Tag Archives: manufacturing error

Certain 2022-2024 Ford F-150 Lightning BEVs May Have A Battery Defect

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A potential safety issue has been identified in a small number of 2022-2024 Ford F-150 Lightning Battery Electric Vehicles (BEVs). The problem affects the high voltage battery cells, which may have a manufacturing defect that can cause an internal short circuit. This defect is due to misaligned electrodes in the battery cells, which can occur over repeated charge and discharge cycles.

The issue was first brought to Ford’s attention in October 2024, when a fire was reported in a 2022 model year F-150 BEV. Further investigation revealed two additional fires in 2022 and 2023 model year vehicles, prompting Ford to launch a broader inquiry into the matter. Although no physical samples were initially available for analysis, Ford’s Field Review Committee authorized a program to collect and evaluate additional samples from the field.

The subsequent tear-down analysis of the returned battery arrays revealed evidence of misaligned electrodes in the high voltage battery cells. The supplier also found that eight stacker machines between two production lines had produced cells with cathode shift, which did not meet the design requirements. This manufacturing concern resulted in overlap that fell short of the required standards. Notably, some of the cells from vehicles that experienced fires were manufactured during this time frame.

On February 18, 2025, Ford learned of a fifth report of a vehicle fire and decided to approve a safety recall. The recall affects certain 2022-2024 Ford F-150 Lightning BEVs, and owners are advised to take precautions until the repair is completed. Specifically, owners should only charge their vehicles to a maximum of 80% battery capacity to minimize the risk of an internal short circuit.

To address this issue, dealers will inspect and replace the high voltage battery array as necessary. Owner notification letters are expected to be mailed on March 17, 2025. Ford’s recall number for this issue is 25S18, and the National Highway Traffic Safety Administration (NHTSA) has assigned a campaign number of 25V-131.

Fuel Leak: 2021-2023 Acura TLX

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The fuel filler neck and fuel tank junction in a small number of 2021-2023 Acura TLX vehicles may have an incomplete weld that could separate. An incomplete weld can cause separation, leading to a fuel leak while driving or parked. This defect poses a significant risk to vehicle occupants and bystanders, as fuel leaks can ignite and cause fires.

Background of the Issue

Honda first became aware of the issue in November 2023, when they received a warranty claim related to a fuel leak in an affected TLX vehicle. The company promptly launched an investigation, which revealed that a defect related to motor vehicle safety existed. As a result, Honda decided to conduct a safety recall to address the problem. To date, the company has received two warranty claims related to this issue, but fortunately, there have been no reports of injuries, fires, or deaths.

Cause of the Defect

The root cause of the defect lies in the production process of the fuel tank assembly. During manufacturing, the fuel filler neck was improperly loaded into the gripper fixture, resulting in a tilted position and uneven contact between the fuel tank and fuel filler neck during the weld procedure. Additionally, the fuel filler neck melt depth was incorrectly set for the weld equipment, leading to a shallow melt weld depth between the components. This combination of factors created an incomplete weld that can separate over time, allowing fuel to escape.

Symptoms of a Fuel Leak

If you own a 2021-2023 Acura TLX, it’s essential to be aware of the symptoms of a fuel leak. One of the most common signs is a strong gasoline odor wafting through the vehicle while driving. This can be caused by a variety of factors, including worn-out seals, cracked fuel lines, or faulty fuel system components. As cars age, the rubber components in their fuel systems can deteriorate, allowing gas to escape. Common culprits behind these leaks include the fuel pump, filter, and injectors, as well as parts of the emissions system.

Risks Associated with Fuel Leaks

A gasoline smell is not just a minor annoyance; it can also be a sign that your engine is burning more fuel than necessary, which can hit you in the pocketbook. More alarmingly, prolonged exposure to gas fumes can have serious health consequences, including respiratory damage. Given the potential risks to both your wallet and well-being, it’s crucial to address any issues causing a gasoline smell in your TLX promptly.

Recall Details

To rectify the issue, dealers will replace the fuel tank assembly. Owner notification letters are expected to be mailed on February 10, 2025. Acura’s number for this recall is JKX, and the NHTSA campaign number is 24V-950. If you receive a notice for this problem, it’s essential to schedule a service appointment as soon as possible to have the fuel tank assembly replaced.

Engine Cup Oil Leak In 2024-2025 Ford & Lincoln Vehicles

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Low Oil Pressure WarningFord Motor Company have identified a critical issue in certain 2024-2025 F-150, 2024 Expedition, and 2024 Lincoln Navigator vehicles equipped with the 3.5L GTDI engine. A misaligned engine cup plug has been found to potentially result in a rapid oil leak, posing serious safety risks.

The Problem: Misaligned Engine Cup Plug

The defect stems from a misalignment of the hydraulic press used to insert engine cup plugs into the cylinder head bore during assembly. This misalignment, approximately 1.5 mm off center, distorts the cup plug, reducing its retention within the bore. This defect may result in:

  • Rapid Oil Leak: A misaligned plug can cause sudden, large-volume oil loss.
  • Increased Fire Risk: Oil leaks in the presence of hot engine or exhaust components may lead to a fire.
  • Loss of Motive Power: A sudden loss of oil can result in reduced engine performance or a complete loss of motive power, increasing the risk of a crash.

Warning Signs for Customers

Drivers of affected vehicles may notice several warning signs, including:

  • Low Oil Pressure Warning: A warning light on the instrument cluster.
  • Burning Smell or Smoke: White smoke or a burning odor from the engine compartment.
  • Oil Leak or Engine Noise: Visible oil leakage or unusual noises from the engine.

Discovery and Investigation

The issue first came to Ford’s attention in October 2024 during a vehicle evaluation at the Kansas City Assembly Plant. A 2024 F-150 equipped with the 3.5L GTDI engine experienced a significant oil leak caused by the expulsion of a 13mm engine cup plug on the exhaust side.

Ford’s Critical Concern Review Group (CCRG) conducted an investigation and tear down analysis. They found no damage to the cylinder head bore but discovered that the cup plug was off center. The misalignment was traced back to maintenance work on the cylinder head assembly line at the Cleveland Engine Plant between September 9, 2024, and September 16, 2024. Other stations were confirmed to have proper alignment.

Field Action and Customer Notification

As of October 30, 2024, Ford has not received any warranty claims or field reports from customers regarding this issue. However, the company is taking measures to ensure customer safety:

  • Field Action Approval: Ford’s Field Review Committee approved the recall on November 1, 2024.
  • Dealer Inspections and Repairs: Dealers will inspect the cup plug alignment and replace any misaligned plugs.
  • Customer Notifications: Owner notification letters are scheduled to be mailed by December 2, 2024.

Recall Details

  • Ford Recall Number: 24S70
  • NHTSA Campaign Number: 24V-851

Next Steps for Vehicle Owners

Ford advises owners of the affected 2024-2025 F-150, 2024 Expedition, and 2024 Lincoln Navigator vehicles to monitor for any signs of the defect and to schedule an inspection with their dealer once notified. This precautionary recall aims to address the issue and ensure vehicle safety and reliability.

Certain 2023-2024 GM Vehicles Fail to Meet FMVSS for Brake Systems

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Certain 2023-2024 Cadillac, Chevrolet and GMC vehicles fail to meet the Federal Motor Vehicle Safety Standard (FMVSS) for light vehicle baking systems. The problem is, the driver may not receive an indicator of a loss of brake fluid before the level is below FMVSS 135’s requirement.

The FMVSS 135 requires that vehicles have a system in place to warn the driver when the brake fluid level drops to a certain point. This allows time for the problem to be addressed before it affects braking performance. However, in the affected vehicles, the brake fluid warning light may not illuminate in time to alert the driver before the fluid drops below the required level. This delay in the warning light could lead to reduced brake performance, increasing the risk of a crash.

