Category Archives: Ford

News about Ford automobile manufacturer. News about Ford recalls, technical service bulletins (TSB), and problems regarding Ford vehicles.

2020-2023 Lincoln Aviator And Corsair Seat Belt Warning Malfunction

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Ford Motor Company (Ford) has decided that a defect affecting the seat belt warning system could exist in certain 2020-2023 Lincoln Aviator and 2020-2023 Lincoln Corsair vehicles. The vehicles affected are equipped with a Revel Audio System.

The problem was discovered in November 2022 when Ford’s Critical Concern Review Group received complaints pertaining to the seat belt warning chime reminder on a 2022 Lincoln Aviator PHEV.

The seat belt reminder system was tested on various combinations of powertrain and audio systems of Lincoln Aviators in an attempt to reproduce the problem. It was discovered that some Lincoln Aviator PHEV vehicles could experience an initial chime duration of fewer than 4 seconds. An audible signal that is activated for less than 4 seconds can result in decreased safety belt usage, increasing the risk of injury during a crash.

The engineering team and audio supplier conducted a design of experiments to gain a better understanding of the cause and scope of the problem. They found that the problem affected vehicles equipped with the Revel audio system, introduced on the 2020 Lincoln Aviator and Corsair. Further seat belt reminder system evaluations were conducted at Ford assembly plants and it was concluded that 2020-2023 Lincoln Aviator and 2020-2022 Corsair vehicles could experience the symptom of a chime duration of fewer than 4 seconds

According to the defect report, when the driver’s seat belt is not buckled and the vehicle is started, the seat belt warning system may activate the audible warning chime for an insufficient amount of time of fewer than 4 seconds. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standards for occupant crash protection.

Owners receiving notices will be asked to contact their dealers about updating the audio control module software in their vehicles. Ford’s number for this recall is 22C35 and the NHTSA campaign number is 22V-953.

2022 Ford Mustang Mach-E Half Shaft Replacement

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Ford will be contacting a small number of 2022 Ford Mustang Mach-E owners regarding a defect affecting the half-shaft in their cars. Some Mach-E vehicles may have been manufactured with a right rear half-shaft that could break under load.

Ford’s Critical Concern Review Group became aware that there was a problem in July 2022, when product engineering identified two vehicles with broken rear right half-shafts. One broken half-shaft was found during a squeak and rattle validation, and a second just before it was being loaded for transport.

Further investigation found that improper placement during the green turning in the lathe caused too much material to be removed, exceeding the specified minimum wall thickness of 9.1mm. Supplier records showed that inspection of the bottom wall thickness of the rear right half-shaft outer race had been suspended for a period of time which allowed non-compliant parts to pass inspection and be installed in finished rear right half-shaft assemblies. Ford’s team reviewed supplier maintenance records to determine the population of affected parts to have been produced between 07/18/2022 and 07/29/2022.

A broken half-shaft will result in loss of transmission torque to the rear wheels, necessary for motive power and for the transmission to hold the vehicle in park. If the electronic parking brake (EPB) is not manually applied, the loss of the primary park torque will allow the vehicle to roll with the transmission in park.

Owners receiving notifications will be instructed to take their vehicle to a Ford or Lincoln dealer. Dealers will photograph the label on the right rear half-shaft to confirm the suspect serial number(s). If the serial number matches, the dealer will replace the right rear half-shaft. Customers will be advised to manually apply the parking brake until the inspection and repair is completed. Ford’s number for this recall is 22S55 and the NHTSA campaign number is 22V-646.

Ford And Lincoln Vehicles Investigated For Brake Hose Ruptures

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Automotive Defect Investigation The National Highway Traffic Safety Administration (NHTSA) Office of Defects Investigation (ODI) is continuing to investigate certain Ford Fusion and Lincoln MKZ sedans for front brake hoses that could prematurely rupture.

The vehicles under investigation include:

2013-2018 Ford Fusion
2013-2018 Ford Fusion Hybrid
2013-2018 Lincoln MKZ
2013-2018 Lincoln MKZ Hybrid

In August 2020, Ford issued a safety recall (NHTSA campaign number 20V-469) for certain 2015-2018 Ford Edge and 2016-2018 Lincoln MKX vehicles, because these vehicles were experiencing premature brake hose (jounce hoses) rupturing. The investigation that led to the recall found that the problem was due to localized failures of the internal reinforcement braid because of cyclic fatigue during suspension and steering movement. The recalled part was introduced into Ford Edge production on June 25, 2014, and was taken out of production on December 21, 2017. The recall had dealers replacing both front brake jounce hoses with a newly revised braid material and performing a brake system bleed.

The ODI has continued to receive complaints alleging front brake hose failures on 2013-2018 Ford Fusion and 2013-2018 Lincoln MKZ vehicles that were not included in the Safety Recall (20V-469). Customer complaints allege the brake hoses are rupturing and leaking brake fluid, with little to no warning. The leaked brake fluid can cause drivers to experience a soft brake pedal, increased pedal travel, and/or extended braking distances. The ODI has received over 50 complaints related to this problem. One complaint alleged a crash as the result of a failed brake hose.

