Ford Motor Company is recalling more than 185,000 2021-2022 F-150 pickups. In a required filing with the National Highway Traffic Safety Administration, Ford said that underbody heat and noise insulators may loosen and contact the aluminum driveshaft, which could damage the driveshaft and cause it to fracture. A fractured driveshaft may result in loss of motive power while driving, unintended vehicle movement while the vehicle is in park, if the parking brake is not applied, and may result in secondary damage to surrounding vehicles.
Affected vehicles are F-150 4×4 145” wheelbase Crew Cab configurations with 302A and above equipment group and sound insulation package that are equipped with an aluminum driveshaft. Ford said it is not aware of any reports of accident or injury related to this safety hazard. (see AutoInformed on: Ford Motor Recalls F-Series, Ranger, Bronco, Transit, Transit Connect, Maverick for Various Safety Defects; Bad Brakes – Ford Recalls Bronco Sport, Escape SUVs; Three More Ford Recalls – 885,569 F-Series, Explorers, Aviators)
Chronology
July – August 2021 On July 1,2021, Ford’s Critical Concern Review Group (CCRG) initiated an investigation into reports of inadequate underbody insulator adhesion on 2021 MY F-150 vehicles based on warranty claims of insulators coming loose. Two underbody acoustic/thermal insulators are installed on Crew Cab F-150 vehicles with the 302A and above option package. Two push pins assist in attachment of each insulator to the cab underbody in addition to pressure sensitive adhesive. Warranty claims at the time described sagging of one or both insulators, in some cases contacting the U-joint at the transfer case end of the driveshaft on HEV units that was audible to a driver. No reports of driveline fracture attributed to insulator contact had been received, and CCRG’s investigation into potential vehicle effects continued.
September 2021 On September 16, 2021, Driveline Engineering informed CCRG that seven reports of driveshaft damage on 2021 MY F-150 vehicles had been received and were likely caused by underbody insulator contact. Package and vehicle complexity studies were conducted and found that 4×4 145” wheelbase Crew Cab vehicles are equipped with an aluminum driveshaft that is susceptible to contact from a sagging passenger side insulator.
October – November 2021 Vehicle package and CAD studies continued, including assessment of powertrain variation. Field return parts were also evaluated. A vehicle clinic was conducted to evaluate all potential effects of a loose insulator on a variety of F-150 vehicle configurations, including proximity to other driveline configurations, fuel lines, brake lines, and electrical systems. Subsequent analysis found that the risk of driveline contact exists with a loose or sagging driver or passenger side insulator.
As of December 7, 2021 there have been 27 reports of fractured aluminum driveshafts potentially related to a sagging underbody insulator on these vehicles. On December 9, 2021, Ford’s Field Review Committee reviewed the concern and approved a field action.
Dealers will inspect and repair the driveshaft as necessary, and properly attach the underbody insulators, free of charge as required by law. Owner notification letters are expected to be mailed January 31, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 21S56. 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 Ken Zino
Ken Zino, editor and publisher of AutoInformed, is a versatile auto industry participant with global experience spanning decades in print and broadcast journalism, as well as social media. He has automobile testing, marketing, public relations and communications experience. He is past president of The International Motor Press Assn, the Detroit Press Club, founding member and first President of the Automotive Press Assn. He is a member of APA, IMPA and the Midwest Automotive Press Assn.
He also brings an historical perspective while citing their contemporary relevance of the work of legendary auto writers such as Ken Purdy, Jim Dunne or Jerry Flint, or writers such as Red Smith, Mark Twain, Thomas Jefferson – all to bring perspective to a chaotic automotive universe.
Above all, decades after he first drove a car, Zino still revels in the sound of the exhaust as the throttle is blipped during a downshift and the driver’s rush that occurs when the entry, apex and exit points of a turn are smoothly and swiftly crossed. It’s the beginning of a perfect lap.
AutoInformed has an editorial philosophy that loves transportation machines of all kinds while promoting critical thinking about the future use of cars and trucks.
Zino builds AutoInformed from his background in automotive journalism starting at Hearst Publishing in New York City on Motor and MotorTech Magazines and car testing where he reviewed hundreds of vehicles in his decade-long stint as the Detroit Bureau Chief of Road & Track magazine. Zino has also worked in Europe, and Asia – now the largest automotive market in the world with China at its center.
