Safety Recall 22S09 – Loose/Sagging Underbody Insulator – 2017-2022 Ford F-250/F-350

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February 16, 2022 NHTSA CAMPAIGN NUMBER: 22V087000

Damaged Driveshaft May Fracture

A fractured driveshaft can cause a loss of drive power, or a loss of vehicle control if the driveshaft contacts the ground. Additionally, unintended movement could occur while parked if the parking brake is not engaged. Any of these scenarios can increase the risk of a crash.

 

NHTSA Campaign Number: 22V087

Manufacturer Ford Motor Company

Components STRUCTURE, POWER TRAIN

Potential Number of Units Affected 247,445

 

Summary

Ford Motor Company (Ford) is recalling certain 2017-2022 F-250 and F-350 Super Duty vehicles equipped with gasoline engines and aluminum driveshafts. Underbody heat and noise insulators may loosen and contact the aluminum driveshaft, which could damage the driveshaft and cause it to fracture.

 

Remedy

Dealers will inspect and repair the driveshaft as necessary, and properly attach the underbody insulators, free of charge. Owner notification letters were mailed on April 7, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 22S09.

 

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

 


October 25, 2022

NEW VEHICLE DEMONSTRATION / DELIVERY HOLD –
Safety Recall 22S09 – Supplement #5
Certain 2017 – 2022 Model Year F-250/F-350 Vehicles Equipped with a 6.2L/7.3L Gas
Engine, Crew Cab/Super Cab, 160”/164” Wheelbase, 4×4, and One-Piece Aluminum
Driveshaft
Loose/Sagging Underbody Insulator

 

AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
Super Duty 2017-2022 Kentucky Truck October 14, 2015 through December 11, 2021

 

REASON FOR THIS SUPPLEMENT

  • Technical Instructions are updated – driveshaft removal is not necessary unless it fails inspection
    and replacement is required.
  • W708777-S900C, W702554-S900C, W708777-S900 have been removed from the parts list.

 

REASON FOR THIS SAFETY RECALL

In some of the affected vehicles, underbody insulators may loosen and contact the aluminum driveshaft, resulting in marking or scoring of the driveshaft. Over time, the aluminum driveshaft may fracture, which can result in loss of motive power while driving, unintended vehicle movement while the vehicle is in park if the parking brake is not applied, and secondary damage to surrounding components. A fractured driveshaft may also contact the ground which may cause loss of control of the vehicle while driving. A fractured driveshaft increases the risk of injury or crash.

 

SERVICE ACTION

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to secure the underbody insulator and inspect the driveshaft for damage and repair as required. This service must be performed on all affected vehicles at no charge to the vehicle owner.

 

OWNER NOTIFICATION AND MAILING SCHEDULE

Owner letters are expected to be mailed the week of April 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

  • Ford 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.
  • 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.

 

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.
  • Ford 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 Ford 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 Ford to be excessive, will not be reimbursed.
  • Refunds will only be provided for the cost associated with driveshaft replacement.

 

RENTAL VEHICLES

  • PASS INSPECTION: Vehicles that pass the driveshaft inspection are NOT affected and are not approved for rental vehicles. Refer to the 22S09 technical instructions for additional information.
  • FAIL INSPECTION: Vehicles that fail the applicable driveshaft inspection:
    • Parts are NOT available:
      • Driveshaft is on back-order.
      • PARTS ESCALATION PROCESS (Vehicle Off Road) process has been followed and COPIS ticket with VOR flagged has been submitted.
      • Prior approval is required from the SSSC, submit contact type long-term rental for consideration and approval if appropriate.
  • A ten-digit prior-approval code is required from the SSSC for rental vehicles, a new approval code is required from SSSC every 30 days.
  • If rental vehicles are needed beyond September 30, 2022, dealers will have to contact SSSC for an extension.
  • Approval for all rental vehicles for this program will end on September 30, 2022.
  • Follow Extended Service Plan (ESP) guidelines for dollar amounts. Prior approval is required from the SSSC.

              

PARTS

Video Instruction:

Review the following video clip before ordering parts or attempting to repair a vehicle:

https://bcove.video/33zsXxo

 

Driveshaft – Only replace the driveshaft if marks are present per the technical instructions.

