Ford Axle Recalls on 2023 F-150, Expedition, Lincoln Navigator

Ford Motor Company is recalling a small number of 2023 F-150, Expedition, and Lincoln Navigator vehicles. The front axle pinion may not have been heat-treated, which can cause it to fracture. Mailing of owner notification letters is expected to begin March 20, 2023 and is expected to be completed by March 24, 2023, according to the required filing with the National Highway Traffic Safety Administration just made public.

The driver may hear a loud noise when the pinion breaks or as the drive shaft and flange hit the frame cross member and stability bar after pinion fracture. The failure mode could occur at any time in 4×4 application but is expected to occur primarily while in reverse as the pinion is subject to higher loads.

A Ford investigation discovered that the fractured pinions did not go through the required heat treatment or annealing process at Ford’s axle manufacturing plant to reduce hardness and brittleness of the pinion stem threads. In the filing Ford said, “a team was immediately dispatched to conduct eddy current hardness checks of all available stock at affected assembly plants.

“Testing of axle assemblies determined this condition is limited to pinions in 3.73:1 gear ratio axles. The CCRG investigative team reviewed plant process records to determine a build population of suspect dates to derive the population of axles with pinions that may have bypassed the heat treat process. As of February 13, 2023, Ford is not aware of any warranty, field reports or customer complaints related to this subject.”

Dealers will replace the front axle pinion gear set. If there is a broken front axle pinion, the entire axle assembly will be replaced. Repairs will be performed free of charge. Owner notification letters are expected to be mailed April 10, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 23S07. 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. about 23V128.