow dot is visible on driveshaft but not on the pinion flange, add corresponding mark on pinion flange. See Figure 4. 11. Remove the driveshaft flange to pinion flange bolts. See Figure 4. NOTE: The driveshaft flange fits tightly on the flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the flange pilot. Pry only in the area shown with a suitable tool, to disconnect the driveshaft flange from the flange pilot or damage to the driveshaft flange can occur. 12. Using a small pry bar, separate the driveshaft flange from the pinion flange. See Figure 4. 13. Support the driveshaft. See Figure 4. FIGURE 4 21334D x4 ATTACHMENT III PAGE 5 OF 17 SAFETY RECALL 21S54-S3 CPR © 2021 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 09/2022 14. Remove and set aside the driveshaft CV-joint to transfer case flange bolts and the retaining straps/washers. See Figure 5. NOTE: Index mark is not required at the Transfer Case CVJ interface. NOTE: The driveshaft CV-joint fits tightly on the flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft CV-joint from the flange pilot. Pry only in the area shown with a suitable tool, to disconnect the driveshaft CV-joint from the flange pilot or damage to the driveshaft CV-joint can occur. 15. Using a small pry bar, separate the driveshaft CV-joint from the transfer case flange. See Figure 5. 16. Support the driveshaft. See Figure 5. FIGURE 5 PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 21334E x6 x2 ATTACHMENT III PAGE 6 OF 17 SAFETY RECALL 21S54-S3 CPR © 2021 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 09/2022 NOTE: The driveshaft is long and heavy with multiple U-joints. Do not over articulate the driveshaft or damage may occur. NOTE: This step requires the aid of another technician. 17. Remove and discard the driveshaft center bearing bolts and remove the driveshaft. This will require pulling the driveshaft rearward to clear the front safety strap/hoop. For Medium Wheelbase see Figure 6. For Long Wheelbase see Figure 7. FIGURE 6 FIGURE 7 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 21334F x2 x2 21334G x2 x2 x2 ATTACHMENT III PAGE 7 OF 17 SAFETY RECALL 21S54-S3 CPR © 2021 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 09/2022 18. Drain the transfer case. Please follow WSM procedures in Section 308-07B. NOTE: Note the position of the component before removal. 19. Using Special Service Tool (205-126 Holding Fixture, Drive Pinion Flange), hold the flange, remove and discard the flange nut. See Figure 8. FIGURE 8 20. Remove the spacer. See Figure 9. FIGURE 9 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 21334H 205-126 21334J ATTACHMENT III PAGE 8 OF 17 SAFETY RECALL 21S54-S3 CPR © 2021 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 09/2022 21. Remove the seal. See Figure 10. FIGURE 10 22. Using Special Service Tool (2 or 3 Jaw Puller), remove the outlet flange and set aside for warranty return. See Figure 11. FIGURE 11 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 21334K 205-D027 21334L ATTACHMENT III PAGE 9 OF 17 SAFETY RECALL 21S54-S3 CPR © 2021 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 09/2022 23. Remove the transfer case rear output shaft seal dust cover. See Figure 12. FIGURE 12 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 21334M 24. Remove and discard the transfer case rear output shaft seal. See Figure 13. FIGURE 13 STUD FOR MISSING NUT 21334N ATTACHMENT III PAGE 10 OF 17 SAFETY RECALL 21S54-S3 CPR © 2021 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 09/2022 25. Use Special Service Tool (205-1018 Installation Tube, 205-1067 Installer), to install the special tool to the seal. See Figure 14. FIGURE 14 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 21334O 205-1067 205-1018 26. Using the special tool, install the transfer case rear seal. See Figure 15. FIGURE 15 205-1067 205-1018 STUD FOR 21334P ATTACHMENT III PAGE 11 OF 17 SAFETY RECALL 21S54-S3 CPR © 2021 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 09/2022 27. Install the transfer case rear output shaft seal dust cover. See Figure 16. FIGURE 16 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 21334Q 28. Install the new transfer case output flange. See Figure 17. FIGURE 17 STUD FOR MISSING NUT 21334R