We have a 2019 Transit with aftermarket aluminum wheels (Black Rhino Journey). We have had a problem with the rear wheel studs breaking since the vehicle was first delivered. The first event happened at 3,100 miles when I rotated the tires and one wheel stud twisted off the left rear axle when the lug nut was removed.

This wheel stud was immediately replaced along with two other wheel studs adjacent to the broken one. We subsequently replaced the two remaining original wheel studs as a preventative measure.

Some time later four of the five wheel studs broke on the right rear axle. We were able to stop the van before the fifth wheel stud broke. All five wheel studs were replaced. One of the five replacements just recently broke.

All the broken wheel studs exhibit classic signs of fatigue failure.

So, come to find out that in January 2020 Ford issued a TSB for this issue; see TSB 19-2376 attached if you’re interested.

The wording of the TSB: “Some 2019 Transit vehicles built on 1-Oct-2018 and through 31-Jul-2019 with aluminum alloy single rear wheels (SRW) may exhibit broken rear wheel stud(s). This may be due to variation in the axle flange to wheel mating surface of the axle shafts. To correct the condition, follow the Service Procedure steps to replace both rear axle shafts and all rear wheel lug nuts.”

Note they are recommending the replacement of the axle shafts and lug nuts, not the aluminum wheels. The replacement axle has a different part number than the axle the van was built with.

My assessment of this TSB is that the axle shafts used during a specific time period exhibit some problem. It probably has to do with the flange perpendicularity being out of tolerance with respect to the axis of rotation. This will induce a bit of wobble in a wheel. An aluminum wheel is going to be stiffer than a steel wheel in this area thereby inducing more stress on the wheel studs subsequently resulting in a crack that will result in a fatigue failure over time.

We brought the van to Villa Ford, a local Ford dealer in Orange County, to have the TSB implemented. As the van had been “modified” with aftermarket aluminum wheels they denied the TSB. I insisted they try harder so they did contact the Ford Technical Assistance Center where an engineer confirmed that the work should be performed as directed in the TSB.

However, the Villa Ford Warranty Administrator denied the work as our van has aftermarket wheels. For the TSB to be in play the vehicle had to be delivered with aluminum wheels from the factory.

We called the Ford Technical Assistance Center and was told by the engineer who answered (Grant) that they were only allowed to talk to technicians at the dealers and not to vehicle owners. He suggested we call the Ford Customer Resource Center.

We were told by the CRC rep to post the issue on the appropriate forums or pay for the repair out of pocket. The CRC rep also said there was virtually no way to further escalate this within Ford. Villa Ford also told me they had escalated this to the highest possible levels within the Ford Warranty department short of going to the President of Ford. Sure.

Correct me if I’m wrong here but this kind of, a little bit, maybe, seems like a safety issue. Why won’t Ford acknowledge the issue can be applied to aftermarket as well as factor aluminum alloy wheels?

Our only recourse at this time is to pay out of pocket for the axles to be replaced or keep driving with the defective axles and wait for a catastrophe to occur.

Has anyone else experienced this issue on their Transit (or any Ford vehicle)?

Anyone have any words of wisdom?

 

Not having oem rims is a bull**** reason to deny coverage, that said if you've got the oem rims put them back on and take the vehicle to another dealer to get it covered. If your still under bumper to bumper warranty you might be able to fight with Ford corp to cover this as they should. Yeah the Ford engineer assistance is for dealer techs to use when there's a issue we cannot figure out.

 

Thanks for the reply Scott. Unfortunately I no longer have the OEM steel wheels. However, this would not help as the Warranty Administrator is interpreting the TSB to say this vehicle was sent from the factory with steel wheels so the TSB can't be applied! No common sense being used here.