Ford Motor Company has announced a safety defect affecting certain 2024–2026 Ford Ranger vehicles. Some Rangers could experience a wiring issue that can, in rare cases, lead to smoke or fire inside the vehicle.
What’s the Problem?
The issue is tied to the wiring harness connected to the sun visor and headliner. In some vehicles, this wiring may have been installed incorrectly or wrapped with excessive protective tape. These conditions can cause the wiring to become pinched or damaged as it passes through metal openings near the A-pillar, which is the structural area along the windshield. If the wiring becomes damaged and contacts metal, it can create an electrical short. This short may generate heat or sparks, potentially leading to smoke, melting components, or even a fire in the A-pillar area. Any smoke or fire inside a vehicle increases the risk of injury or a crash. Even before a fire occurs, smoke or melting materials can distract the driver or reduce visibility.
While no accidents or injuries have been reported, there has been at least one case involving flames and several others showing signs of smoke or burn damage.
What Caused It?
Ford’s investigation found two main contributing factors. First, excessive tape thickness on the wiring harness can cause it to bind or become damaged when passing through tight metal openings. Second, insufficient controls during installation may allow the wiring to be routed incorrectly, increasing the chance of contact with metal edges.
Over time, damaged wiring can become exposed. Combined with repeated resets of the Body Control Module after a fault, this can lead to ongoing electrical arcing, soot buildup, and eventually a fire risk.
Warning Signs to Watch For
Drivers may notice early warning signs before a more serious issue develops. These include flickering or non-functioning sun visor mirror lights or overhead console lights. These symptoms may indicate a problem with the circuit and should not be ignored.
Timeline of the Investigation
Ford’s investigation began on October 31, 2025, after a fire was reported in the A-pillar area of a 2024 Ranger. Early findings pointed to an electrical short in the sun visor power circuit, confirmed by a diagnostic trouble code. The issue was escalated to Ford’s Critical Concern Review Group on November 6, 2025.
Over the following months, engineers reviewed supplier specifications and installation procedures, identifying risks related to wiring thickness and routing. Testing in early 2026 confirmed that materials were not inherently flammable, but electrical system behavior could still lead to fire over time.
By March 20, 2026, Ford had identified multiple reports tied to four vehicles, including one case involving flames. On April 7, 2026, the Field Review Committee approved a field service action.
What’s the Fix?
Ford dealers will inspect the wiring harness for damage, replace it if necessary, and update the Body Control Module software. he recall will be carried out in phases. Owners of 2025 model year vehicles will be notified the week of May 31, 2026. Owners of 2026 models will be notified the week of June 29, 2026, followed by 2024 model owners the week of July 27, 2026.
Interim letters informing owners of the safety risk are expected to be mailed starting April 27, 2026. Additional letters will be sent once the full repair remedy is available, anticipated in August 2026.
Ford has assigned recall number 26S29, and it is listed under NHTSA campaign number 26V-238.
