Ford – California Lemon Law blog

Ford has decided that a safety defect exists involving the high-voltage battery packs inside certain plug-in hybrid vehicles—specifically the 2020–2024 Ford Escape PHEV and 2021–2024 Lincoln Corsair PHEV. At the center of the issue is a manufacturing defect inside one or more battery cells, which can lead to an internal short circuit and, in the worst cases, battery thermal venting or vehicle shutdown.

This problem originally surfaced years ago, was addressed by a previous recall, and now—based on new field data—Ford has determined that the prior fix may not have been enough.

What’s Causing the Problem?

Inside the high-voltage battery pack, each cell has a separator layer that keeps the cathode and anode apart. If this thin separator layer becomes damaged, the cell can short internally. Ford, its engineering teams, and the battery cell supplier have all pointed to variability in the supplier’s production process as the likely cause. This inconsistency may lead to small imperfections or weaknesses in the separator layer.

When the separator is compromised, the result can be:

Internal short circuits
Loss of propulsion power
Battery overheating
Thermal venting
Potential vehicle fire

Ford has not yet identified the complete root cause. Tear down investigations are still ongoing.

Safety Risks: What Can Happen

If a battery cell shorts internally:

1. Loss of Motive Power While Driving

The vehicle may suddenly shut down its propulsion system.
A red “Stop Safely Now” warning appears on the instrument cluster.

Although steering, braking, and lights still work, a sudden loss of acceleration dramatically increases crash and injury risk.

2. Battery Thermal Venting / Fire Risk

A shorted cell can overheat and vent hot gas, which can ignite surrounding components.
This is a significant safety hazard, particularly if venting occurs during or after charging.

To date, Ford reports no injuries or accidents connected to this defect.

A Look Back: The 24V-954 / 24S79 Recall

Ford already attempted to fix this issue once.

In December 2024, Ford approved recall 24V-954 (Ford) / 24S79 (Lincoln), which rolled out the following remedy:

Updated Battery Energy Control Module (BECM) software
Added enhanced detection of battery cell anomalies
Stopped battery charging automatically if anomalies were detected
Alerted owners through messages in the instrument cluster

This fix was intended to catch separator-layer damage before it caused a short circuit. However, new field reports show this strategy was not always effective.

The Turning Point: New Thermal Venting Cases in 2025

July–August 2025

Three European Ford Kuga PHEV vehicles (the Kuga is the European variant of the Escape PHEV) experienced battery thermal venting even AFTER receiving the recall software update.

September 2025

Two more cases surfaced.

August–October 2025 Investigation

Ford’s Critical Concern Review Group (CCRG) opened a formal investigation on August 27, 2025.
Recovered battery packs and control modules showed:

No detectable anomalies before venting
Significant thermal damage making root-cause confirmation difficult
The updated software did NOT trigger any warnings prior to failure

Meanwhile, tear down analysis from other replaced battery packs (those that were flagged by the software and did not vent) has not yet identified a definitive cause.

As of November 5, 2025

Ford reports:

7 total venting incidents, all from European Kuga PHEV vehicles
All had already received the 24V-954 software update
No injuries or accidents

November 7, 2025

Ford approved a new field action—leading to today’s recall.

The New Recall: 25SC4 (Ford) / 25V-789 (NHTSA)

Because of the new cases, Ford has issued a new recall to replace the old one.

Affected Vehicles:

2020–2024 Ford Escape Plug-In Hybrid
2021–2024 Lincoln Corsair Plug-In Hybrid
(These vehicles were previously included in recall 24V-954.)

Ford’s New Instructions to Owners

Until the final fix is ready, Ford advises:

Only use Auto EV mode
Limit the maximum charge of the high-voltage battery
Wait for mailed instructions and further updates

Interim owner letters are scheduled to go out December 1, 2025, detailing the safety risks and how to limit battery charging. A second letter will follow once a permanent remedy is available.

The Final Remedy Is Still Under Development

Ford has not yet determined what the permanent fix will look like—likely because the underlying defect is still not fully understood.

Conclusion

Ford’s latest recall highlights an unresolved and potentially serious defect in the high-voltage battery cells used in its Escape and Corsair plug-in hybrid models. The original software-based solution from 2024 was not enough to catch every instance of cell separator damage, and new thermal-venting cases have forced Ford to develop a more comprehensive fix. Until that final remedy is completed, owners must limit charging, follow Ford’s interim instructions, and watch for important recall notices.

