Manufacturer defect – Page 3 – California Lemon Law blog

(Recall: SB-25-16-005 / NHTSA Campaign 25V-690)

If you own or are considering buying a 2025 Model 3 or 2026 Model Y from Tesla, there’s a safety issue you should know about. Certain vehicles built between early March and mid-August 2025 are affected by a battery pack contactor fault that may result in an unexpected loss of drive power. This article explains what the issue is, which vehicles are affected, what the risks are, and what owners should do next.

What is the issue?

Tesla has determined that certain 2025 Model 3 and 2026 Model Y vehicles are equipped with a battery pack contactor manufactured with an InTiCa solenoid that may have a poor coil termination connection.

If the contactor opens unexpectedly while the vehicle is in drive, the driver loses the ability to apply torque through the accelerator pedal, resulting in a loss of propulsion. This sudden loss of drive power could increase the risk of a collision.

There is no warning prior to the failure. However, when it occurs, the driver receives an immediate visual alert on the user interface instructing them to safely pull over.

Which vehicles are affected?

2025 Tesla Model 3 vehicles manufactured between March 8 and August 12, 2025.
2026 Tesla Model Y vehicles manufactured between March 15 and August 15, 2025.

Tesla estimates roughly 13,000 vehicles in total are affected, including around 5,000 Model 3s and nearly 8,000 Model Ys produced within those date ranges.

Timeline of Investigation & Recall

August 8, 2025: Tesla’s Field Reliability team began investigating service cases where vehicles were unable to enter drive and high coil resistance was detected in the pack contactor.
August 8 – September 26, 2025: Tesla collected contactors from the field and performed detailed failure analysis.
September 29 – October 2, 2025: Tesla reviewed the failure analysis results, along with repair and production records.
October 3, 2025: Tesla completed its investigation and determined the scope of affected vehicles, initiating a voluntary recall.
December 9, 2025: Owner notification letters are expected to be mailed to customers.

As of early October 2025, Tesla had identified 36 warranty claims and 26 field reports related to this issue, with no known injuries, collisions, or fatalities.

What is the remedy?

Tesla Service will correct the problem by replacing the high-voltage battery pack contactor. The updated parts do not include the defective InTiCa solenoid and have improved coil termination connections. The repair takes approximately one hour to complete, and Tesla will notify all affected owners by mail.

Why this matters

Safety risk

A sudden loss of propulsion without warning can be dangerous, especially when driving at highway speeds or in traffic. While no injuries have been reported, Tesla’s recall emphasizes the importance of addressing this issue promptly.

Financial and resale considerations

Unresolved recalls can affect resale value, financing, and insurance. Ensuring the recall repair is completed not only improves safety but also helps preserve the vehicle’s long-term value.

What owners should do if their Tesla vehicle is affected.

Schedule a service appointment through the Tesla app or by contacting your nearest Tesla Service Center.
Pay attention to alerts while driving. If a visual warning or loss of power occurs, pull over safely and contact Tesla support immediately.
Keep documentation of the recall repair for future reference or resale.
If buying used, confirm with the seller that any open recalls have been completed.

This recall serves as a reminder that even advanced electric vehicles like Tesla are not immune to hardware issues. While Tesla can often fix software defects through over-the-air updates, mechanical components such as contactors and solenoids require physical inspection and replacement.

Frequently Asked Questions

Q: Does this recall affect all 2025 Model 3 and 2026 Model Y vehicles?
A: No. Only vehicles built between March and August 2025 with the affected InTiCa solenoid contactor are included.

Q: My car feels fine — do I still need the repair?
A: Yes. The failure can occur without warning, so even if your car shows no symptoms, Tesla recommends completing the replacement.

Q: How long will the repair take?
A: The contactor replacement typically takes about one hour and is performed free of charge.

Q: Can I continue driving before the repair?
A: Tesla advises that owners continue driving normally but schedule service as soon as possible. If your vehicle shows a propulsion loss alert, pull over safely and contact Tesla.

Conclusion

If you drive a 2025 Tesla Model 3 or 2026 Model Y, this recall deserves your attention. The contactor defect can cause sudden loss of drive power, posing a potential safety risk. Tesla is replacing the affected parts at no cost to owners, with notifications beginning December 2025.

Ford Motor Company has issued a recall for certain 2025 Ford Ranger trucks due to a potential problem with the passenger airbag system. According to the automaker, a manufacturing error could prevent the airbag from deploying properly in the event of a collision, creating an increased risk of injury for passengers.

