Category Archives: Ford

News about Ford automobile manufacturer. News about Ford recalls, technical service bulletins (TSB), and problems regarding Ford vehicles.

2020-2022 Ford Explorer Repeated Repair Attempts

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Ford Explorer Axle Problem
Certain 2020-2022 Ford Explorer Vehicles May Still Be at Risk

A critical issue affecting certain 2020-2022 Ford Explorer vehicles has come to light, despite previous repair attempts under recalls 23V-199 or 22V-255. The problem lies in the rear axle horizontal mounting bolt, which may fracture and cause the driveshaft to disconnect. This can lead to a loss of forward power, increased risk of crash and injury, and even unintended vehicle movement.

The root cause of the issue is attributed to a software tool malfunction that failed to upload the correct software update to the vehicle during previous repair attempts. As a result, the underlying condition specified in Safety Recalls 23S16 / 23V-675 and 22S27 / 22V-255 may still exist, putting drivers and passengers at risk.

The Technical Explanation

Affected vehicles were built with a 3-point mounted axle design, which can lead to a fracture of the rear axle horizontal mounting bolt. When powertrain torque is applied through the driveline, it causes axle rotation, exerting a bending force on the rear axle bolt. Repeated peak torque events, typically experienced during launch events, can cause fatigue failure of the bolt. This can result in a loud, grinding, binding, or clunking noise, as well as severe vibration.

The Consequences

If the rear axle bolt breaks, the driveshaft or half-shafts may become disconnected, leading to a loss of forward power and transmission torque to the rear wheels. This increases the risk of crash and injury. Furthermore, if the parking brake is not applied, the loss of primary park torque can allow the vehicle to roll in park, increasing the risk of crash and injury.

The Solution

To correct the problem, dealers will update the powertrain control module (PCM) software. Ford’s number for this recall is 25S22, and the NHTSA campaign number is 25V-166. It is essential that owners of affected vehicles take immediate action to have their vehicle repaired to prevent any potential accidents or injuries.

Certain 2022-2024 Ford F-150 Lightning BEVs May Have A Battery Defect

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A potential safety issue has been identified in a small number of 2022-2024 Ford F-150 Lightning Battery Electric Vehicles (BEVs). The problem affects the high voltage battery cells, which may have a manufacturing defect that can cause an internal short circuit. This defect is due to misaligned electrodes in the battery cells, which can occur over repeated charge and discharge cycles.

The issue was first brought to Ford’s attention in October 2024, when a fire was reported in a 2022 model year F-150 BEV. Further investigation revealed two additional fires in 2022 and 2023 model year vehicles, prompting Ford to launch a broader inquiry into the matter. Although no physical samples were initially available for analysis, Ford’s Field Review Committee authorized a program to collect and evaluate additional samples from the field.

The subsequent tear-down analysis of the returned battery arrays revealed evidence of misaligned electrodes in the high voltage battery cells. The supplier also found that eight stacker machines between two production lines had produced cells with cathode shift, which did not meet the design requirements. This manufacturing concern resulted in overlap that fell short of the required standards. Notably, some of the cells from vehicles that experienced fires were manufactured during this time frame.

On February 18, 2025, Ford learned of a fifth report of a vehicle fire and decided to approve a safety recall. The recall affects certain 2022-2024 Ford F-150 Lightning BEVs, and owners are advised to take precautions until the repair is completed. Specifically, owners should only charge their vehicles to a maximum of 80% battery capacity to minimize the risk of an internal short circuit.

To address this issue, dealers will inspect and replace the high voltage battery array as necessary. Owner notification letters are expected to be mailed on March 17, 2025. Ford’s recall number for this issue is 25S18, and the National Highway Traffic Safety Administration (NHTSA) has assigned a campaign number of 25V-131.

Ford Fusion Energi Problems: Understand the Risks and Your Options

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The 2019-2020 Ford Fusion Energi has been plagued by a series of problems, including a critical safety recall that has left many owners concerned about their vehicle’s reliability and safety. This article talks about the issues affecting these vehicles, including recall 23S33, and provide you with essential information to help you navigate this situation.