ATTACHMENT III PAGE 12 OF 17 SAFETY RECALL 21S54-S3 CPR © 2021 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 09/2022 29. Install the output flange seal. See Figure 18. FIGURE 18 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 21334S 30. Install the output flange spacer. See Figure 19. FIGURE 19 STUD FOR MISSING NUT 21334T ATTACHMENT III PAGE 13 OF 17 SAFETY RECALL 21S54-S3 CPR © 2021 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 09/2022 31. Use Special Service Tool (205-126 Holding Fixture Drive Pinion Flange), to install the new output shaft flange nut. See Figure 20. •Torque: 136 lb. ft (185 Nm) FIGURE 20 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 21334U 205-126 ATTACHMENT III PAGE 14 OF 17 SAFETY RECALL 21S54-S3 CPR © 2021 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 09/2022 NOTE: The driveshaft is long and heavy with multiple U-joints. Do not over articulate the driveshaft or damage may occur. NOTE: This step requires the aid of another technician. NOTE: Only tighten the bolts finger tight at this stage. 32. Install the driveshaft and the new driveshaft center bearing bolts. See Figure 21 for Medium Wheel base. See Figure 22 for Long Wheelbase. FIGURE 21 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 21334V x2 x2 FIGURE 22 21334W x2 x2 x2 ATTACHMENT III PAGE 15 OF 17 SAFETY RECALL 21S54-S3 CPR © 2021 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 09/2022 33. Install the new driveshaft CV-joint to the transfer case flange bolts and the retaining straps/washers. See Figure 23. •Torque: 52 lb.ft (70 Nm). FIGURE 23 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 21334X x6 x2 FIGURE 24 21334Y x4 34. Align the index-mark on the driveshaft and rear drive pinion flange (yellow dot). Install the new driveshaft to the rear drive pinion flange bolts. See Figure 24. •Torque: 76 lb.ft (103 Nm) ATTACHMENT III PAGE 16 OF 17 SAFETY RECALL 21S54-S3 CPR © 2021 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 09/2022 35. Check all center bearings alignment for bind, twist, or rub. See Figure 25. FIGURE 25 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 21334Z ATTACHMENT III PAGE 17 OF 17 SAFETY RECALL 21S54-S3 CPR © 2021 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 09/2022 37. Refill the Transfer Case. Please follow WSM procedures in section 308-07B. Recall is complete. FIGURE 26 PLACE COPY HERE PLACE COPY HERE PLACE COPY HERE STUD FOR MISSING NUT STUD FOR MISSING NUT STUD FOR MISSING NUT 21334BB x2 36. Tighten the new driveshaft center bearing bolts. 2 on Medium wheel base, 4 on Long wheel base, and 6 on Extra-Long Wheelbase. See Figure 26 for Medium Wheelbase. See Figure 27 for Long Wheelbase. •Torque: 35 lb.ft (48 Nm) FIGURE 27 STUD FOR 21334AA x2 x2
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-978 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Ford Motor Company Submission Date : DEC 16, 2021 NHTSA Recall No. : 21V-978 Manufacturer Recall No. : 21S54 Manufacturer Information : Manufacturer Name : Ford Motor Company Address : 330 Town Center Drive Suite 500 Dearborn MI 48126-2738 Company phone : 1-866-436-7332 Population : Number of potentially involved : 4,548 Estimated percentage with defect : 17 % Vehicle Information : Vehicle 1 : 2020-2020 Ford Transit Vehicle Type : LIGHT VEHICLES Body Style : Power Train : NR Descriptive Information : Affected vehicles are equipped with All Wheel Drive (AWD) built between May 1, 2019 and February 1, 2020. These vehicles are not produced in VIN order. Information as to the applicability of this action to specific vehicles can best be obtained by either calling Ford’s toll-free line (1-866-436-7332) or by contacting a local Ford or Lincoln dealer who can obtain specific information regarding the vehicles from the Ford On-line Automotive Service Information System (OASIS) database. Production Dates : MAY 01, 2019 – FEB 01, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : Reduced clamp load for the bolts that attach the rear driveshaft to the transfer case can lead to loosening and/or damage of those attachment bolts and potential separation of the driveshaft from the transfer case. