Nearly 30,000 Ford Lightning Trucks Recalled for Suspension Problems

1% or 295 of 29,501 recalled vehicles are affected by the 2025 Ford Lightning Suspension Recall, which targets a serious suspension defect involving the electric pickup’s front upper control arm.

According to filings with the National Highway Traffic Safety Administration (NHTSA), the component may not have been properly tightened during assembly, creating a risk that it could separate from the knuckle and lead to a crash.

The affected vehicles include select 2024 and 2025 model year F-150 Lightnings. Ford began investigating the issue after a March 6 field report from an owner who experienced a front wheel failure after only 634 miles of driving.

Although no injuries have been reported, the automaker confirmed one case of property damage. Ford also noted that the defective vehicles were not built in VIN order, which could complicate identification.

This latest campaign expands on the earlier NHTSA recall 24V-949 and underscores ongoing concerns over assembly quality in the Lightning’s front suspension system.

WWhy Is There a 2025 Ford Lightning Suspension Recall?

The issue centers on a key suspension component: the ball joint nut that secures the front upper control arm to the steering knuckle.

According to Ford’s statement to safety regulators, this nut may not have been properly torqued during assembly.

If the nut is loose or missing, the control arm can separate from the knuckle—potentially causing a partial loss of steering control.

That scenario reportedly occurred on March 6, 2025, when an owner experienced a right front wheel failure after just 634 miles.

A dealership inspection confirmed that the upper control arm had detached because the nut was missing.

Ford’s Critical Concern Review Group (CCRG) began examining the issue and ultimately recommended a safety recall on May 16, 2025.

This new action follows the earlier campaign (NHTSA Recall No. 24V-949, Ford FSA 24S76), which covered 2023–2024 F-150 Lightning BEVs produced before February 13, 2024.

At that time, Ford’s Rouge Electric Vehicle Center in Dearborn, Michigan, had no secondary verification process in place to confirm torque accuracy on the upper control arm nuts.

Although a secondary torque check was introduced after that earlier production period, Ford’s investigation revealed that the manual validation process was not catching every improperly torqued nut.

In fact, the March 6 incident involved a truck produced after that verification step had been implemented. A statistical review of torque data failed to isolate improperly torqued joints, prompting Ford to broaden the recall.

Ultimately, the CCRG concluded that additional vehicles manufactured between February 14, 2024, and April 14, 2025, could be at risk.

As of the May 16 recall approval, Ford acknowledged one property damage claim and one field report associated with the defect.

Out of the 29,501 vehicles included in this expanded recall, 20,528 are 2024 model year trucks, while the remaining 8,973 are from the 2025 model year.

Ford reports that the affected F-150 Lightnings were built between February 15, 2024, and April 14, 2025.

2024 Ford Lightning Suspension Recall

Ford previously issued a safety recall in December 2024 for close to 12,000 F-150 Lightning trucks from the 2023 and 2024 model years due to the same critical suspension defect that could affect steering control.

If this ball joint nut is not tightened to specification, the control arm may detach—posing a significant crash risk.

The 2024 Ford Lightning Recall defect is believed to stem from a misaligned factory tool during assembly, which led to inconsistent torque application.

When the control arm separates from the knuckle, drivers may experience a sudden loss of directional control.

According to reports submitted to the National Highway Traffic Safety Administration (NHTSA), warning signs may include vibrations or clunking noises during suspension movement.

As a remedy, dealerships inspected the torque of the upper control arm ball joint nuts on both sides of the vehicle.

If the torque fell within specifications, the nuts were replaced. If the torque was insufficient, both the knuckle and nut were replaced at no cost to the owner.

How Do I Know if My Ford Lightning Is Affected?

If you own a Ford F-150 Lightning, you will first want to find out whether your truck is included in either of these suspension recalls.

Some drivers may notice early warning signs, such as unusual vibrations while driving or a clunking or rattling sound when going over bumps—both of which could point to a loose upper control arm connection.

These symptoms may indicate that the ball joint nut securing the front upper control arm to the steering knuckle wasn’t properly torqued during assembly.

The first recall involves 11,922 electric trucks from the 2023 and 2024 model years, built between November 6, 2023, and February 12, 2024.

