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Ford Motor Company has issued a safety recall for 29,501 of its 2024-2025 F-150 Lightning electric pickup trucks due to a defect that could lead to a partial loss of steering control. The National Highway Traffic Safety Administration (NHTSA) has assigned recall number 25V341 to this issue, which Ford identifies internally as recall number 24S76. The submission date for this recall was May 23, 2025.
Key Highlights:
- Affected Vehicles: Certain 2024-2025 Ford F-150 Lightning BEV trucks.
- Number of Units: 29,501 vehicles are potentially involved. This includes 20,528 units from the 2024 model year and 8,973 from the 2025 model year.
- The Defect: The front upper control arm ball joint nut may not have been properly tightened during assembly.
- The Risk: An improperly torqued nut can lead to the separation of the front upper control arm from the knuckle assembly, potentially causing a partial loss of directional control and increasing the risk of a crash.
- The Remedy: Ford dealers will inspect the torque of the left and right upper control arm ball joint nuts. If the inspection passes, the nut will be replaced. If it fails, both the knuckle and nut will be replaced, free of charge.
- Owner Notification: Owners are expected to be notified by mail starting June 9, 2025, with notifications completed by June 13, 2025.
The recall concerns F-150 Lightning vehicles manufactured between February 15, 2024, and April 14, 2025. Ford estimates that 1% of the recalled vehicles may have the defect. The core of the problem lies with an improperly torqued nut on the ball joint, which secures the front upper control arm to the knuckle assembly.
Ford stated the cause of the defect might be a variation in the alignment or orientation between the fastening tool and the fastener. This could have induced lateral forces on the tool, preventing it from properly seating and achieving the correct torque. Drivers of affected vehicles might notice vehicle vibration or hear a clunk or rattle noise during suspension movement if the ball joint nut is loose or missing.
This current recall, 25V-341 (Ford #24S76), expands on a previous NHTSA recall (24V-949). The earlier recall, Ford Field Service Action (FSA) 24S76, was submitted on December 20, 2024, for 2023-2024 F-150 BEV models built from November 5, 2023, through February 13, 2024. This was when Ford’s assembly plant lacked a secondary validation process for upper control arm nut torque.
However, on March 6, 2025, Ford received a field report about a 2024 F-150 BEV, built on March 3, 2024 (after the previous recall’s production end date), where the right front upper control arm nut was missing, and the control arm had detached. This vehicle was produced even after a secondary torque verification station was implemented. Further investigation by Ford’s Critical Concern Review Group (CCRG) determined that statistical analysis of torque data couldn’t definitively identify all improperly torqued joints and that the manual secondary validation might not catch every instance of low torque. Consequently, the CCRG recommended a safety recall for vehicles produced from February 14, 2024, through April 14, 2025, which is when tooling with an improved design was implemented.
As of May 16, 2025, Ford was aware of one field report and one property damage claim related to this issue for this specific population. Ford’s Field Review Committee approved this new field action on the same day.
Dealers were scheduled to be notified of the recall on May 27, 2025. Vehicle Identification Numbers (VINs) for affected vehicles were expected to be searchable from that date as well. Owners seeking more information can contact Ford’s toll-free line at 1-866-436-7332 or their local Ford or Lincoln dealer. Owners who have already paid for repairs related to this issue may be eligible for reimbursement under Ford’s general reimbursement plan.
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