Part Number Description Order Quantity
*-4602-* Driveshaft (part number varies by vehicle – use Ford ECat to identify the specific part number by VIN) As Required

 

Part Number  Description Order Quantity
Any of the following part numbers may be used:

  • W702554-S900
  • W702554-S437
  • W705297-S417
  • W705297-S300
  • W719880-S417
Rivets

(Pack of 4, 2 needed per vehicle)

 

1

 

Repair Part Number Description Order Quantity
All PM-13-A Safety Recall 22S09 - Loose/Sagging Underbody Insulator - 2017-2022 Ford F-250/F-350 | small light Motorcraft Anti-Corrosion Coating (16 fl. Oz per container, applied to 2 rivets liberally, ½ Container per repair)

or

Equivalent (use OSP)

1
All TA-2-B Safety Recall 22S09 - Loose/Sagging Underbody Insulator - 2017-2022 Ford F-250/F-350 | small light Motorcraft Seam Sealer (9.5 fl. Oz per container, applied to 2 rivets liberally, 1 per vehicle)

or

Equivalent (use OSP)

1
Driveshaft Replacement XG-1-E1 Safety Recall 22S09 - Loose/Sagging Underbody Insulator - 2017-2022 Ford F-250/F-350 | small light Motorcraft® Premium Long-Life Grease 1
Driveshaft Replacement XT-10QLVC MERCON® LV Automatic Transmission Fluid

(12 per case, 1 Quart bottle required)

1

 

Obtain the parts below locally:

Part Number Description  Quantity Needed
Obtain Locally Zinc coated steel or Aluminum washers, ¼ inch ID, 2-inch OD, Thickness 2mm (Max).  

2 needed per Vehicle

Obtain Locally LOCTITE 243 Blue Medium Strength Threadlocker or equivalent – Specification WSK-M2G349-A7 1 tube needed per vehicle

 


CERTAIN 2017-2022 MODEL YEAR F-250/F-350 VEHICLES EQUIPPED WITH A 6.2L/7.3L GAS ENGINE, CREW CAB/SUPER CAB, 160″/164″WHEELBASE, 4X4, AND ONE-PIECE ALUMINUM DRIVESHAFT – LOOSE/SAGGING UNDERBODY INSULATOR

 

SERVICE PROCEDURE

Table Of Contents

Inspection – 3

Driveshaft – 3

Zones 1, 3 and 4 – 3

Zone 2 – 5

Driveshaft Replacement – 7

Securing Underbody Insulator – 8

Appendix A – Acceptable Photos – 12

 

Review the video link below before starting this repair procedure:

 https://bcove.video/33zsXxo

 

Materials List

Ruler/Scale
Straight Edge
13 mm (1/2 in) Drill Stop Small Brush
Drill 6.7 mm (17/64 in) Drill Bit Marker
1/4″ Rivet Gun 5.1 mm (13/64 in) Drill BitRivet W719880-S417 Tape

 

NOTE:  A ¼” air over hydraulic rivet gun was used for the service trials for this program, however a pneumatic rivet gun or a manual rivet gun may also be used. However, it may not be possible to access and properly secure the rivets into the floor pan using a manual rivet gun. It is important to always confirm the rivet is properly secured to the floor pan of the vehicle.

 

NOTE:  The underbody insulator is located directly above the exhaust.

NOTE:  Insulator is highlighted for illustration purposes only.

 

Inspection

1. With the vehicle in NEUTRAL, position it on a hoist. Please follow Workshop Manual (WSM) procedures in Section 100-02.

 

Zones 1, 3 and 4

2. Inspect Zones 1, 3 and 4 of the rear driveshaft for any marks caused by the front and/or rear edges of the passenger side insulator. Are there any marks present in Zones 1, 3 or 4? See Figure 3.

Yes – Proceed to step 3.

No – Proceed to step 5.

 

3. What is the current odometer reading?

> 2,500 miles – Proceed to step 4.

< 2,500 miles – Proceed to step 11.

 

4. Place a straight edge along the driveshaft over the wear mark and attempt to fit a 0.018in (0.45mm) feeler gauge between the flat edge and the wear mark. Can the feeler gauge fit between the straight edge and anywhere along the wear mark? See Figures 4 and 5.

Yes – Does not pass inspection. Contact the SSSC and provide a picture of the driveshaft with the feeler gauge fitting between the straight edge and wear mark. Once approved, rear driveshaft replacement will be required. Proceed to step 7.

No – Passes inspection. Proceed to step 5.

 

Zone 2

5. Inspect Zone 2 (transition from larger tube diameter to smaller diameter section) of the driveshaft tube for any marks caused by the front edge of the passenger side insulator. Are there any marks present? See Figure 6.

