On Sunday, October 8th 2023, my wife and I were returning home on a remote stretch of US Highway 24, 15 miles east of Buena Vista, Colorado, when we got a flat rear passenger tire. I pulled over at a safe location to change the tire. While attempting to remove the flat tire, I was unable to get the factory supplied lug wrench on any of the 6 lug nuts. Because of the remote location we had very limited cell service and were having challenges contacting a towing service. I eventually found a rock and was able to pound the lug wrench socket onto several of the lug nuts and managed to remove 4 of 6 lug nuts. The final 2 nuts became stripped and I could not remove them. Meanwhile, my wife contacted a tow service and 3 hours later, they arrived. The tow truck drive used a large hammer to pound a 7/8" socket onto the remaining nuts and used an impact wrench to remove them and then to put all the lug nuts back on. He informed me this is a common issue with my year and make of truck and they are called "Swollen lug nuts." I was very surprised that this was a known issue and there was not a recall issued to replace defective parts. It is extremely irresponsible to not notify owners of this issue, especially when I was sold a 4x4 wheel drive, off road vehicle and live in a state (Colorado) where cell service can be limited to non-existent. This issue could easily lead to death by not being able to replace a flat tire.

- Colorado Springs, CO, USA

Steel Wheel cracked at bead area approximately 6" Immediate loss of air. No apparent impact or damage to wheel, part of crack appears old (rusty). was on front of sheriff vehicle and is used at high speeds. Failure at speed would be catastrophic.

- Albia, IA, USA

Front wheel bearing driver side started failing (but I did not know it) shortly after 5ok miles. Had it replaced when noise became very pronounced at 56K miles. Dealer has not confirmed the problem. However dealer-€™S parts man recognized the part number by site, and hinted that the problem is not uncommon, although usually at higher mileage. Dealer was (and still is) unable to obtain the replacement part. Repair was performed by a 3rd party garage using aftermarket part. Warnings: The TPMS monitor started alerting that it was not recieving the tire pressure from the affected wheel, when driving long distances on the highway. This has not occurred since the bearing was replaced.

- Mason, OH, USA

My 2017 Ford F150 with 40k miles was in dealership for tire rotation. Mechanic says my truck has swollen lug nuts. I reside in Ga and road salt not typically used in winter. Cost me $130 for something poorly engineered.

- Sugar Hill, GA, USA

Dec. 29, 2022: I was advised that the lug nuts are warped and the tires could not be rotated without replacing the lug nuts. Was advised if I did not replace them, I may not be able to remove them if I had a flat tire or worse, they might not get tightened properly causing a wheel to come off while driving. Vehicle is still at Ford Dealership service dept.

- Redlands, CA, USA

Koons Ford, Woodbridge, VA could not rotate my tires due to swollen lug nuts that cost almost $400 to replace. They also informed me that if I were to have a flat tire I could not change it with the standard jack supplied by ford.

- Woodbridge, VA, USA

I brought my ford in to have tires rotated and they were unable to do because ford installed factory lug nuts are distorted. I brought my truck to a reputable tire shop and they told me it is a common problem on Ford F-150 from 2016 to present. I ordered replacement lug nuts to remedy the problem. I am saving the old lug nuts in case I have to take them to small claims.

- Greenfield, CA, USA

Swollen lug nuts had to be replaced before they caused a safety issue

- Austin, TX, USA

What compontent: The lug nuts on my Truck swelled and are distorted so at risk of cracking. I couldn't get them off when i had a flat tire. It is available for inpsection. Safety: Safety put at risk 1. i couldn't change my flat, and couldn't tightne them correctly when i DID force it and 2. they are at risk of cracking, they ahve deterioated so wheels at risk of failing. Inependent verification: Costco changed my tires and noticed the issue, having to use other size sockets bc they were swelled so much. Warnings: No warnings or anything as purely mechanical/steel parts. You only know when you try to take ethe tires off, you think the jack is the wrong size. Its messed up how big they got. its ALL OF THEM. These SUCK. dealers so no recal so to be safe i guess I have to buy new ones and replace (Parts AND labor). Thank you

- Woodstock, GA, USA

I had to replace defective (swollen) lug nuts on my 2017 Ford F-150 pickup. This issue was identified by the local Ford dealer. Could have caused a serious issue had they not been replaced.

