• Nearly 30,000 Ford F-150 Lightning EVs are being recalled.
• The nut on the ball joint that secures the upper control arm to the knuckle might not have been torqued correctly.
• If the nut has fallen off, the knuckle could separate from the upper control arm.

Ford is recalling nearly 30,000 F-150 Lightning electric pickup trucks sold in the United States because a suspension nut might be loose or missing.

In total, 29,501 units built between February 15, 2024, and April 14, 2025, are affected by this recall. According to Ford, certain vehicles from this period may have an improperly torqued nut on the ball joint that secures the front upper control arm to the knuckle assembly. The majority of potentially affected trucks, 20,528, are 2024 model year cars, while the remaining 8,973 are 2025 model year vehicles.

If the ball joint nut is loose or missing, the driver might hear clunks or rattles over bumps, and the vehicle might also vibrate while driving. Ford says the nut might not have been torqued properly during the assembly process “due to variation in the alignment or orientation between the fastening tool and the fastener that may have induced lateral forces on the tool, preventing it from properly seating on the fastener.”

Ford is aware of a single field report related to this issue, dated March 6, 2025. An owner of a 2024 F-150 Lightning, who had driven the truck just 634 miles after taking delivery, reported experiencing a right front wheel failure. The EV was towed to a dealership, where a service technician saw that the control arm had detached from the knuckle because the ball joint nut was missing.

The automaker improved the design of the factory tooling on April 14, so trucks built after this date are not part of this recall. To fix the issue for existing cars, Ford and Lincoln dealers will inspect the torque of the left and right upper control arm ball joint nut. If the inspection passes, technicians will replace the nut. If the inspection fails, the knuckle and nut will be replaced.

The Ford F-150 Lightning is currently the best-selling electric pickup in the United States. In the first quarter of this year, Ford sold 7,187 F-150 Lightnings in the U.S., narrowly beating the Tesla Cybertruck, which was America’s best-selling battery-powered truck last year.

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Source: Ford