Safety Recall 22S23 – Front Driver and Passenger Head Restraint Replacement – 2022 Lincoln Aviator

April 14, 2022 NHTSA CAMPAIGN NUMBER: 22V247000

Head Restraint Cushion May Detach

A detached head restraint cushion can increase the risk of injury during a crash.

 

NHTSA Campaign Number: 22V247

Manufacturer Ford Motor Company

Components SEATS

Potential Number of Units Affected 933

 

Summary

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.

 

Remedy

Dealers will replace the front-row passenger and driver head restraints, free of charge. Interim owner notification letters to notify owners of the safety risk were mailed May 11, 2022. Owner notification letters were mailed July 29, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 22S23.

 

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

 


July 15, 2022

NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – 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

AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
Aviator2022ChicagoJune 24, 2021 through February 16, 2022

Affected vehicles are identified in OASIS and FSA VIN Lists.

 

REASON FOR THIS SAFETY RECALL

In some of the affected vehicles, with 30-way power adjustable front memory seats, the front driver and passenger head restraint cushion could detach from the adjuster mechanism. A detached head restraint cushion increases the risk of injury during a crash.

 

SERVICE ACTION

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to replace the front driver and passenger head restraints. Due to limited part supply, dealers must submit a part request, including a copy of the signed sales agreement for stock units, to the Special Service Support Center (SSSC). 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 July 25, 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, if they discontinue usage of the head restraint power adjust feature. It should be kept in the furthest rearward position while operating the vehicle.
  • 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 48121-6251.
  • 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 replacement of the front driver or passenger seat head restraint(s).

 

RENTAL VEHICLES 

Rental vehicles are not approved for this program.

 

LINCOLN PICKUP AND DELIVERY

Owners of 2017 MY and newer Lincoln vehicles have the option of requesting pickup and delivery service with a Lincoln loaner (up to 2 days), from their dealership. For details, reference EFC08749, 2021 Lincoln Pickup & Delivery Updates.

 

PARTS REQUIREMENTS

Part Number  Description Order Quantity
****-78611A08/9-**Driver and passenger side front seat head restraints. Contact the SSSC for the correct part numbers.2

 


CERTAIN 2022 MODEL YEAR LINCOLN AVIATOR VEHICLES WITH 30-WAY POWER ADJUSTABLE (PERFECT POSITION) FRONT MEMORY SEAT —  FRONT DRIVER AND PASSENGER HEAD RESTRAINT REPLACEMENT

 

SERVICE PROCEDURE

1. Before starting this recall contact the Special Service Support Center (SSSC) to request parts.

  • For customer owned vehicles submit a VIN specific part request.
  • For new in stock vehicles submit a VIN specific part request including a copy of the signed sales agreement. Part requests that do not include a signed sales agreement will not be approved.

NOTE: This procedure is to be preformed on both front seats.

2. Position the front head restraint in the full up, full outward position and position the upper seat backrest in the full outward position. See Figure 1.

NOTE: Passenger side seat shown, driver side seat similar.

 

NOTICE: The backrest panel finish can be easily marred or torn, use care when working around it.

3. Release the front head restraint retaining tabs from the front seat backrest panel. See Figure 2.

NOTE: Passenger side seat shown, driver side seat similar.

NOTE: Front seat backrest panel removed for clarity, rear retaining tabs shown, front retaining tabs similar.

 

4. Does the front head restraint effortlessly raise more than approximately 1/2″ (13 mm)?

CAUTION: Vehicles built on or before January 3, 2022 have head restraints retained with two unaccessible fasteners on the underneath side. To prevent damage while servicing these vehicles, the Workshop Manual (WSM) procedure must be followed. The seat does not require removal from the vehicle.

YES – Proceed to Step 5.

NO  –  Replace front driver and passenger side head restraints. Follow the WSM procedures in Section 501-10A.

NOTE: For this procedure it is not necessary to remove the driver and passenger seats. Insert a clean piece of cardboard, towel or similar item that will not damage the backrest or center console between the seat and the center console to protect the front seat backrest panel. See Figure 3. Recall is complete.

NOTE: Passenger side seat shown, driver side seat similar.

 

5. Carefully separate the upper portion of the front seat backrest panel, and using your fingers press the retaining clips toward each other to release the front head restraint posts. See Figure 4.

NOTE: Passenger side seat shown, driver side seat similar.

 

6. Lift and remove the front head restraint.

7. Install the new front head restraint by reversing the removal procedure.

8. Operate the new power head restraint in all directions through the full range of travel to set soft stops and avoid a premature stopping point occurrence after the vehicle is returned to the customer.

IMPORTANT NOTE: Federal law prohibits selling motor vehicle parts or components that are under safety, compliance, or emissions recall. Unless a part is requested to be returned to Ford, all parts replaced under this FSA must be scrapped in accordance with all applicable local, state and federal environmental protection and hazardous material regulations. Refer to the Parts Retention, Return, & Scrapping section of the FSA dealer bulletin for further information.

 


Date of Submission: 4/14/2022
FSA #22S23- Certain 2022 model year Lincoln Aviator vehicles Power Head Restraint Bun
Engagement

Chronology

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

Vehicle

MAKEMODELYEAR
LINCOLNAVIATOR2022

 


10 Associated Documents

Recall Acknowledgement

RCAK-22V247-5011.pdf 645.213KB

 


Defect Notice 573 Report

RCLRPT-22V247-8881.PDF 213.895KB

 


Miscellaneous Document – Chronology

RMISC-22V247-4208.pdf 11.188KB

 


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

RCMN-22V247-1627.pdf 167.894KB

 


ISSUED Interim Owner Notification Letter(Part 577)

RIONL-22V247-8282.pdf 77.728KB

 


Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – 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

RCMN-22V247-4458.pdf 1161.194KB

 


ISSUED Owner Notification Letter(Part 577) (parts available)

RCONL-22V247-7703.pdf 79.737KB

 


Recall Quarterly Report #1, 2022-3

RCLQRT-22V247-2263.PDF 211.129KB

 


ISSUED Renotification Notice

RCRN-22V247-5630.pdf 444.961KB

 


Recall Quarterly Report #2, 2022-4

RCLQRT-22V247-1435.PDF 211.229KB

 


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