A small number of 2021-2022 Ford Escape and 2022 Lincoln Corsair hybrid power-train SUVs have been manufactured with a high voltage battery that could fail and result in a sudden loss of motor power. The problem was brought to Ford’s Critical Concern Review Group in October 2021 after an issue pertaining to an overheated high voltage battery bus bar was reported in Germany. Through a search of warranty reports, Ford identified an additional vehicle in Europe that reported a loss of function due to the overheated high voltage battery bus-bar.
During the manufacturing process, the high voltage bus-bar pad was not properly seated and could cause the pad to be mounted out of position prior to bus-bar welding. This condition could reduce the contact area between the cell terminal and the bus bar, giving it a high resistance. The high resistance could eventually result in an overheat situation.
According to the defect report, an overheated bus bar terminal may create a high resistance connection that could cause the battery pack high voltage bus voltage to fall below an operational level. If this happens, the hybrid power-train control module will sense the high voltage and detect a fault. A diagnostic trouble code will be sent and the vehicle will lose power. Drivers will also notice a “Stop Safely Now” warning message displayed on the instrument panel.
Ford’s team reviewed supplier process and production records to determine the population of affected parts. Affected vehicles are equipped with the 2.5L Hybrid power train and the suspect high voltage battery pack.
Dealers will replace the high voltage battery. Ford’s number for this recall is 21S48 and the NHTSA campaign number is 22V-149.
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