Safety Recall 22S27 Rear Axle Bolt Fractures

[CareerFiremanGuy]

More info:
https://ford.oemdtc.com/7934/safety-recall-22s27-rear-axle-bolt-fractures-2020-2022-ford-explorer

Chronology of Defect / Noncompliance Determination

Date of submission: 4/14/2022

Ford Motor Company (Ford) Recall No. 22S27 – Certain 2020-2022 model year Explorer vehicles – Rear Axle Bolt Fractures.

Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision.

On August 10, 2021, Engineering presented an issue to Ford’s Critical Concern Review Group where the rear axle horizontal mounting bolt was fracturing on some 2020-2021 MY Explorer vehicles built with a 3-point mounted axle design. These failures were discovered by Engineering when reviewing warranty claims.

On August 18, 2021, CCRG requested to kick off a 14D to understand the effect on vehicle operation, and the scope of vehicles affected. From August to December 2021, Engineering analyzed manufacturing data and returned warranty parts, as well as completed CAE analysis and fastener testing, to determine rate of occurrence, affected population, and potential effects on vehicle operation.

From January to February 2022, CCRG worked with Engineering and data & analytics specialists to deep dive into the differences between power packs, effects on vehicle operation, and the scope of the populations. This analysis identified loss of park as a potential effect on vehicle in severe cases.

In March 2022, Engineering worked with Ford Dealerships to confirm the effects on vehicle operation. Two dealerships confirmed damage on the rear driveshaft that resulted in the loss of park. Engineering confirmed Police units are built with a park by cable and would require a hardware change to avoid the loss of park condition, unlike retail units which are built with electronic park brake software and require a software update to avoid a loss of park condition.

Wow, that is some great info.
Thanks!

 

[CareerFiremanGuy]

... But if I am reading the threads correctly the option we have (if Ford doesn’t make it right) is the stiffy diffy option that might not be the best fix or buy a new (or used ) 4 bolt girdle for thousand plus

There's also Whoosh Motorsport's no-drill brace:
https://whoosh-motorsports.myshopif...s/awr-racing-rear-diff-mount-2020-explorer-st

 

[Cruising68]

Has anyone asked how hard it is to covert the 3 bolt girdle to a four bolt girdle? Is it totally different? Or can you find a shop to convert with bushings and a bolt. (I know it is not that simple)

But if I am reading the threads correctly the option we have (if Ford doesn’t make it right) is the stiffy diffy option that might not be the best fix or buy a new (or used ) 4 bolt girdle for thousand plus

Have to purchase a new cross member as there is an insulator musing from the seconh hole. Does not appear from looking at my 2 bolt in my garage that there is any way to upgrade from the one bolt without replacing it.

Crossmember was $1500 and quote I received from ford to install was $1300. Still deciding if I want to do the 8 hour job myself.


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[CareerFiremanGuy]

Crossmember was $1500 and quote I received from ford to install was $1300. Still deciding if I want to do the 8 hour job myself.

Well get it done already, will 'ya.
We're waiting for the install vid!

 

[Cruising68]

Well get it done already, will 'ya.
We're waiting for the install vid!

I know I know but I am a life long procrastinator lol


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[CareerFiremanGuy]

I know I know but I am a life long procrastinator lol

And I am a life long procrastinator pusher.

Quick, before I run out of snacks!

 

[Cruising68]

And I am a life long procrastinator pusher.

Quick, before I run out of snacks!

View attachment 12223

My wife tells me I have to finish the stereo install so I can clean out the garage before I spend another weekend doing other stuff. After 30 years of marriage I have learned to listen to her

 

[CareerFiremanGuy]

My wife tells me I have to finish the stereo install so I can clean out the garage before I spend another weekend doing other stuff. After 30 years of marriage I have learned to listen to her

Craaaaaaaaaaaaaaaack!

 

[rasparks0967]

Does anyone know if there is a PCM update for a 22 Explorer Platinum Hybrid with the 3.3L motor.

 

[AKS-10]

Does anyone know if there is a PCM update for a 22 Explorer Platinum Hybrid with the 3.3L motor.