Recall 23S33: A Fire Risk in the Trunk Area

In recent months, Ford has issued a voluntary recall (23S33) for certain 2019-2020 Ford Fusion Energi models due to a potential fire risk in the trunk area. According to the defect report, the high-voltage battery in these vehicles can overheat, causing a fire that may spread to other parts of the vehicle. This defect can occur when the vehicle is being driven or parked. It’s not uncommon for owners to experience symptoms such as:

  • A burning smell while driving
  • The vehicle displaying a “Stop Safely Now” message
  • A loss of power within seconds
  • A fire breaking out in the trunk area

Other Problems Affecting the Ford Fusion Energi

In addition to the recall, many owners have reported other issues with their 2019-2020 Ford Fusion Energi vehicles. Some common problems include:

  • Transmission Issues: Owners have complained about rough shifting, hesitation, and failure to engage gears properly.
  • Electrical System Malfunctions: Faulty wiring, faulty sensors, and software glitches have caused a range of issues, including erratic behavior from the vehicle’s systems.
  • Battery Drain: Some owners have experienced premature battery drain, which can leave them stranded.

Lemon Laws and Your Rights

If your 2019-2020 Ford Fusion Energi has been plagued by repeated problems, you may be entitled to relief under state or federal lemon laws. These laws are designed to protect consumers from defective vehicles and provide a range of remedies, including refunds, replacements, and compensation for damages.

Conclusion

The 2019-2020 Ford Fusion Energi recall is a serious issue that affects not only the vehicle’s safety but also its overall reliability. If you’re an owner of one of these vehicles, it’s crucial to stay informed about the latest developments and take proactive steps to protect yourself and your passengers. By understanding your options and rights under lemon laws, you can navigate this situation with confidence and ensure that your voice is heard.

Electrical System Concerns In Ford Bronco and Maverick Vehicles

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The National Highway Traffic Safety Administration (NHTSA) has launched an investigation into certain Ford Bronco and Maverick vehicles due to concerns with their electrical systems. The Office of Defects Investigation (ODI) opened a Preliminary Evaluation in January 2024 to investigate allegations of loss of motive power in model year 2021 Ford Bronco Sport vehicles.

What’s Happening?

In April 2024, Ford issued a safety recall (24V-267) covering 456,565 model year 2021-2024 Ford Bronco Sport and model year 2022-2023 Ford Maverick vehicles. The recall addressed occurrences of loss of motive power resulting from sudden degradation of the 12V battery during the drive cycle. When the battery failure occurs, consumers may experience a complete loss of engine power without the ability to restart, accompanied by the loss of 12V accessories, including hazard lights.

The Remedy

The recall remedy consists of software updates to the body control module and powertrain control module, which were designed to provide improved detection of the 12V battery state of charge during the drive cycle and provide warning to consumers if the battery is degraded.

New Concerns Arise

Despite the recall, the ODI has since received 15 reports from vehicle owners describing loss of motive power incidents for model year 2021 Ford Bronco Sport vehicles that received the 24V-267 recall remedy. Consumers describe that prior to the loss of motive power, there were no warnings related to the 12V battery or vehicle electrical system. Additionally, multiple consumers reported that after the vehicle was towed to the dealership following the loss of motive power, the event was diagnosed to the 12V battery, and a battery replacement was the only required repair.

What’s Being Done About It?

The NHTSA has opened an investigation (RQ24014) to further examine this issue. The agency will review the data and determine if additional action is necessary to ensure public safety.

What to Do Next

If you own one of these vehicles and have experienced a loss of motive power, it’s crucial to:

  1. File a report : Share your experience with the NHTSA by submitting a complaint on their website.
  2. Stay informed : Keep an eye on this investigation and any updates from the manufacturer or the NHTSA.

Your safety is paramount, and staying proactive can help prevent potential electrical system failures and keep you safe on the road.

Key Facts

  • Affected Vehicles: Certain Ford Bronco and Maverick models (2021-2024 Ford Bronco Sport and 2022-2023 Ford Maverick)
  • Component: Electrical System
  • NHTSA Action Number: RQ24014
  • Opened From: November 15, 2024–Present

Engine Cup Oil Leak In 2024-2025 Ford & Lincoln Vehicles

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Low Oil Pressure WarningFord Motor Company have identified a critical issue in certain 2024-2025 F-150, 2024 Expedition, and 2024 Lincoln Navigator vehicles equipped with the 3.5L GTDI engine. A misaligned engine cup plug has been found to potentially result in a rapid oil leak, posing serious safety risks.

The Problem: Misaligned Engine Cup Plug

The defect stems from a misalignment of the hydraulic press used to insert engine cup plugs into the cylinder head bore during assembly. This misalignment, approximately 1.5 mm off center, distorts the cup plug, reducing its retention within the bore. This defect may result in:

  • Rapid Oil Leak: A misaligned plug can cause sudden, large-volume oil loss.
  • Increased Fire Risk: Oil leaks in the presence of hot engine or exhaust components may lead to a fire.
  • Loss of Motive Power: A sudden loss of oil can result in reduced engine performance or a complete loss of motive power, increasing the risk of a crash.

