Ford Recalls Nearly 30,000 F-150 Lightning EVs Due to Suspension Nut Issue

Ford is recalling nearly 30,000 F-150 Lightning electric pickup trucks in the United States due to a potential issue with a suspension nut that may be loose or missing. This defect could lead to the separation of the front upper control arm from the knuckle assembly, posing a risk of partial loss of steering control.

Affected Vehicles and the Specific Defect

The recall impacts a total of 29,501 Ford F-150 Lightning units manufactured between February 15, 2024, and April 14, 2025. This includes 20,528 vehicles from the 2024 model year and 8,973 from the 2025 model year.

Ford has identified that certain vehicles within this production period may have an improperly torqued nut on the ball joint. This nut is crucial for securing the front upper control arm to the knuckle assembly. The improper torque is believed to be due to variations in the alignment or orientation between the fastening tool and the fastener during the assembly process, which may have prevented the tool from seating properly and applying the correct torque.

Potential Consequences and Warning Signs

If the ball joint nut is loose or missing, drivers may experience:

• Clunks or rattles over bumps.
• Vehicle vibration while driving.
• In severe cases, the knuckle could separate from the upper control arm, potentially leading to a partial loss of directional control and increasing the risk of a crash.

Ford is aware of one field report dated March 6, 2025, detailing a 2024 F-150 Lightning owner who reported a right front wheel failure after just 634 miles. A dealership technician found that the control arm had detached from the knuckle due to a missing ball joint nut.

Remedy and Production Adjustment

Ford improved the design of its factory tooling on April 14, 2025, meaning trucks built after this date are not included in this recall. Still, it’s not the only recall this year, hopefully, Ford steps up EV quality soon.

To address the issue in affected vehicles, Ford and Lincoln dealers will perform the following actions:

• Inspect the torque of both the left and right upper control arm ball joint nuts.
• If the torque inspection passes, technicians will replace the nut.
• If the torque inspection fails (indicating a loose or missing nut), the knuckle and nut will be replaced. All repairs will be provided free of charge to owners.

Context in the EV Market

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

Despite this issue, the F-150 Lightning remains one of the top electric trucks out there, even when compared to the Cybertruck. Thinking of buying one? Check our best Ford EV deals.