Ford Motor Company has expanded a significant safety recall affecting certain plug-in hybrid vehicles after discovering that additional high-voltage battery cells may be susceptible to failure. The recall impacts thousands of Ford Escape and Lincoln Corsair plug-in hybrid vehicles and raises concerns about sudden loss of power and potential fire risk.
The expanded recall is listed under NHTSA Campaign Number 26V-091 and covers approximately 24,690 vehicles nationwide.
What Vehicles Are Affected?
The recall applies to:
- 2023–2025 Ford Escape Plug-In Hybrid (PHEV)
- 2023–2026 Lincoln Corsair Plug-In Hybrid
These vehicles may contain high-voltage battery cells manufactured before updated supplier quality controls were implemented in October 2024. This action expands earlier recalls addressing the same underlying battery defect.
What Is the Battery Problem?
According to Ford and the National Highway Traffic Safety Administration (NHTSA), certain high-voltage battery cells may develop an internal short circuit due to manufacturing variability.
Investigators determined that inconsistencies during battery production may create microscopic defects inside the battery cell. These defects can damage the separator layer between the cathode and anode — a critical safety component designed to prevent internal electrical contact. If the separator becomes compromised, the battery cell may fail.
Safety Risks Associated With the Defect
A battery internal short circuit can lead to serious safety issues, including:
- Sudden shutdown of the vehicle’s propulsion system
- Display of a “Stop Safely Now” warning message
- Loss of motive power while driving
- Battery thermal venting
- Increased risk of vehicle fire
Ford states that steering, braking, and lighting systems remain functional during a propulsion shutdown, but loss of power while driving significantly increases the risk of a crash or injury.
Why the Recall Was Expanded
Ford previously issued recalls (24V-954 and 25SC4/25V-789) covering vehicles with battery cells manufactured before April 1, 2023.
However, continued investigation revealed that the issue extended beyond the originally identified production window.
After reviewing field reports and conducting battery tear-downs and manufacturing analysis, Ford determined that battery cells produced until additional supplier quality controls were implemented on October 10, 2024 may also be vulnerable.
As of February 10, 2026:
- Two battery venting incidents were reported in Europe outside the original recall population.
- Ford reports no known U.S. incidents, accidents, or injuries related to the expanded population.
Warning Signs Drivers May Experience
Drivers experiencing a battery failure may notice:
- A red “Stop Safely Now” message displayed on the instrument cluster
- Sudden loss of propulsion power
- Warning alerts related to the hybrid system
If this message appears, drivers should safely pull over as soon as possible.
What Owners Should Do Right Now
Because a permanent repair is still being developed, Ford has issued interim safety instructions.
Owners are advised to:
- Use “Auto EV” mode only
- Limit battery charging to 80% capacity
- Follow instructions provided in owner notification letters
Ford expects interim notification letters to be mailed beginning March 6, 2026, with additional letters sent once a final repair becomes available.
Recall Information
- Manufacturer Recall Number: 25SC4
- NHTSA Campaign Number: 26V-091000
- Expanded Recalls: 24V-954 and 25V-489
- Vehicles Affected: Approximately 24,690
This recall expands on an earlier battery defect investigation affecting Ford plug-in hybrid vehicles. You can read our previous analysis here:
