NHTSA Safety Recall (23V-896) on 113,000 F-150 Trucks with Trailer Tow Max Duty Package

[thudnblunder]

I just got the rattle from my rear passenger side today. They checked the axles less than 3K miles ago as part of the recall and “everything was fine” though they didn’t do a preemptive repair.

I’m taking it in tomorrow.

Bummer.

Before going to the dealer, I popped the hubcap off to find the shorn bolt sitting in there. I took pictures.

Went to the dealer, they asked me if I had an appointment, my name etc and as he was looking it up, he said "Hmm, in for a recall?" and I was like "Yup, this one." and plopped the shorn bolt and washer on the counter.

The guy's eyes went wide and he was "Where'd that come from?!?" and I said "It was ratting inside the wheel hub, and if you read through the recall I linked in the service appointment you'll find more details on it."

He read up and said "We're going to put this back in the wheel and take some pictures to send to Ford" and I said "Already got you covered, if you like I can email you the pictures." and he said "Sweet! Yup, that saves time! We can use that to get a parts order going."

Anyway to cut it short, they're ordering in the parts, hope to have them tomorrow and let me leave with my truck. They didn't need to put it on a lift or anything, I showed them my pictures and they said that's good enough for them to use.

They'll hopefully do the repair the same day, so I won't be without my truck for long.

Quite painless, I'm not upset at all with them or Ford. Problems and faults happen, and they're dealing with it very reasonably.

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[Snakebitten]

Still, it's a bit irritating to need to guide the dealership through the TSB procedure.
It's far from the only TSB requiring the pictures accompanying the parts order.

 

[thudnblunder]

Still, it's a bit irritating to need to guide the dealership through the TSB procedure.
It's far from the only TSB requiring the pictures accompanying the parts order.

Not sure if they'd have needed guidance TBH, seemed like the guy got it pretty quick and got on it. I just happened to have read up on this specific issue before I went in and had that advantage.

 

[Snakebitten]

Not sure if they'd have needed guidance TBH, seemed like the guy got it pretty quick and got on it. I just happened to have read up on this specific issue before I went in and had that advantage.

Ahhhh.
Perhaps I'm still a bit tender from the extra day involved in my procedure because they didn't read, thus submit properly. The parts order was rejected by Ford.
Then neither the tech or the parts guy could successfully attach pics, so the service writer intervened and handled the "computer skills" portion.

I will admit that the parts arrived next day after successfully submitting per instructions. Both sides! And the truck was repaired same day as well, although I wasn't notified.

I took the truck home and immediately removed the two new factory bolts and replaced with what I am hoping are superior fasteners. And torqued less, as well.

I figure I have nothing to lose and perhaps might have improved reliability. It'll be interesting, but anecdotal at best.

 

[thudnblunder]

Ahhhh.
Perhaps I'm still a bit tender from the extra day involved in my procedure because they didn't read, thus submit properly. The parts order was rejected by Ford.
Then neither the tech or the parts guy could successfully attach pics, so the service writer intervened and handled the "computer skills" portion.

I will admit that the parts arrived next day after successfully submitting per instructions. Both sides! And the truck was repaired same day as well, although I wasn't notified.

I took the truck home and immediately removed the two new factory bolts and replaced with what I am hoping are superior fasteners. And torqued less, as well.

I figure I have nothing to lose and perhaps might have improved reliability. It'll be interesting, but anecdotal at best.

I'm tempted to install a more ductile bolt (with threadlocker to compensate for less torque) and spring loaded washers to allow the axle some room to move before shearing the bolt.

 

[oncechance]

I just received another notice from Ford on this recall. As everyone knows, fix has been pushed out to 2025. Damn...

 

[thudnblunder]

I'm tempted to install a more ductile bolt (with threadlocker to compensate for less torque) and spring loaded washers to allow the axle some room to move before shearing the bolt.

Perhaps something like a clover dome spring between the bolt and the washer?

https://catalog.monroeengineering.c...clover-dome-spring-stainless-steel/m1000043ss

Maybe a couple of them to get the "load and deflection" scenario covered?

