June 10, 2022 NHTSA CAMPAIGN NUMBER: 22V411000
A malfunctioning child safety lock increases the risk of injury to a child occupant.
NHTSA Campaign Number: 22V411
Manufacturer Ford Motor Company
Potential Number of Units Affected 53,103
Ford Motor Company (Ford) is recalling certain four-door 2021-2022 Bronco vehicles. The passenger-side rear door may be opened from inside of the vehicle when the child safety lock is in the “ON” position.
Dealers will inspect the passenger-side child safety locks door child safety lock and latch, and replace them, if necessary, free of charge. Owner notification letters are expected to be mailed July 25, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 22S44.
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|
|Bronco||2021||Michigan Assembly||September 23, 2020 through December 22,
|Bronco||2022||Michigan Assembly||August 31, 2021 through April 11, 2022|
REASON FOR THIS SAFETY RECALL
In some of the affected vehicles, the rear door may be opened from the inside of the vehicle, despite the indication of the child safety lock in the “ON” position, increasing the risk of injury to an unrestrained second-row occupant.
Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to inspect and if necessary, replace the rear door latch. 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 5, 2022. Dealers should inspect and if necessary, repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.
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.
- Ford has not issued instructions to stop selling/delivering or driving used vehicles under this safety 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.
- 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.
- 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 the replacement of the rear door latch due to a defective child safety lock.
Rental vehicles are not approved for this program.
With proper dealer parts ordering and service appointment scheduling, rental vehicles should not be required. However, if you have a unique owner circumstance that may require a rental vehicle, please contact the SSSC via the SSSC Web Contact Site.
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.
- 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.
|Part Number||Description||Order Quantity|
|M2DZ-78264A26-C||RH rear door latch||1|
|M2DZ-78264A27-D||LH rear door latch||1|
|Part Number||Description||Order Quantity|
|Consumables Required for latch replacement|
|Obtain Locally||200mm x 2.5mm Zip Tie (one for each latch)||Claim as MISC OTHER|
CERTAIN 2021-2022 MODEL YEAR BRONCO 4-DOOR — CHILD LOCK NOT FUNCTIONING
1. With door open, engage the child lock on both rear left-hand (LH) and rear right-hand (RH) doors. See Figure 1.
NOTE: LH side shown, RH side similar.
2. Roll down both rear LH and rear RH windows before getting into vehicle.
3. Close and lock the doors.
4. While sitting in the rear seat of the vehicle, pull the interior door handle fully, 5 times in succession. See Figure 2. Repeat with opposite door handle. Did either door open during this procedure?
Yes – Continue to Step 5.
No – Recall complete.
5. Exit the vehicle using the exterior door handle, roll-up the window and disengage the child lock.
NOTE: The window procedure below must be done before beginning the latch replacement procedure.
6. With the window rolled up and the door open, apply painters tape or equivalent to window glass, lining it up with the window seal. This will aid in re-installation of the glass. See Figure 3.
NOTE: If latch(es) are equipped with a zip tie, remove from assembly. Zip tie is to be replaced during reassembly. See Figure 4.
8. Place glass back into door making sure to line up the tape with the window seal.
NOTE: When reinstalling the window glass, align the tape with the window seal to ensure proper fit before tightening the fasteners. Door window glass adjustment is not necessary when following this procedure.
22S44 – CERTAIN 2021-2022 MODEL YEAR BRONCO VEHICLES WITH FOUR DOORS –CHILD SAFETY LOCK
Date of Submission: June 10, 2022
Chronology of Defect / Noncompliance Determination
Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision.
March 2022: On March 17, 2022, Ford’s Critical Concern Review Group (CCRG) opened an investigation into reports from Michigan Assembly Plant of non-functional child safety locks on right-hand rear doors of 2021-2022 model year (MY) Bronco four-door vehicles.
The CCRG investigation found that the first non-functional child safety lock was identified during a quality audit at Michigan Assembly Plant on March 2, 2022. In that audit, the right-hand rear door of a 2022 MY Bronco vehicle was opened using the inside door handle with the child safety lock in the “ON” position. Initial investigation did not identify any contributing factors on this vehicle. All vehicles at the plant were quarantined and inspected for this condition, with 1.5% exhibiting the condition on rear right-hand latches and no reports on rear left-hand latches.
Enhanced inspection protocols were also implemented at the rear door latch module supplier because the rear door latch module includes the child safety lock mechanism. The supplier inspection found that the child safety locks were functional prior to installation in the sheet metal doors.
Subsequent investigation and vehicle audits were undertaken to identify potential system interaction contributors that could lead to a door being opened from the inside with the child safety lock in the “ON” position.
April – May 2022: Further CCRG investigation identified that the right-hand rear door latch attachment hole locations on the door sheet metal were out of design specification due to a manufacturing tolerance expansion. The resulting variation in sheet metal attachment hole locations could cause deformation of the latch housing and frame plate when attached to the door, potentially affecting proper function of the child safety lock. Child safety lock functionality was found to be restored with subsequent installation of a new latch module due to slight changes in the sheet metal latch attachment holes caused by installation of the original latch module.
Left-hand rear door sheet metal attachment hole locations were also found to be out of design specification, but at a level that did not affect child safety lock functionality on left-hand rear doors. There are no reports from the field of left rear child lock malfunction.
Door latch attachment hole locations on the rear door sheet metal assemblies were returned to design specification positions at Ford’s stamping plant, without the manufacturing tolerance expansion, which corrected the concern. Review of sheet metal stamping plant records did not identify any changes or factors believed to contribute to out-of-specification sheet metal attachment hole location dating from Job #1 through the date of the vehicle stop-ship. Ford is not aware of any warranty or field reports related to this concern.
On June 3, 2022, Ford’s Field Review Committee (FRC) reviewed the concern and approved a field action for the right rear child safety lock on vehicles produced between September 23, Page 1 of 2
2020, and April 11, 2022. Out of an abundance of caution, the FRC approval also included inspection and replacement (if necessary) of the left rear child safety lock.
Ford is not aware of any reports of accident or injury related to this condition.
2 Affected Products
4 Associated Documents
Miscellaneous Document – Chronology
Defect Notice 573 Report
Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Safety Recall 22S44 Certain 2021-2022 Model Year Bronco 4-door Rear Door Child Safety Lock Inspection
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