Ford has announced a new recall affecting 41,000 F-150 Lightning electric trucks in Canada and the United States. The issue stems from a potentially loose or improperly torqued ball joint nut in the front suspension system, which could lead to a loss of steering control and increase the risk of a crash.
According to the documents posted to the Transport Canada (#2025-286) and National Highway Traffic Safety Administration (NHTSA, 25V341) websites, the recall applies to 2024 and 2025 model year F-150 Lightning pickups produced between February 14, 2024, and April 14, 2025.
In these vehicles, the nut that secures the front upper control arm to the steering knuckle may not have been correctly tightened during assembly. If the nut is loose or missing, the control arm could detach from the knuckle, impairing steering functionality.
In total, 11,409 units in Canada are affected, while a further 29,501 units are included in the NHTSA recall in the U.S.
Ford says it first became aware of the problem in March 2025 when a 2024 F-150 Lightning with only 634 miles (1,020km) on the odometer experienced a front wheel failure. The vehicle was towed to a dealership where technicians discovered the upper control arm nut was missing, causing a detachment from the knuckle.
Since this is a mechanical issue, owners will have to bring their vehicles to a Ford or Lincoln dealership for an inspection. If the ball joint nuts are found to be within specification, the nuts will still be replaced as a precaution. If they are loose or missing, the knuckle and nuts will be replaced entirely, free of charge.
You can read the full NHTSA recall notice below, or read the Transport Canada recall here.
