Category Archives: Ford

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

Ford Mustang Mach E Battery Contactor Could Overheat

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Certain 2021-2022 Ford Mustang Mach-E cars might face a power problem due to an overheated high voltage battery contactor, potentially leading to an increased risk of accidents.

In June 2022, Ford’s Field Review Committee (FRC) gave the green light to a Field Service Action (FSA) named 22S41, specifically designed to tackle concerns regarding the overheating of the high voltage battery main contactor in select 2021-2022 Mustang Mach-E vehicles. To fix this issue, dealers updated the software for the Secondary On-Board Diagnostic Control Module (SOBDMC) and the Battery Energy Control Module (BECM). The enhanced SOBDMC software keeps an eye on the contactor’s temperature and smartly reduces the battery’s power output to prevent further damage. Meanwhile, the upgraded BECM software checks the contactor’s resistance to identify any damage, then it generates a diagnostic trouble code (DTC) and lowers the vehicle’s power to avoid more harm.

At the time of approving this FSA, Ford’s Critical Concern Review Group (CCRG) and Electrical Propulsion Engineering (EPE) teams found the software updates for BECM and SOBDMC to be a suitable way to minimize the safety risks linked to power loss. The software update, by monitoring contactor resistance, warns customers if the resistance exceeds a certain limit. Alongside the warning, the software reduces power to prevent further contactor damage and the associated power loss risk. Even with the reduced power, customers can safely accelerate to highway speeds. This approach was also reviewed with the National Highway Traffic Safety Administration (NHTSA).

In June 2022, Ford Motor Company decided to issue a safety recall (NHTSA Recall 22V-412) for 48,924 model year 2021-2022 Ford Mustang Mach-E vehicles produced between May 27, 2020, and May 24, 2022. This recall was prompted by concerns about high voltage battery contactors overheating, primarily due to direct current (DC) fast-charging and repeated full-throttle pedal events. This overheating could lead to arcing or deformation of the electrical contact surfaces. If this occurs, the contactor could either remain open or get welded shut. An overheated contactor that opens while driving may lead to an immediate loss of power without re-engagement.

Following consumer complaints, the Office of Defects Investigation (ODI) initiated a Recall Query (RQ) for 2021-2022 Ford Mach-E vehicles included in Recall 22V-412. These vehicles had previously received a remedy involving a Secondary On-Board Diagnostic Control Module (SOBDMC) software update to monitor contactor temperature and reduce battery power to protect the contactor, as well as a Battery Energy Control Module (BECM) software update to monitor contactor resistance and reduce vehicle power in case of an overheated contactor.

To address this issue, dealers will replace the high voltage battery junction box. This recall is identified by Ford as 23S56, and the corresponding NHTSA campaign number is 22V-687. Vehicles included in this recall that were previously repaired under recall 22V-412 will need to have the new remedy completed.

Battery Fire Risk in Certain Lincoln Aviator and Ford Explorer Vehicles

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Ford Motor Company (Ford) is taking action to address a safety concern with specific 2020-2022 Lincoln Aviator and 2020-2022 Ford Explorer vehicles that are equipped with 3.0L PHEV (Plug-in Hybrid Electric Vehicle) engines. These vehicles may have a manufacturing defect in one or more of the high voltage battery cells, which could lead to an internal short circuit and a potential battery fire.

Discovery of the Issue

Ford became aware of this issue in June 2023 when they received a report regarding thermal venting problems with the PHEV battery used in these vehicles. The report highlighted a 2021 model year Transit Custom in France experiencing PHEV battery thermal venting. Subsequent analysis, conducted by the battery cell supplier, revealed an internal short circuit in the vehicle’s high voltage battery pack, partly due to the presence of a folded anode tab, which occurred during the cell manufacturing process.

