Ford has issued a safety recall for 11,431 Super Duty pickups after the brand identified a rear driveshaft weld problem that can lead to separation and a sudden loss of drive power.
The action covers 2025-2026 Ford F-250 SD and F-350 SD models built between May 31, 2025 and December 22, 2025. Ford’s filing says 9,280 F-250s and 2,151 F-350s are potentially involved, with the issue tracing back to certain aluminium rear driveshafts supplied by Dana Incorporated. Ford estimates 9% of the recalled population may carry the issue.
But while the population is relatively contained, the defect itself is very serious with it affecting a major part of the vehicle. According to the marque, the rear driveshaft may separate at the friction weld because of poor weld penetration.
Vehicles Included in the Ford Recall
- 2025 Ford F-250 Super Duty
- 2026 Ford F-250 Super Duty
- 2025 Ford F-350 Super Duty
- 2026 Ford F-350 Super Duty
If that happens on the road, the truck can lose power and could potentially lead to an accident. The Blue Oval says drivers may get some warning in the form of a loud popping noise, followed by major noise, vibration or harshness from the broken driveshaft spinning beneath the chassis.
The safety report notes that the issue first surfaced on December 22, 2025, when three 2025 model year Super Duty trucks suffered this issue during end-of-line testing at Ford’s Kentucky Truck Plant.
The separation was found at the friction weld between the driveshaft tube and the end yoke. Delivery of the vehicles involved was quickly stopped while a fix could be made.
Further testing by Ford and its supplier found that all three failed shafts had been built on one of the two friction welders used for aluminium tube welding. The company said the fault was isolated to that machine with the rotating spindle not reaching the required speed necessary to create a strong enough weld.
Ford escalated this to its Critical Concern Review Group on January 8, 2026, then reviewed production history and weld-quality data to identify the batch of cars involved. By the end of February, Ford said it was aware of six warranty claims and five field reports tied to driveshaft separation, spanning six unique VINs.
Fortunately, so far it hasn’t been made aware of any accidents linked to the issue. Further action is now in place to remedy the situation for owners.
How Ford Is Fixing The Issue
Owners will be asked to take their trucks to a Ford or Lincoln dealer, where technicians will check the rear driveshaft serial number against a suspect list. If the part matches, the driveshaft will be replaced free of charge.
Ford says VINs became searchable on March 4, dealer notification was scheduled for March 4, interim owner letters are due between March 16 and March 20, and letters explaining the fix are expected to follow between March 30 and April 3.
Owners now await their letter, but the full scale of the issue is yet to be confirmed.
