Ford Broncos and Rangers recalled for loose and missing nuts

Ford is recalling 2,416 Broncos and Rangers because the nut on the ball joint that secures the front upper control arm to the steering knuckle assembly may be missing or improperly torqued. This is a major oversight as it can cause the upper control arms to separate and result in loss of steering.

Ford first became aware of the issue in August when they received a warranty report showing that the left front upper control arm ball joint separated from the steering knuckle in a 2024 Ranger with only 291 miles (468 kilometers) on the odometer.

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Two days later, stop-ship orders were issued for the Bronco and Ranger because both models are built at the Michigan assembly plant. As the investigation continued into September, it was determined that factory employees “failed to secure the upper control arm to the steering knuckle ball joint on certain vehicles.” The investigation also found that the “hold and drive” socket broke three times, which may have been a contributing factor.

While that sounds like a lot of blame, Ford is aware of at least four warranty reports related to the issue. On the bright side, the automaker found no injuries or incidents.

The recall affects 2024-2025 Broncos and 2024 Rangers produced between June and early September. The dealer will inspect the vehicle to determine if any nuts are missing or loose. If either condition is found, the entire ball joint and knuckle assembly will be replaced free of charge.

Notification letters are expected to be mailed to vehicle owners on October 28. Dealers are also advised not to take delivery of any vehicles until the recall is resolved.