 

[Snakebitten]

I'm tempted to install a more ductile bolt (with threadlocker to compensate for less torque) and spring loaded washers to allow the axle some room to move before shearing the bolt.

Pretty much exactly what I did.
The threads on the factory bolts are gnarly compared to the machining of the axle threads, or for any bolts I collected as potential replacement.

I then looked up the typical torque suggestions for bolts of that grade and size and found it to be very common to torque less than what Ford states. And although I am no master mechanic, the suggested torque range felt plenty tight. Plenty!

And as you suggested, I also added "spring" to the bolts.
On one side, an appropriate "Belleville" Washer.
On the other side I'm trying a polymer washer between the factory steel washer and hub face. A second approach to address possible fatigue of the factory bolt design?

Anyways, I rotate my own tires about 4-5000 miles. I'll check both sides each time and scrutinize what I see. I intend to verify the torque of each combination, as well as if the press-fit is still press-fit.

 

[thudnblunder]

Pretty much exactly what I did.
The threads on the factory bolts are gnarly compared to the machining of the axle threads, or for any bolts I collected as potential replacement.

I then looked up the typical torque suggestions for bolts of that grade and size and found it to be very common to torque less than what Ford states. And although I am no master mechanic, the suggested torque range felt plenty tight. Plenty!

And as you suggested, I also added "spring" to the bolts.
On one side, an appropriate "Belleville" Washer.
On the other side I'm trying a polymer washer between the factory steel washer and hub face. A second approach to address possible fatigue of the factory bolt design?

Anyways, I rotate my own tires about 4-5000 miles. I'll check both sides each time and scrutinize what I see. I intend to verify the torque of each combination, as well as if the press-fit is still press-fit.

Very cool. When I get my new parts in, I'll be doing the same.

I just posted this video I saw in another comment.



Multiple washers stacked in the "load and deflection" configuration might be a good fit for what we're dealing with here. Probably more resilient than polymer?

 

[Snakebitten]

Very cool. When I get my new parts in, I'll be doing the same.

I just posted this video I saw in another comment.



Multiple washers stacked in the "load and deflection" configuration might be a good fit for what we're dealing with here. Probably more resilient than polymer?

I'm just a layman who is testing/experimenting with alternatives. So trying different approaches on each side.

If I find the elastic deteriorated at all after a few thousand miles, I'll replace it with a fresh one.

One of the advantages of this particular misfortune is that it's very easy access and almost effortless to swap out the bolt. I'm mostly hoping for the press-fit to hold up. Afterall, it could actually be the root of the issue, rather than a byproduct.

 

[thudnblunder]

I got a text from the dealership this morning that the parts were in, so I went in and dropped the truck off at 9:30am. Got a call at 1pm that the axle shaft, and wiper motor recalls were done and the truck was ready for pickup.

Pretty happy with how quickly they got it done. Livermore Ford, CA.

 

[Snakebitten]

That's how it's supposed to be handled!
Just imagine how much less angst about a potential sheared bolt would have ever mustered if your story was common. The norm.

 

[{tpc}]

I kept getting emails from ford wanting me to get this done. Or so I thought. I'm now on the secodn or third usps letter stating that I'd get another letter when parts were available, but I could do the interim fix.

My truck hasn't suffered the issue (37k miles). A few weeks back I had scheduled a pick up and drop off for this service but I called them and they said it was the interim fix and they didn't have the parts. And it would be more of a all day, or 2 day repair.

Color me annoyed at this point. What is the holdup? Why is it so long to fix if they get it first thing in the morning? Why can't scheduling be better?

 

[J17GT]

I just received another notice from Ford on this recall. As everyone knows, fix has been pushed out to 2025. Damn...

I got that same letter yesterday. Q1 2025!? I forget what the first letter said, but it sure wasn't 2025. Unreal.

 

[Nasto]

I got that same letter yesterday. Q1 2025!? I forget what the first letter said, but it sure wasn't 2025. Unreal.

First letter said Q2 2024.

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