April 14, 2022 NHTSA CAMPAIGN NUMBER: 22V247000
A detached head restraint cushion can increase the risk of injury during a crash.
NHTSA Campaign Number: 22V247
Manufacturer Ford Motor Company
Potential Number of Units Affected 933
Ford Motor Company (Ford) is recalling certain 2022 Lincoln Aviator vehicles. The front-row driver and passenger seat power head restraint cushion may detach from the head restraint assembly when adjusted to the full forward position.
Dealers will replace the front-row passenger and driver head restraints, free of charge. Owner notification letters are expected to be mailed May 9, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 22S23.
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.
|Vehicle||Model Year||Assembly Plant||Build Dates|
|Aviator||2022||Chicago||June 24, 2021 through February 16, 2022|
REASON FOR THIS SAFETY RECALL
In some of the affected vehicles, with 30-way power adjustable front memory seats, it’s possible the front driver and passenger head restraint cushion could detach from the adjuster mechanism. A detached head restraint cushion may increase the risk of injury during a crash.
DO NOT DEMONSTRATE OR DELIVER any new in-stock vehicles involved in this safety recall. A complete Dealer Bulletin will be provided to dealers by the end of 2nd quarter 2022 when it is anticipated that parts ordering information and repair instructions will be available to support this safety recall.
IMPORTANT: Dealers should open a Repair Order (RO) only when a full dealer bulletin is published. Opening an RO against an Awareness or Advance Notice will result in warranty rejections against a recall.
Owners of record will be notified via first-class mail after repair instructions and parts ordering information have been provided to dealers.
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 prior to delivery.
On February 22, 2022, an issue pertaining to 2022 MY Aviator power head restraint foam buns that could detach was brought to Ford’s Critical Concern Review Group for review by Chicago Assembly Plant (CAP) PVT and PD.
The issue was initially detected on Navigators at the Ford Kentucky Truck Plant (KTP) on January 31, 2022. All affected Navigators were contained by KTP. PD and KTP and CAP PVTs conducted a program read across for this head restraint design and identified that the 2022 MY Aviator uses the same head restraint system.
On February 10, 2022, containment actions were put into place at CAP and a clean point of February 14, 2022, was established. Between the implementation (2022 MY) of this Gen2 head restraint on Aviator and the clean point, a total of 1,417 Aviator vehicles were built and shipped globally with suspect head restraints.
The issue was investigated by PD and the supplier in February and March. They discovered that the incorrect spring force was used, and the force was not strong enough to engage forward hard stop on head restraint to bun sleeves. PD and the supplier investigated further to understand why the condition was not occurring consistently and concluded that this condition could only exist after the head restraint is cycled a minimum of 30 times and motor logic is in calibration mode. Once in calibration mode, the soft motor stops are disabled, and the motor will utilize the hard stops to recalibrate the bun fore/aft location. If the bun is moved full forward and the hard stop does not function properly due to the insufficient spring force, the bun will continue to move forward until it detaches from the head restraint assembly.
The Technical Review Group met on March 9, 2022 and determined it would be beneficial to allow members of the CCRG team to evaluate the condition to better understand the failure mode and use conditions that cause the failure mode. A vehicle review was held on March 18.
The concern only affects 2022 MY as a new head restraint was implemented for the 2022 MY. The prior design utilized a different mechanism for engaging forward hard stop.
On April 7, 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
1 Affected Product
4 Associated Documents
Defect Notice 573 Report
Miscellaneous Document – Chronology
Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice – Safety Recall 22S23 Certain 2022 Model Year Lincoln Aviator Vehicles with 30-Way Power Adjustable (Perfect Position) Front Memory Seats Front Driver and Passenger Head Restraint Replacement
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