2022 Lincoln Aviator

22C13 – Inspect Engine Rail Assembly – 2022 Lincoln Aviator & Ford Explorer

by
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June 24, 2022 NHTSA CAMPAIGN NUMBER: 22V454000

Engine Rails Improperly Heat-Treated/FMVSS 208

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

 

Summary

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.”

 

Remedy

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 were mailed August 22, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 22C13.

 

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

 

April 17, 2023

NEW VEHICLE DEMONSTRATION / DELIVERY HOLD
Compliance Recall 22C13 – Supplement #1
Certain 2022 Model Year Aviator and Explorer Vehicles
Inspect Engine Frame Rail Assembly

 

REASON FOR THIS SUPPLEMENT

  • Service Action: Added instructions for vehicle buyback process.
  • Pick-Up and Delivery: Section Added.
  • Alternative Transportation: Section Added.
  • Additional Repair (Labor Time and/or Parts): Note added to contact the SSSC for approval to replace the affected frame rails.
  • Claims Preparation and Submission: Pick-Up, Delivery and Sublet claiming instructions added.
  • Labor Allowances Update: The labor allowances chart has been updated to include the labor operations for engine frame rail replacement.
  • Parts Ordering Information and Parts List Update: Parts are available for open orders.
    Parts lists have been updated to include parts required for engine frame rail replacement.
  • Technical Information: Updated Technical Information.

 

AFFECTED VEHICLES

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

U.S. Population of affected vehicles is 776.

Affected vehicles are identified in OASIS and FSA VIN Lists.

 

REASON FOR THIS COMPLIANCE RECALL

Some of the affected vehicles were built with an engine frame rail that does not maintain its integrity in a crash and as a result does not meet the requirements specified by Federal Motor Vehicle Safety Standard (FMVSS) No. 208 Occupant Crash Protection and FMVSS No. 301 Fuel System Integrity. A vehicle that does not comply with FMVSS 208/301 increases the risk of injury in a crash.

 

SERVICE ACTION

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to test the hardness of both left hand (LH) and right hand (RH) engine frame rails per technical instructions. If both engine frame rails pass the initial hardness test, then this recall is complete. If an engine frame rail fails the initial hardness test, then the suspect engine frame rail must be checked again using a calibrated hardness tester. If the rail does not meet a minimum specified hardness, customers will be given the option of a replacement of the engine frame rail assembly or, because of the extensive nature of this repair, a vehicle buyback. This service must be performed on all affected vehicles at no charge to the vehicle owner.

Note: To be eligible for a vehicle buyback program, one or both engine frame rail(s) must not meet the hardness test specification per the outlined Tech Instructions. If the customer wants to pursue vehicle buyback, please provide a signed copy of the customers vehicle Bill-Of-Sale (B.O.S.) and contact the SSSC Center for next steps.

 

OWNER NOTIFICATION AND MAILING SCHEDULE

Owner letters were mailed the week of August 22, 2022. Dealers should inspect and 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 $26,315 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 compliance recall. Owners should contact their dealer for an appointment to have their vehicles remedied as soon as practicable.
  • 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 compliance 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 engine frame rail replacement.

 

RENTAL VEHICLES

If the owner’s vehicle fails the first portion of the inspection test, dealers are pre-approved for up to 2 days for a comparable rental vehicle while waiting for the handheld hardness tester. Follow Extended Service Plan (ESP) guidelines for dollar amounts. Rentals will only be reimbursed for the day(s) the vehicle is at the dealership waiting for the handheld hardness tester portion of the inspection and for part replacement (if needed). Prior approval for more than 2 rental day(s) is required from the SSSC. Contact the SSSC via the SSSC Web Contact Site for consideration and approval if appropriate.

 

PICK-UP AND DELIVERY

All customers affected by this program have the option of complimentary Vehicle Pick-up & Delivery service (at participating dealers) instead of a rental vehicle. Refer to EFC12071, 2023 Remote Experience Program, Pickup & Delivery (PDL) Offset section for additional details.