While the issue affects only a limited number of vehicles, Ford is taking immediate action to ensure compliance with federal safety standards and to protect customer safety.

The Issue: Faulty Instrument Panel Scoring

The concern originates from the instrument panel (IP) assembly—specifically the laser scoring process used on the underside of the IP topper. The scoring defines the precise way the airbag deploys through the dashboard surface.

Ford discovered that the supplier, Yanfeng (YF), had unintentionally altered the laser scoring parameters during production. This seemingly small change resulted in a deviation from the approved design, affecting the scoring pattern in certain 2025 Ford Ranger vehicles.

This flaw may cause the passenger airbag to deploy more slowly or not fully deploy at all, especially during cold-temperature conditions or low-output deployments. During internal safety testing, Ford observed that in some cases, the airbag cushion failed to completely exit the panel surface, creating a potential hazard and violating Federal Motor Vehicle Safety Standards (FMVSS) 208, which govern occupant crash protection performance.

Timeline of Events

The airbag concern was identified and escalated through Ford’s quality and safety review process over the course of several weeks:

September 10, 2025: Supplier Yanfeng notifies Ford of an unintended change to the laser scoring process.
September 18, 2025: Ford’s Critical Concern Review Group (CCRG) launches a detailed investigation into the issue.
September 9, 2025: The supplier revises the laser scoring process to match the original specifications and validates the fix.
October 3, 2025: Ford’s Field Review Committee reviews the findings, confirms non-compliance with FMVSS 208, and authorizes a field action.

Although Ford is not aware of any crashes, injuries, or customer complaints linked to the problem, the company has decided to act out of caution and replace affected components.

What Ford Owners Need to Know

Owners of affected 2025 Ford Ranger trucks will be contacted directly by Ford. Here’s what you should know about the recall:

Recall Number: 25C54
NHTSA Campaign ID: 25V-678
Remedy: Ford dealers will replace the instrument panel assembly.
Notification Schedule:
- Interim owner letters were mailed on October 24, 2025, to inform customers of the issue.
- Final remedy letters will be mailed once replacement parts are available and the repair process begins.

Fiat Chrysler Automobiles (FCA US LLC) has identified a serious issue affecting certain 2022–2026 Jeep Grand Cherokee Plug-In Hybrid Electric (PHEV) vehicles. A software error within the Hybrid Control Processor (HCP) can result in a sudden loss of drive power, creating potential safety risks for drivers and passengers.

What’s the Problem?

The issue stems from the Battery Pack Control Module (BPCM) microprocessor. In some vehicles, the microprocessor may become overloaded and reset. During specific reset events, the HCP may misinterpret signals from the BPCM, causing the system to incorrectly shut down propulsion.

This defect could lead to a loss of drive power while operating, increasing the risk of a crash if drivers are unable to maintain control of their vehicles.

When Were the Vehicles Built?

The suspect period began on July 23, 2021, when the faulty HCP software was introduced into production, and ended on August 29, 2025, when FCA placed affected vehicles under plant control. Engineering records and assembly plant data were used to define this production window.

Chronology of Events

The chronology of events surrounding the discovery of the software problem in certain 2022–2026 Jeep Grand Cherokee Plug-In Hybrid Electric (PHEV) vehicles began on May 1, 2025, when FCA US LLC received a Preliminary Information Request from NHTSA’s Office of Defect Investigations, followed by FCA’s response on May 23, 2025. A supplemental request from NHTSA arrived on June 23, 2025, with FCA responding on July 14, 2025. Meanwhile, on June 24, 2025, FCA’s Technical Safety and Regulatory Compliance (TSRC) team opened an investigation into loss of propulsion complaints in Jeep Grand Cherokee PHEVs. Between June and August 2025, FCA US TSRC worked with FCA US Engineering to review the issue, analyze possible failure modes, and identify the suspect vehicle population. By August 18, 2025, FCA had recorded 96 customer assistance records, 110 field reports, and 320 service records related to the issue, though no accidents or injuries had been reported. Finally, on August 28, 2025, FCA’s Vehicle Regulations Committee concluded that a defect affecting motor vehicle safety potentially exists in all affected vehicles.

Recall Information

Chrysler Recall Number: 73C
NHTSA Campaign Number: 25V-576
Affected Vehicles: Certain 2022–2026 Jeep Grand Cherokee Plug-In Hybrid Electric (PHEV)

At this time, the remedy is still under development. FCA US expects to begin mailing owner notification letters on October 23, 2025.

Final Thoughts

The Jeep Grand Cherokee PHEV recall highlights the challenges of integrating advanced hybrid technology with complex vehicle software systems. While no accidents or injuries have been reported, the risk of propulsion loss makes this a critical safety concern.

Owners are encouraged to stay informed, act quickly once notifications arrive, and ensure their vehicles are repaired as soon as the remedy becomes available.

General Motors (GM) has confirmed a serious safety defect affecting certain 2019–2024 Chevrolet Silverado Medium Duty trucks. This issue involves the brake pressure sensor assembly, which may allow brake fluid to leak into the electrical components of the brake pressure switch. Over time, the defect can lead to short circuits, loss of brake system function, and even under hood fires, creating a significant risk of property damage and personal injury.

What Models Are Affected?

The following Chevrolet Silverado Medium Duty trucks are included in this safety defect:

2019 Chevrolet 6500
2019–2024 Chevrolet Silverado 4500
2019–2021, 2023–2024 Chevrolet Silverado 5500
2019, 2021–2024 Chevrolet Silverado 6500

Trucks produced before 2019 use a different brake sensor design and are not affected. Certain 2024 Silverado Medium Duty models built with a brake switch wire harness that includes silicone sealant are also excluded.

Why This Is a Safety Concern

If brake fluid leaks past the diaphragm seal into the electrical portion of the brake pressure sensor:

The switch and fuse can short circuit.
The circuit may generate excessive heat, leading to a fire risk.
A fire can occur even when the vehicle is parked and unattended.

This is not only a performance issue but a direct safety hazard for owners and the public.

Chronology of Events Leading to the Defect Finding

The journey to identifying this defect spans several years, beginning with earlier issues and continuing into 2025:

April 13, 2023 – GM issued NHTSA Recall 23V-266 addressing zinc sealant fragmentation in brake pressure sensors that could cause brake fluid leaks and under hood fires.
October 11, 2024 – GM’s quality team received a report of unintended brake pump activation in a 2023 Silverado Medium Duty truck that was not part of the earlier recall. The issue was escalated through the Speak Up For Safety (SUFS) program.
November 24, 2024 – GM opened a formal investigation after discovering brake fluid in the wiring harness of the newer sensor design.
December 18, 2024 – Another field report surfaced involving a 2021 Silverado truck already repaired under the 23V-266 campaign. GM’s analysis confirmed fluid intrusion.
January 2025 – Additional warranty-returned parts tested positive for brake fluid contamination in the harness.
March 3, 2025 – GM and International Motors partnered with Akron Rubber Development Lab (ARDL) for material analysis.
April 24, 2025 – Testing revealed that the rubber diaphragm was degrading due to the supplier’s use of an unauthorized chemical that reacted with brake fluid.
April 30, 2025 – GM identified one confirmed fire among 160 reports and began deeper field analysis.
May 28, 2025 – GM inspected the affected vehicle and concluded the fire was linked to the defect.
June 5, 2025 – GM’s Safety Field Action Decision Authority (SFADA) determined a safety defect existed in 2019–2024 Silverado Medium Duty trucks.

The Cause of the Safety Defect

Investigations revealed that a supplier used an unauthorized chemical in the rubber diaphragm of the brake pressure sensor assembly. This material degraded when exposed to brake fluid, allowing leaks into the sensor’s electrical system and creating the potential for fires.

Warning Signs Owners May See

Drivers may notice a “Service Brake System” warning light on the dashboard as the defect develops. GM advises that vehicles should be parked outdoors and away from buildings until the problem is corrected.

The Fix for Silverado Owners

GM’s remedy involves replacing the brake pressure switch wire harness with an improved design.

Interim owner notifications were mailed on July 29, 2025.
A second notification will be sent once parts are fully available.
Vehicles that were previously repaired under Recall 23V-266 will also require the updated repair.

GM has assigned this campaign number N242482680, and the NHTSA campaign number is 25V-390.

If you drive a 2021 Audi A6, A7, A8, Q7, or Q8 — including performance models like the S6, RS7, or SQ8 — there’s a recall that could affect your vehicle’s instrument panel display. Audi has confirmed a software defect that may cause the digital gauge cluster to go completely blank while driving.

This isn’t just frustrating — it’s a potential safety issue. And if you’re in California, this might also be a qualifying condition under the California Lemon Law.

What’s the issue?

Audi says a software error in the instrument panel can cause the entire display to fail without warning. That includes:

Your speedometer
Warning lights
Fuel level
Navigation prompts
And other critical driving data

In a digital-only dash setup, losing your display means flying blind — and that’s a safety risk Audi is now acknowledging.

Which vehicles are affected?

2021 Audi A6, A7, A8
2021 Audi S6, S7, S8, RS6, RS7, RS8
2021 Audi Q7, Q8, SQ7, SQ8

In total, around 44,000 vehicles are involved in the recall. Audi dealerships are offering a software update to resolve the problem, and repairs are already underway.

What if this has already happened to you?

If your dash has glitched, gone dark, or needed multiple visits to the dealer for software issues, your experience might not be a one-off. Under California’s Lemon Law, you could be eligible for:

A replacement vehicle
A buyback or refund
Reimbursement for related expenses, like towing or rentals

Lemon Law doesn’t require the problem to occur dozens of times — just that the manufacturer has been given a reasonable chance to fix it, and it hasn’t been resolved.

What should you do?

If you’ve noticed display problems — even intermittently — make sure they’re documented at the dealership
Get the recall repair as soon as possible, and keep all paperwork
If the issue recurs after repair, or your vehicle has had multiple electronic issues, talk to a Lemon Law attorney

Digital dashboards are a modern convenience — but when they fail, they become a safety risk. If Audi hasn’t resolved the issue quickly and effectively, you may be entitled to more than just another software patch.

If you’re driving an Audi with repeated problems, let’s talk. You may be entitled to compensation or a replacement vehicle under California’s Lemon Law, and there’s no cost to have your case reviewed.

If you drive a Chevrolet Silverado, GMC Yukon, or Cadillac Escalade equipped with the 6.2L V8 engine (RPO L87), your vehicle may be at risk of sudden engine failure due to defective engine components. (Safety Recall N252494001 and NHTSA campaign number 25V-274)

Vehicles Affected by the Recall

Chevrolet: Silverado 1500, Suburban, Tahoe (2021–2024)
GMC: Sierra 1500, Yukon, Yukon XL (2021–2024)
Cadillac: Escalade, Escalade ESV (2021–2024)

Over 600,000 GM vehicles are included in this recall.

The Engine Defect Explained

The recall stems from manufacturing defects in the connecting rods and crankshaft, which may include:

Sediment in connecting rods and crankshaft-oil galleries
Crankshaft dimension issues
Improper surface finishing

These defects can lead to engine failure, posing a serious safety risk.

Potential Dangers and Symptoms

According to GM, drivers may notice warning signs before total engine failure, including:

Unusual Engine Noises – Knocking, banging, or metallic sounds
Check Engine Light – Illumination of the dashboard warning light
Performance Problems:
- Hesitation or stumbling during acceleration
- High or unusual RPMs
- Abnormal or rough shifting
- Reduced propulsion or loss of power
- No-start condition (engine fails to start)

If the engine fails while driving, drivers may lose propulsion, significantly increasing the risk of a crash. GM has already linked the defect to 12 potential crashes and 12 reported injuries in the U.S.

The Official GM Remedy

General Motors dealers will inspect affected vehicles. Depending on results, remedies include:

Higher Viscosity Oil – Offers added protection against component wear
New Oil Fill Cap & Oil Filter Replacement
Owner’s Manual Insert – Updated guidance for owners

Is My Vehicle Safe to Drive?

While GM notes that the condition does not affect braking or cause an abrupt stop, an engine failure during operation will cause a loss of propulsion, requiring drivers to coast and maneuver to the side of the road. This can create a serious safety hazard.

Until recall repairs are complete, GM advises owners to stay alert for unusual engine noises, warning lights, and changes in performance.

California Lemon Law: Your Rights as a Consumer

If you’re a California resident and your Chevrolet, GMC, or Cadillac has been in the shop multiple times for the same issue, or if you’ve lost significant time without your vehicle, you may qualify for relief under the California Lemon Law.

Lemon law protections may entitle you to a:

Buyback (refund)
Vehicle replacement
Cash compensation

Our experienced California Lemon Law attorneys can guide you through the process and ensure you receive the compensation you deserve.

What to Do If Your Vehicle is Affected

Schedule a Dealer Inspection – Don’t wait until your engine fails; get ahead of the issue.
Document All Repairs and Symptoms – Keep records for potential lemon law claims.
Call for a Free Case Review – If you’ve had repeated problems, call 1-866-785-4477 for a free California Lemon Law consultation.

