Nearly 185,000 Ford F-150 pickups may have serious driveshaft problem

Ford Motor Co. will begin the new year mailing recall notices to 184,698 owners of certain 2021-22 Ford F-150 pickups, warning the driveshaft may fracture and prevent wheels from turning properly — increasing crash risk, according to a filing with federal regulators.

The driveshaft, which transfers torque to other parts of the vehicle, may become fractured in affected trucks, Ford said.

Ford notified the National Highway Traffic Safety Administration on Dec. 16 that thermal and acoustic insulators on the underbody of the F-150s “may loosen and contact with the aluminum driveshaft,” which may fracture because of heat buildup or other damage.

A fractured driveshaft may result in loss of power while driving, unintended vehicle movement while the vehicle is in park if the parking brake is not applied, and may result in secondary damage to surrounding components, Ford said.

A broken driveshaft may also drag on the road, which may cause loss of vehicle control and risk of injury or crash, Ford said.

27 reports of fractured driveshafts

An explanation submitted to safety regulators said the problem is caused by inadequate adhesion of the insulators to the vehicle underbody, which results in loosening and sagging of the insulators.

As of Dec. 7, Ford had received 27 reports of fractured aluminum driveshafts possibly related to sagging underbody insulators on the F-150s, the automaker said.

Ford reported to safety regulators that 10% of the trucks built from Jan. 10, 2020, to Nov. 20, 2021, may be affected by the recall.

Drivers may notice a loose underbody insulator, or they may hear a rattling, clicking or clunking noise due to a loose underbody insulator making contact with the driveshaft, Ford said. 

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The vehicles were not produced in VIN order, and Ford suggested that consumers call Ford’s toll-free line 866-436-7332 to see whether their vehicle may be affected.

Warranty claims 

The automaker said owner notification letters were expected to be mailed Jan. 31 to Feb. 4. Dealers were notified Dec. 21. Dealers will inspect and repair the driveshaft as needed and fully attach underbody insulators, Ford said.