Ford Sued for Faulty Lug Nuts

A lawsuit filed in a federal district court in Detroit claims at least five of Ford Motor Co.’s high-volume models use flawed lug nuts that can fail within months, making it almost impossible to remove a wheel.

The complaint, which cites dozens of owner complaints, seeks class-action status for owners of Ford Escape small crossovers, Flex large crossovers, Focus compact cars, Fusion midsize sedans and F-Series pickup trucks.

The lawsuit asserts that the nuts are a safety hazard because they can swell and distort, making them nearly impossible to remove if the owner experiences a flat tire. Plaintiffs claim Ford has known about the problem for years but has declined to recall the fasteners or replace them under warranty.

Lug nuts are made of solid steel and typically last the life of the vehicle. The Ford fasteners consist of a threaded steel core sheathed by a cosmetic cap made of aluminum, stainless steel or chrome. The lawsuit says the boundary between the nut and its sheath can corrode and separate, thereby expanding and distorting the cap so it no longer fits the vehicle’s tire iron or any other conventional wrench.

Owners report the problem arising in as little as 12,000 miles. They also complain of being charged between $200 and $435 to have the misshapen nuts forced off with special tools and then replaced.