Warning Signs for Customers

Drivers of affected vehicles may notice several warning signs, including:

  • Low Oil Pressure Warning: A warning light on the instrument cluster.
  • Burning Smell or Smoke: White smoke or a burning odor from the engine compartment.
  • Oil Leak or Engine Noise: Visible oil leakage or unusual noises from the engine.

Discovery and Investigation

The issue first came to Ford’s attention in October 2024 during a vehicle evaluation at the Kansas City Assembly Plant. A 2024 F-150 equipped with the 3.5L GTDI engine experienced a significant oil leak caused by the expulsion of a 13mm engine cup plug on the exhaust side.

Ford’s Critical Concern Review Group (CCRG) conducted an investigation and tear down analysis. They found no damage to the cylinder head bore but discovered that the cup plug was off center. The misalignment was traced back to maintenance work on the cylinder head assembly line at the Cleveland Engine Plant between September 9, 2024, and September 16, 2024. Other stations were confirmed to have proper alignment.

Field Action and Customer Notification

As of October 30, 2024, Ford has not received any warranty claims or field reports from customers regarding this issue. However, the company is taking measures to ensure customer safety:

  • Field Action Approval: Ford’s Field Review Committee approved the recall on November 1, 2024.
  • Dealer Inspections and Repairs: Dealers will inspect the cup plug alignment and replace any misaligned plugs.
  • Customer Notifications: Owner notification letters are scheduled to be mailed by December 2, 2024.

Recall Details

  • Ford Recall Number: 24S70
  • NHTSA Campaign Number: 24V-851

Next Steps for Vehicle Owners

Ford advises owners of the affected 2024-2025 F-150, 2024 Expedition, and 2024 Lincoln Navigator vehicles to monitor for any signs of the defect and to schedule an inspection with their dealer once notified. This precautionary recall aims to address the issue and ensure vehicle safety and reliability.

2024 Ford Mustang Low Voltage Problem

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The 2024 Ford Mustang has recently come under scrutiny due to a low voltage problem affecting the Remote Cluster Box (RCB). This issue can result in significant communication disruptions and software initialization problems that prevent the Instrument Panel Cluster (IPC) from functioning as intended. Here’s a breakdown of the problem and the potential risks.

The low voltage events impacting the 2024 Mustang can lead to the IPC failing to illuminate during vehicle startup or a drive cycle. When this occurs, the IPC goes completely dark, leaving the driver without crucial information, such as telltales and gauges. These elements are essential for the safe operation of the vehicle and are regulated under Federal Motor Vehicle Safety Standards (FMVSS), including:

  • FMVSS 101: Controls and displays
  • FMVSS 102: Transmission shift lever sequence, starter interlock, and transmission braking effect
  • FMVSS 108, 126, 135, 138, and 208: Additional standards related to lighting, electronic stability control, braking, tire pressure, and occupant protection

The malfunctioning IPC means safety-related telltales and gauges, like those for speed, fuel level, or warning indicators, become unreadable. This significantly raises the risk of a crash, as the driver cannot access critical safety information.

Problem Chronology

The timeline of events provides insight into how Ford discovered and began addressing the issue:

  1. August 20, 2024: The Flat Rock Assembly Plant’s Plant Vehicle Team (PVT) identified the IPC illumination problem during an analysis of warranty claims. The issue was escalated to Ford’s Critical Concern Review Group (CCRG) for a thorough review.
  2. August to October 2024: The CCRG conducted an extensive warranty claims analysis, examining whether similar problems affected other Ford vehicle lines using the same type of IPC. Fortunately, no other models showed the same failure.
  3. June 11 to October 7, 2024: Ford identified 58 warranty claims related to this issue in Mustang vehicles. Notably, there were no Vehicle Owner Questionnaires (VOQs) reported for this condition.
  4. October 18, 2024: The concern was presented to Ford’s Field Review Committee, which approved a field action to address the defect.

Although Ford is not aware of any accidents or injuries linked to the low voltage problem, the malfunction poses a significant safety risk. A non-illuminated IPC can make it impossible for drivers to monitor vital vehicle functions, potentially leading to hazardous situations on the road. The inability to see essential gauges or receive visual warnings compromises the driver’s ability to respond appropriately to changing vehicle conditions.

Ford dealers will update the IPC software to ensure the cluster functions correctly, eliminating the risk of low voltage events causing display failures.

  • Owner Notifications: Ford plans to mail notification letters to affected Mustang owners starting November 11, 2024.
  • Recall Information: The recall is identified by Ford as 24C35 and registered with the National Highway Traffic Safety Administration (NHTSA) under campaign number 24V-802.