Ford has announced a safety recall for certain 2025–2026 Ford Bronco and Bronco Sport models after discovering a software defect that can cause the instrument panel cluster (IPC) to fail at startup. While the failure rate appears low so far, the issue can disable the display of critical safety information—and that creates a significant risk for drivers.

The Problem: A Startup Timing Error That Can Blank the Instrument Panel

The Instrument Panel Cluster (IPC) is responsible for displaying essential vehicle information, including speed, engine warnings, braking system alerts, and other important safety telltales.

In the affected vehicles, the IPC can fail to initialize at startup. When that happens, the screen stays completely blank.

The Root Cause

Ford traced the issue to a timing-related software fault:

During the IPC’s sleep-entry sequence, there is a narrow window where a CAN wake-up interrupt can occur.
If this interrupt happens at the wrong moment, it triggers a memory protection fault in the cluster’s control unit.
The result: the IPC fails to boot, leaving the driver with a blank screen.

A blank cluster means no speedometer, no warning lights, and no safety indicators, which can significantly increase the risk of a crash if the vehicle is driven in that condition.

Why This Matters for Drivers

If the IPC is blank when the vehicle starts:

The driver cannot see speed, engine warnings, brake indicators, turn signals, or safety alerts.
Important telltales required under federal safety regulations may not display.
The driver loses critical information needed for safe operation.

Although the vehicle can still move, driving without a functioning instrument panel is dangerous—especially in traffic, at night, or in poor weather conditions.

Ford reports no accidents or injuries linked to this defect as of November 2025, but the potential safety impact is clear.

Ford’s Internal Investigation Timeline

The issue first surfaced on September 18, 2025, when reports of blank screens in 2025–2026 Broncos and Bronco Sports were escalated to Ford’s Critical Concern Review Group (CCRG). Over the next several weeks, the CCRG analyzed failure reports, warranty data, and comparisons to a similar prior recall (25S88 / 25V-540).

What they found was significant:

Warranty claims were low so far, but
68% of connected vehicles had ignition cycles falling within the window of susceptibility to this startup timing failure—almost identical to the earlier recall population.
No clear factor suggested the newer vehicles were at lower risk than the previously recalled models.

The first warranty claim was logged on May 15, 2025, and by November 7, 2025, Ford had documented 12 potentially related claims.

On that same date—November 7—the Field Review Committee approved a formal field action, confirming the need for a recall.

Which Vehicles Are Affected?

Ford has issued a recall for certain:

2025 Ford Bronco
2025 Ford Bronco Sport
2026 Ford Bronco
2026 Ford Bronco Sport

These vehicles are equipped with the susceptible SX2 Instrument Panel Cluster.

Ford’s recall number is 25SC3, and the corresponding NHTSA campaign number is 25V-788.

How the Problem Will Be Fixed

Ford will correct the IPC issue through an instrument panel cluster software update, available:

At Ford dealerships, or
Through an over-the-air (OTA) update (for vehicles equipped to receive OTA updates)
Ford plans to begin mailing recall notices on December 8, 2025.

What Bronco and Bronco Sport Owners Should Do

If your instrument panel cluster ever boots up blank:

Do not drive the vehicle until the IPC initializes correctly.
If your Ford Bronco is affected, contact your Ford dealer to schedule a repair.
Check for OTA update availability.
Monitor for recall notifications and verify your VIN’s status on Ford’s recall lookup page.

Even if you haven’t experienced the issue yet, your vehicle may still be at risk due to the timing-related nature of the fault.

If You Continue to Experience IPC Problems

If the problem persists after the recall repair—or if Ford is unable to fix the defect—owners may be eligible for repurchase, replacement, or compensation, according to California Lemon Laws.

Ford Motor Company has issued a recall for certain 2025 Ford Ranger trucks due to a potential problem with the passenger airbag system. According to the automaker, a manufacturing error could prevent the airbag from deploying properly in the event of a collision, creating an increased risk of injury for passengers.

While the issue affects only a limited number of vehicles, Ford is taking immediate action to ensure compliance with federal safety standards and to protect customer safety.

The Issue: Faulty Instrument Panel Scoring

The concern originates from the instrument panel (IP) assembly—specifically the laser scoring process used on the underside of the IP topper. The scoring defines the precise way the airbag deploys through the dashboard surface.