 

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 EFC09879, 2022 Lincoln Pickup & Delivery Updates. Claim any additional rental days approved by the SSSC as instructed. Claim the difference of pre-approved days, or any additional rental days approved by the SSSC as instructed.

 

ALTERNATIVE TRANSPORTATION

If a customer is unable or does not wish to rent a vehicle but still requires transportation, the rental reimbursement allowance can be used for alternative transportation. Alternative transportation is approved for $100 per day for both Ford and Lincoln customers. The dollar-per-day allowance can be cumulative across multiple rides per day (e.g. ride to work $20 and ride home $24).

  • Alternative transportation reimbursement can be claimed for both short-term and long-term scenarios.
  • Any amount over the cost-per-day limits will be the customer’s responsibility.
  • The customer will need to pay upfront and provide proof of payment to the dealer.
  • Dealers will then need to submit for reimbursement following the Rental Vehicle Reimbursement Process to refund the customer.

Examples of alternative transportation:

  • Taxi
  • Public Transportation – Subway, Train, or Bus
  • Rideshare alternatives (Uber, Lyft, etc.)

 

PARTS REQUIREMENTS

Parts are available for open orders.

Parts lists have been updated to include parts required for engine frame rail replacement.

Part Number  Description Order Quantity
Parts To Order For First Inspection Test
W505255-S450 Torque test bolt – Package contains 4 pieces

NOTE: The Ford bolt shown must be used for the inspection procedure as it has been validated for this process. Due to the nature of this procedure, a non-Ford bolt is not authorized.

1
W712961-S439 Steering shaft bolt for torque test (all except 2.3L) – Package contains 2 pieces 1
All Vehicles – Parts To Order If Replacing One Engine Front Side Member (Frame Rail) –

Left Hand (LH) Or Right Hand (RH) Only

DS7Z-19B596-A Condenser fitting O-ring seals As Required
*-6758-* Crankcase vent tube without quick connects (as needed) As Required
W712961-S439 Steering shaft bolt 1
*-19B596-* A/C compressor line O-ring seal As Required
W714660-S439 Brake caliper anchor plate bolts – Package contains 4 pieces 1
LB5Z-3B477-A Wheel hub nut 2
W520517-S440 Lower strut to wheel knuckle nuts – Package contains 4 pieces 1
W715932-S439 Lower strut to wheel knuckle bolts – Package contains 4 pieces 1
W715618-S437eBay Torque converter nuts 6 (4 for 3.3L) – Package contains 4 pieces As Required
W719506-S440 Sway bar link to strut nut – Package contains 4 pieces 1
W719413-S439eBay Front and Middle subframe bolts – Package contains 4 pieces 1
W716979-S439eBay Rear subframe bolts – Package contains 4 pieces 1
W708777-S900C Blind Rivet – Package contains 100 pieces 1
W702512-S900C Blind Rivet – Package contains 100 pieces 1

 

Part Number  Description Order Quantity
All Vehicles – Parts To Order – If Replacing – Both – Engine Front Side Members (Frame Rails)
DS7Z-19B596-A Condenser fitting O-ring seals As Required
*-6758-* Crankcase vent tube without quick connects (as needed) As Required
W712961-S439 Steering shaft bolt 1
*-19B596-* A/C compressor line O-ring seal As Required
W714660-S439 Brake caliper anchor plate bolts – Package contains 4 pieces 1
LB5Z-3B477-A Wheel hub nut 2
W520517-S440 Lower strut to wheel knuckle nuts – Package contains 4 pieces 1
W715932-S439 Lower strut to wheel knuckle bolts – Package contains 4 pieces 1
W715618-S437eBay Torque converter nuts 6 (4 for 3.3L) – Package contains 4 pieces As Required
W719506-S440 Sway bar link to strut nut – Package contains 4 pieces 1
W719413-S439eBay Front and Middle subframe bolts – Package contains 4 pieces 1
W716979-S439eBay Rear subframe bolts – Package contains 4 pieces 1
W708777-S900C Blind Rivet – Package contains 100 pieces 1
W702512-S900C Blind Rivet – Package contains 100 pieces 1
Include Engine Front Side Member(s) – (Frame Rail(s) –

