Ford is currently addressing a significant manufacturing oversight that could potentially impact the steering function of thousands of its popular F-150 trucks. The issue concerns the 2025 model year of the F-150, which is among the most widely sold vehicles in the United States. According to the latest reports, Ford is recalling a total of 9,181 units due to a problem involving improperly secured steering components that may compromise driver control.
The root of the issue lies in a loose or possibly missing fastener that connects the lower intermediate shaft to the steering gear. The National Highway Traffic Safety Administration (NHTSA) has stated that the fastener may not have been torqued to the necessary specifications during the assembly process. This lack of proper torque can eventually lead to the detachment of steering components, posing a serious risk of steering failure and, by extension, the possibility of a crash.
Ford attributes the problem to a flaw in its “error proofing process control” on the assembly line. Specifically, the system responsible for ensuring the secure attachment of the fastener was not properly synchronized with the tool used at that particular assembly station. As a result, the system incorrectly identified some incomplete or improperly fastened connections as secure.
The issue came to light in March 2025 when a dealership employee took a 2025 F-150 out for a test drive during a routine pre-delivery inspection. The employee noticed abnormal steering behavior—referred to as “excessive steering play”—which prompted further investigation. Upon inspection, technicians discovered that the fastener for the lower intermediate shaft was missing entirely. This discovery triggered a deeper internal review by Ford, which confirmed that the issue was more widespread than initially suspected.
Although Ford has only received one warranty claim related to this defect, the company has emphasized that no accidents or injuries have been reported so far. Nonetheless, as a precautionary measure, Ford is taking proactive steps to notify affected vehicle owners.
Official recall notices are expected to be sent out by the end of the month. Owners will be instructed to bring their trucks to authorized Ford dealerships, where service technicians will examine the I-shaft fastener. If needed, the fastener will be either tightened to the proper torque specification or replaced entirely, all at no cost to the customer.
This recall highlights the importance of rigorous quality control processes, especially in high-volume production vehicles like the Ford F-150, where even a small error can have wide-reaching safety implications.