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Loose or damaged driveshaft attachment bolts can lead to separation of the driveshaft from the transfer case. This can result in a loss of motive power while driving, or unintended vehicle movement in park without the parking brake applied. In addition, separation of the driveshaft can result in secondary damage to surrounding components, including brake lines. A Part 573 Safety Recall Report 21V-978 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 driveshaft separation increases the risk of crash. Description of the Cause : The cause for reduced attachment bolt clamp load is unknown. Ford’s investigation is ongoing. Identification of Any Warning that can Occur : A loose driveshaft will result in driveline noise and vibration from underneath the vehicle that can be heard and felt by occupants inside the vehicle while driving. Involved Components : Component Name 1 : Bolt and Washer Assembly Component Description : Bolt and Washer Assembly / Driveshaft Component Part Number : LK41-4B496-CA Component Name 2 : Driveshaft Assembly Component Description : Driveshaft Assembly / 2PCS Component Part Number : LK41-4K145-DAE Component Name 3 : Driveshaft Assembly Component Description : Driveshaft Assembly / 2PCS Component Part Number : LK41-4K145-FAE Component Name 4 : Driveshaft Assembly Component Description : Driveshaft Assembly / 3PCS Component Part Number : LK41-4K357-YAG Component Name 5 : Driveshaft Assembly Component Description : Driveshaft Assembly / 3PCS Component Part Number : LK41-4K357-ZAF Part 573 Safety Recall Report 21V-978 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 6 : Driveshaft Assembly Component Description : Driveshaft Assembly / 4PCS Component Part Number : LK41-4K357-AAF Supplier Identification : Component Manufacturer Name : NEAPCO HOLDINGS LLC Address : 6735 HAGGERTY ROAD BELLEVILLE Michigan 48111-5271 Country : United States Chronology : Chronology is provided as an attachment Description of Remedy : Description of Remedy Program : Owners will be notified by mail and instructed to take their vehicle to a Ford or Lincoln dealer to have all 6 driveshaft to transfer case CVJ attachment bolts inspected for looseness. If one bolt is loose, the dealer is to replace the driveshaft, all driveshaft bolts, center bearing bracket bolts, driveshaft to rear axle companion flange bolts, transfer case flange kit, and transfer case seal. On vehicles that do not have a loose bolt, the dealer will replace all driveshaft bolts at the transfer case interface per Ford’s workshop manual. There will be no charge for this service. Ford is excluding reimbursement for costs because the original warranty program would provide for a free repair for this concern. Ford will forward a copy of the notification letters to dealers to the agency when available. How Remedy Component Differs from Recalled Component : The attachment bolts and driveshaft service part assemblies will be replaced and properly torqued per Ford’s workshop manual. Identify How/When Recall Condition was Corrected in Production : NR Part 573 Safety Recall Report 21V-978 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Recall Schedule : Description of Recall Schedule : Notification to dealers is expected to occur on December 17, 2021. Mailing of owner notification letters is expected to begin January 31, 2022 and is expected to be completed by February 4, 2022. Planned Dealer Notification Date : DEC 17, 2021 – DEC 17, 2021 Planned Owner Notification Date : JAN 31, 2022 – FEB 04, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-978 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Ford Motor Company Submission Date : JAN 14, 2022 NHTSA Recall No. : 21V-978 Manufacturer Recall No. : 21S54 Manufacturer Information : Manufacturer Name : Ford Motor Company Address : 330 Town Center Drive Suite 500 Dearborn MI 48126-2738 Company phone : 1-866-436-7332 Population : Number of potentially involved : 4,548 Estimated percentage with defect : 17 % Vehicle Information : Vehicle 1 : 2020-2020 Ford Transit Vehicle Type : LIGHT VEHICLES Body Style : Power Train : NR Descriptive Information : Affected vehicles are equipped with All Wheel Drive (AWD) built between May 1, 2019 and February 1, 2020. These vehicles are not produced in VIN order. Information as to the applicability of this action to specific vehicles can best be obtained by either calling Ford’s toll-free line (1-866-436-7332) or by contacting a local Ford or Lincoln dealer who can obtain specific information regarding the vehicles from the Ford On-line Automotive Service Information System (OASIS) database. Production Dates : MAY 01, 2019 – FEB 01, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : Reduced clamp load for the bolts that attach the rear driveshaft to the transfer case can lead to loosening and/or damage of those attachment bolts and potential separation of the driveshaft from the transfer case. