Safety Recall 22S07 – Front Passenger Knee Airbag Module Replacement – 2021-2022 Ford Mustang

February 16, 2022 NHTSA CAMPAIGN NUMBER: 22V083000

Passenger Knee Air Bag May Deploy Improperly

An improper air bag deployment can increase the risk of injury during a crash.

 

NHTSA Campaign Number: 22V083

Manufacturer Ford Motor Company

Components AIR BAGS

Potential Number of Units Affected 327

 

Summary

Ford Motor Company (Ford) is recalling certain 2021-2022 Mustang vehicles. An insufficient weld on the front passenger knee air bag may result in an improper air bag deployment.

 

Remedy

Dealers will replace the front passenger knee air bag, free of charge. Owner notification letters were mailed on March 8, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 22S07.

 

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

 


AFFECTED VEHICLES

VehicleModel YearAssembly PlantBuild Dates
Mustang2021-2022Flat RockAugust 23, 2021 through September 21, 2021

 

REASON FOR THIS SAFETY RECALL

In some of the affected vehicles, it is possible there are inadequate plastic welds between components of the front passenger knee air bag module bladder. If the front passenger knee airbag weld integrity is compromised during deployment, it may not provide design intent occupant knee restraint and increase the risk of injury during a crash event that necessitates knee airbag deployment.

 

SERVICE ACTION

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to replace the front passenger knee airbag module. 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 March 7, 2022. Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

PLEASE NOTE:

Federal law requires dealers to complete this recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $21,000 per vehicle. Correct all vehicles in your new vehicle inventory before delivery.

 

SOLD VEHICLES

  • 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. Owners can continue to safely drive their vehicles.
  • Immediately contact any of your affected customers whose vehicles are not on your VIN list but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date.
  • Correct other affected vehicles identified in OASIS which are brought to your dealership.
  • Dealers are to prioritize repairs of customer vehicles over repairs of new and used vehicle inventory.

 

STOCK VEHICLES

  • Correct all affected units in your new vehicle inventory before delivery.
  • Use OASIS to identify any affected vehicles in your used vehicle inventory.

 

DEALER-OPERATED RENTAL VEHICLES

The Fixing America’s Surface Transportation (FAST) Act law effective June 2016 prohibits a rental company from selling, renting or leasing vehicles subject to a safety or compliance recall. Please consult your legal counsel for legal advice.

 

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this recall.

 

OWNER REFUNDS

  • This safety recall must still be performed, even if the owner has paid for a previous repair. Claiming a refund will not close the recall on the vehicle.
  • 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 front passenger knee airbag module replacement.

 

RENTAL VEHICLES 

Rental vehicles are not approved for this program.

 

PARTS

Part NumberDescriptionOrder QuantityClaim Quantity
KR3Z-63060T10-BCPassenger knee air bag module11

 


CERTAIN 2021 MODEL YEAR MUSTANG VEHICLES – FRONT PASSENGER KNEE AIRBAG MODULE REPLACEMENT

SERVICE PROCEDURE

1. Remove and replace the passenger knee airbag. Please follow the Workshop Manual (WSM) procedure in Section 501-20B.

 


Date of Submission:  2/16/2022
FSA #22S07 – Certain 2021 and 2022 model year Ford Mustang vehicles – Front Passenger Knee Airbag Weld Separation

Chronology

On September 28, 2021, the Critical Concern Review Group (CCRG) reviewed a report of a front passenger knee airbag that exhibited weld separation between the bladder and outer door during testing being conducted related to a previous anomaly (weld separation between the bladder and inner door).

The concern was identified by the front passenger knee airbag supplier, Faurecia, on September 20, 2021, after heat aging 25 passenger knee airbags and deploying at cold temperature (-20C). One knee airbag exhibited weld separation between the bladder and outer door resulting in loss of pressure within the bladder.  The remaining 24 knee airbags performed per design intent.  An additional 3 heat aged knee airbags were deployed at ambient temperature in linear impact testing resulting in acceptable performance.

October – November 2021 – Supplier Technical Assistance (STA) team conducted root cause analysis for the weld separation.  Based upon elimination of all unique potential root causes, the team concluded that the cause of the weld failure was related to the original anomaly, weld separation between the bladder and inner door.  The root cause for the original anomaly was a set up issue on the knee airbag hot plate welder during a tool changeover on August 20, 2021. On August 24, 2021, Faurecia reset process parameters and conducted weld testing to confirm proper weld strength.  The front passenger knee airbags produced at Faurecia between August 20, 2021 and August 24, 2021 are considered suspect.

Full traceability between the front passenger knee airbag inflator serial numbers and the vehicle VIN’s enabled the team to determine the suspect vehicle population that escaped Ford assembly plant.

December 2021 – Vehicle level Computer Aided Engineering (CAE) was conducted by Ford’s Vehicle Crash Safety team simulating the concern in an unbelted frontal crash mode.  The results indicated a small kinematic difference in head positioning during the event.

January 2022 – CCRG determined that while the CAE resulted in a small kinematic effect to occupant, the concern may represent an increased risk to occupant safety as the deployment does not meet design intent.

On February 9, 2022, 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.

 


2 Affected Products

Vehicle

MAKEMODELYEAR
FORDMUSTANG2021-2022

 


10 Associated Documents

Recall 573 Report

RCLRPT-22V083-6677.PDF 213.831KB

 


Defect Notice 573 Report

RCLRPT-22V083-8397.PDF 213.82KB

 


Recall Acknowledgement

RCAK-22V083-9726.pdf 677.448KB

 


Miscellaneous Document – Chronology of Defect

RMISC-22V083-8093.pdf 13.331KB

 


Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 22S07 Certain 2021-2022 Model Year Mustang Vehicles Passenger Knee Airbag Module Replacement

RCMN-22V083-8473.pdf 251.333KB

 


ISSUED Owner Notification Letter(Part 577)

RCONL-22V083-0351.pdf 52.126KB

 


ISSUED Renotification Notice

RCRN-22V083-8002.pdf 549.076KB

 


Recall Quarterly Report #2, 2022-2

RCLQRT-22V083-2006.PDF 211.24KB

 


Recall Quarterly Report #3, 2022-3

RCLQRT-22V083-8743.PDF 211.325KB

 


Recall Quarterly Report #4, 2022-4

RCLQRT-22V083-9491.PDF 211.434KB

 


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