Ongoing Investigation

The supplier’s investigation indicated that another, as yet unidentified, factor is necessary for the folded anode tab condition to lead to battery thermal venting. The supplier is actively conducting component-level testing to pinpoint this second factor. While this factor remains unknown, the Ford Critical Concern Review Group (CCRG) has been working to identify the group of vehicles that may potentially have the cell folded anode tab condition.

Additional Incidents

Ford was aware of three more instances of cells with folded anode tabs in the field. These incidents involved a 2020 model year Aviator in the United States, resulting in PHEV battery thermal venting, another 2020 model year Aviator in the United States resulting in a Malfunction Indicator Light (MIL) but no battery thermal venting, and a 2020 model year Aviator in Canada, also resulting in an MIL but no battery thermal venting.

Preventive Measures

To address this issue, Ford has reviewed the cell supplier’s manufacturing process and made improvements during cell production to reduce the occurrence of the folded anode tab condition. The timing of these process enhancements has been used by the CCRG to determine the affected population of vehicles.

Recall Procedure

Owners of the affected vehicles will be notified and requested to visit their authorized Ford dealers for a Battery Energy Control Module (BECM) diagnostic test. If the test identifies a battery problem, the high voltage battery pack will be replaced at no cost to the owner. To check if your vehicle is part of this recall, refer to Ford’s recall number 23S53 and the NHTSA campaign number 23V-626.

Ford Mustang Mach-E Battery Problems Continue

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In the realm of electric vehicles (EVs), the 2021-2022 Ford Mustang Mach-E gained significant attention for its sleek design and promising performance. However, beneath its exterior allure, a complex challenge emerged that put the spotlight on battery-related issues. In June 2022, Ford Motor Company took steps to issue a safety recall (NHTSA Recall 22V-412) for a range of Mustang Mach-E vehicles, acknowledging battery problems that had the potential to impact both safety and performance.

2021-2022 Ford Mustang Mach-E Battery Recall

The safety recall was prompted by concerns related to high voltage battery main contactors. These components, integral to the functioning of the vehicle’s battery system, were at risk of overheating. The primary culprits behind this issue were the effects of direct current (DC) fast-charging and frequent aggressive acceleration events, which placed excessive stress on these contactors. Overheating, led to arcing or deformation of the electrical contact surfaces. Perhaps the most alarming consequence was the potential for a contactor to remain open, resulting in a sudden loss of motive power during driving. This raised significant safety concerns due to the increased risk of accidents resulting from unexpected power loss.

The Office of Defects Investigation

The recall was further complicated by the involvement of the Office of Defects Investigation (ODI). Following the initial recall (22V-412) involving approximately 48,924 vehicles, the ODI received a series of consumer complaints. These complaints highlighted incidents of high voltage battery main contactor failures even after the prescribed remedy had been implemented. This indicated that the initial software updates, aimed at temperature monitoring and power reduction, might not have fully resolved the underlying issues. This discrepancy called into question the effectiveness of the initial recall and the adequacy of its remedy.

Ford’s Response

In response to the ongoing concerns, Ford issued a Technical Service Bulletin TSB 23-2020 which focused on replacing the High Voltage Battery Junction Box (HVBJB) in the affected vehicles. The HVBJB is a crucial component that facilitates the connection between various parts of the high voltage battery system. Consumers who had experienced a loss of motive power post the initial recall were directed towards this bulletin. The bulletin aimed to ensure that the remedy for the contactor failures was comprehensive and addressed any lingering issues.

Addressing The Problem

The complexity of addressing battery-related problems in the 2021-2022 Ford Mustang Mach-E underscored the challenges of integrating advanced EV technology into mainstream vehicles. The initial recall and its subsequent developments shed light on the interplay between software solutions and hardware replacements. While software updates were intended to mitigate the risks, the need for a hardware replacement (HVBJB) became evident as consumer complaints persisted.

