Ford Motor Company has announced a safety recall affecting select 2023–2025 model year F-150 Lightning electric trucks due to a potentially loose or missing upper control arm ball joint nut. The defect, if present, could result in the separation of the control arm from the knuckle assembly, leading to a partial loss of steering control and increasing the risk of a crash.
The issue stems from a manufacturing process where improper torque may have been applied to the ball joint nut, possibly due to lateral forces during tool alignment. As a result, affected vehicles could exhibit vibration or clunking noises, particularly during suspension movement, serving as a potential warning to drivers.
This latest recall (NHTSA Campaign No. 25V341 / Ford No. 24S76) expands on a previous field action initiated in December 2024 that covered F-150 Lightning units built between November 5, 2023 and February 13, 2024. The new recall includes vehicles manufactured from February 14, 2024 through April 14, 2025, when updated torque tooling was put into place. The updated process was intended to correct the issue, but a March 2025 incident involving a vehicle with only 634 miles showed the problem could still occur.
As of May 16, 2025, Ford has received one field report and one property damage claim related to this defect.
To address the issue, Ford will notify owners by mail beginning June 9, 2025. Affected vehicles will be inspected at no cost to the owner. If the torque passes inspection, only the nut will be replaced. If it fails, both the knuckle and the nut will be replaced. Owners who previously paid for related repairs may be eligible for reimbursement under Ford’s general recall reimbursement plan.
Dealers were notified of the recall on May 27, and vehicle identification numbers (VINs) became searchable in Ford’s recall system on the same day.