Recall – New F-Series Aluminum Driveshafts Fracture
Ford Motor Company is recalling more than 185,000 2021-2022 F-150 pickups. In a required filing with the National Highway Traffic Safety Administration, Ford said that underbody heat and noise insulators may loosen and contact the aluminum driveshaft, which could damage the driveshaft and cause it to fracture. A fractured driveshaft may result in loss of motive power while driving, unintended vehicle movement while the vehicle is in park, if the parking brake is not applied, and may result in secondary damage to surrounding vehicles.
Affected vehicles are F-150 4×4 145” wheelbase Crew Cab configurations with 302A and above equipment group and sound insulation package that are equipped with an aluminum driveshaft. Ford said it is not aware of any reports of accident or injury related to this safety hazard. (see AutoInformed on: Ford Motor Recalls F-Series, Ranger, Bronco, Transit, Transit Connect, Maverick for Various Safety Defects; Bad Brakes – Ford Recalls Bronco Sport, Escape SUVs; Three More Ford Recalls – 885,569 F-Series, Explorers, Aviators)
Chronology
July – August 2021 On July 1,2021, Ford’s Critical Concern Review Group (CCRG) initiated an investigation into reports of inadequate underbody insulator adhesion on 2021 MY F-150 vehicles based on warranty claims of insulators coming loose. Two underbody acoustic/thermal insulators are installed on Crew Cab F-150 vehicles with the 302A and above option package. Two push pins assist in attachment of each insulator to the cab underbody in addition to pressure sensitive adhesive. Warranty claims at the time described sagging of one or both insulators, in some cases contacting the U-joint at the transfer case end of the driveshaft on HEV units that was audible to a driver. No reports of driveline fracture attributed to insulator contact had been received, and CCRG’s investigation into potential vehicle effects continued.
September 2021 On September 16, 2021, Driveline Engineering informed CCRG that seven reports of driveshaft damage on 2021 MY F-150 vehicles had been received and were likely caused by underbody insulator contact. Package and vehicle complexity studies were conducted and found that 4×4 145” wheelbase Crew Cab vehicles are equipped with an aluminum driveshaft that is susceptible to contact from a sagging passenger side insulator.
October – November 2021 Vehicle package and CAD studies continued, including assessment of powertrain variation. Field return parts were also evaluated. A vehicle clinic was conducted to evaluate all potential effects of a loose insulator on a variety of F-150 vehicle configurations, including proximity to other driveline configurations, fuel lines, brake lines, and electrical systems. Subsequent analysis found that the risk of driveline contact exists with a loose or sagging driver or passenger side insulator.
As of December 7, 2021 there have been 27 reports of fractured aluminum driveshafts potentially related to a sagging underbody insulator on these vehicles. On December 9, 2021, Ford’s Field Review Committee reviewed the concern and approved a field action.
Dealers will inspect and repair the driveshaft as necessary, and properly attach the underbody insulators, free of charge as required by law. Owner notification letters are expected to be mailed January 31, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 21S56. 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 Ken Zino
Ken Zino, editor and publisher of AutoInformed, is a versatile auto industry participant with global experience spanning decades in print and broadcast journalism, as well as social media. He has automobile testing, marketing, public relations and communications experience. He is past president of The International Motor Press Assn, the Detroit Press Club, founding member and first President of the Automotive Press Assn. He is a member of APA, IMPA and the Midwest Automotive Press Assn. He also brings an historical perspective while citing their contemporary relevance of the work of legendary auto writers such as Ken Purdy, Jim Dunne or Jerry Flint, or writers such as Red Smith, Mark Twain, Thomas Jefferson – all to bring perspective to a chaotic automotive universe. Above all, decades after he first drove a car, Zino still revels in the sound of the exhaust as the throttle is blipped during a downshift and the driver’s rush that occurs when the entry, apex and exit points of a turn are smoothly and swiftly crossed. It’s the beginning of a perfect lap. AutoInformed has an editorial philosophy that loves transportation machines of all kinds while promoting critical thinking about the future use of cars and trucks. Zino builds AutoInformed from his background in automotive journalism starting at Hearst Publishing in New York City on Motor and MotorTech Magazines and car testing where he reviewed hundreds of vehicles in his decade-long stint as the Detroit Bureau Chief of Road & Track magazine. Zino has also worked in Europe, and Asia – now the largest automotive market in the world with China at its center.