Conclusion

The battery problems encountered by the 2021-2022 Ford Mustang Mach-E vehicles served as a valuable lesson for both automakers and consumers in the evolving world of electric vehicles. The recall (22V-412), the Office of Defects Investigation’s involvement, and Ford’s multi-faceted response emphasized the importance of thorough and quick problem-solving in this rapidly advancing domain. As the automotive industry continues to innovate, experiences like these pave the way for safer and more reliable electric vehicles in the future.

2021-2022 Ford Mustang Mach-E Lemon Vehicle

If you find yourself grappling with persistent issues in your 2021-2022 Ford Mustang Mach-E vehicle, the California Lemon Law can offer you a potential lifeline. Designed to protect consumers from purchasing or leasing defective vehicles, this law provides a pathway to relief if your vehicle is deemed a “lemon.” If your Mustang Mach-E experiences substantial defects that impair its use, safety, or value, and these issues persist despite a reasonable number of repair attempts within the vehicle’s warranty period, you may be entitled to a replacement vehicle or a refund of the purchase price. The California Lemon Law serves as a crucial safeguard, empowering you to take decisive action to address your vehicle’s ongoing problems and helping you move forward with confidence.

Ford F-150 Unintended Activation of Electric Parking Brake

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Ford has been monitoring certain 2021-2023 Ford F-150 trucks equipped with single exhaust systems due to potential issues with the electric parking brake. Reports have surfaced indicating an unexpected activation of the parking brake, sparking concern among owners and the automaker alike. In response, Ford’s Critical Concern Review Group (CCRG) launched an investigation to assess the problem’s magnitude and potential root causes.

The initial investigation began after Ford received troubling reports of unintended parking brake application on a 2021 model year F-150 truck. Warranty and field reports revealed signs of damage to the wiring harness housing the rear electric parking brake circuits. Such damage raised red flags, necessitating a closer look to ensure the safety and reliability of these vehicles.

Looking deeper into the issue, Ford’s team of experts discovered that the damaged wiring was a component of the rear axle wiring harness assembly. This particular harness assembly not only houses wires for the rear electric parking brakes but also serves other essential electrical components. The investigation highlighted that, in certain scenarios, the rear axle wiring harness bundle could make contact with the rear axle housing, leading to chafing of the wiring bundle.

Over time, this chafing effect could wear through the abrasion-resistant tape and circuit insulation, ultimately exposing the underlying copper wiring. The consequence of this exposure could be the grounding of circuits on the rear axle housing, which in turn could cause unintended activation of the electric parking brake. Adding to the complexity, corrosion on the rear axle housing could accelerate the abrasion process, compounding the problem.

Ford’s engineering team took the investigation further by conducting comprehensive vehicle-level testing and data analysis. The goal was to understand the implications of damaged circuits within the wiring harness bundle. They discovered that if the low side electric parking brake motor circuit experienced a short to ground, it could trigger the unintended activation of the electric parking brake, potentially leading to hazardous situations.

Ford are initiating a recall to resolve this issue. Owners of affected vehicles will receive official notices instructing them to take their vehicles to authorized Ford or Lincoln dealers for thorough inspections of the rear axle wiring harness.

During the inspection, if the technicians observe any wear on the abrasion tape covering the wire bundle, the suspect harness will be replaced with a new service harness. In cases where the abrasion tape shows no signs of wear, the dealer will take preventive measures by installing a protective tie strap and tape wrap, ensuring the wiring remains secure and safeguarded against future issues.

Ford is aware of 918 warranty and three field reports in North America for the wire chafing condition. Of these reports, 299 indicated that the electric parking brake had unintended activation, of which nineteen (19) allege electric parking brake application while driving. Ford has assigned a recall number to this campaign, which is 23S35. Additionally, the National Highway Traffic Safety Administration (NHTSA) has designated the campaign as number 23V-509.

Ford Fusion PHEV Battery Problem
Risk Of Stall Or Fire

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Ford Fusion with smoke from trunk

Certain Ford Fusion PHEV vehicles may experience damage to their Battery Energy Control Module (BECM) due to excessive voltage and current flow. This issue can lead to a loss of motive power and pose safety risks such as the possibility of a crash or a localized fire around the BECM. Ford is currently working on a fix for this safety issue.

