Ford recalls F-150 over possible rear axle rattling noise

Ford recalls F-150 over axle issue

Ford announced a recall for particular F-150 pickup trucks built between January 2023 and May 2025. This affects 103,174 trucks with the Max Tow package and a 9.75-inch HD 3/4 float rear axle. The recall follows reports of a rattling sound possibly linked to a loose hub bolt.

According to Ford, this is its 96th recall in 2025 alone, an unusually high number. Owners are advised to be alert for the noise, as early detection could prevent more serious damage or safety risks while driving or towing.

How the F-150 axle fault develops

The issue involves rear axle hub bolts that may break from fatigue. Once a bolt breaks, tiny movements can occur between the hub and axle shaft splines, which should stay firmly locked together under regular use.

These movements cause wear that worsens in salty winter conditions or after driving through water. If left unchecked, this can lead to loss of drive in two-wheel mode or allow the parked truck to roll away, especially when pulling heavy trailers.

Chances and history of the axle defect

Ford believes only about one percent of the recalled trucks will have the defect. Still, the company has already processed 194 warranty claims for the problem, showing that even rare faults can’t be dismissed.

With towing capacities of up to 13,500 pounds, an axle failure during hauling could be dangerous. This is why Ford acted quickly to organize a recall and prepare a repair process, ensuring affected owners can have peace of mind when using their trucks.

Ford’s plan to repair recalled trucks

Newly built F-150s are already receiving an updated rear axle design with improved spline geometry, a larger contact area, and a stronger M24 stud and nut. These changes aim to prevent the bolt fatigue seen in earlier builds.

Repairs for recalled trucks are expected to begin at dealerships in late summer 2025 at no cost to owners. Until then, Ford advises drivers to listen for rattling sounds inside the wheel cap, as this could be the first warning sign.

F-150 appears in trade discussions

While addressing the recall, the F-150 also entered trade talks between the United States and Japan. U.S. President Donald Trump mentioned the “very beautiful Ford F-150” when describing what Japan would accept under a recently announced trade agreement.

The agreement came as Japan’s chief negotiator visited Washington to push for lowering U.S. auto tariffs from 27.5% to 15%. According to Reuters, the 27.5% rate includes an older 2.5% tariff plus an extra 25% imposed during Trump’s administration.

Tariff deal details still unresolved

Japan’s Prime Minister Shigeru Ishiba confirmed the trade deal but said implementation has proven more complex than the agreement. Tariffs will remain at 27.5% until both countries settle the final terms.

Negotiator Ryosei Akazawa noted that the U.S.–UK trade deal began within 54 days and hopes his ninth trip to Washington will secure a similar outcome. The Tokyo Stock Price Index rose one percent as Japanese automakers anticipated potential tariff reductions.

Disagreement over tariff limits

One dispute is whether the 15% rate would fully replace existing tariffs or be applied on top of them. Akazawa insists the final tariff should be capped at 15%, but an executive order suggests the cap may only apply to the European Union.

Trump has long argued that American cars fail in Japan because of trade barriers. Experts counter that large U.S. vehicles like the F-150 are too big for Japan’s narrow streets, where many roads measure less than four meters across.

Questions over investment promises

Trump described a $550 billion Japanese investment package as a “signing bonus” for the United States, comparing it to a sports contract payout. He said the funds could be used in any way the U.S. chooses.

According to NHK, Japan clarified that only one to two percent of the total is actual investment. The rest are loans and guarantees, with projects decided by private companies. Building supply chains in the U.S. remains a shared priority for both governments.

F-150 sales remain strong in 2025

Despite recall news and trade uncertainties, F-150 sales stayed robust. In the first half of 2025, Ford sold nearly 413,000 F-Series pickups, up 17.2% from the same period in 2024.

General Motors led U.S. sales with 1.4 million vehicles, followed by Toyota Motor North America with 1.237 million. Ford ranked third with 1.113 million. According to Automotive News, GM also topped the full-size truck segment by combining Silverado sales of 289,000 with Sierra sales of 169,000.

