Image Credit: Ford.Ford has been struck with several recalls in recent months, and out of them all, this one seems to be the most severe, considering the National Highway Traffic Safety Administration (NHTSA) has advised affected owners not to drive their vehicles.The NHTSA usually sends out such warnings when operating or driving the vehicle, which could increase the risk of a crash and injury.The recall report states that 4,653 vehicles have been recalled. Ford's team is said to have reviewed plant records to ascertain the total number of affected vehicles.AdvertisementAdvertisementThe vehicles are said to be affected by a front lower control arm ball joint problem that sparked the recall.Ford Maverick and Bronco Sport RecalledImage Credit: Ford.The recall report revealed that 2,357 units of the 2022-2026 Ford Maverick and 2,296 units of the 2021-2026 Ford Bronco Sport have been affected by a problem with improperly assembled front lower control arm ball joints. It stated:"For production dates prior to June 1, 2025, affected vehicles may have improperly assembled front lower control arm ball joints. Unsold vehicles and vehicles with less than 3 months in service as of May 18, 2026, from this production period are included in the recall population based on Ford's understanding of the issue and observed occurrences in the field which indicate it will manifest very early in the vehicle's lifetime.""For production dates June 1, 2025, or later, affected vehicles have front lower control arm ball joints that may have been improperly repaired at the vehicle assembly plant. Vehicles from this production period that were sent to in-plant repair stations for inspection/repair of the joint are included in the recall population."AdvertisementAdvertisementThe issue is being perceived as a serious safety hazard because a lower control arm ball joint separation from the knuckle may lead to loss of vehicle control. The report explained:"An incorrect assembly or repair that results in partial engagement of the ball stud to the knuckle may result in lower control arm ball joint separation from the knuckle which may result in loss of vehicle control while driving, increasing the risk of crash."NHTSA Reveals Cause of Front Lower Control Arm Ball Joint IssueFor affected Ford vehicles produced before June 1, 2025, a reported error by the vehicle assembly plant operator may have caused the problem, whereas vehicles produced on or after June 1, 2025, require an in-plant repair. The report stated:"For vehicles built prior to June 1, 2025, the vehicle assembly plant operator may not have fully inserted the front lower control arm ball stud into the front wheel knuckle before securing an associated pinch bolt.AdvertisementAdvertisement"For vehicles built on June 1, 2025, or later, vehicles identified as requiring an in-plant repair to ensure proper bolt secure may have been shipped without the repair being completed."Unfortunately, there is no prior warning or sign that can inform the driver about the problem beforehand.The issue was brought to the notice of Ford after its Chassis team identified a warranty claim for a 2025 Bronco Sport vehicle on April 30, 2026, in which the left-front wheel became misaligned while driving after only one month in service.On May 12, 2026, Ford's Critical Concern Group (CCRG) initiated its investigation and approved a field action just days later on May 19, 2026. Notably, Ford is unaware of any reports of accidents or injuries that occurred due to this issue.Remedy Program For Affected OwnersPhoto Courtesy: Ford.Ford is contacting owners to instruct them not to drive their Maverick and Bronco Sport vehicles until the vehicles have been inspected by an authorized dealership. The report stated:AdvertisementAdvertisement"Ford is contacting owners and instructing them to not drive their vehicle. Owners are asked to work with a Ford or Lincoln dealer to have their vehicle inspected at their location or towed in for service."Dealers will inspect for proper assembly of the front lower control arm ball joint to knuckle attachment on the left and right side of the vehicle and repair, as necessary. There will be no charge for these services."Owners will be contacted by Ford via phone and email. The report added:"Mailing of owner notification letters is expected to begin June 1, 2026, and is expected to be completed by June 5, 2026."