Problem was first discovered in July 2022, when Ford’s Trend and Early Warning Support (TEWS) team alerted the Critical Concern Review Group (CCRG) about five fire reports involving 2019 Fusion PHEV vehicles equipped with 30Ah high voltage batteries. These fires occurred while the vehicles were at dealerships during a replacement BECM service to address various issues like voltage sense Diagnostic Trouble Codes (DTCs), check engine light, no start, or loss of motive power concerns. Ford’s High Voltage Battery Systems Team conducted an analysis and determined that the fires originated from the BECM. Further examination by the supplier revealed that the Current Interrupt Device (CID) had been activated in the high voltage battery cells of the affected units, though the reason behind this activation remains unknown. Due to the rate and severity of the concern, Ford’s CCRG initiated an investigation.

In February 2023, Ford published a Technical Service Bulletin (TSB) that advises replacing the high voltage battery if vehicles come in for service with one or more voltage sense DTCs, instead of just replacing the BECM. This measure aims to address the underlying issue and prevent further damage.

While a permanent remedy is under development, Ford urges owners not to charge their vehicles until the remedy is implemented. To ensure owners are aware of the safety risk, interim letters have been sent to them as of July 14, 2023. Second letters will follow once the remedy becomes available. This recall is identified as 23S33 by Ford, and the NHTSA campaign number is 23V-440.

Ford Escape, Ford Maverick And Lincoln Corsair Engine Failure

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Ford Motor Company (Ford) has recently announced a crucial safety recall for specific models of Ford Escape, Ford Maverick, and Lincoln Corsair vehicles. The recall aims to address a potential issue that could lead to a vehicle fire, urging affected owners to promptly visit their dealers for necessary repairs and precautions.

The vehicles affected by this recall include those equipped with 2.5L HEV/PHEV engines, manufactured during the specified time frames. The identified problem revolves around the premature failure of these engines, which can have severe consequences. When an engine fails, there is a risk of significant quantities of engine oil and/or fuel vapor being released under the vehicle’s hood. These substances may then migrate to and accumulate near potential ignition sources, posing a potential fire hazard. In addition to the risk of fire, localized melting of components or the emission of smoke may also occur.

The specific models affected by this recall are the 2020-2023 Ford Escape, the 2022-2023 Ford Maverick, and the 2021-2023 Lincoln Corsair. Ford has identified isolated engine manufacturing issues as the root cause of the 2.5L HEV/PHEV engine failures that result in engine block or oil pan breaches. Despite the breach, the HEV/PHEV system continues to propel the vehicle, allowing the driver to continue operating it. Unfortunately, this means that as the driver continues to drive after a block breach, oil and/or fuel vapor continues to be expelled and accumulate near ignition sources, exacerbating the risk.

Owners of the affected vehicles should be aware of the signs indicating engine failure. These signs include loud noises such as a metal-to-metal clank, which will be audible to the vehicle’s occupants. Additionally, an engine failure will lead to a reduction in engine torque. If drivers notice any unexpected engine noises, experience an unexpected torque reduction, or observe smoke emanating from the engine compartment, they are strongly advised to safely park the vehicle and promptly shut off the engine.

Ford is actively working on developing the remedy for this issue. In the meantime, interim letters have been sent out to notify owners of the safety risk. These letters were mailed on June 23, 2023, to inform owners about the importance of addressing the issue. Once the remedy is available, a second round of letters will be sent out to inform owners and provide instructions for getting the necessary repairs. It’s important to note that this recall, identified by Ford as recall number 23S27, expands and replaces the previous recall number 22V-484. Therefore, even if the vehicles have been previously repaired under recall number 22V-484, owners will still need to have the new remedy completed to ensure their safety.

