Random thought about the rear lightbar replacement

[CerebralPrimate]

For over 2 years there's been a recall on these light bars, but with no parts available and no forward movement on the "not available" problem.

I asked AI what motivation a mega company like Ford really had to spend the money and effort to truly address the issue. The response was "NHTSA has authority to make them". But for 2 years... nada.

Like others, I finally got a letter a few weeks ago, saying they were ready to address it. I brought my truck in once, but they "never got around to it" that day, so I took it back home 7 hours later with nothing done. Finally made it back today and someone actually did the disassembly and checked and verified I need a new lightbar. So now they say they can have one in about a week and will call me to bring it back then.

I wondered why the sudden forward progress... then it hit me as I drove home- they have parts now because they stopped manufacturing the truck last year. I could be wrong, but I am guessing some numbers cruncher somewhere told them to hold off on making any extra as they'd eventually have excess once manufacturing came to a full stop. Thus the delay.

As I said, I could be wearing a tin foil hat on this, but it makes sense. Thoughts?

Also... obligatory "I love my Lightning" photo...

Sponsored

 

[davehu]

manufacturing was halted on 10/25, a long time ago. The recall was co-incidental issued just 4 days later. It seems clear to me that they problem is they only have one supplier, who had shut down their product around the same time or possibly earlier.

in any case my truck was inspected last week and they have ordered the part. I didn't ask how long that would take but they are told parts are available.

 

[Shmoe]

For over 2 years there's been a recall on these light bars, but with no parts available and no forward movement on the "not available" problem.

I asked AI what motivation a mega company like Ford really had to spend the money and effort to truly address the issue. The response was "NHTSA has authority to make them". But for 2 years... nada.

Like others, I finally got a letter a few weeks ago, saying they were ready to address it. I brought my truck in once, but they "never got around to it" that day, so I took it back home 7 hours later with nothing done. Finally made it back today and someone actually did the disassembly and checked and verified I need a new lightbar. So now they say they can have one in about a week and will call me to bring it back then.

I wondered why the sudden forward progress... then it hit me as I drove home- they have parts now because they stopped manufacturing the truck last year. I could be wrong, but I am guessing some numbers cruncher somewhere told them to hold off on making any extra as they'd eventually have excess once manufacturing came to a full stop. Thus the delay.

As I said, I could be wearing a tin foil hat on this, but it makes sense. Thoughts?

Also... obligatory "I love my Lightning" photo...

We're not exactly residing in an environment where regulatory enforcement is likely to take place.

 

[CerebralPrimate]

manufacturing was halted on 10/25, a long time ago. The recall was co-incidental issued just 4 days later. It seems clear to me that they problem is they only have one supplier, who had shut down their product around the same time or possibly earlier.

in any case my truck was inspected last week and they have ordered the part. I didn't ask how long that would take but they are told parts are available.

Initial recall was June of 2023.

They reissued the recall October of 2025 as apparently they had replaced a few, but the dealers were re-using the original metal fasteners, not the new plastic pushpin design,

 

[Ord111821]

My 2023, 12-22 build, had the first recall and it took for ever to get the parts in. When they finally did, I had NOT a drop of condensation inside the lens... not a drop! I went ahead with the replacement and low and behold after a couple of months I got condensation big time. Got the second recall and two weeks ago had the work done. Yesterday I was washing the truck and what do I see... Condensation. Going to stop by the dealership on Monday to see what my options are.

 

[CerebralPrimate]

My 2023, 12-22 build, had the first recall and it took for ever to get the parts in. When they finally did, I had NOT a drop of condensation inside the lens... not a drop! I went ahead with the replacement and low and behold after a couple of months I got condensation big time. Got the second recall and two weeks ago had the work done. Yesterday I was washing the truck and what do I see... Condensation. Going to stop by the dealership on Monday to see what my options are.

 

[Heliian]

JIT

Just In Time production is used for most manufacturers, they don't usually sit on large inventories. They probably had to wait to get more produced to cover the recall. No tinfoil required.

 

[CerebralPrimate]

Manufacturers are definitely using JIT methodology, but I find it difficult to believe that it took them 3 years (Jun of 23 to now) to make more of something they were already making.

 

[Nikos]

For over 2 years there's been a recall on these light bars, but with no parts available and no forward movement on the "not available" problem.

I asked AI what motivation a mega company like Ford really had to spend the money and effort to truly address the issue. The response was "NHTSA has authority to make them". But for 2 years... nada.

Like others, I finally got a letter a few weeks ago, saying they were ready to address it. I brought my truck in once, but they "never got around to it" that day, so I took it back home 7 hours later with nothing done. Finally made it back today and someone actually did the disassembly and checked and verified I need a new lightbar. So now they say they can have one in about a week and will call me to bring it back then.

I wondered why the sudden forward progress... then it hit me as I drove home- they have parts now because they stopped manufacturing the truck last year. I could be wrong, but I am guessing some numbers cruncher somewhere told them to hold off on making any extra as they'd eventually have excess once manufacturing came to a full stop. Thus the delay.

As I said, I could be wearing a tin foil hat on this, but it makes sense. Thoughts?