That Failed Handheld Hardness Test — Left/Right Hand Only Or Both

*-7810463-* Engine Front Side Member (Frame Rail) Assembly – Floor Side – LH 2.3L, 3.0L, 3.3L VIN Specific
*-7810463-* Engine Front Side Member (Frame Rail) Assembly – Floor Side – LH 3.3L Hybrid and 3.0L PHEV VIN Specific
*-7810462-* Engine Front Side Member (Frame Rail) Assembly – Floor Side – RH 2.3L, 3.0L, 3.3L VIN Specific
*-7810462-* Engine Front Side Member (Frame Rail) Assembly – Floor Side – RH 3.3L Hybrid and 3.0L PHEV VIN Specific

 

Part Number  Description Order Quantity
VIN Specific – Include With Required Parts For: 2WD And/Or AWD/4WD Wheel Drive Units
*-4B422-* AWD RH halfshaft circlip 1
*-4B422-* AWD LH halfshaft circlip 1
*-00815-* AWD LH halfshaft O-ring 1
CN1Z-7H424-B Front axle seal 1
*-9F598-* Front axle sealing ring 1
W716375-S900eBay Transfer case mounting bolts – Package contains 5 pieces 2
*-4421-* Front driveshaft slip yoke boot 1
*-3B478-* Front driveshaft slip yoke clamp 1
*-7H424-* RH front halfshaft seal (only RH needed) 1
*-4B422-* Front axle pinion stem circlip 1
*-00815-* Front axle pinion stem O-ring 1
W719431-S439eBay 4WD transmission support bolts – Package contains 4 pieces 1
W520214-S440 4WD transmission support nut – Package contains 2 pieces 1
W719511-S439eBay If RWD Only driveshaft flex coupling to transmission flange bolts – Package contains 4 pieces 1
W719431-S439eBay If RWD Only transmission support bolts – Package contains 4 pieces 1
W520214-S440 If RWD transmission support nut – Package contains 2 pieces 1

 

Part Number  Description Order Quantity
Include With 2.3L Engine
L1MZ-6L612-AeBay 2.3L Catalytic converter to turbocharger gasket 1
W719699-S442eBay 2.3L Catalytic converter to turbocharger nuts 3
W720485-S439 2.3L LH motor mount bolts HB1 – Package contains 4 pieces 1
W719326-S439 2.3L LH motor mount bolts HB2 – Package contains 4 pieces 1
W720485-S439 2.3L RH motor mount bolts HB1 – Package contains 4 pieces 1
*-4382-* 2.3L RH motor mount bolts HB3 2
L1MZ-6L612-AeBay 2.3L Turbocharger to catalytic converter gasket 1
W719699-S442eBay 2.3L Turbocharger to catalytic converter nuts 3
W721083-S439eBay 2.3L Transmission support insulator bolts – Package contains 4 pieces 1
W715131-S442eBay Park manual release cable bolts – hybrid with rotary or button gear selector – Package contains 4 pieces 1
Include With 3.0L And 3.0L PHEV
*-6N652-* 3.0L Turbocharger coolant supply tube O-ring seal 2
L1MZ-6L612-BeBay 3.0L Turbocharger gasket to catalytic converter 2
W716117-S437 3.0L Turbocharger mounting bolt to exhaust manifold 2
*-6N652-* 3.0L Turbocharger oil return tube O-ring seal 2
*-6N652-* 3.0L Turbocharger oil return tube to engine block gasket 2
*-6C683-* 3.0L Turbocharger oil supply tube filter 2
*-6N652-* 3.0L Turbocharger oil supply tube O-ring seal lower 2
*-6N652-* 3.0L Turbocharger oil supply tube O-ring seal upper 2
W717521-S440 3.0L LH & RH engine mount nut 2
L1MZ-6L612-BeBay 3.0L LH & RH catalytic converter gasket 2
W719699-S442eBay 3.0L LH & RH catalytic converter nuts – Package contains 4 pieces 1
*-6A666-* 3.0L PCV non-hybrid valve 1