Ford discovered that the supplier, Yanfeng (YF), had unintentionally altered the laser scoring parameters during production. This seemingly small change resulted in a deviation from the approved design, affecting the scoring pattern in certain 2025 Ford Ranger vehicles.

This flaw may cause the passenger airbag to deploy more slowly or not fully deploy at all, especially during cold-temperature conditions or low-output deployments. During internal safety testing, Ford observed that in some cases, the airbag cushion failed to completely exit the panel surface, creating a potential hazard and violating Federal Motor Vehicle Safety Standards (FMVSS) 208, which govern occupant crash protection performance.

Timeline of Events

The airbag concern was identified and escalated through Ford’s quality and safety review process over the course of several weeks:

September 10, 2025: Supplier Yanfeng notifies Ford of an unintended change to the laser scoring process.
September 18, 2025: Ford’s Critical Concern Review Group (CCRG) launches a detailed investigation into the issue.
September 9, 2025: The supplier revises the laser scoring process to match the original specifications and validates the fix.
October 3, 2025: Ford’s Field Review Committee reviews the findings, confirms non-compliance with FMVSS 208, and authorizes a field action.

Although Ford is not aware of any crashes, injuries, or customer complaints linked to the problem, the company has decided to act out of caution and replace affected components.

What Ford Owners Need to Know

Owners of affected 2025 Ford Ranger trucks will be contacted directly by Ford. Here’s what you should know about the recall:

Recall Number: 25C54
NHTSA Campaign ID: 25V-678
Remedy: Ford dealers will replace the instrument panel assembly.
Notification Schedule:
- Interim owner letters were mailed on October 24, 2025, to inform customers of the issue.
- Final remedy letters will be mailed once replacement parts are available and the repair process begins.

If you drive a 2020 or 2021 Ford Super Duty F-250, F-350, or F-450, there’s a new recall you should know about. Ford has confirmed a steering defect that could cause you to suddenly lose control of your truck while driving.

And here’s the bigger issue: these trucks already have a long history of recalls. If your Super Duty keeps going back to the dealership for repairs, it may be more than just bad luck — your truck could be a lemon.

What’s the Problem?

The recall centers on the steering column upper shaft. In certain trucks, the part doesn’t meet Ford’s own strength requirements. That means it can actually separate while driving, causing you to lose the ability to steer.

Safety Risk: Loss of steering control makes a crash much more likely.
No Warning Signs: There are no dashboard messages or alerts — the failure can happen without warning.
Affected Trucks: Ford believes the defect affects trucks built at the Kentucky Truck Plant before October 1, 2020.

How Ford is Handling the Recall

Ford has issued recall number 25S94 (NHTSA 25V-626). Here’s what they’re telling owners:

Notices in the Mail: Letters started going out in October 2025 to warn owners.
Dealer Inspections: Dealers will check your steering column.
- If it fails inspection → the part will be replaced.
- If it passes → it will be modified to improve durability.
Final Fix: A long-term repair solution is expected by December 2025.

Ford Super Duty: Too Many Recalls?

Unfortunately, this isn’t the first time Super Duty owners have faced recalls. The 2020–2021 lineup has been hit with recalls for:

Driveshaft separations
Brake system problems
Electrical issues

When you add the steering shaft defect to the list, it paints a troubling picture. For owners, these repeated issues can mean frustration, downtime, and serious safety worries.

Could Your Truck Be a Lemon?

Here’s the bottom line: If you’ve had to bring your F-250, F-350, or F-450 back to the dealer again and again for serious repairs, you may not just have a bad truck — you may have a lemon.

Lemon Law Basics: If a defect affects your truck’s safety, value, or reliability, and the manufacturer can’t fix it after a reasonable number of tries, you may qualify for a buyback, replacement, or cash settlement.
Why Steering Defects Matter: Because steering is critical to safe driving, repeated failures or incomplete fixes could make your case even stronger.

What Should You Do Now?

Keep Records: Save every repair order, recall notice, and warranty claim. Documentation is key if you ever need to pursue a claim.
Pay Attention to Repeat Repairs: If you’ve had the same issue fixed more than once, or your truck keeps going back to the dealer, you may have lemon law rights.
Get Help if Needed: Don’t wait until you’re out of patience (or warranty). Talk to a lemon law professional if you suspect your Super Duty qualifies.

FAQ: Ford Super Duty Steering Recall & Lemon Law

Q: Is it safe to drive my truck before the repair?
A: Because there are no warning signs before the steering defect happens, it’s risky to keep driving an affected truck. Schedule a dealer inspection as soon as possible.

