2,416 2024 Broncos and Rangers recalled over loose and missing nuts on front Upper Control Arm (UCA)

[Toccoa]

Oct 16,2024
Manufacturer Recall Number24S64
NHTSA Recall Number24V770
Recall StatusRecall Incomplete, remedy not yet available
SummarySOME OF THESE VEHICLES MAY HAVE A MISSING OR IMPROPERLY TORQUED NUT ON THE BALL JOINT THAT SECURES THE FRONT UPPER CONTROL ARM TO THE KNUCKLE ASSEMBLY, WHICH CAN RESULT IN SEPARATION OF THE FRONT UPPER CONTROL ARM FROM THE KNUCKLE ASSEMBLY.


Safety RiskSEPARATION OF THE FRONT UPPER CONTROL ARM FROM THE KNUCKLE ASSEMBLY MAY RESULT IN PARTIAL LOSS OF DIRECTIONAL CONTROL WITHOUT WARNING, INCREASING THE RISK OF A CRASH.

RemedyFORD MOTOR COMPANY IS WORKING TO PRODUCE PARTS FOR THIS REPAIR. WHEN PARTS BECOME AVAILABLE, FORD MOTOR COMPANY WILL NOTIFY YOU VIA MAIL TO SCHEDULE A SERVICE APPOINTMENT WITH YOUR DEALER FOR REPAIRS TO BE COMPLETED FREE OF CHARGE PARTS AND LABOR.

_____________________

Ford is recalling 2,416 Broncos and Rangers built between June and early September of 2024 as they may have a missing or improperly torqued nut on the ball joint that secures the front upper control arm to the knuckle assembly. This is a significant oversight as it can result in the upper control arm detaching and causing a loss of steering.

Ford first became aware of the issue in August, when they received a warranty report that indicated the front left upper control arm ball joint detached from the knuckle on a 2024 Ranger with just 291 miles (468 km) on the odometer. As the investigation continued into September, it was determined that employees at the plant “failed to secure the upper control arm to the knuckle ball joint on certain vehicles.” The investigation also found that the “hold-and-drive” socket broke three times and this could have been a contributing factor.

Dealers will inspect the vehicles to determine if their nuts are missing or loose. If either condition is found, the entire ball joint and knuckle assembly will be replaced free of charge.

https://www.carscoops.com/2024/10/ford-bronco-and-ranger-recalled-over-loose-and-missing-nuts/

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[Newbie]

 

[Lowcountry Bronco]

Wow, Ford really is going after the Jeep market ...

 

[TrailRaider]

Loose nuts, never a good thing.

 

[FootPain]

The nut runners probably showed a green light that the required torque was met. Obviously it wasn't calibrated as they should be checked multiple times a shift.

 

[IROCnRoll]

Oh nuts.

 

[Bugkillah]

I bet it was a Friday.

 

[huey]

The nut runners probably showed a green light that the required torque was met. Obviously it wasn't calibrated as they should be checked multiple times a shift.

Does Ford run Stanley nut runners? There are other good brands of nut runners that have features to prevent this as well, but Stanley is BIG.
Stanleys or other tools should never loose the calibration. However pre shift checks should be completed before the first cycle of each shift(or multiple times as Footpain mentions) to verify the bolts / nuts reach torque with a secondary tool to verify torque gun is reaching proper torque. If not checked (and pass the check) the tool should never run a single fastener.
Should also have thread / rev counting vs torque threshold turned on. Basically checks that torque is not reached too quickly, a minimum number of tool revolutions has to be completed before target torque is reached. This prevents cross threaded run downs.

Sounds like pre shift checks are bypassed, or not setup properly.

 

[derichio02]

Damn, I have an August 1st build. Guess it’s time to break out the torque wrench.

46 ft/lbs I believe is the oem spec. @Ducati1098 correct me if I’m wrong.

 

[Nc211]

Interesting... There is a post on here somewhere of an owner who thought his Bronco felt a little loose, so he went around the suspension components on his own to check it, and sure enough found a few loose bolts, including the ball joints if memory serves correct.

 

[ABQ_Bronco1982]

Do we have to wait till the 28th for the notification or do you think I can take it in for inspection and the dealership will know what I’m talking about? Hate to risk it for 6 more days considering my family rides in it everyday.

 

[Mega3000]

Hello. First post here. Just got my new ‘24 Wildtrak two weeks ago. Was about to take it on a road trip to the Vegas Off-Rodeo tomorrow.

I just went to the NHTSA site https://www.nhtsa.gov/recalls and typed in my VIN. No recalls showing (yet?)

 

[ABQ_Bronco1982]

Same here. Picked mine up on September 20th.

 

[C6ZZGT]

Mine shows it BUT it is just an advanced notice --- Meaning all they can do it check it for tightness. No repair info is available yet

 

[Fordified1]

Ford is recalling 2,416 Broncos and Rangers built between June and early September of 2024 as they may have a missing or improperly torqued nut on the ball joint that secures the front upper control arm to the knuckle assembly. This is a significant oversight as it can result in the upper control arm detaching and causing a loss of steering.

Ford first became aware of the issue in August, when they received a warranty report that indicated the front left upper control arm ball joint detached from the knuckle on a 2024 Ranger with just 291 miles (468 km) on the odometer. As the investigation continued into September, it was determined that employees at the plant “failed to secure the upper control arm to the knuckle ball joint on certain vehicles.” The investigation also found that the “hold-and-drive” socket broke three times and this could have been a contributing factor.

Dealers will inspect the vehicles to determine if their nuts are missing or loose. If either condition is found, the entire ball joint and knuckle assembly will be replaced free of charge.

https://www.carscoops.com/2024/10/ford-bronco-and-ranger-recalled-over-loose-and-missing-nuts/

“CAUSING A LOSS OF STEERING”. Is an understatement. It would be CATASTROPHIC at 70 mph. I encourage anyone who thinks their Bronco falls in that timeline to put an 18mm wrench on those nuts before going anywhere.

This is what can happen at less than 5mph. (caused by me not Ford) Imagine what would happen at higher speeds.

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