 

Part Number  Description Order Quantity
W715131-S442eBay Park manual release cable bolts – hybrid with rotary or button gear selector – Package contains 4 pieces 1
Include With 3.3L Duratec And 3.3L Hybrid
W721083-S439eBay 3.3L Transmission support insulator bolts – Package contains 4 pieces 1
W717521-S440 3.3L LH & RH engine mount nuts 2
W714265-S442eBay 3.3L LH & RH Catalytic converter to exhaust manifold nuts – Package contains 4 pieces 1
JL3Z-9E464-F 3.3L EGR tube gasket 1
9L8Z-9J469-A 3.3L EGR tube O-ring seal 1
JL3Z-9E464-F 3.3L EGR valve inlet tube gasket 1
W710726-S442eBay 3.3L Police Park manual release cable bolts – Package contains 4 pieces 1
7T4Z-8590-A 3.3L Thermostat housing O-ring seal 1
W715131-S442eBay Park manual release cable bolts – hybrid with rotary or button gear selector – Package contains 4 pieces 1

 

Part Number  Description Order Quantity
Include Following Parts Needed For Engine Front Side Member – (Frame Rails) Replacement
Obtain Locally Metal Bonding Adhesive (Or Equivalent)

TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

 As Required
Obtain Locally Seam Sealer (Or Equivalent)

TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

 As Required
Obtain Locally Flexible Foam Repair (Or Equivalent) 3M™ 08463, LORD Fusor® 121 As Required
PM-4-A Motorcraft® Metal Brake Parts Cleaner PM-4-A, PM-4-B, APM-4-C 2
PM-20 Motorcraft® DOT 4 LV High Performance Motor Vehicle Brake Fluid 2
XG-3-A Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound XG-3-A 2
XG-1-E1 Motorcraft® Premium Long-Life Grease XG-1-E1 2
Obtain Locally ValuGard™ Premium Undercoating (Or Equivalent) VG101, VG101A As Required
Obtain Locally ValuGard™ Rust Inhibitor (Or Equivalent) VG104, VG104A As Required
ZC-31-B Motorcraft® Metal Surface Prep Wipes ZC-31-B 2
VC-13DL-G Motorcraft® Yellow Prediluted Antifreeze/Coolant As Required

 

CERTAIN 2022 MODEL YEAR AVIATOR AND EXPLORER VEHICLES — INSPECT ENGINE RAIL ASSEMBLY

 

SERVICE PROCEDURE

Table Of Contents

Vehicles Equipped with a 2.3L Engine – 1
Bolt Torque Test – 1
Hardness Test – 3
All Other Vehicles – 5
Bolt Torque Test – 5
Hardness Test – 9

 

Vehicles Equipped with a 2.3L Engine

Bolt Torque Test

NOTE: The Ford bolt shown must be used for the inspection procedure as it has been validated for this process.  Due to the nature of this procedure, a non-Ford bolt is not authorized.

1.   Open the LH (left-hand) front door.

2.   Fully pull the hood release lever and let it completely retract. See Figure 1.

NOTE:  This action releases the hood latch.

 

3.   Fully pull the hood release lever for a second time.

NOTE:  This action fully releases the hood.

4. Open the hood.

NOTE:  There is no secondary latch under the hood.

5. In the engine compartment, locate the existing hole on the inboard side of the LH frame rail. See Figure 2, showing the hole from underneath the vehicle for better clarity.

 

6. Hand start the bolt part number W505255-S450 into the existing hole. See Figure 3.

 

7. Using a digital torque wrench, tighten and torque the bolt to 5.9 lb. ft (8 Nm).

8. Did the bolt successfully torque to 5.9 lb. ft (8 Nm)?

Yes – Passes inspection, proceed to step 9.

No – Fails inspection. Remove the bolt from the hole, then proceed to step 9.

