Control Arm Ball Joint Fastener Problem Affects Certain Ford Vehicles

Ford has identifies two critical safety issues affecting certain 2024-2025 model year vehicles, including the Bronco, Ranger, and F-150 Lightning BEV. The problem lies with the front upper control arm ball joint fastener, which may be missing or improperly tightened, potentially leading to a detachment of the front upper control arm from the knuckle assembly.

For the Ford F-150 Lightning BEV vehicle, the issue was first reported on March 6, 2025, when a customer filed a complaint about their 2024 F-150 BEV vehicle experiencing a right front wheel failure at just 634 miles. An investigation revealed that the right front upper control arm nut was missing, causing the control arm to detach from the knuckle assembly.

The root cause of the problem is attributed to variations in the alignment or orientation between the fastening tool and the fastener, which may have induced lateral forces on the tool, preventing it from properly seating on the fastener. As a result, the nut on the upper control arm ball joint may not have achieved the correct torque, leading to a potential separation of the front upper control arm from the knuckle assembly.

If the ball joint nut becomes loose, drivers may notice a clunk or rattle noise during suspension jounce and rebound. However, in severe cases, the separation of the front upper control arm from the knuckle assembly can result in partial loss of directional control without warning, increasing the risk of a crash.

The exact timeline for the discovery and reporting of this issue on the 2024-2025 Bronco and Ranger vehicles is not available. However, it is essential for owners of affected vehicles to take immediate action and schedule an appointment with their local Ford dealer to have their vehicle inspected and repaired.

To address this issue, Ford dealers will inspect and tighten or replace the ball joint fastener as necessary. Owner notification letters were mailed on May 23, 2025. The recall numbers for this issue are 25S45 (Ford's number) and 25V-310 (NHTSA campaign number) for the Bronco and Ranger vehicles, and 25V-341 for the 2024-2025 F-150 Lightning BEV vehicles.

It is crucial for owners of affected vehicles to take prompt action and have their vehicle repaired to ensure a safe driving experience. If you receive a notice for your 2024-2025 Bronco, Ranger, or F-150 Lightning BEV vehicle, please contact your local Ford dealer to schedule an appointment as soon as possible.