Q: What if the dealer already repaired my steering issue once, but the problem came back?
A: If the same issue keeps happening after repairs, that’s a red flag. Repeated failures may qualify your truck as a lemon under state or federal law.

Q: How many repairs does it take before my Ford is considered a lemon?
A: It depends on your state. In many states, two or more failed repair attempts for a serious safety issue (like steering) may be enough. In others, it may take three or four attempts.

Q: Can I get a buyback or replacement if my truck is a lemon?
A: Yes. Lemon laws can entitle you to a buyback of your vehicle or a replacement truck, if the manufacturer can’t fix the defect after a reasonable number of tries.

Q: Do I need a lawyer to file a lemon law claim?
A: While not required, most lemon law cases are easier with legal help. Many lemon law attorneys work on a no-cost-to-you basis, since the law requires the manufacturer to pay legal fees if you win.

Final Thoughts

The 2020–2021 Ford Super Duty trucks are built to tackle tough jobs, but repeated recalls and a dangerous steering defect have many owners concerned. If your F-250, F-350, or F-450 is spending more time in the shop than on the road, don’t ignore it. Your truck may qualify as a lemon, and knowing your rights could help you get the compensation or replacement you deserve.

Ford Motor Company has announced a safety defect affecting several 2025 Ford and Lincoln models due to a potential braking issue. Certain vehicles may experience a loss of power brake assist, which could extend stopping distances and increase the risk of a crash—particularly when Advanced Driver Assistance System (ADAS) features are in use.

Which Ford And Lincoln Vehicles Are Affected?

The recall involves specific 2025 models, including:

Ford F-150
Ford Expedition
Ford Bronco
Ford Ranger
Lincoln Navigator

Ford’s investigation found that the Electronic Brake Booster (EBB) module may malfunction while driving or when ADAS features are active.

What’s the Problem?

The issue was first detected on May 14, 2025, when the Expedition/Navigator Rapid Response Team identified a Ford Management Lease Vehicle with a loss of brake boost. The malfunction triggered a Diagnostic Trouble Code (DTC), prompting Ford to review connected vehicle data, driver reports, and incident logs.

Customers reported a sudden loss of brake boost, along with extended brake pedal travel and longer stopping distances. While Ford confirmed that affected vehicles still meet Federal Motor Vehicle Safety Standards (FMVSS 135, 105, and 126), the unexpected nature of the issue poses a safety risk.

Incident Reports

Between March 13 and June 26, 2025, Ford received 37 warranty claims related to this problem.
As of July 14, 2025, there has been one alleged low-speed crash potentially linked to the defect.
No injuries or fires have been reported.

The Recall Process

On July 18, 2025, Ford’s Field Review Committee approved a field action.

The fix involves an Electronic Brake Booster software update, which can be delivered over-the-air (OTA) or performed at a dealership.
Owner notification letters are expected to be mailed on August 25, 2025.
Ford recall number: 25S77
NHTSA campaign number: 25V-488

What Owners Should Do If Their Ford Or Lincoln Is Affected

If you own one of the affected vehicles:

Schedule a dealer visit or wait for the OTA update if applicable.
Monitor your braking performance, especially when using ADAS features such as adaptive cruise control or automatic emergency braking. If you experience unusual brake feel or extended stopping distances, seek service immediately.

Safety Reminder

Even with this issue, Ford states the braking systems remain functional, but stopping distances may be longer without power brake assist. Extra caution is advised until the repair is complete.

A widespread Ford recall could impact your ability to safely back up your vehicle — and it might also qualify you for relief under California’s Lemon Law.

What’s going on?

Ford is recalling over 1 million vehicles due to a software glitch that affects the rearview camera. The image might freeze, lag, or not show up at all when you’re in reverse. That’s more than just an inconvenience — it’s a real safety issue, especially in tight parking lots or near pedestrians.

Which models are included?

Ford: 2021–2025 Bronco, Escape, Edge, Expedition, F-Series, Mustang, Mach-E, Ranger, Transit
Lincoln: Nautilus, Corsair, Navigator (2021–2025)

Ford plans to notify owners starting June 16, 2025, and repairs will be done either at the dealership or possibly via an over-the-air software update — depending on your vehicle.

