Ford is initiating a recall of 223,472 F-150 pickup trucks, model years 2023 through 2027, due to improperly attached front fuel tank straps that pose a significant safety risk. According to a report filed with the National Highway Traffic Safety Administration (NHTSA), the straps may detach from the frame rail, potentially causing the fuel tank to fall off the vehicle.
The defect arises from issues during the manufacturing process, where assembly line cameras used to verify strap installations were discontinued, leading to insufficient attachment. Over time, exposure to road salt, moisture, and debris can cause corrosion of the straps and frame, weakening the connection further. In severe cases, or following a collision, the fuel tank could detach completely.
A loose or detached fuel tank presents multiple hazards. It could leak gasoline, creating a fire risk if it comes into contact with hot exhaust components. A stalled engine due to disrupted fuel delivery is also a possibility. Furthermore, a tank falling off on a highway could become a dangerous obstacle for other vehicles.
Ford has stated it is not aware of any accidents or injuries linked to this specific defect, though 16 warranty claims related to it have been identified worldwide as of August 27. The automaker noted that only an estimated 1% of the recalled vehicles are believed to actually have the defect, but due to the lack of an in-vehicle warning system, inspections are critical for all affected owners.
Owners of affected vehicles will be notified by mail between September 21 and September 28. The company began allowing owners to check for affected vehicle identification numbers (VINs) on September 14. Ford dealerships will inspect and replace the fuel tank straps free of charge. This recall follows a previous one in April, where over one million F-150 trucks were recalled due to a gearshift defect that led to two injuries and an accident.