June 24, 2022 NHTSA CAMPAIGN NUMBER: 22V454000
Improperly heat-treated engine rails may reduce the vehicle’s structural protection in a crash, increasing the risk of injury. In addition, an engine rail may detach and contact the road while driving, increasing the risk of a crash.
NHTSA Campaign Number: 22V454
Manufacturer Ford Motor Company
Components STRUCTURE, ENGINE
Potential Number of Units Affected 1,000
Ford Motor Company (Ford) is recalling certain 2022 Lincoln Aviator and Ford Explorer vehicles. The engine rails may have been improperly heat-treated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard numbers 208, “Occupant Crash Protection” and 301, “Fuel System Integrity.”
Dealers will perform an engine rail strength test and replace the rails as necessary, free of charge. If the engine rails require replacement, owners will have the option for a vehicle replacement or buyback. Owner notification letters are expected to be mailed August 1, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 22C13.
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||April 4, 2022 through May 2, 2022|
|Chicago SHO Center||April 5, 2022 through May 3, 2022|
|Explorer||2022||Chicago||April 4, 2022 through May 2, 2022|
|Chicago SHO Center||April 4, 2022 through May 4, 2022|
REASON FOR THIS COMPLIANCE RECALL
Some of the affected vehicles were built with an engine rail that may not maintain its integrity in a crash and as a result may not conform to the requirements specified by Federal Motor Vehicle Safety Standard (FMVSS) No. 208 Occupant Crash Protection and 301 Fuel System Integrity. Noncompliance with FMVSS 208/301 increases the risk of injury in a crash.
DO NOT DEMONSTRATE OR DELIVER any new in-stock vehicles involved in this compliance recall. A complete Dealer Bulletin will be provided to dealers during the week of July 25, 2022, when it is anticipated that parts ordering information and repair instructions will be available to support this compliance 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 affected vehicles will not be notified until after dealers have received service repair and parts ordering information. It is anticipated that customer notification will begin on or before August 1, 2022.
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.
Ford Recall 22C13
Chronology of Defect / Noncompliance Determination
Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision.
On April 20, 2022, Ford Chicago Assembly Plant (CAP) began to experience an intermittent bolt strip-out condition when securing the front subframe to the front apron assembly (left-hand and right-hand). CAP notified the Tier 1 apron assembly supplier Autokiniton Global Group (AGG) and Ford Supplier Technical Assistance (STA) for help defining root cause. Sub-tier supplier analysis of the engine rail sub-assemblies concluded that the mechanical properties did not meet the design intent yield strength requirement of >=260 MPa (Actual is 58 MPa). Sub-tier supplier records indicate 656 engine rail sub-assemblies were sent out for an unapproved repair procedure (thermal e-coat stripping) which annealed the material, degrading the mechanical properties. 367 of these 656 suspect rails were used to produce apron assemblies at the Tier 1 supplier AGG and 137 suspect aprons were shipped to CAP as early as April 4, 2022. CAP issued a Stop Ship on April 28, 2022. CAP began inspecting over 5000 vehicles in their yard for engine rail hardness.
On May 10, 2022, STA introduced this concern into the Ford Critical Concern Review Group (CCRG) meeting and the CCRG opened a formal investigation into this matter. CAP continued to inspect vehicles in their yard for engine rail hardness. The yard inspection identified 60 “out-of-spec” engine rails, leaving 77 suspect engine rails unaccounted for. CAP discovered that an unknown quantity of suspect engine rails may have scrapped by the CAP Body Shop without documentation and these parts were not available for inspection.
As of June 13, 2022, 77 suspect engine rails had not been found during the vehicle inspection and may have been built into vehicles that were shipped to dealers. Investigation into the affected vehicle population led Engineering to conduct a statistical analysis on the CAP torque data for all bolts attached to the engine rail. Analysis of three engine rail ground strap bolts was used to identify vehicles which may have been built with these 77 suspect engine rails.
CAP build clean date is May 4, 2022.
On June 17, 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
4 Associated Documents
Miscellaneous Document – Chronology of Defect / Noncompliance Determination
Manufacturer Notices(to Dealers,etc) – Advance Notice re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice – Compliance Recall 22C13 Certain 2022 Model Year Aviator and Explorer Vehicles Inspect Engine Rail AssemblyRCMN-22V454-8850
Noncompliance Notice 573 ReportRCLRPT-22V454-3437
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