Why California Lemon Law applies

If your rearview camera has failed repeatedly, or if the issue has made your vehicle unsafe to drive, California law may consider your car a “lemon.” Even if it’s just one issue, if it affects safety and the dealership can’t fix it in a reasonable amount of time, you might qualify for:

A replacement vehicle
A refund
Payment for out-of-pocket expenses

The law applies whether your car was new or used, as long as it’s still under the manufacturer’s warranty.

What to do if this affects you:

Check your records — has your camera failed before?
If so, document everything and keep copies of repair orders.
Don’t wait for the dealership to tell you what your options are. A Lemon Law attorney can evaluate your case for free, and most clients never pay out of pocket.

You deserve a vehicle that works the way it’s supposed to — especially when safety is involved.

If you’re concerned about your Ford or Lincoln defects or have questions about your rights under the California Lemon Law, Call Now for a FREE Case Review – 888-395-3666 or fill in the contact form at the top of the page. Our experienced team is here to help you navigate the process and ensure you receive the compensation you deserve. Don’t wait – take action today to protect your rights as a California consumer!

According to Ford’s records, certain 2020-2021 Aviator vehicles were recorded as having the repair successfully completed, but may still be at risk due to the incorrect software installation. If the correct software update remedy is not installed on the vehicle, the manufacturing defect can cause a lower capacity cell to develop an internal short circuit, leading to a battery power off and potentially resulting in a vehicle fire.

The issue was first brought to Ford’s attention in November 2024, when an audit revealed insufficient data to confirm correct software application across all field service actions (FSAs) using the FDRS service tool. A team was formed to investigate further and created templates to track software lineage part numbers. In December 2024, Ford informed the National Highway Traffic Safety Administration (NHTSA) of the concern and discussed a plan to address the mismatched vehicles. After conducting an audit, it was found that 99.3% of the repairs conducted under recall 23S53 had the correct software installed. However, they identified specific vehicles that were recorded as receiving the remedy but still had software that did not address the safety risk.

To rectify the situation, Ford has approved a field action and will update the Battery Energy Control Module software for the affected vehicles. The company is not aware of any reports of accidents or injuries related to this condition. Dealers will correct the problem by updating the software with the correct version.

The recall number for this issue is 25S58, and the NHTSA campaign number is 25V-349. If you own a 2020-2021 Lincoln Aviator vehicle equipped with a 3.0L PHEV engine, and you receive a recall notice, contact your dealer for repairs to ensure your safety on the road.

A major safety concern has been uncovered by Ford, affecting several of its 2024 and 2025 models, including the popular Bronco, Ranger, and electric F-150 Lightning. At the heart of the issue is a potentially faulty front upper control arm ball joint fastener, which may have been improperly secured or even missing altogether. This oversight could lead to a catastrophic failure, where the front upper control arm becomes detached from the knuckle assembly, compromising the vehicle’s stability and control.

The first reported incident involving the F-150 Lightning BEV occurred on March 6, 2025, when a customer’s vehicle suffered a right front wheel failure after just 634 miles on the road. Upon investigation, it was discovered that the upper control arm nut was missing, which had caused the control arm to separate from the knuckle assembly.

Further analysis revealed that the root cause of the problem lies in the manufacturing process, where inconsistencies in the alignment between the fastening tool and the fastener may have prevented the nut from being properly secured. As a result, the ball joint nut may not have been tightened to the correct torque specification, creating a risk of separation.

Drivers who experience this issue may initially notice unusual noises, such as clunks or rattles, when driving over bumps or uneven terrain. However, in more severe cases, the loss of directional control can occur without warning, significantly increasing the risk of an accident.

While the exact timeline for the discovery of this issue on the Bronco and Ranger models is not publicly available, it is imperative that owners of affected vehicles take immediate action to ensure their safety on the road. Ford dealers will inspect and repair the ball joint fastener as necessary, and owner notification letters were sent out on May 23, 2025.

The recall numbers for this issue are 25S45 (Ford’s internal number) and 25V-310 (NHTSA campaign number) for the Bronco and Ranger, and 25V-341 for the F-150 Lightning BEV. If you receive a notification regarding your vehicle, it is essential to contact your local Ford dealer promptly to schedule an appointment and have the necessary repairs carried out.

In conclusion, the safety of drivers and passengers is paramount, and it is crucial that owners of affected Ford vehicles take swift action to address this critical issue. By doing so, they can ensure a safe and reliable driving experience, and minimize the risk of accidents caused by this potentially hazardous fault.