Ford Motor Co. has recalled certain F-Series super-duty trucks for a condition where water may intrude into the Tailgate Park Assist Sensor Interface Module and cause the display screen for the rear cameras to work intermittently, according to the National Highway Traffic Safety Administration.
The recall covers 24,950 model year 2023-2024 F-250, F-350, and F-450 Super Duty pickups. It also adds to Ford's long list of recalls in 2024: The latest recall is its 58th this year according to the NHTSA. Last month, the company reported that its Q3 profit was down $100 million year over year, which it attributed to high warranty costs and other factors.
If the camera problem occurs, customers may also encounter a blue or a black screen for the tailgate top camera display when putting the truck into reverse when the tailgate is down, or see a “reverse brake assist unavailable” warning message in the dashboard.
Customers are being advised to schedule a service appointment for a fix. Owners will be notified by mail and instructed to take their vehicle to a dealer to have the repairs made. Ford started sending notification letters to customers on Oct. 29.
To repair the issue, dealers will replace the tailgate top camera, wire harness and Tailgate Park Assist Sensor Interface Module, as well as perform an update to the image processing module software, which will be free.
How Ford identified the tailgate camera problem
The camera in the top of the tailgate was introduced by Ford in 2023 as an option on some F-Series Super Duty variants. It includes a camera and sensors on the top of the tailgate to provide visual and audible alerts when it’s lowered to make backing up in a parking space, loading dock or connecting a trailer easier for drivers.
Ford uses a separate rear-facing primary backup camera in the trucks that’s activated when shifting into reverse, a safety feature that’s mandated on all vehicles sold in the U.S.
Ford learned of the camera problem on Feb. 6, 2024, after a prototype modifications supplier observed a black screen while working on a 2023 model year F-Series truck, according to the NHTSA report.
A Ford investigation discovered the potential for water to leak at the interface between the connector on the tailgate top camera and connector seal on the coaxial cable that’s plugged into it.
As the investigation unfolded, Ford’s engineers identified multiple causes for the water intrusion related to its manufacture and design. Among the issues, the camera connector itself was oblong and out of tolerance. The connector sealing ribs on the coaxial harness connector were also found to be out of tolerance.
The investigation also revealed that the camera bracket had not been designed or tested for water before series production of the trucks. The camera and related hardware was manufactured by Tier 1 supplier Aptiv.
Ford issued a software update for the tailgate camera module On Feb. 25, 2024, to direct the Image Processing Module to continue the initialization process even if one of the truck’s two cameras failed to connect to the display, as in the case of a tailgate top camera. As a precautionary move, Ford’s Kentucky Truck Plant issued a “stop ship” order of certain F-Series trucks on March 1.
Ford’s Critical Concern Review Group opened its own investigation into the tailgate top camera concern on March 7. Its engineers initially determined that the water intrusion problem affecting the tailgate top camera would not affect the primary backup camera display when in reverse.
On March 14, 2024, Ford’s Kentucky Truck Plant addressed the problem by installing what’s described as a “dimensionally correct” connector pigtail between the camera and the coax cable connector in the tailgate to prevent water ingress, according to the NHTSA report.
But in April 2024, Ford’s Advanced Driver Assistance System team identified additional customer claims of water intrusion had caused a black screen for all cameras, including the reverse one.
Between June and July of this year, Ford continued to review field data and warranty claims. But rather than issuing a recall, the automaker decided to continue monitoring warranty claims and collecting returned parts for additional vehicle and bench testing. In September, Ford’s investigation concluded that water intrusion was the root cause for the camera issues and decided to recall the trucks.
Ford is aware of 130 warranty reports for camera faults received from Sept. 5, 2023 to Aug. 22, 2024, and another 11 field reports received from Oct. 2, 2023 to May 15, 2024. An estimated 5% of the nearly 25,000 recalled trucks are believed to have the defect.