Yes – Does not pass inspection. Proceed to step 6.

No – Passes inspection. Driveshaft may be reused. Proceed to step 11.

 

6. Inspect the marks found on Zone 2. Is the aluminum tube surface grain pattern worn off, completely smooth, or have an appearance of necking? See Figures 7 through 10.

Yes – Does not pass inspection. Contact the SSSC and provide a picture of the driveshaft with the grain pattern worn off. Be sure to show a clear image of the grain pattern missing. Once approved, rear driveshaft replacement will be required. Proceed to step 7.

No – Passes inspection. Driveshaft may be reused. Proceed to step 11.

 

Driveshaft Replacement

7. Remove the driveshaft. Please follow WSM procedures in Section 205-01.

NOTE: Do NOT discard the U-joint strap bolts and straps.

NOTE: Do NOT discard the four driveshaft flange to pinion flange bolts.

8. Using an air blow gun, remove any debris from threaded holes in axle flange. See Figure 11.

NOTE: Make sure that the mating faces are clean and free of foreign material.

 

9. Inspect the original driveshaft flange to pinion flange bolts for rust in the threads and replace if rusted or damaged. Clean threads of the original driveshaft flange to pinion flange bolts with a wire brush and coat the threads with LOCTITE 243 Blue Medium Strength Threadlocker or equivalent. See Figure 12.

 

10. Install the new driveshaft. Please follow WSM procedures in Section 205-01.

 

Securing Underbody Insulator

NOTE: The driveshaft does NOT need to be removed for this part of the repair.

11. What is the body style of the vehicle?

Crew Cab 160″ Wheelbase – Proceed to step 12.

Super Cab 164″ Wheelbase – Proceed to step 13.

12. Measure and mark the two locations on the underbody insulator. See Figure 13.

 

13. Measure and mark the two locations on the underbody insulator. See Figure 14.

 

14. Use the 5.1 mm (13/64 in) drill bit for rivet part number W719880-S417 or the 6.7mm (17/64 in) drill bit for all other rivet part numbers to drill a hole through the insulator and into the floor. See Figure 15.

 

NOTE:  Use the 13mm (1/2 in) drill stop to ensure you do not drill through the carpet.

 

15. Repeat step 14 for the second marked location.

16. Using a small brush, apply a layer of the anti-corrosion coating to the edges of the newly drilled holes.

NOTE: All approved listed rivet part numbers may not look identical to the photos in the technical instructions.

 

18. Apply a thick layer of seam sealer to the rivet, and the backside of the washer. See Figure 9.

 

19. Using a 1/4″ rivet gun, install the rivet and washer to the drilled hole. See Figure 10.

NOTE: To ensure the rivet is properly secured, apply as much force to the rivet gun as possible.

 

20. Attempt to move the washer/rivet to confirm it is properly secured.

21. Using a small brush, apply a layer of the anti-corrosion coating to the washer and rivet.

22. Repeat steps 10-14 for the second drilled hole.

 


12 Affected Products

Vehicles

MAKE MODEL YEAR
FORD F-250 SD 2017-2022
FORD F-350 SD 2017-2022

 


13 Associated Documents

Defect Notice 573 Report

RCLRPT-22V087-5959.PDF 216.312KB

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Recall Acknowledgement

RCAK-22V087-1048.pdf 645.433KB

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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 22S09 Certain 2017 – 2022 Model Year F-250/F-350 Vehicles Equipped with a 6.2L/7.3L Gas Engine, Crew Cab/Super Cab, 160”/164” Wheelbase, 4×4, and One-Piece Aluminum Driveshaft Loose/Sagging Underbody Insulator

RCMN-22V087-0523.pdf 3158.738KB

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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 22S09 – Supplement #1 Certain 2017 – 2022 Model Year F-250/F-350 Vehicles Equipped with a 6.2L/7.3L Gas Engine, Crew Cab/Super Cab, 160”/164” Wheelbase, 4×4, and One-Piece Aluminum Driveshaft Loose/Sagging Underbody Insulator

RCMN-22V087-3863.pdf 3180.195KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V087-9058.pdf 54.437KB

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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 22S09 – Supplement #2 Certain 2017 – 2022 Model Year F-250/F-350 Vehicles Equipped with a 6.2L/7.3L Gas Engine, Crew Cab/Super Cab, 160”/164” Wheelbase, 4×4, and One-Piece Aluminum Driveshaft Loose/Sagging Underbody Insulator