9. With the vehicle in NEUTRAL, position it on a hoist. Follow Workshop Manual (WSM) procedures in Section 100-02.

10. Locate the existing hole on the bottom of the RH (right-hand) frame rail, just above the CV axle. See Figure 4.

 

11. Repeat steps 6-7 for the RH frame rail.

12. Did the bolt successfully torque to 5.9 lb. ft (8 Nm)?

Yes – Passes inspection, proceed to step 13.

No – Fails inspection. Remove the bolt from the hole, then proceed to step 13.

13. Did either one or both of the bolts fail to successfully torque to 5.9 lb. ft (8 Nm)?

Yes – Contact the SSSC to request a Webster Hardness Tester. Once a hardness tester has been received, proceed to step 14.

No – Proceed to step 19. No further repairs are needed. Compliance Recall 22C13 is complete.

 

Hardness Test

NOTE:  Ensure hardness tester is properly calibrated before performing hardness test.

NOTE:  Perform steps 14 through 18 ONLY on the side(s) where the bolt torque test failed.

14. Locate the SORB block (located directly behind the front bumper beam.) See Figure 5.

NOTE:  Remove any splash shield screws and push pins and position aside the splash shield as required for access.

 

15. Place the hardness tester on the SORB block vertical fin and actuate the handle with the same force that was used on the gauge bar. See Figure 6.

 

16. What is the hardness tester gauge reading?

Less than 12 – Fails inspection. Proceed to step 17.

12 or greater – Passes inspection. Return the hardness tester, then proceed to step 19.

17. Contact SSSC for further approval to replace the front side member. Once approved, return the hardness tester and order the required parts through normal part ordering process, refer to dealer bulletin. Proceed to step 18.

18. Replace the front side member(s) that failed the hardness test. Refer to WSM Section

19. Lower the hood and allow it to drop under its own weight for the last 10–14 in (25–35 cm).

WARNING:  Make sure that you fully latch the hood before driving. Failure to follow this instruction could result in personal injury or death.

 

All Other Vehicles

Bolt Torque Test

NOTE: The Ford bolt shown must be used for the inspection procedure as it has been validated for this process.  Due to the nature of this procedure, a non-Ford bolt is not authorized.

20. Open the LH (left-hand) front door.

21. Fully pull the hood release lever and let it completely retract. See Figure 7.

NOTE:  This action releases the hood latch.

 

22.  Fully pull the hood release lever for a second time.

NOTE:  This action fully releases the hood.

23. Open the hood.

NOTE:  There is no secondary latch under the hood.

24. Using a holding device, hold the steering wheel. See Figure 8.

 

25. Remove and discard the steering shaft bolt, then separate and position aside the steering shaft. See Figure 9.

 

26. Remove the push pin retainer and position aside the harness. See Figure 10.

NOTE:  This step only applies to hybrid electric vehicles.

 

27. Locate the existing hole on the inboard side of the LH frame rail. See Figure 11.

 

28. Hand start the bolt part number W505255-S450 into the existing hole. See Figure 12.

 

29. Using a digital torque wrench, tighten and torque the bolt to 5.9 lb. ft (8 Nm).

30. Did the bolt successfully torque to 5.9 lb. ft (8 Nm)?

Yes – Passes inspection, proceed to step 31.

No – Fails inspection. Remove the bolt from the hole, then proceed to step 31.

31. Position the harness back into place and reinstall the push pin retainer

NOTE:  This step only applies to hybrid electric vehicles.

32. Position the steering shaft back into place and install the new steering shaft bolt.

  • Torque: 22 lb.ft (30 Nm).

33. With the vehicle in NEUTRAL, position it on a hoist. Follow Workshop Manual (WSM) procedures in Section 100-02.

34. Locate the existing hole on the bottom of the RH (right-hand) frame rail, just above the CV axle. See Figure 13.

 

35. Repeat steps 28-29 for the RH frame rail.

36. Did the bolt successfully torque to 5.9 lb. ft (8 Nm)?

Yes – Passes inspection, proceed to step 37.