Expanding the F-150 lineup

The 2025 F-150 lineup includes XL, STX, XLT, Lariat, King Ranch, Platinum, Tremor, and the high-performance Raptor models, including the Raptor R.For 2026, Ford will introduce the F-150 Lobo, a sporty street truck.

Meanwhile, digital artist Abimelec Arellano created a concept for a competition-ready F-150, complete with a large front splitter, rear wing, open grille, and aggressive hood vents designed for track performance.

A racing-inspired F-150 concept

Arellano initially planned a retro-style F-150 with an SVT Lightning body kit and vintage wheels. Dissatisfied with the look, he reworked it into a modern racing truck for time attack and autocross events.

The final concept is a 2025 F-150 Regular Cab Short Bed imagined for extreme performance. While purely digital, it is a tribute to the original SVT Lightning while exploring how the current model could adapt to competitive motorsport use.

Lightning’s performance earns praise

The all-electric F-150 Lightning has impressed reviewers. Edmunds tested a 2023 Lightning Lariat purchased for $80,000, praising its 580-horsepower and 775 lb-ft of torque, the most in any F-150 variant. Despite weighing 6,781 pounds, the Lightning accelerates quickly.

According to Edmunds, its towing assist features help predict range accurately. When pulling 7,700 pounds, range fell from 320 miles to 150 miles, matching expectations and outperforming some electric rivals in real-world towing conditions.

Comparing electric truck range

The Lightning’s best recorded range was 345 miles, but competitors reach farther. GMC’s 2025 Sierra EV Denali achieved 507 miles, Lucid’s 2022 Air Dream Range reached 505 miles, and Chevy’s 2024 Silverado EV RST managed 484 miles.

The Lightning still offers practical utility. It carried 1,000 pounds without strain and fit large items thanks to foldable rear seats. Testers often chose it over the Rivian R1T, Cybertruck, and Silverado EV for its price, comfort, and technology package.

Limitations of the Lightning model

The Lightning weighs about 1,000 pounds more than Ford’s hybrid F-150, making its ride bouncy at highway speeds. Charging times for the extended battery are also lengthy.

According to Edmunds, its towing range is less than half that of the hybrid. The hybrid’s 3.5-liter V6 with 430 horsepower and 570 lb-ft torque stayed quieter after 50,000 miles than the Lightning did after 22,000 miles. A camera stitching flaw also affects parking visibility.

Lightning repair record and value drop

During long-term testing, the Lightning needed repairs for its parking sensors, hatch control, battery monitor, wiper motor, dashboard mat, rear lightbar, and high-voltage battery module.

According to Edmunds, the truck lost half its value in two and a half years and is now worth about $40,000. The 2021 F-150 Hybrid dropped from $66,000 to $33,000 in value. Reviewers said they would still choose the hybrid nine times out of ten.

Ford’s best-selling F-150 now has an electric version aimed at loyal truck buyers. Read more in F-150 America’s favorite truck goes electric.

Another major Ford recall in 2025

Ford also recalled over 850,000 vehicles for a defective low-pressure fuel pump that could cause engine stalls. Models include the Bronco, Explorer, F-150, Aviator, and Navigator.

Owner notifications began on July 14, 2025. The repair is not yet ready, but will be free of charge. According to Ford, a 25% import tax on some Mexico-built models could add $2.5 billion in costs and potentially reduce U.S. sales by one million units over three years.

Three top electric pickups face off to see which one comes out on top. Full story in Cybertruck vs. Rivian R1T vs. F-150 Lightning: which is best?

Think your truck’s at risk? Share your thoughts.

Read More From This Brand:

• Inside Ford’s bold August 11 manufacturing plan
• Ford recalls 850,000 vehicles over fuel pump defect
• New Isuzu electric truck delivers power at a high cost

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This slideshow was made with AI assistance and human editing.