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Ford F-150 drivers might want to check under their trucks before hitting the gas.
Ford is recalling nearly a quarter-million F-150 pickup trucks due to a defect that’s causing the front fuel tank to come loose and fall off, posing a severe safety hazard, according to federal regulators.
A report filed with the National Highway Traffic Safety Administration (NHTSA) reveals that 223,472 trucks from model years 2023 through 2027 left the factory with front fuel tank straps that were improperly attached to the frame rail.
Fuel tanks can detach or fall off vehicles when repeatedly exposed to severe rust, strap corrosion or frame damage. The loose straps weaken over time from road salt and moisture and debris on the road or a collision can break the mounting even more, increasing the risk of the complete tank detachment.
A detached or loose fuel tank creates a dangerous situation on the road. Leaking gasoline dripping onto hot exhaust components risks triggering a catastrophic fire, while a loose tank could disrupt fuel delivery and stall the engine.
A tank completely detaching on a highway would create a deadly road obstacle for surrounding traffic and drivers trailing the vehicle. Adding to the risk, affected vehicles have no warning system to alert drivers before the fuel tank detaches, meaning it can happen sporadically.
Ford has been leading the automotive industry in recalls for the past five years. Just this April, Ford recalled over 1M F-150 pickup trucks over crash risks linked to a gearshift defect, causing two injuries and an accident related to the issue.
With their new Ford Mobile Artificial Intelligence Vision System (MAIVS), cameras will be used in assembly lines during manufacturing to help capture angles and find defects. MAIVS is able to look at 25 different angles, using smartphones and a 3D-printed structure to hold cameras in place. Ford hopes this will mitigate manufacturing issues going forward.
The recall covers unsold trucks as well as vehicles with fewer than three months in service as of Aug. 27, as the defect typically manifests early in the vehicle’s lifespan. Ford traced the problem to assembly line cameras previously used to verify strap installations that had been discontinued.
The issue was escalated to Ford’s Critical Concern Review Group on July 23. By Aug. 27, the automaker had identified 16 warranty claims worldwide related to the defect. Ford reported that so far, it is not aware of any accidents or injuries linked to the flaw.
Ford will begin mailing notification letters to owners between Sept. 21 and Sept. 28. Affected VINs became searchable on Sept. 14. Dealerships will inspect and replace the fuel tank straps free of charge.
While Ford estimates that only about 1% of the recalled vehicles actually harbor the defect, the lack of an in-vehicle warning prompt makes dealer inspection critical for all affected owners.
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