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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Certain 2016-2018 Ford and Lincoln, trucks and SUVs equipped with 3.5L Ecoboost engines could require more braking effort and distance to stop the vehicle. Ford will be asking owners to return to their dealerships for repairs.

In May 2016, Ford issued a recall (16V-345) for F-150s equipped with the 3.5L Ecoboost engines, because the brake master cylinder could leak and allow brake fluid from the front wheel circuit into the brake booster. After continued field data monitoring and discussions with NHTSA, Ford issued a second recall (20V-332), to extend the population for F-150s.

Ford continued to monitor field reports expanding the coverage into Ford Expedition and Lincoln Navigator vehicles built during the same period. These vehicles share a similar brake master cylinder design as the F-150 3.5L Ecoboost vehicles

Investigation into supplier records and discussion with the supplier identified additional steps taken by the supplier to further improve brake master cylinder seal installation from August 2016 to December 2016. These include an automated process to remove imperfect threads from the master cylinder outlet port, as well as actions to improve the installation of the rearmost cup seal in the master cylinder. Master cylinders with these improvements were incorporated into vehicle production by January 31, 2017.

In March 2022, Ford’s Field Review Committee reviewed the concern and approved a safety
recall action. Ford is aware of 4 low-speed/low-impact accident allegations with no injuries.

Vehicles manufactured with these defective fuel injectors include:
2016-2017 Ford Expedition
2016-2018 Ford F-150
2016-2017 Lincoln Navigator

Dealers will correct the problem by replacing the brake master cylinder. If the master cylinder is leaking, the brake booster will also be replaced. This recall is an expansion of NHTSA recall number 20V-332. Ford’s number for this recall is 22S11 and the NHTSA campaign number is 22V-150.

In December 2020, Ford opened an investigation into a Ford engineering vehicle that experienced a rear drive unit seizure. The final analysis found that the seizure was the result of inadequate lubrication and that a malfunction during the rear drive unit lubricant fill procedure was the cause of the miss-fill. Further investigation found another ten rear drive units with low lubricant fill level and 3 warranty claims for this condition. As a result, Ford will be recalling certain 2020-2021 Ford and Lincoln cars and trucks.

Vehicles Affected Include
2021 Ford Bronco Sport
2020-2021 Ford Edge
2020 Ford Escape
2021 Lincoln Corsair
2020 Lincoln Nautilus
WARNING: Drivers may hear a metallic grinding or whining sound from the rear of the vehicle prior to a rear drive seizure.

Ford will notify owners, and dealers will check the rear drive unit lubricant level. Axles found to have lubricant at the minimum level will be filled to the full level. Axles found to be below the minimum lubricant fill level will be replaced. Ford’s number for this recall is 21S02 and the NHTSA campaign number is 21V-011.

Drivers experiencing engine vibrations in their 2020-2021 Ford Explorer and 2020-2021 Lincoln Aviator SUVs could have vehicles manufactured with engine mounting fasteners that were not correctly installed.

According to a defect report filed with the NHTSA, the automated tool used to secure the right-hand motor mount fasteners was not functioning properly and a manual handheld tool was used.  The manual backup process was not calibrated correctly and the motor mounts were improperly torqued.  Over time, one or more of the mounts could loosen and the engine will begin to vibrate.  If the problem is not fixed the engine mounts could eventually break.

Ford will notify owners to return to their dealers to have the right-hand motor mount fasteners replaced. The recall is expected to begin February 8, 2021. Ford’s number for this recall is 20S72 and the NHTSA campaign number is 20V-788.

Ford have identified a problem affecting the seat back side airbags in a small number of 2020 Ford Explorer and 2020 Lincoln Aviator vehicles.

According to the defect report, the front seat back sub-assemblies may have been placed in the wrong work in progress rack after a machine interruption. Some of the DC runner nuts may have not been torqued, leaving the air bag and seat back module not fully secured. The problem could delay the positioning of the air bag cushioning and the deployment of the airbag could be affected.

Owners receiving notices will be asked to return their their Ford or Lincoln dealer so that they can verify that the fasteners have been properly tightened. Ford’s number for this recall is 20S48 and the NHTSA campaign number is 20V-497.

Ford Motor Company will be asking the owners of certain 2016-2018 Lincoln MKX and 2019-2020 Lincoln Nautilus SUVs, to return to their dealership to fix a wiring problem that could affect the air bags. These vehicles are equipped with 16 way electric tilt seats.

According to the safety report, the seats in these vehicles may have a wiring harness that was not properly protected from the edge of the seat cushion frame. When the tilt function is used, it is possible that the wires could become damaged and, as a result, the airbag system may not function as intended.

Ford is not aware of any accidents or injuries related to this problem, but they will be asking owners to return to their dealerships to have the wire harness inspected and replaced as necessary. Also, a protective flocking tape will be installed onto the exposed edge of the 16-way seat cushion frames. Ford’s number for this recall is 20S37 and the NHTSA campaign number is 20V-414.

Concerns related to improperly welded second row headrest attachment brackets will have some 2020 Ford Expedition and 2020 Lincoln Navigator vehicles recalled for repairs. Dealers are required to inspect and repair the problem before demonstrating or delivering any new stock.

According to the defect report, an in plant inspection found that the headrest to seat back frame attachment bracket was out of position during assembly and some welds did not properly penetrate the headrest bracket. As a result, the strength of the headrests are weakened and they do not meet the Federal Motor Vehicle Safety Standards for head restraints. An improperly welded headrest bracket may not adequately restrain an occupant during a crash.

Those receiving notices will be asked to return to their dealership to have the seat structure inspected and replaced as needed. Ford’s number for this recall is 20C12 and the NHTSA campaign number is 20V-366.

Ford had decided that a problem affecting the collision avoidance system exists in certain 2020 Ford Expedition and 2020 Lincoln Navigator vehicles. The condition affects models equipped with the standard camera-only pre-collision assist built within a certain time period. Vehicles with optional radar plus camera pre-collision assist systems are not affected.

According to the defect report, the affected vehicles are equipped with pre-collision assist features that are not functional. This includes: Forward Collision Warning, Dynamic Brake Support and Automatic Emergency Braking. There is no warning to the driver that these features are not functional, increasing the risk and severity of a frontal collision.

Dealers will correct the problem by reprogramming the software affecting the Body Control Module, Anti-lock Braking System, Instrument Panel Cluster, Headlamp Control Modules and reset the Tire Pressure Monitor System. Ford’s number for this recall is 20S20 and the NHTSA campaign number is 20V-262.