Lincoln MKC Fire Risk While Parked

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Lincoln MKC under hood fire

Ford Motor Company has made a decision regarding a defect that poses a risk to motor vehicle safety in specific models of Lincoln MKC vehicles manufactured between 2015 and 2019. These vehicles, produced during the mentioned time frame, have been found to have a potential for under hood fire, even while the vehicle is parked and turned off.

In March 2023, Ford’s Critical Concern Review Group (CCRG) was made aware of the issue related to 18 reports of under hood fires involving 2015 to 2017 model year MKC vehicles in North America and China. It is noteworthy that all these incidents occurred when the vehicles were parked and not in use.

Ford’s CCRG initiated a thorough investigation that spanned throughout March, April, and May. The investigation encompassed various activities, such as comprehensive vehicle inspections, reviews of suppliers involved in the manufacturing process, assessments of product designs, detailed analysis of field data, and rigorous examination of components and subsystems in laboratory settings.

At present, the investigation has not been able to find the cause or origin of the fires. Nevertheless, it was observed that the fires seemed to originate in close proximity to the vehicles’ 12-volt batteries, which raised concerns regarding the potential link between the fires and the battery system.

As of May 2023, Ford’s CCRG has received information about 19 potentially related incidents of under hood fires, all of which occurred while the vehicles were parked and turned off.

Ford’s Field Review Committee thoroughly examined the matter and decided to undertake a field action to provide guidance to vehicle owners. As part of this field action, Ford advised owners to park their vehicles outside and away from any structures until the completion of the ongoing investigation. This precautionary measure aims to minimize the risk of potential fires until a conclusive resolution is reached.

For reference, customers and owners can refer to Ford’s designated number for this recall, which is 23S28, and the corresponding NHTSA campaign number, which is 23V-378.

Ford F-150 BEV Tail Lights Flicker

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Ford will be contacting the owners of certain 2022-2023 Ford F-150 Battery Electric Vehicles (BEVs) due to a problem that may cause inoperative or flickering back-up lights. This issue came to the attention of Ford’s Critical Concern Review Group (CCRG) in March 2023, following reports of moisture in the rear light bar of select F-150 BEV Platinum and Lariat vehicles from the 2022 and 2023 model years. These vehicles feature a rear light bar that spans the tailgate and houses the supplemental tail lamp and reverse lamp functions. Upon further investigation, Ford discovered an increased rate of warranty reports citing moisture in the rear light bar, which consequently resulted in certain claims of malfunctioning or flickering rear supplemental tail lamps and reverse lamps.

Upon examining the returned parts, Ford observed the presence of water droplets or condensation within the lamp, indicating micro cracks in the outer lens of the light bar. Testing conducted on the parts retrieved from the field revealed that over half of them had either inoperative or flickering supplemental tail lamps and/or reverse lamps. The investigation by the CCRG pinpointed the cause of stress on the light bar to be static and dynamic loading during the assembly plant fit process, which involves aligning the tailgate and surrounding components. Additionally, extreme tailgate surface loading in temperatures below -40 Celsius was also identified as a factor. The forces exerted on the light bar and its housing result in stress being transferred to the lens, potentially leading to the development of micro cracks.

To address this issue, owners who receive notices will be required to visit their dealerships to have the rear light bar replaced. Ford has assigned the recall number 23S30 to this specific recall, while the NHTSA campaign number is 23V-418.

In situations where vehicle owners encounter persistent issues with their newly purchased vehicles, such as the problems described above, they may be protected by lemon laws. Lemon laws vary by jurisdiction but are generally designed to provide legal recourse to consumers who unknowingly purchase vehicles with substantial defects that affect their safety, value, or use. These laws typically require manufacturers to either replace the defective vehicle or refund the purchase price if the vehicle cannot be adequately repaired within a reasonable number of attempts. If you suspect that your vehicle is a lemon, it is advisable to familiarize yourself with the lemon law provisions in your jurisdiction and consult with a legal professional to understand your rights and options for resolution.