A second, expanded recall affects an additional 29,501 trucks from the 2024 and 2025 model years, built between February 15, 2024, and April 14, 2025.

In both cases, the problem stems from a suspension defect that could lead to the control arm detaching from the knuckle, resulting in a loss of steering control.

It’s worth noting that the 2022 model year—the first production year for the F-150 Lightning—is not included in either recall.

To check if your vehicle is affected, you can enter your Vehicle Identification Number (VIN) on Ford’s official website or contact your local Ford dealership for assistance. Taking action early could help prevent a serious issue on the road.

Is There a Ford Lightning Suspension Fix?

Ford is providing a no-cost suspension fix for owners affected by either of the two major F-150 Lightning recalls.

For the first recall, Ford began notifying owners on February 3, 2025, instructing them to visit a dealership for inspection and repair.

Owner notification letters are scheduled to go out between June 9 and June 13, 2025 for the second, expanded recall.

In both cases, owners are instructed to take their vehicles to a Ford or Lincoln dealer, where technicians will inspect the torque on the front upper control arm ball joint nuts.

If the torque is within specification, the nut will still be replaced as a preventative measure. If the torque inspection fails, the technician will replace both the nut and the steering knuckle to correct the defect and ensure safe operation. These repairs will be performed at no cost to the owner.

Although most affected trucks are still under warranty, Ford has committed to reimbursing drivers who may have already paid out of pocket for similar suspension repairs.

To confirm whether your vehicle is covered by either recall, it’s best to contact a local dealership and schedule an inspection.

Taking prompt action could help prevent a loss of steering control linked to the improperly torqued suspension components.

Steps for Affected Ford Lightning Owners

1. Check Recall Status: Visit the National Highway Traffic Safety Administration’s (NHTSA) official recall lookup tool and enter your VIN to see if your vehicle is included in the recall.
2. Contact Your Dealer: Reach out to your local Ford dealership to confirm whether your F-150 Lightning is affected by either the December 2024 or May 2025 suspension recall. They can also help schedule a service appointment.
3. Watch for Recall Notices: Ford sends official notifications to affected owners. If you haven’t received one yet, be proactive and check with your dealer.
4. Schedule and Complete Inspection: At the dealership, a certified technician will inspect the torque on the front upper control arm ball joint nuts. Regardless of the inspection outcome, the nut will be replaced. If torque is inadequate, the technician will also replace the steering knuckle—at no cost to you.
5. Understand Your Legal Rights: If your vehicle has experienced repeated issues or extensive downtime, you may be eligible for compensation under your state’s lemon law.
6. Consult a Lemon Law Attorney: Because each case is unique, seek advice from a qualified Lemon Law attorney who can evaluate your situation and help you pursue a buyback, settlement, or other remedies.
7. Act Promptly: Timely action can protect your safety and maximize your options for compensation and repair.

If your Ford F-150 Lightning is affected by the suspension recall and has experienced repeated problems or required repeat repairs for this or other similar issues, you might be entitled to compensation beyond the free repairs offered by Ford.

This can include reimbursement for out-of-pocket expenses, diminished vehicle value, a repurchase, or other related damages.

Below is an approximate range of potential lemon law settlements for Ford Lightning models impacted by these suspension issues:

Affected Vehicle	Average Lemon Law Settlement
2024 Ford F-150 Lightning BEV	$116,229
2025 Ford F-150 Lightning BEV	$126,681

*Please note, the figures presented in the chart are approximations based on past case results and should not be interpreted as a prediction or guarantee. Each case is unique and requires personalized legal guidance.

Work with the Lemon Law Experts and the Lemon Law!

If you are still experiencing problems with your Ford Lightning or have concerns about how this recall affects your vehicle’s safety and reliability, consulting a qualified Lemon Law attorney can be an important step.

An attorney can help determine if you qualify for a lemon law claim and guide you through options such as pursuing a replacement vehicle, a refund, or other compensation related to the defect.

At the Lemon Law Experts, we have been dedicated to assisting consumers with automotive defect cases since 2009.

Our knowledgeable team understands both state and federal lemon law protections and is committed to helping you achieve the best possible outcome.

If your Ford Lightning continues to have issues despite repairs, contact us today to discuss your case and explore your legal options.