If you own a 2024 Ford Mustang, it is crucial to stay informed about this recall and ensure your vehicle receives the necessary software update. This simple fix will help keep your Mustang safe and compliant with federal safety regulations.

Electrical Issues Affecting 2024 Ford Explorer and Bronco Sport Models

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battery problemsFord Motor Company has announced two significant recalls affecting its 2024 Explorer and Bronco Sport vehicles. Both recalls involve electrical issues that could potentially lead to serious problems for vehicle owners. Here’s what you need to know about each recall:

2024 Ford Explorer Recall (NHTSA Campaign Number: 24V-685)

Ford is recalling certain 2024 Explorer models equipped with 3.3L Hybrid engines. The issue stems from the 12-volt battery cable, which may chafe against the Belt-integrated Starter Generator (BiSG). If this occurs, it could lead to a short circuit.

This kind of electrical short can cause the vehicle to lose power, increasing the risk of a crash. In some cases, the short circuit could also result in a fire hazard. Ford is taking action to notify owners and replace or repair affected parts to ensure safety.

Key Concerns:

  • Affected Vehicles: 2024 Ford Explorers with 3.3L Hybrid engines
  • Problem: 12-volt battery cable could chafe against the BiSG, leading to a short circuit
  • Risks: Potential loss of power and fire hazard

2024 Ford Bronco Sport Recall (NHTSA Campaign Number: 24V-683)

The second recall involves certain 2024 Ford Bronco Sport vehicles. In these models, the body and powertrain control modules may fail to detect changes in the state of charge of the 12-volt battery. This issue can lead to incorrect readings and could affect the vehicle’s performance.

If the control modules fail to detect the battery’s actual charge, the vehicle may stall unexpectedly, which could increase the risk of an accident. Ford plans to update the control module software to fix the issue.

Key Concerns:

  • Affected Vehicles: 2024 Ford Bronco Sport
  • Problem: Control modules may not detect changes in the battery’s state of charge
  • Risks: Vehicle stalling unexpectedly, raising the likelihood of accidents

Ford will notify owners of the affected vehicles and instruct them to take their cars to authorized dealers for inspection and repair. The repairs, include replacing cables or updating control module software.

If you own a 2024 Ford Explorer Hybrid or Bronco Sport, it’s important to stay alert for communication from Ford about these recalls. In the meantime, you can also contact Ford’s customer service or visit the National Highway Traffic Safety Administration (NHTSA) website to check if your vehicle is part of the recall. By addressing these issues promptly, Ford aims to prevent potential accidents and ensure the continued safety of their customers.

Ford And Lincoln Engine Intake Valves May Break

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Ford Motor Company (Ford) have discovered a defect affecting certain 2021-2022 Bronco, F-150, Edge, Explorer, Lincoln Nautilus, and Lincoln Aviator vehicles equipped with either a 2.7L or 3.0L Nano EcoBoost engine. The engine intake valves may break while driving, which can result in engine failure and a loss of drive power.

The following vehicle models are affected by this recall:

2021-2022 Ford Bronco
2021-2022 Ford Edge
2021-2022 Ford Explorer
2021-2022 Ford F-150
2021-2022 Lincoln Aviator
2021-2022 Ford Bronco

In January 2022, an investigation was opened into certain 2021 Lincoln Aviator and Nautilus vehicles equipped with 2.7L and 3.0L Nano EcoBoost engines after 22 instances of engine failure were reported within three months of service. The issue involved left-hand engine intake valve fractures, which led to catastrophic engine damage and Loss of Motive Power (LOMP). A tear down analysis confirmed intake valve fractures in 251 engines from warranty repairs.

Ford traced the problem to intake valves exceeding the hardness specification due to faulty grinding processes by the supplier. The intake valve material was changed for vehicles produced after October 31, 2021, to improve robustness.

On May 5, 2022, Ford opened an internal investigation into early intake valve fractures, and on May 27, 2022, the National Highway Traffic Safety Administration (NHTSA) began its own investigation after receiving reports from Ford Bronco owners. NHTSA expanded the scope of the investigation in July 2022.

On September 29, 2023, NHTSA expanded their investigation to include all 2021 and 2022 Ford/Lincoln models with 2.7L and 3.0L engines. As of August 9, 2024, Ford reported 811 global warranty claims and 267 field reports related to fractured intake valves. On August 16, 2024, Ford’s Field Review Committee approved a field action to address the issue.

Dealers will perform an engine cycle test and replace the engine as necessary. Owner notification letters are expected to be mailed October 7, 2024. Ford’s number for this recall is 24S55 and the NHTSA campaign number is 24V-635.