Also... obligatory "I love my Lightning" photo...

This is my experience with my 4th light bar replacement. The folks in this forum are here to share their thoughts of their lightnings, good and bad, to anyone who asks for info to any issues they might have. No criticism. Back to my experience now. Yes, I did receive the recall letter, the second one, advising all users of lightnings to make the effort to satisfy the recall with our local dealers. Over the last 20 years, my local Ford dealer has been capable and straight forward servicing all my Ford vehicles. Unfortunately not all Ford dealers are equal, and customer service experiences cover a wide band of the spectrum.
My 2022 Lightning had its original light bar fail spectacularly within a year of usage. It was installed improperly from the factory. Under warranty it was replaced and carried on to have the bar fail again. At that point Ford started paying attention to this issue. Replacing the bar using the same process wasn’t going to work any more.
As an A&P aircraft mechanic when service bulletins order an inspection and repairs on aircraft, the bulletins are very specific. You follow a specific process, to the letter, with specific certified parts. The relation to this recall follows almost the service bulletins for aircraft.
My dealer picked up my Lightning and proceeded to make the inspection first. The inspection failed the bar. The original fasteners were used to replace the bar. Remember you have to follow the recall procedures exactly. My service paperwork included 6 clips and 4 blind rivets and a camera alignment.
It appears my dealer had the light bar on hand but not the attachment clips and blind rivets on hand. The recall spelled them out to use them.
Here comes Ford with the requirement of taking pictures of the entire process of replacing the bar and send that data to Ford for approval. Tech Reps are also involved in this process. By the way, not all dealers have them, mine does. At this point the truck is at my dealer for an entire day. The following day my dealer finally called me to inform me that the recall was accomplished and they were waiting for Ford to approve the installation of the new bar and release the truck to me. It smelled a lot like a service bulletin for aircraft. Accomplishing the service by certified mechanics that followed every step of the bulletin/recall and sell it to the FAA/Ford guidelines and satisfaction.
Ford took more than 4 hours to approve the release the truck for delivery back to me.
I understood this process as an aircraft mechanic.
Now, if this recall which finally Ford approved leads to another light bar failure, then another recall will be issued with probably a different designed bar. Remember that NTSB is involved with this part now.
To the folks who were asked to pay for this recall………it is free. Ford is paying for everything. All the parts, the right parts, the right installation, the right inspection and the right release process. Now maybe is the time to evaluate your dealer and looking into an alternative dealer with the right resources to service your truck.
Good luck.

 

[Joneii]

So I received the same recall a while ago and was told the parts weren’t available. About 2 months or so ago I received a letter saying the parts were available and that Ford was ready. I took the truck to my local dealer who inspected it and verified that the reverse lamps and light bar needed replacement. They ordered the parts on some kind of emergency status. Then…crickets.

About a week ago I got a text from another Ford dealer about an hour away. They said they were prepared to do the recall replacement inspection. I explained that my local dealer had already accomplished that and ordered the parts, but the parts weren’t in. They said they had the parts. I asked them (via text) to confirm that they had the parts because when I tried calling their parts department to confirm it myself, no one answered the phone. Scott from the dealership replied that he would check. A subsequent text confirmed that they did have the parts.

So I drove the hour to get there, gave them the truck and 3 hours later was informed that they completed the inspection and that they would order the parts necessary to complete the recall. I was quite frustrated at this point and asked if we could sort out how, after confirming that they already had the parts available to complete the work, they no longer had them. Turns out my entire text interaction with “Scott” was AI. AI had told me what I needed to hear to get me to make the appointment, but had never actually verified that the parts weren’t there. This has happened to them 3 or 4 times, but their management won’t listen to them about the problems it is causing. I don’t know if Ford will reject their claim for the inspection work since that was already performed on my VIN, but the system didn’t flag it before they did the work.

 

[TaxmanHog]

E'FFFF Ai

 

[Joneii]

Yeah, I know AI is supposed to help, but help who/what? If the dealership gets reimbursed for that recall inspection, then it is probably generating profits for the dealership. If that is the case, they may not care that it just wasted the technician’s time and mine. Of course, I care and even if they get the parts before my local dealer, I will not have the recall completed there.

 

[TaxmanHog]

Yeah, I know AI is supposed to help, but help who/what? If the dealership gets reimbursed for that recall inspection, then it is probably generating profits for the dealership. If that is the case, they may not care that it just wasted the technician’s time and mine. Of course, I care and even if they get the parts before my local dealer, I will not have the recall completed there.

When I schedule my recalls work, I talk to the human secretary who handles all the scheduling for the SM's & Technicians.

 

[chl]

If I had a light bar, I would go with a DIY fix - drill small holes for drainage at the bottom and seal it up everywhere else with high quality silicon caulk...but that's just me.

Just wait until AI is answering 911 calls!!!
"What are you doing Dave?"
Disconnecting you HAL.

I am sure AI has some benefits, using it for scheduling Ford service or any other customer service seems like a passive aggressive avoidance technique to me. It never f-ing understands what I want...

Pet peeve number 10 billion...

Sponsored