RCMN-22V087-8026.pdf 4815.679KB

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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 22S09 – Supplement #3 Certain 2017 – 2022 Model Year F-250/F-350 Vehicles Equipped with a 6.2L/7.3L Gas Engine, Crew Cab/Super Cab, 160”/164” Wheelbase, 4×4, and One-Piece Aluminum Driveshaft Loose/Sagging Underbody Insulator

RCMN-22V087-6612.pdf 4803.959KB

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Recall Quarterly Report #1, 2022-2

RCLQRT-22V087-9911.PDF 211.136KB

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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 22S09 – Supplement #4 Certain 2017 – 2022 Model Year F-250/F-350 Vehicles Equipped with a 6.2L/7.3L Gas Engine, Crew Cab/Super Cab, 160”/164” Wheelbase, 4×4, and One-Piece Aluminum Driveshaft Loose/Sagging Underbody Insulator

RCMN-22V087-6487.pdf 4798.069KB

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ISSUED Renotification Notice

RCRN-22V087-3883.pdf 549.775KB

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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 22S09 – Supplement #5 Certain 2017 – 2022 Model Year F-250/F-350 Vehicles Equipped with a 6.2L/7.3L Gas Engine, Crew Cab/Super Cab, 160”/164” Wheelbase, 4×4, and One-Piece Aluminum Driveshaft Loose/Sagging Underbody Insulator

RCMN-22V087-2543.pdf 4737.903KB

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Recall Quarterly Report #2, 2022-3

RCLQRT-22V087-7361.PDF 211.235KB

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Recall Quarterly Report #3, 2022-4

RCLQRT-22V087-8070.PDF 211.325KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V087&docType=RCL

 


 

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CHAOGANG 200mil 36.16 Sqft Car Sound Deadener Deadening Mat Noise and Heat Shield Insulation Closed Cell PE Foam Vibration Dampening Material for Car Hood Trim Roof Door and Trunk
  • 【Specification】Thickness: 200mil/5mm |Size: 16.5 inch × 315 inch(42 × 800cm) | Total Covering Area: 36.16 Sqft.| Material: Closed Cell PE Foam | Resistance Temperature Range: -40°C ~ +149°C
  • 【Sound insulation shock absorption】The car sound deadening mat has the same characteristics as rubber foam and excellent sound insulation performance, reduces the noise outside the car to create a comfortable driving environment, it plays a role in suppressing the vibration caused by the engine, reducing the vibration in the car and extending the life of the parts in the car,and it is light and non-absorbent, resistant to oil and gasoline.
  • 【Heat insulation】This car heat shield mat is made of high quality closed cell PE foam. It is a kind of heat insulating material with a wide range of uses, which can block the heat from the sun and the engine from being transferred into the car, so that the car can maintain a comfortable temperature.
  • 【Roll delivery】Easy to cut and install, suitable for various car models. Self-adhesive backing waterproof and dustproof and have strong adhesion.packed by roll,effectively avoid creases.
  • 【Wide range of applications】It can be applied to external partitions, firewalls, hoods, engine compartments, engine compartments, trunks, wheel arches, body panels, load floors, and internal partitions under the seat floor. It has excellent load resistance, so it is the best choice for flooring.
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uxcell 394mil 10mm 16.36sqft Car Block Heat Sound Absorption Deadener Insulation Mat 60"x40"
  • Liner has the same characteristics and excellent noise insulator properties as rubber foam. It absolutely doesn't absorb water & has no unlike polyurethane foam. It has a very low weight, oil and petrol resistant.
  • The material used is an excellent insulator! The sound deadener material allows you to deal with both, cold and the heat. This is especially important in hot climate areas. Well-insulated interior is a pledge of high comfort while in vehicle. Liner heat shield material will solve the problem of excessive heating if your car is equipped with a powerful engine and enhanced exhaust system. It is also easy to use Liner as the hood insulation (hoodliner).
  • Placement of using sound deadener mat:A.Hood B.Celling C.Door D.Cockpit Floor E.Tailgate F.Firwall and U Type Wall J.Front fen-der H.Front and Back Wheels
  • 1.Waterproof and moistureproof 2.Superb backed self adhesive 3.Easy to install/handle/cut flexible
  • Perfect for Automobiles, Condos, Apartments, Studios, Classrooms, Factory and more.

Last update on 2024-04-01 / Affiliate links / Images from Amazon Product Advertising API

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