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Loose or damaged driveshaft attachment bolts can lead to separation of the driveshaft from the transfer case. This can result in a loss of motive power while driving, or unintended vehicle movement in park without the parking brake applied. In addition, separation of the driveshaft can result in secondary damage to surrounding components, including brake lines. A Part 573 Safety Recall Report 21V-978 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 driveshaft separation increases the risk of crash. Description of the Cause : The cause for reduced attachment bolt clamp load is unknown. Ford’s investigation is ongoing. Identification of Any Warning that can Occur : A loose driveshaft will result in driveline noise and vibration from underneath the vehicle that can be heard and felt by occupants inside the vehicle while driving. Involved Components : Component Name 1 : Bolt and Washer Assembly Component Description : Bolt and Washer Assembly / Driveshaft Component Part Number : LK41-4B496-CA Component Name 2 : Driveshaft Assembly Component Description : Driveshaft Assembly / 2PCS Component Part Number : LK41-4K145-DAE Component Name 3 : Driveshaft Assembly Component Description : Driveshaft Assembly / 2PCS Component Part Number : LK41-4K145-FAE Component Name 4 : Driveshaft Assembly Component Description : Driveshaft Assembly / 3PCS Component Part Number : LK41-4K357-YAG Component Name 5 : Driveshaft Assembly Component Description : Driveshaft Assembly / 3PCS Component Part Number : LK41-4K357-ZAF Part 573 Safety Recall Report 21V-978 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 6 : Driveshaft Assembly Component Description : Driveshaft Assembly / 4PCS Component Part Number : LK41-4K357-AAF Supplier Identification : Component Manufacturer Name : NEAPCO HOLDINGS LLC Address : 6735 HAGGERTY ROAD BELLEVILLE Michigan 48111-5271 Country : United States Chronology : Chronology is provided as an attachment Description of Remedy : Description of Remedy Program : Owners will be notified by mail and instructed to take their vehicle to a Ford or Lincoln dealer to have all 6 driveshaft to transfer case CVJ attachment bolts inspected for looseness. If one bolt is loose, the dealer is to replace the driveshaft, all driveshaft bolts, center bearing bracket bolts, driveshaft to rear axle companion flange bolts, transfer case flange kit, and transfer case seal. On vehicles that do not have a loose bolt, the dealer will replace all driveshaft bolts at the transfer case interface per Ford’s workshop manual. There will be no charge for this service. Ford is excluding reimbursement for costs because the original warranty program would provide for a free repair for this concern. Ford will forward a copy of the notification letters to dealers to the agency when available. How Remedy Component Differs from Recalled Component : The attachment bolts and driveshaft service part assemblies will be replaced and properly torqued per Ford’s workshop manual. Identify How/When Recall Condition was Corrected in Production : NR Part 573 Safety Recall Report 21V-978 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Recall Schedule : Description of Recall Schedule : Notification to dealers is expected to occur on December 17, 2021. Mailing of owner notification letters is expected to begin January 31, 2022 and is expected to be completed by February 4, 2022. Planned Dealer Notification Date : DEC 17, 2021 – DEC 17, 2021 Planned Owner Notification Date : JAN 31, 2022 – FEB 04, 2022 * NR – Not Reported
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