Ford has issued a recall affecting 103,174 F-150 pickup trucks from the 2023, 2024, and 2025 model years. The recall targets trucks equipped with the Trailer Tow Max Duty package and the heavy-duty 9.75-inch rear axle, which features a three-quarter float axle design. This recall comes in response to reports of fatigued rear axle-hub bolts that may break over time and cause safety concerns.
The Defect & Its Consequences
The faulty rear axle-hub bolts can fracture due to fatigue, potentially allowing micromovements between the hub splines and the axle-shaft splines. This can lead to wear or stripping of the hub splines, causing a loss of torque transfer to the rear wheels. A critical consequence of this issue is the increased risk of a vehicle rollaway when parked without applying the parking brake, especially since torque may not be delivered to the rear wheels in rear-drive mode.
Before a complete failure, drivers might notice a clicking noise from the rear of the vehicle. Following a break, rattling noises can occur, though the broken bolt head is designed to stay contained within the wheel centre cap.
Investigation & Fix
Ford began investigating the problem in June 2025 after an increase in reports of broken rear axle bolts surfaced. The issue was linked to trucks produced with the Trailer Tow Max Duty package and heavy-duty axle after a previous recall for similar issues in 2021-2023 vehicles.
In response, Ford has developed a revised rear axle shaft assembly with updated spline geometry to increase contact area and stronger fasteners. Starting in May 2025, this new assembly was introduced into production.
Ford plans to notify affected F-150 owners starting in mid-August 2025, with the recall and repair campaign scheduled through May 2026. The repair involves replacing the left and right rear axle shaft assemblies free of cost at dealerships.
Safety Impact
Thankfully, Ford has not reported any accidents or injuries tied to this defect but acknowledges the safety risk it poses. The company urges owners of affected vehicles to wait for official recall notices and to schedule repairs promptly.
Conclusion
This recall adds to Ford’s growing list of safety campaigns in recent years and highlights the automaker’s efforts to proactively address mechanical issues. If you own a 2023-2025 Ford F-150 with the Trailer Tow Max Duty package, it is advisable to stay alert for recall notifications and consult your dealer to have the axle assembly inspected and, if necessary, replaced.