Final Thoughts

The 6.2L V8 engine defect in GM vehicles is a serious safety concern affecting hundreds of thousands of drivers. If you own a 2021–2024 Chevrolet Silverado, Suburban, Tahoe, GMC Sierra, Yukon, or Cadillac Escalade, don’t wait for the engine to fail — take action now to protect your safety and your rights.

✅ Free Case Review: Contact our California Lemon Law attorneys today at 1-866-785-4477 or fill out our online form at the top of the page to learn if your GM vehicle qualifies for a buyback, replacement, or compensation.

Porsche has issued a recall affecting two of its most popular electric vehicles: the 2022–2023 Taycan and the 2024–2025 Macan EV. While the Taycan faces a potential airbag malfunction, the Macan EV is dealing with a rearview camera issue — both of which raise serious safety concerns.

If you own one of these vehicles in California, here’s what you need to know — especially when it comes to your rights under the state’s Lemon Law.

What are the problems?

Taycan (2022–2023): A defect in the passenger seat sensor may cause the airbag to fail to deploy in a crash. Porsche is replacing the entire passenger seat cushion in affected vehicles to resolve the issue.
Macan EV (2024–2025): Owners are reporting rearview camera malfunctions due to wiring or software faults. Porsche plans to issue software updates and, where necessary, address hardware issues related to the camera system.

In both cases, these are active safety systems, and failure could put drivers and passengers at risk.

What’s being done?

Repairs are already underway at Porsche dealerships. Taycan owners will receive a new seat cushion with an updated sensor module. Macan EV owners will either receive a software patch or additional service to fix camera system components.

Why Lemon Law may apply in California

Here’s where things matter for Porsche owners in California: If your vehicle has required multiple trips to the dealer, or if these repairs leave your car out of service for an extended period, you may qualify for protection under the California Lemon Law.

That includes:

Safety system failures (like airbags or backup cameras)
Delays in getting proper parts or repairs
Ongoing electrical or software issues that affect performance or reliability

Even luxury vehicles like Porsche aren’t immune to defects — and when problems start to stack up, the law is on your side.

What you should do:

Keep a clear record of all repair visits and communication with Porsche service departments
Take note if you’re told parts are on backorder or if repairs are delayed
Reach out to a Lemon Law attorney if your vehicle continues to have issues or you’ve lost confidence in its safety

You invested in a high-end electric vehicle — and you have every right to expect high-end reliability and support.

If your Porsche Taycan or Macan EV has been giving you problems, especially related to safety features or software bugs, reach out today. Call Now for a FREE Case Review at 888-395-3666 or fill in the contact form at the top of the page. Our experienced team is here to help you navigate the process and ensure you receive the compensation you deserve. You may be entitled to a refund, replacement, or compensation under California law.

If you drive a 2024 or 2025 Volkswagen Atlas or Atlas Cross Sport, there’s a recall you should know about — and it’s not something to ignore. Volkswagen has recalled approximately 177,000 vehicles because a loose engine cover could come into contact with hot engine parts, increasing the risk of fire.

For California drivers, this issue may also open the door to a Lemon Law claim, especially if repairs have been delayed or your vehicle has shown signs of repeated defects.

What’s the issue?

According to Volkswagen, the engine cover may not be properly secured, and during driving, it can shift out of place. If it comes into contact with the exhaust manifold or other high-temperature components, it could melt or ignite — which is a clear safety risk.

This is the kind of problem that’s easy to overlook — until it becomes dangerous.

What’s being done?

Volkswagen dealerships are currently performing repairs, which may include either removing or properly securing the engine cover. Owners should be notified, but if you’re concerned about your vehicle, you can contact your local dealer to ask if you’re affected.

Why it matters under California Lemon Law

If your vehicle is under warranty and has a serious safety defect, California’s Lemon Law is designed to protect you. That includes issues that:

Create a fire hazard or compromise safety
Require multiple repair attempts
Keep the car in the shop for long periods

Even if this is the first recall you’ve faced, if your Atlas has had other issues, or if this repair takes a long time to complete, it may be worth exploring whether your vehicle qualifies as a lemon.

What you should do:

Check your repair history and note any previous service visits related to engine components or unusual smells
Schedule a repair with your dealer as soon as possible
Keep every service invoice and communication
Speak with a Lemon Law professional if your vehicle has been unreliable or unsafe

You don’t need to wait for something to go wrong. If your Atlas has had repeated problems or spent too much time off the road, you may be eligible for a refund or replacement.

California law gives you real options — and you don’t need to pay anything upfront to find out if your case qualifies. We’re here to help you understand your rights and take the next step.