I just bought a new 2021 Limited Hybrid (left over stock) on May 2. I still have not actually got the vehicle yet. They say there is a problem with the update. It's not showing up in FDRS for my car yet, even though the bulletin says it should be available for my car. So I have no idea when I'll get the car. At this point I'm bugging the crap out of the dealership several times a day hoping they will stop putting it at the bottom of their to-do list.
I can tell you that the bulletin said (as of 5/14/22) that the update for the 22 hybrid was still 'under development'.

 

[rasparks0967]

I know mine was a 22 Platinum Hybrid, but it is still waiting on the PCM software, and for mine it is till showing under development. I am truly thinking I may need to find a different vehicle. I am trying to wait patiently, but that is hard for me to do.

 

[Cruising68]

Just an FYI. I have a Ford subscription and a Bosch VCI. I was playing around on the ST and noticed three updates available. A front door module update, a rear door update and a PCM update. I am assuming the PCM update is the recall but not 100%. FWIW I can feel no difference in power with the new PCM update. This is basically the same tool the Ford techs use. It checks your vin, connects to ford, and provides any updates along with a lot of other cool stuff it can do.

That is all.

 

[rasparks0967]

Just an FYI. I have a Ford subscription and a Bosch VCI. I was playing around on the ST and noticed three updates available. A front door module update, a rear door update and a PCM update. I am assuming the PCM update is the recall but not 100%. FWIW I can feel no difference in power with the new PCM update. This is basically the same tool the Ford techs use. It checks your vin, connects to ford, and provides any updates along with a lot of other cool stuff it can do.

That is all.

Is there any way to manually check a VIN?

 

[Cruising68]

If you want to PM me your VIN I can try. It does have a place to manually enter a vin. Just don't know if it will show anything when not connected to your ST.

 

[Sgt1411]

I think it is pretty telling that the police units with the 3.0 engine are not included since they still have the 4 bolt, just like the Aviators.

Got a Service update today from Ford Engineering, the 3.0L vehicles are not having the issues. They have no data to support this issue affecting the3.0L. Retail or Police. Continued delays on getting parts.

The PCM flash to engage the E Brake cannot be done on the Police version because it has hard cable transmission shifter on column not like fly by wire rotary shifter on the retail Explorer.

 

[rasparks0967]

Got a Service update today from Ford Engineering, the 3.0L vehicles are not having the issues. They have no data to support this issue affecting the3.0L. Retail or Police. Continued delays on getting parts.

The PCM flash to engage the E Brake cannot be done on the Police version because it has hard cable transmission shifter on column not like fly by wire rotary shifter on the retail Explorer.

I guess if I had just ordered the non-hybrid model, I would have gotten my car by now. Hopefully the update comes out soon for the hybrid so I can get my Explorer shipped to me.

 

[CareerFiremanGuy]

Got a Service update today from Ford Engineering, the 3.0L vehicles are not having the issues. They have no data to support this issue affecting the3.0L. Retail or Police...

This is big news!
No wonder FORD's data (and even our own poll here) show virtually zero breaks.

 

[Dark Knight]

Got a Service update today from Ford Engineering, the 3.0L vehicles are not having the issues. They have no data to support this issue affecting the3.0L. Retail or Police. Continued delays on getting parts.

The PCM flash to engage the E Brake cannot be done on the Police version because it has hard cable transmission shifter on column not like fly by wire rotary shifter on the retail Explorer.

are they delaying PIU 3LTT production? I wonder if no PIU are affected because they have the upgraded rear end

 

[Cruising68]

Just an update, I notice the Ebrake much more now. Every time I shift from park into either reverse or Drive the ebrake is on until I hit the accelerator pedal. ST won't roll when I shift into Drive until I hit the gas.

 

[KANSAS]

Just an update, I notice the Ebrake much more now. Every time I shift from park into either reverse or Drive the ebrake is on until I hit the accelerator pedal. ST won't roll when I shift into Drive until I hit the gas.

This is how all 2020-2022 Explorers work when the Ebrake is on.