Dive Brief:
- Ford Motor Co. has recalled more than 115,000 F-Series trucks for a condition where the steering column upper shaft could detach, resulting in a loss of steering control that could increase the risk of a crash, according to the National Highway Traffic Safety Administration.
- The recalled vehicles include model year 2020-2021 F-250, F-350, and F-450 Super Duty trucks built between Feb. 19, 2019, and Sept. 30, 2020. Ford estimates 1% of the recalled trucks have the defect.
- Dealers will inspect the steering column on the vehicles and repair or replace the upper steering column shaft as required, free of charge. Letters notifying customers of the safety risk are slated to be mailed Oct. 6. Additional notifications will be sent once a fix is available, which is expected to be in December.
Dive Insight:
Ford has issued 116 recalls to date in 2025 – the highest number of recalls in a single year by a major automaker and surpassing the previous record-high of 84 recalls by General Motors in 2014.
In the F-Series truck recall, an issue involving upper steering column shaft separation was brought to Ford’s Critical Concern Review Group for review on June 26, and the automaker subsequently launched a probe to determine potential causes.
In July and August, Ford reviewed the design history of the steel column upper shaft and discovered that parts used a single staking from the start of 2020 model year F-Series production until February 2021, when a second staking was added to the upper shaft during manufacturing.
Staking is a manufacturing process used to permanently join two metal components without bolts. In a vehicle's steering column, staking connects the telescoping section of the upper steering shaft to prevent separation. This section is designed to telescope or slide inward in a front end collision to absorb energy during and reduce injury to the driver. But due to improper staking during manufacturing, the steering shaft can pull apart and separate under normal driving conditions, posing a safety risk.
Ford sourced the steering column shafts from South Korea-based Tier 1 supplier HL Mando. The automaker analyzed manufacturing data with the supplier that included an assessment of “pull apart force data” on the upper shafts, the recall notice said. The investigation confirmed variances in steering column shafts manufactured after March 2020, with the single staking having a higher potential for separation.
Based on its findings, Ford’s Field Review Committee approved the recall on Sept. 12.
As of Sept. 11, Ford was aware of three vehicle owner questionnaires received by the NHTSA, along with seven warranty claims, three field reports and four customer call hotline reports potentially related to inadequate staking of the steering column. The reports were received between Sept. 15, 2020 and April 7 of this year. However, Ford is not aware of any accident or injuries related to this condition.
The recall was Ford’s 115th of 2025. The automaker’s Field Review Committee approved its 116th recall on Sept. 12 for over 4,500 Expedition and Lincoln Navigator SUVs. A short circuit within the underhood battery junction box that can lead to an engine bay fire.
Chrysler (FCA US) has issued the second-highest number of recalls this year, with 35 recalls to date.
