July 7, 2023 NHTSA CAMPAIGN NUMBER: 23E051000
Ball Joint Failure May Cause Loss of Steering
Loss of steering control increases the risk of a crash.
NHTSA Campaign Number: 23E051
Manufacturer Ironman 4×4 USA II LLC
Components SUSPENSION
Potential Number of Units Affected 6,345
Summary
Ironman 4×4 USA II LLC (Ironman) is recalling certain Pro Forge upper control arms. Please see the recall report for a list of the affected part numbers. The upper control arm ball joint may experience premature wear and fail, causing a loss of steering.
Remedy
Dealers will replace the ball joint, free of charge. Owner notification letters are expected to be mailed September 1, 2023. Owners may contact Ironman customer service at 1-855-476-5714 or email at [email protected].
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
Chronology :
On March 10, 2023, the purchasing team at Ironman 4×4 USA received notification from Australia-based parent company Ironman 4×4 PTY Ltd. to cease purchases of the subject upper control arms due to elevated warranty claims on the component in the Australian market. Ironman 4×4 USA promptly ceased such purchases for the US market.
As of March 2023, Ironman 4×4 USA had received 9 warranty claims on the affected upper control arms sold into the US market. None of the 9 claims alleged loss or failure of steering; all of the claims reported noise emanating from the subject upper control arms.
The parent company conducted an investigation of Australian warranty claims involving the subject upper control arms, which were offered for sale in the US and Australia. That investigation identified the potential for dirt and water to enter the ball joint of the upper control arm and cause premature wear of the ball joint.
On June 23, 2023, Ironman 4×4 Pty Ltd (Ironman Australia) submitted a Product Safety Recall to the Australian Competition and Consumer Commission for the subject upper control arms.
On June 27, 2023, Ironman 4×4 US instituted a stop-sale order for US sales of the subject upper control arms.
Also on June 27, Ironman 4×4 USA received a 10th warranty claim on the subject upper control arms, again for noisy steering.
On June 29, 2023, Ironman 4×4 USA decided to conduct a voluntary safety recall in the United States to remedy the identified population of upper control arms with the affected ball joint component.
As of June 29, 2023, Ironman 4×4 USA is aware of 10 warranty claims, received between August 11, 2021, and June 27, 2023, in the US due to noise or squeaking in the upper control arms; no field or service reports in the US; and no reports of reduction or loss of steering control associated with this issue in the US. There are no reports of injuries associated with this issue.
1 Affected Product
Equipment
| BRAND | PART NO. | PRODUCTION DATES |
| IRONMAN 4X4 | PRO FORGE | |
3 Associated Documents
Defect Notice 573 Report
RCLRPT-23E051-8251.PDF 215.299KB
Defect Notice 573 Report
RCLRPT-23E051-5561.PDF 215.299KB
Recall Acknowledgement
RCAK-23E051-3042.pdf 697.301KB
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23E-051 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Ironman 4×4 USA II LLC Submission Date : JUL 07, 2023 NHTSA Recall No. : 23E-051 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Ironman 4×4 USA II LLC Address : 12905 SW Tualatin-Sherwood Road Sherwood OR 97140 Company phone : 855-476-5714 Population : Number of potentially involved : 6,345 Estimated percentage with defect : 100 % Equipment Information : Brand / Trade 1 : Ironman 4×4 Model : Pro Forge Part No. : UCA001FA, UCA001FAJ+ Size : NR Function : NR Descriptive Information : Certain Ironman 4×4 Pro Forge upper control arms with a certain supplier’s ball joint offered for sale as an aftermarket component. How population determined: The recall population has been determined based on a review of production records against sales data. How recall population differs from population not in the recall: Ironman 4×4 Pro Forge upper control arms equipped with a ball joint from another supplier have not exhibited the failure mode. All Part #’s impacted: UCA001FA, UCA001FAJ, UCA001FA-K500018, UCA001FAT,UCA001FAT-K80811, UCA001FAX,UCA048FA, UCA048FA-P, UCA048FA-X, UCA054FAS, UCA056FA, UCA073FA, UCA075FA, UCA075FA-DT Production Dates : JAN 01, 2019 – JUN 27, 2023 Part 573 Safety Recall Report 23E-051 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Defect : Description of the Defect : Premature wear of the ball joint installed in the upper control arm may result in the failure of the ball joint and the reduction or loss of steering control while the vehicle is in operation. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Reduction or loss of steering control while a vehicle is in operation could increase the risk of a crash. Description of the Cause : The ball joint in the upper control arm is susceptible to ingress of dirt and water, which creates an abrasive environment between the ball and socket of the joint, leading to premature wear or failure of the ball joint. Identification of Any Warning that can Occur : None Involved Components : Component Name : Ball Joint Component Description : Ball joint component of the upper control arm. Component Part Number : UBJ001K Component Name : Upper control arm Component Description : Front suspension component Component Part Number : See equipment information, above. Supplier Identification : Component Manufacturer Name : Masuma China Address : No.19, Liwu Road Huadou Disrict Guangzhou Foreign States Country : China Chronology : Part 573 Safety Recall Report 23E-051 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 On March 10, 2023, the purchasing team at Ironman 4×4 USA received notification from Australia-based parent company Ironman 4×4 PTY Ltd. to cease purchases of the subject upper control arms due to elevated warranty claims on the component in the Australian market. Ironman 4×4 USA promptly ceased such purchases for the US market. As of March 2023, Ironman 4×4 USA had received 9 warranty claims on the affected upper control arms sold into the US market. None of the 9 claims alleged loss or failure of steering; all of the claims reported noise emanating from the subject upper control arms. The parent company conducted an investigation of Australian warranty claims involving the subject upper control arms, which were offered for sale in the US and Australia. That investigation identified the potential for dirt and water to enter the ball joint of the upper control arm and cause premature wear of the ball joint. On June 23, 2023, Ironman 4×4 Pty Ltd (Ironman Australia) submitted a Product Safety Recall to the Australian Competition and Consumer Commission for the subject upper control arms. On June 27, 2023, Ironman 4×4 US instituted a stop-sale order for US sales of the subject upper control arms. Also on June 27, Ironman 4×4 USA received a 10th warranty claim on the subject upper control arms, again for noisy steering. On June 29, 2023, Ironman 4×4 USA decided to conduct a voluntary safety recall in the United States to remedy the identified population of upper control arms with the affected ball joint component. As of June 29, 2023, Ironman 4×4 USA is aware of 10 warranty claims, received between August 11, 2021, and June 27, 2023, in the US due to noise or squeaking in the upper control arms; no field or service reports in the US; and no reports of reduction or loss of steering control associated with this issue in the US. There are no reports of injuries associated with this issue. Description of Remedy : Description of Remedy Program : Owners will be provided a ball joint replacement through an order process and will be directed to a local dealer to have the new ball joint installed free of charge. How Remedy Component Differs from Recalled Component : The remedy component will be procured from a different supplier; the remedy component supports the process of flushing out foreign materials and contaminants with fresh grease via a grease nipple on the top of the joint, reducing the risk of premature wear. Identify How/When Recall Condition was Corrected in Production : Upper control arms built after June 26, 2023, were built with ball joints from another supplier; ball joints from this supplier have not exhibited the failure mode. Recall Schedule : Description of Recall Schedule : Ironman 4×4 USA offers these products for sale directly to consumers and also sells through dealers. Ironman will notify its dealers of the recall on/before September 1, 2023. Ironman 4×4 USA will notify owners on/before September 1, 2023, by letter sent via USPS, informing owners of this campaign and how to obtain the remedy free of charge. Ironman 4×4 USA will also post this same information on its website. Planned Dealer Notification Date : SEP 01, 2023 – SEP 01, 2023 Part 573 Safety Recall Report 23E-051 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Planned Owner Notification Date : SEP 01, 2023 – SEP 01, 2023 Purchaser Information : The following manufacturers purchased this defective/noncompliant equipment for possible use or installation in new motor vehicles or new items of motor vehicle equipment: Name : NR Address : NR NR Country : NR Company Phone : NR * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23E-051 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Ironman 4×4 USA II LLC Submission Date : JUL 07, 2023 NHTSA Recall No. : 23E-051 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Ironman 4×4 USA II LLC Address : 12905 SW Tualatin-Sherwood Road Sherwood OR 97140 Company phone : 855-476-5714 Population : Number of potentially involved : 6,345 Estimated percentage with defect : 100 % Equipment Information : Brand / Trade 1 : Ironman 4×4 Model : Pro Forge Part No. : UCA001FA, UCA001FAJ+ Size : NR Function : NR Descriptive Information : Certain Ironman 4×4 Pro Forge upper control arms with a certain supplier’s ball joint offered for sale as an aftermarket component. How population determined: The recall population has been determined based on a review of production records against sales data. How recall population differs from population not in the recall: Ironman 4×4 Pro Forge upper control arms equipped with a ball joint from another supplier have not exhibited the failure mode. All Part #’s impacted: UCA001FA, UCA001FAJ, UCA001FA-K500018, UCA001FAT,UCA001FAT-K80811, UCA001FAX,UCA048FA, UCA048FA-P, UCA048FA-X, UCA054FAS, UCA056FA, UCA073FA, UCA075FA, UCA075FA-DT Production Dates : JAN 01, 2019 – JUN 27, 2023 Part 573 Safety Recall Report 23E-051 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Defect : Description of the Defect : Premature wear of the ball joint installed in the upper control arm may result in the failure of the ball joint and the reduction or loss of steering control while the vehicle is in operation. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Reduction or loss of steering control while a vehicle is in operation could increase the risk of a crash. Description of the Cause : The ball joint in the upper control arm is susceptible to ingress of dirt and water, which creates an abrasive environment between the ball and socket of the joint, leading to premature wear or failure of the ball joint. Identification of Any Warning that can Occur : None Involved Components : Component Name : Ball Joint Component Description : Ball joint component of the upper control arm. Component Part Number : UBJ001K Component Name : Upper control arm Component Description : Front suspension component Component Part Number : See equipment information, above. Supplier Identification : Component Manufacturer Name : Masuma China Address : No.19, Liwu Road Huadou Disrict Guangzhou Foreign States Country : China Chronology : Part 573 Safety Recall Report 23E-051 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 On March 10, 2023, the purchasing team at Ironman 4×4 USA received notification from Australia-based parent company Ironman 4×4 PTY Ltd. to cease purchases of the subject upper control arms due to elevated warranty claims on the component in the Australian market. Ironman 4×4 USA promptly ceased such purchases for the US market. As of March 2023, Ironman 4×4 USA had received 9 warranty claims on the affected upper control arms sold into the US market. None of the 9 claims alleged loss or failure of steering; all of the claims reported noise emanating from the subject upper control arms. The parent company conducted an investigation of Australian warranty claims involving the subject upper control arms, which were offered for sale in the US and Australia. That investigation identified the potential for dirt and water to enter the ball joint of the upper control arm and cause premature wear of the ball joint. On June 23, 2023, Ironman 4×4 Pty Ltd (Ironman Australia) submitted a Product Safety Recall to the Australian Competition and Consumer Commission for the subject upper control arms. On June 27, 2023, Ironman 4×4 US instituted a stop-sale order for US sales of the subject upper control arms. Also on June 27, Ironman 4×4 USA received a 10th warranty claim on the subject upper control arms, again for noisy steering. On June 29, 2023, Ironman 4×4 USA decided to conduct a voluntary safety recall in the United States to remedy the identified population of upper control arms with the affected ball joint component. As of June 29, 2023, Ironman 4×4 USA is aware of 10 warranty claims, received between August 11, 2021, and June 27, 2023, in the US due to noise or squeaking in the upper control arms; no field or service reports in the US; and no reports of reduction or loss of steering control associated with this issue in the US. There are no reports of injuries associated with this issue. Description of Remedy : Description of Remedy Program : Owners will be provided a ball joint replacement through an order process and will be directed to a local dealer to have the new ball joint installed free of charge. How Remedy Component Differs from Recalled Component : The remedy component will be procured from a different supplier; the remedy component supports the process of flushing out foreign materials and contaminants with fresh grease via a grease nipple on the top of the joint, reducing the risk of premature wear. Identify How/When Recall Condition was Corrected in Production : Upper control arms built after June 26, 2023, were built with ball joints from another supplier; ball joints from this supplier have not exhibited the failure mode. Recall Schedule : Description of Recall Schedule : Ironman 4×4 USA offers these products for sale directly to consumers and also sells through dealers. Ironman will notify its dealers of the recall on/before September 1, 2023. Ironman 4×4 USA will notify owners on/before September 1, 2023, by letter sent via USPS, informing owners of this campaign and how to obtain the remedy free of charge. Ironman 4×4 USA will also post this same information on its website. Planned Dealer Notification Date : SEP 01, 2023 – SEP 01, 2023 Part 573 Safety Recall Report 23E-051 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Planned Owner Notification Date : SEP 01, 2023 – SEP 01, 2023 Purchaser Information : The following manufacturers purchased this defective/noncompliant equipment for possible use or installation in new motor vehicles or new items of motor vehicle equipment: Name : NR Address : NR NR Country : NR Company Phone : NR * NR – Not Reported
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