Lemon laws are state and federal laws that provide protection for consumers who buy or lease cars, trucks, SUVs, motorcycles and other consumer goods. The goal of such lemon laws is to provide compensation to consumers for defective products that fail to meet the standards of quality and performance asserted in manufacturers’ warranties.

If your vehicle is experiencing repeated problems like the ones listed above, it could be a Lemon. Know your Lemon Law Rights. If you have any questions about your rights and the California Lemon Law, please call our office at 1-888-395-3666 and get some great Lemon Law advice!

2022 Ford Maverick
Side Curtain Air Bag Malfuntion

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Certain 2022 Ford Maverick pickup trucks could experience an improper air bag deployment that could increase the chance of injury during an accident. Because of this improper deployment, these vehicles fail to meet the Federal Motor Vehicle Safety Standards (FMVSS) for “Ejection Mitigation”.

Ford became aware of the problem in June 2022 when they were contacted by the National Highway Traffic Safety Administration (NHTSA) Office of Vehicle Safety Compliance, regarding the results of a compliance audit on a 2022 model year Maverick. The compliance audit showed that the displacement results for the front lower primary target exceeded the federal regulation of 100 mm. Ford opened an investigation that included comparing their data to the NHTSA test vehicle data, but they were not able to determine the cause of the problem. The cause of the airbag problem is still under investigation.

According to the defect report, trucks included in this action were built with side curtain air bags that may not meet the displacement requirements of FMVSS 226 S4.2.1 for the first row lower primary target location. A vehicle that does not comply with FMVSS 226 increases the risk of occupant injury in a crash. Approximately 65,000 – 2022 model year Ford Maverick vehicles with build dates from February 3, 2021, through July 9, 2022, are affected by this air bag recall.

Owners who receive notices will be instructed to take their Maverick to a Ford dealer to have the left and right side curtain air bag modules replaced with modules of a new design. Ford’s number for this recall is 22C20 and the NHTSA campaign number is 22V-594.

The NHTSA urges all vehicle owners to take immediate action after receiving a notice of a safety defect with their vehicle. Despite recall notices and public warnings, some vehicle and vehicle equipment recalls are never repaired. In 2019 in the United States, there were 966 safety recalls affecting more than 53 million vehicles and motor vehicle equipment. While not all recalls are high profile, all recalls are important. Don’t risk your safety, that of your loved ones, or others on the road!

2022 Ford Explorer And 2022 Lincoln Aviator Engine Rail Sub-Assembly Failure

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Ford Motor Company (Ford) will be contacting the owners of certain 2022 Ford Explorer and 2022 Lincoln Aviator SUVs because the vehicles they are driving may not comply to the Federal Motor Vehicle Safety Standards for occupant crash protection and fuel system integrity.

Ford first became aware of the problem in April 2022 when one of their assembly plants started experiencing intermittent bolt strip-out conditions when securing the front sub-frame to the front apron assembly. An investigation into engine rail sub-assembly failures found that the mechanical properties of the engine rails did not meet the intended strength requirements. Supplier records showed that over six hundred engine rail sub-assemblies were sent out for an unapproved repair procedure (thermal e-coat stripping) which degraded the mechanical properties and weakened the metal. Some of the suspect rails were used at the Tier 1 supplier and 137 suspect rails were shipped to the assembly plant. A Stop Shipment was issued on April 28, 2022 and an inspection of engine rail hardness was carried out on over 5000 vehicles.

According to the defect report, the vehicles affected were built with an engine rail that may not
maintain its integrity in a crash and as a result, does not meet the Federal Motor Vehicles Safety Standards (FMVSS) for Occupant Crash Protection and Fuel System Integrity requirements. A weakened engine rail could also become loose, resulting in a clunking noise during acceleration, deceleration, or contact with potholes, speed bumps, or other road surface irregularities.

Owners will be notified by mail and instructed to take their vehicle to a Ford or Lincoln dealer for an engine rail inspection. If the vehicle does not pass the strength test, owners will be given the option of a replacement of the engine rail assembly or, because of the extensive nature of this repair, vehicle replacement or a buyback. Owners opting for repairs will be sent awareness letters and instructed to bring their vehicles in when parts become available. Ford’s number for this recall is 22C13 and the NHTSA campaign number is 22V-454.

Are you thinking of taking a replacement or buyback? Under the California Lemon Law, if your vehicle qualifies, you should recover your down payment, (including registration fees, licensing fees, taxes, transportation costs, etc.), plus your total monthly lease or loan payments. The manufacturer will also pay off the balance of your loan or lease. The manufacturer will also pay all or most of your attorney’s fees.

If you have any questions about your rights and the California Lemon Law, please call our office at 1-888-395-3666 and get some great Lemon Law advice!

2021-2022 Ford Mustang Mach E High Voltage Battery Could Overheat

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Ford will be contacting the owners of certain 2021-2022 Mustang Mach E vehicles because the high voltage battery in their cars may overheat. The problem may lead to loss of power and could increase the chance of an accident.

