A problem with rear axle hub bolts snapping is causing 103k 2023-2025 Ford F-150 trucks recalled to fix the issue before crashes could occur.
2023-2025 Ford F-150 Trucks Recalled
According to a NHTSA.gov filing, Ford Motor Company is recalling certain 2023-2025 Ford F-150 trucks equipped with the Trailer Tow Max Duty package and a 9.75-inch heavy duty axle with a 3/4 float axle design. The rear axle hub bolt may fatigue and break, which can result in damage to the axle hub splines.
The rear axle hub bolt may break due to fatigue and will no longer prevent micro-movement between
the hub splines and the axle shaft splines. Over time, in a corrosive environment, corrosion and the
micro-movement may result in wearing of the hub splines which can lead to loss of torque transfer to
the wheel end.
Stripped rear axle hub splines can result in vehicle roll away when the vehicle is in park without the
parking brake applied, or cause a loss of motive power in 4X2 operation. Both of these conditions can
increase the risk of a crash.
Affected vehicles are equipped with the Trailer Tow Max Duty package and a 9.75-inch heavy duty (HD)
axle with a ¾ float axle design and were built between January 02, 2023, and May 21, 2025.
Ford says it will affect less than 1% of the trucks it is recalling.
Owners will be notified by mail and instructed to take their vehicle to a Ford or Lincoln dealer to have
the left and right rear axle shaft assemblies replaced with assemblies containing revised spline
geometry and fasteners. There will be no charge for this service.
The left and right rear axle assemblies that will replace the recalled assemblies (ML3W-4725-C and
ML3W-4234-C) are designed with revised spline geometry and fasteners.
Recall Chronology Report
On June 5, 2025, an issue pertaining to an increase in reports of broken rear axle hub bolts and stripped
wheel end hub splines on certain 2023 Model Year F-150 vehicles equipped with the 9.75-inch HD 3/4
float axle was brought to Ford’s Critical Concern Review Group (CCRG) for review. As part of its
investigation, the CCRG reviewed the previously recalled population for 23S65/23V896. The prior recall,
approved by Ford’s Field Review Committee (FRC) on December 15, 2023, addressed a rear axle
stripped hub spline concern on certain 2021–2023 Model Year (MY) Ford F-150 vehicles equipped with
the 9.75-inch Heavy Duty (HD) 3/4 float axle. The CCRG team also reviewed a Vehicle Owner
Questionnaire (VOQ) that The Automotive Safety Office (ASO) Trends and Early Warning Support Team
(TEWS) had initially discussed on May 21, 2025 during a weekly review of the incoming National
Highway Traffic Safety Administration (NHTSA) VOQs. The VOQ described a 2023 MY Ford F-150 with an alleged rear axle stripped spline condition and a roll in park incident. The vehicle in that VOQ was
outside of the previously recalled population for 23S65/23V896.
Through June and into July 2025, Ford’s Critical Concern Review Group (CCRG) and Global Driveline
Engineering team investigated an increase in reports of broken rear axle hub bolts and stripped wheel
end hub splines on certain 2023 Model Year F-150 vehicles equipped with the 9.75-inch HD 3/4 float
axle produced after the cutoff date for the 23S65 population. This investigation included in-depth
reviews of potentially related warranty claims to identify claims where a stripped spline condition was
indicated. Additionally, a broad VOQ query was reviewed identifying 12 vehicles produced after the
23S65 cutoff date reporting rear axle bolt breakage. None of those VOQs included allegations of roll in
park or loss of motive power. CCRG noted that a new rear axle shaft assembly design was launched in
May 2025. This revised axle shaft assembly design included new spline geometry with a larger contact
area and an M24 stud/nut for the hub.
As of July 14, 2025, Ford is aware of 194 warranty claims, received between September 27, 2023, and
July 8, 2025, describing stripped splines occurring on vehicles produced after the conclusion of 23S65
through May 2025 when the new axle shaft assembly design was introduced.
On August 1, 2025, Ford’s Field Review Committee reviewed the concern and approved a field action.
Ford is not aware of any vehicle accidents or injuries related to this condition.
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