Ford Recalls Over 29,000 F-150 Lightning Electric Trucks for Potential Steering Defect

Ford Motor Company has announced a safety recall affecting 29,501 of its 2024 and 2025 F-150 Lightning electric trucks due to a defect in the front upper control arm assembly. The issue stems from improperly torqued ball joint nuts, which could lead to a separation of the control arm from the knuckle assembly, posing a risk of partial loss of directional control and increasing the likelihood of a crash.

The affected vehicles, built between February 15, 2024, and April 14, 2025, may have ball joint nuts that were not tightened to the correct specifications during assembly. Ford identified the problem through field reports, including one incident where a vehicle suffered a right front wheel failure at just 634 miles. An internal investigation revealed that lateral forces during assembly might have compromised the tool’s ability to properly torque the nuts, even with manual secondary torque validation procedures in place.

In response, Ford’s Field Review Committee approved a recall on May 16, 2025. The company will notify owners beginning June 9, 2025, and inspections will be performed at no cost. Dealers will check the torque on the control arm nuts and replace them if necessary. If the nuts fail the inspection, both the knuckle and nut will be replaced to ensure safety compliance.

Ford has also indicated that it will reimburse owners who previously paid for related repairs. The manufacturer has assured customers that improvements have been made to assembly tooling to prevent recurrence. Notifications to dealers were scheduled for May 27, 2025, with VINs becoming searchable on the same date for concerned owners.

Article by multiple RFHC contributors, based upon information from Ford Motor Company and the National Highway Traffic Safety Administration.

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