Ford’s Critical Concern Review Group first became aware of the problem in April 2022, after hearing of an issue pertaining to the high voltage battery main contactor overheating in a Mustang Mach E. A review of warranty reports found approximately 286 warranty claims where the problem was an open or welded battery contactor. According to the defect report, it is possible that the high voltage battery main contactors may overheat, which can result in an open contactor or a welded condition.

Contactors that are welded shut while driving, will result in an illuminated powertrain malfunction warning light on the next drive cycle, along with a no-start condition.

Contactors that become open while driving, will result in a powertrain malfunction warning light, the vehicle will display “Stop Safely Now” on the instrument panel, and the vehicle will lose power.

In both cases, all 12V systems including power brakes and steering will remain functional.

Ford will correct the problem by installing a Secondary On-Board Diagnostic Control Module (SOBDMC) and updating the Battery Energy Control Module (BECM) software. Ford is expected to begin Over-The-Air (OTA) updates for the SOBDMC and BECM software in July 2022. Owners will also have the option to take their vehicle to a Ford or Lincoln dealer to have the software update completed.

The updated SOBDMC software (LJ98-14G069-AXG, LJ98-14G069-AZG, LJ98-14G069-BBG, LJ98-14G069-BDG) will monitor contactor temperature and intelligently reduce battery power to prevent damage to the contactor. The updated BECM software (NJ98-14C197-AE, NJ98-14C197-BD) will monitor contactor resistance to identify an overheated contactor and reduce vehicle power to prevent further damage.

Ford’s number for this recall is 22S41 and the NHTSA campaign number is 22V-412.

2019-2020 Ford Mustang Powertrain Control Module Malfunction

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Certain 2019-2020 Mustang vehicles equipped with 5.0L engines and manual transmissions, could experience a problem with the Powertrain Control Module (PCM). The PCM could broadcast a faulty signal to the modules controlling the reverse camera, reverse light, and driver-assist features. Owners will be instructed to return to their dealerships for repairs.

According to the safety report, the 2019 Mustang 5.0L Manual Transmission Model is the first to introduce a new Rev matching feature that includes a new Manual Gear Position Sensor and associated software/calibration.

In July 2020, Ford Product Development engineers identified a small number of warranty claims associated with the Manual Gear Position Sensor which caused the rear view camera and reverse lamps to stop functioning, but based on the low occurrences, the Critical Concern Review Group (CCRG) closed the investigation. By April 2022, 102 warranty claims alleging non-functioning rear view camera display and/or non-functioning reverse lamps and 94 warranty claims of potentially related non-functioning of various driver-assist features (traction control, forward collision warning, blind-spot warning, cross-traffic indicator) caused Ford’s Field Review Committee to reopen the investigation and issue a recall.

According to the defect report, some unique driving scenarios or vehicle conditions, including clutch slip, causing incorrect ratio, extended reverse driving, miscalibration of odd/even shift gates, customer modifications, a mismatch between the gear position sensor signal and the estimated gear calculation, might be detected by the PCM. The PCM will interpret the degraded signal to mean a fault and may disable the modules controlling the reverse camera, reverse lamps, and driver-assist features.

Owners receiving notices will be asked to return to their dealers to have the PCM software updated in their Mustang. Ford’s number for this recall is 22S37 and the NHTSA campaign number is 22V-382.

If you are experiencing repeated problems with your vehicle, it could be a lemon. If you have any questions about your rights and the California Lemon Law, please call our office at 888-395-3666 and get some great Lemon Law advice!

Insufficient Welds In Ford Escape And Lincoln Corsair High Voltage Batteries

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The high voltage batteries in certain 2020 Ford Escape and 2021 Lincoln Corsair vehicles may have been manufactured with insufficient welds that could fail and cause a loss of drive power. These vehicles are equipped with 2.5L hybrid powertrains.

Ford’s Critical Concern Review Group first became aware of the problem in February 2022 when they were informed, by the supplier, that there was an issue with the weld penetration on the bus bars of certain high voltage batteries. A review of the manufacturers’ records showed that the suspect cause of the problem was damage to the laser cooling line caused by maintenance of the laser air knife. The damage to the laser cooling line resulted in an out-of-control weld process and insufficient welds. The suspect time period was between June 6, 2020, and June 12, 2020.

According to the safety report, insufficient weld penetration between the bus bar and cell terminal could result in a loss of electrical contact at the bus-bar weld joint inside the high voltage battery. Loss of electrical contact will result in a loss of motive power and an increased risk of an accident.

The vehicle warning display will illuminate a “Stop Safely Now” message, a wrench lamp, and an audible alert when the vehicle loses motive power.

Owners receiving notices will be asked to take their vehicle to their Ford or Lincoln dealer to have the High Voltage Battery replaced. The new High Voltage Battery LX68-10B759-R will have a bus bar that has proper weld penetration. The supplier repaired a damaged coolant line on June 27, 2020. High voltage batteries produced after June 27, 2020 were produced with sufficient bus bar weld penetration. Ford’s number for this recall is 22S33 and the NHTSA campaign number is 22V-331.