Front Upper Control Arm Ball Joint Problem Affects F-150 Lightning BEVs

On 2024-12-31 13:10:30

Ford Motor Company (Ford) has identified an issue affecting certain 2023-2024 F-150 Lightning BEV vehicles. This critical safety issue affects the front upper control arm ball joint nut. An improperly tightened nuts can cause the front upper control arm to detach from the knuckle assembly, posing significant safety risks.

 

Chronology of Events

September – November 2024

  • Incident Report : Ford received a Global Common Quality Indicator System (GCQIS) incident report regarding a missing left front upper control arm ball joint nut on a 2024 F-150 BEV vehicle. The customer reported experiencing intermittent vibration while driving at highway speed, which eventually caused the vehicle to make an uncommanded left turn into a side rail.

  • Dealer Inspection : Upon inspection by a dealer technician, it was discovered that the upper control arm nut was missing, and the joint had separated from the knuckle.

Ford's Investigation

  • Critical Concern Review Group (CCRG) : The CCRG opened an investigation into this issue. They reviewed assembly plant retorquing station data where 100% torque inspection was in place.

  • Data Analysis : Based on the review, CCRG determined that certain vehicles built between November 6, 2023, and February 12, 2024, may have failed to achieve the required torque due to variations in alignment or orientation between the DC nutrunner tool and the nut securing the upper control arm to the knuckle ball joint.

  • Suspect Vehicle Population : The suspect vehicles, including the one that experienced the accident, were built within this date range.

Incident Reports

  • Field Reports and Warranty Claims : As of November 14, 2024, Ford is aware of two field reports and one warranty claim representing two incidents related to this concern. These reports were received from September 12, 2024, through October 23, 2024.

Field Action Approval

  • Field Review Committee : On December 13, 2024, Ford's Field Review Committee reviewed the concern and approved a field action to address this issue.

Problem Details:  Cause of the Issue

The nut on the upper control arm ball joint may not have achieved the correct torque due to variations in alignment or orientation between the fastening tool and the fastener. This misalignment can induce lateral forces on the tool, preventing it from properly seating on the fastener. An improperly torqued nut can result in separation of the front upper control arm from the knuckle assembly.

 

Symptoms

If the ball joint nut is loose or missing, drivers may experience:

  • Vehicle Vibration : Intermittent vibrations while driving.

  • Noise : A clunking or rattling sound from the suspension.

 

Owner Notification

  • Notification Letters : Owner notification letters are expected to be mailed on February 3, 2025. These letters will provide detailed instructions on how to proceed with the recall process.

Dealers will:

  • Inspect the upper control arm ball joint nut.

  • Replace the nut and/or knuckle assembly as necessary to ensure proper torque is achieved.

Recall Information

  • Ford's Number : 24S76

  • NHTSA Campaign Number : 24V-949