No – Fails inspection. Remove the bolt from the hole, then proceed to step 37.

37. Did either one or both of the bolts fail to successfully torque to 5.9 lb. ft (8 Nm)?

Yes – Contact the SSSC to request a Webster Hardness Tester. Once a hardness tester has been received, proceed to step 38.

No – Proceed to step 43. No further repairs are needed. Compliance Recall 22C13 is complete.

 

Hardness Test

NOTE:  Ensure hardness tester is properly calibrated before performing hardness test.

NOTE:  Perform steps 38 through 42 ONLY on the side(s) where the bolt torque test failed.

38. Locate the SORB block (located directly behind the front bumper beam.) See Figure 14.

NOTE:  Remove any splash shield screws and push pins and position aside the splash shield as required for access.

 

39. Place the hardness tester on the SORB block vertical fin and actuate the handle with the same force that was used on the gauge bar. See Figure 15.

 

40. What is the hardness tester gauge reading?

Less than 12 – Fails inspection. Proceed to step 41.

12 or greater – Passes inspection. Return the hardness tester, then proceed to step 43.

41. Contact SSSC for further approval to replace the front side member. Once approved, return the hardness tester and order the required parts through normal part ordering process, refer to dealer bulletin. Proceed to step 42.

42. Replace the front side member(s) that failed the hardness test. Refer to WSM Section

43. Lower the hood and allow it to drop under its own weight for the last 10–14 in (25–35 cm).

WARNING:  Make sure that you fully latch the hood before driving. Failure to follow this instruction could result in personal injury or death.

 

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.

There have been no field reports related to engine rail assemblies on 2022 Explorer or Aviator vehicles.

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.

August 2, 2022 Update: Ford revised the affected population and the owner notification dates for parts availability.

 

2 Affected Products

Vehicles

MAKE MODEL YEAR
FORD EXPLORER 2022
LINCOLN AVIATOR 2022

 

14 Associated Documents

Recall Acknowledgement

RCAK-22V454-7855.pdf 645.926KB

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Miscellaneous Document – Chronology of Defect / Noncompliance Determination

RMISC-22V454-5553.pdf 78.244KB

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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 Assembly

RCMN-22V454-8850.pdf 145.331KB

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Noncompliance Notice 573 Report

RCLRPT-22V454-3437.PDF 217.023KB

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Miscellaneous Document – Chronology of Defect

RMISC-22V454-1288.pdf 97.276KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V454-4473.pdf 164.367KB

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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Compliance Recall 22C13 Certain 2022 Model Year Aviator and Explorer Vehicles Inspect Engine Frame Rail Assembly

RCMN-22V454-1093.pdf 2860.887KB

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Recall 573 Report – 6/24/22

RCLRPT-22V454-8206.PDF 217.023KB

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Recall 573 Report 8/2/22

RCLRPT-22V454-3861.PDF 217.342KB

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Recall Quarterly Report #1, 2022-3

RCLQRT-22V454-4362.PDF 211.138KB

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ISSUED Renotification Notice

RCRN-22V454-7429.pdf 400.039KB

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Recall Quarterly Report #2, 2022-4

RCLQRT-22V454-3216.PDF 211.24KB

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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Compliance Recall 22C13 – Supplement #1 Certain 2022 Model Year Aviator and Explorer Vehicles Inspect Engine Frame Rail Assembly

RCMN-22V454-0318.pdf 1960.918KB

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Recall Quarterly Report #3, 2023-1

RCLQRT-22V454-2971.PDF 211.324KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V454&docType=RCL

 

 