- Topeka, KS, USA

The wheel lugs have seized and are unable to be removed with a tire wrench or impact wrench. This is a huge safety issue as the driver is unable to change a flat tire. The dealer informed me the lugs are made of aluminum and are subject to overheating and corrosion. I was informed the lugs are a two-piece set and have to be replaced and need to be cut off with a cutting torch. Ford is aware of the problem, however, dismisses a recall because they say the dealer service centers are using the wrong tools. The problem is the lugs are inferior metal and easily swell up and seize. Ford has used aluminum lugs since 2000. Since a driver can't change the tire this vehicle needs to be towed. Not being able to change the tire is a huge safety issue.

- Hinckley, OH, USA

While driving my vehicle I began to notice a clicking noise in relation to my tires/speed. No sensors came on, all gauge readings were normal. I pulled over and viewed the tires to check for a flat, all seemed fine and pressure was reading normal. When I resumed driving, I came back into my lane turning slightly left and noticed that the steering wheel began to vibrate. I slowed the vehicle again and put on my hazard lights while attempting to reach a freeway exit. The vehicle began shaking as though I had a flat but again I did not. I decided to turn off an exit and when I attempted to make a left turn into a parking lot, my front passenger wheel flew completely off. My two four year olds and I were then left without control of the truck, finally grinding to a stop blocking two directions of traffic on a Highway unable to get out of harms way. It was night, cars were coming in either direction. I had to emergently remove my children from their car seats and get away from the vehicle to safety. The lug nuts/bolts were completely sheered off. The wheel flew into a field several yards away from the vehicle. If I would not have exited the freeway, I shutter to imagine what would have happened to us as other large trucks would not have been able to stop at the rate that we were forced too. Please. This vehicle/part needs an official recall!

- Mechanicsburg, IL, USA

I got a flat tire on Interstate 75 North in central Georgia. I had an issue with the lug nuts coming off. This issue put me and my family in grave danger. Instead of a simple tire change I had to wait on the side of the interstate for roadside assistance due to the issued lug nut wrench not working properly because of the swollen lug nuts! This is a very unsafe! Please contact Ford to make them accountable!

- Warner Robins, GA, USA

swollen lug nuts

- Mendota Hts, MN, USA

Lug nuts are swollen. Dealer told me they needed to be replaced at a cost of $160. Not covered under warranty. Correctly made lug nuts do not need to be replaced. ALL tire changed and rotations have been done by FORD.

- Littleton, CO, USA

Went to change tires on 09/18/2021 @ Discount Tire and found that the rug nuts on wheels are swelled. In order to replace tires, I had to buy new sets of rug nuts. Ford sold its BEST SELLING trucks with defective/deficient rug nuts.

- Tomball, TX, USA

Had tire failure on interstate 59 in Alabama. Went to change tire on truck and found lug nut wrench would not fit any of the lug nuts. All lug nuts distorted. Alabama State Trooper came to assist. He had a an electric impact wrench with multiple sockets and found an oversized socket and proceeded to remove lug nuts. Called local Ford dealership ( Cleveland Tn.) that has performed 100% of service on my truck since purchase And was told that lug nuts were swollen-€¦. Asked service manager if they check lug nuts during tire rotation, and was told they inform customers if they need to be replaced.. Asked why I wasn-€™t informed-€¦ Also, is it reasonable to expect a lug nut wrench to fit in a roadside emergency? Replied that other auto manufacturers have the same problem.. Apparent design issue. Two piece hollow cap design hex collapses / distorts when torqued. Service techs just move to a larger socket which further distorts during impact wrench torquing.

- Cleveland , TN, USA

[xxx] information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Brockton, MA, USA

[xxx] information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Massachusetts City, MA, USA

Dealer called and said my lugnuts were swollen and would get worse in the future and make it difficult to remove wheels. Dealer replaced them with aftermarket lugnuts.

- Cleveland, TN, USA