Ford – Page 2 – California Lemon Law blog

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.

A software error has been identified as the cause of rear view camera problems in certain Ford and Lincoln vehicles, prompting a field action to update the affected systems. The issue can cause the rear view camera image to delay, freeze, or not display when the vehicle is in reverse, potentially increasing the risk of accidents.

The National Highway Traffic Safety Administration (NHTSA) first contacted Ford about the problem in January 2025, after receiving 37 vehicle owner questionnaires (VOQs) regarding rear-view camera complaints on 2021-2023 Model Year Ford F-150 vehicles. An investigation by Ford’s Automotive Safety Office revealed that 15 of these complaints alleged a frozen rear-view camera image while in reverse, with an additional 18 related to SYNC and/or APIM concerns.

Further review by Ford’s Critical Concern Review Group (CCRG) and the SYNC engineering team led to the identification of the causal factors as specific SYNC4 software variants between 1.7 and 1.9. A read-across analysis revealed that other vehicle lines also utilized the affected software versions, resulting in a total of 232 warranty claims in North America.

The affected vehicles include various Ford models, such as the Bronco, F-150, Edge, Escape, and Expedition, as well as Lincoln models like the Nautilus, Navigator, and Corsair. The issue is caused by a software error in the accessory protocol interface module (APIM), which will be updated by a dealer or through an over-the-air update.

According to Ford, one minor crash resulting in property damage has been reported, but no injuries have been linked to this concern. To address the issue, Ford will be conducting a field action, with interim letters notifying owners of the safety risk expected to be mailed on June 16, 2025. A second letter will be sent once the remedy is available, anticipated for the third quarter of 2025.

Vehicle owners can identify this recall by Ford’s number, 25S49, and the NHTSA campaign number, 25V-315. It is essential for affected vehicle owners to take note of this issue and follow the instructions provided by Ford to ensure their rear view camera system is updated and functioning correctly to minimize the risk of accidents.

The vehicles affected include:

2021-2024 Ford Bronco
2021-2024 Ford F-150
2021-2024 Ford Edge
2023-2024 Ford Escape
2023-2024 Ford F-250 SD
2023-2024 Ford F-350 SD
2023-2024 Ford F-450 SD
2023-2024 Ford F-550 SD
2023-2024 Ford F-600 SD
2022-2024 Ford Expedition
2022-2025 Ford Transit
2021-2023 Ford Mach-E
2024 Ford Ranger
2024 Ford Mustang
2021-2023 Lincoln Nautilus
2022-2024 Lincoln Navigator
2023-2024 Lincoln Corsair

In summary, a software error has been identified as the cause of rear view camera problems in certain Ford and Lincoln vehicles, and a field action has been initiated to update the affected systems. Vehicle owners are advised to be aware of this issue and take necessary steps to ensure their safety on the road.

F-150 Lower Steering Shaft

Ford Motor Company has issued a recall for certain 2025 model year F-150 vehicles due to a potential problem with the lower intermediate shaft fasteners. The issue affects the attachment of the lower intermediate shaft to the steering gear, which may not have been properly secured during the assembly process.

According to Ford, the problem was first identified on March 28, 2025, when a warranty claim was filed for a vehicle that exhibited “excessive steering play” during a pre-delivery inspection. Upon investigation, it was discovered that a lower intermediate shaft fastener was missing. Although an initial yard campaign did not reveal any additional vehicles with loose or missing fasteners, further review by Ford’s Critical Concern Review Group (CCRG) determined that the assembly plant’s labor rebalance operation may have caused the error proofing process control to be misaligned with the assembly station tool.

As a result, the error proofing system may have recorded a successful joint secure for vehicles that did not actually have a properly secured fastener. This means that some affected vehicles may have been released from the factory with a loose or missing lower intermediate shaft fastener, which could lead to separation of steering system components and a loss of steering control.

If the fastener securing the lower intermediate shaft to the steering gear is loose or missing, drivers may hear a rattle noise coming from the steering system while driving or experience excessive steering play prior to separation. In the worst-case scenario, this could result in a crash. Fortunately, Ford has reported only one warranty claim related to this concern and is not aware of any accidents or injuries.

To address the issue, dealers will inspect and replace the lower intermediate shaft fasteners as necessary. Vehicle owners can identify their vehicle’s recall status by checking Ford’s website or contacting their local dealership. The recall number for this issue is 25S46, and the National Highway Traffic Safety Administration (NHTSA) campaign number is 25V-309.

Ford’s ability to trace lower intermediate shaft production to the specific vehicle in which it is installed has allowed the company to identify the affected population and take corrective action. By inspecting and replacing the lower intermediate shaft fasteners, Ford aims to prevent any potential accidents or injuries related to this concern.

Vehicle owners who receive a notice about their F-150’s safety should contact their local dealership to schedule an inspection and repair if necessary. With prompt attention, Ford can ensure that all affected vehicles are brought up to standard and provide safe and reliable transportation for drivers.

A critical issue affecting the transmission valve body of certain Ford Bronco, Explorer, F-150, Mustang, Ranger, and Lincoln Aviator vehicles can cause reverse gear failure or unexpected forward movement while in reverse or neutral gear. This problem could be a significant safety risk to drivers and passengers.

According to Ford, the issue is attributed to an incorrectly machined transmission valve body, specifically the Outer Valve Body (OVB) of the transmission main control. The machining tool used during production did not maintain proper specifications, resulting in out-of-specification dimensions that can prevent the vehicle from entering reverse gear when commanded by the gear shift module.

Symptoms of the problem include no reverse motion when the gear selector is in reverse, and in some cases, the vehicle may move forward with the gear selector in either reverse or neutral position. The Malfunction Indicator Light (MIL) and Wrench light will illuminate on the dashboard when this malfunction occurs.

The recall affects vehicles, including:

2024-2025 Ford Bronco
2025 Ford Explorer
2024-2025 Ford F-150
2025 Ford Mustang
2024 Ford Ranger
2025 Lincoln Aviator

Ford’s investigation into the matter began in February 2025, after a transmission failure was reported on a 2025 Mustang at the Flat Rock Assembly Plant. The company subsequently issued a Stop Ship order for affected models and launched an analysis of the suspect transmissions.

Using advanced data analytics, including Machine Integrated Learning and Optimization (MILO) modeling, Ford identified individual Outer Valve Body units that were likely to experience this condition. The company then conducted evaluations of vehicles equipped with suspect parts and confirmed the symptoms reported by customers.

As of February 21, 2025, Ford had received five warranty reports related to this issue. On March 7, 2025, the company’s Field Review Committee approved a field action, which includes replacing the transmission main control valve body.

Ford has notified owners of affected vehicles and has begun repairing the transmissions. The recall is identified as Ford’s number 25S19 and NHTSA Campaign Number 25V-164.

This recall highlights the importance of rigorous quality control measures in the automotive manufacturing process. The issue serves as a reminder that even minor defects can have significant consequences on vehicle safety and performance.

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.

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.

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.

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:

File a report : Share your experience with the NHTSA by submitting a complaint on their website.
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

Category Archives: Ford

Ford Rattles And Clunks From Ball Joint Fastener Problem

Software Error Causes Rear View Camera Issues In Ford and Lincoln Vehicles

2025 Ford F-150 Lower Intermediate Shaft Fastener Problem

Ford and Lincoln Transmission Valve Failure

2020-2022 Ford Explorer Repeated Repair Attempts

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

Ford Fusion Energi Problems: Understand the Risks and Your Options

Electrical System Concerns In Ford Bronco and Maverick Vehicles