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CRC GDI IVD Intake Valve & Turbo Cleaner
CRC GDI IVD Intake Valve & Turbo Cleaner
  • Proven to clean intake valves on GDI engines and turbo systems
  • Easily installed through the air intake system
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  • Proven to remove up to 46% of GDI Intake Valve deposits in 1 hour
  • 150X more concentrated than fuel additives
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Gumout 540028 Foaming Intake Valve & Turbo Cleaner, 11 oz
Gumout 540028 Foaming Intake Valve & Turbo Cleaner, 11 oz
  • Deep Cleans GDI (Gasoline Direct Injection) / PFI (Port Fuel Injection) Intake Valves, As Well As, The Throttle Body, Intake Ports, Fuel Injectors and Combustion Chambers
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CRC Industries 05319 Intake Valve Cleaner 11 Ounce Aerosol Can (4)
CRC Industries 05319 Intake Valve Cleaner 11 Ounce Aerosol Can (4)
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Bestseller No. 4
CRC 05319 Intake Valve Cleaner 11 Oz
CRC 05319 Intake Valve Cleaner 11 Oz
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FIRSTINFO A1601 4 In 1 Intake Valve Cleaner Combustion Chamber Cleaner/Vacuum System Cleaner/Vacuum System Pressure Tester Kit
FIRSTINFO A1601 4 In 1 Intake Valve Cleaner Combustion Chamber Cleaner/Vacuum System Cleaner/Vacuum System Pressure Tester Kit
  • 【 Maintain Engine Performance 】 Perfect for air intake system, combustion chamber, EGR Valves, intake valves and oxygen sensors. Easy operation for making the fuel injectors spray smoothly and properly.
  • 【 Easy to Use 】 Simply fill with air intake cleaning liquids and connect the vacuum hose of vehicle vacuum system. Reduce carbon deposits easily.
  • 【 Multiple Applications 】 Use to clean the intake valve, combustion chamber, vacuum system and test the vacuum system pressure. Provides more thorough cleaning than other methods. Effectively remove engine carbon deposits and increase gas mileage performance.
  • 【 Equipped with Negative Pressure Gauge 】 The liquid-filled gauge for accurate vacuum pressure reading and monitoring chemical flow.
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MP Care GDI Induction Cleaner, Intake Manifold, Air System, EGR, Valves, Turbo Cleaner
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  • GDI Induction cleaner Air system
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Berryman Products 2611 Intake Valve and Combustion Chamber Cleaner, 16-Ounce Aerosol
Berryman Products 2611 Intake Valve and Combustion Chamber Cleaner, 16-Ounce Aerosol
  • Formulated for Use In All Fuel-Injected Gasoline Engines, Including GDI
  • Contains Polyetheramine (“PEA”) to Dissolve Carbon Buildup in Combustion Chambers
  • Cleans ALL Types of Intake Valves, Including Those Found in PFI, TBI, and GDI Engines
  • Safe On Catalytic Converters and Oxygen Sensors
  • Not For Use In Diesel Engines
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CRC Industries, Inc. Intake Valve Cleaner (11 oz) Bundled with Latex Gloves (3 Items)
CRC Industries, Inc. Intake Valve Cleaner (11 oz) Bundled with Latex Gloves (3 Items)
  • Bundle comes with:
  • 2 - CRC 05319 Industries Intake Valve Cleaner (11 oz)
  • 2 Pairs (4 Gloves) of CLC2316L Latex Gloves - Large
  • Fit type: Universal
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New Turbo II Model 46 Pre-Cleaner with 6' Inlet/Air Intake & 350 to 700 CFM
New Turbo II Model 46 Pre-Cleaner with 6" Inlet/Air Intake & 350 to 700 CFM
  • One New Replacement Turbo Ii Pre-Cleaner.
  • Fits Model 46
  • Inlet Size: 6" And Operating Range: 350-700 Cfm
  • Powered by Intake Air, Installs in Seconds, Saves Money, Extends Air Filter Life, Saves Fuel
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Smilyeez BG GDI Air Intake & Valve Cleaner PN 260 With Pocket Screwdriver (1)
Smilyeez BG GDI Air Intake & Valve Cleaner PN 260 With Pocket Screwdriver (1)
  • Restores MPG
  • Restores engine performance
  • Restores power
  • Reduces harmful emissions
  • Requires pressurized tool
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Last update on 2024-03-23 / Affiliate links / Images from Amazon Product Advertising API

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