The following vehicle models are affected by this problem:

2023-2024 Cadillac Escalade
2023-2024 Cadillac Escalade ESV
2023 Chevrolet Silverado 1500
2023-2024 Chevrolet Suburban 1500
2023-2024 Chevrolet Tahoe
2023 GMC Sierra 1500
2023-2024 GMC Yukon
2023-2024 GMC Yukon XL

GM became aware of this issue through its Speak Up for Safety (SUFS) program. A GM engineer noticed during a brake fluid leak test that the required warning light (referred to as the BRAKE telltale) did not illuminate as expected. This led GM to launch a full investigation. The issue was traced to a mismatch in the software and calibrations of the Electronic Brake Control Module (eBCM). This software mismatch was preventing the vehicle from detecting a brake fluid leak in time to alert the driver. Fortunately, GM has not received any reports of crashes or injuries related to this issue, but the potential for delayed notification of a brake fluid leak poses a safety concern.

In the event of a brake fluid leak, the vehicle’s brake pedal could become less responsive before the warning light appears. This degraded brake performance, combined with the delayed warning, could increase the likelihood of a crash. However, GM has confirmed that even in these circumstances, the vehicles still meet federal stopping distance requirements, meaning they should still be able to stop within the legally required distance.

Owners of affected vehicles will be notified by mail starting October 28, 2024. GM will provide a software update for the eBCM that will correct the issue. This update can be done remotely through an over-the-air (OTA) update or by visiting a dealership. If you own one of these vehicles, you do not need to take immediate action unless you notice any issues with your brakes. The recall is precautionary, and the software update will ensure that your vehicle meets all federal safety standards moving forward.

GM’s recall number for this issue is N242447990, and the National Highway Traffic Safety Administration (NHTSA) campaign number is 24V-674.

Jeep Gladiator And Wrangler Instrument Panel Failure

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Jeep Instrument Panel FailureFiat Chrysler Automobiles (FCA) US have decided that there is a safety related problem affecting certain 2020-2024 Jeep Gladiator and 2018-2024 Jeep Wrangler vehicles. The recall was prompted by an issue that could cause the instrument panel cluster (IPC) to fail, leading to a blank display. This defect may occur due to an internal short circuit, which could compromise the instrument panel’s functionality and cause the vehicle to fall out of compliance with Federal Motor Vehicle Safety Standard (FMVSS) No. 101, which governs controls and displays in vehicles.

The problem was first identified by FCA’s Technical Safety and Regulatory Compliance (TSRC) organization, which had received reports of blank IPCs in affected models. Following this, the TSRC conducted a detailed analysis, including reviewing patterns of IPC failures and performing warranty part return inspections. After collaborating with suppliers and conducting rigorous testing, it was determined that the IPCs in certain vehicles might experience an internal short circuit, causing the display to go blank unexpectedly.

A non-functional instrument panel cluster is a serious concern, as it can result in drivers losing access to critical vehicle information such as speed, fuel levels, and warning indicators. This increases the risk of accidents and reduces the driver’s ability to make informed decisions while operating the vehicle.

On August 30, 2024, FCA US decided, through its Vehicle Regulations Committee, to issue a safety recall for the affected vehicles. The recall applies to Jeep Wrangler models manufactured between 2018 and 2024, as well as Jeep Gladiator models produced from 2020 to 2024. To address the issue, FCA will replace the faulty instrument panel cluster in affected vehicles.

The recall is identified as FCA campaign number 30B, and the corresponding National Highway Traffic Safety Administration (NHTSA) campaign number is 24V-652.

Airbag Issue in 2021 and 2024 Nissan Titan Vehicles

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A recent safety concern has emerged for a small number of 2021 and 2024 Nissan Titan vehicles due to a potential issue with their Air Bag Control Unit (ACU). This problem, if left unaddressed, could increase the risk of injury to occupants in the event of a crash.

In May 2024, Nissan was alerted by their airbag supplier about a production error that involved a missing spacer between the ACU fastener and the base plate. This spacer plays a critical role in ensuring that the ACU is properly secured. Without it, there is a risk that the fastener could interfere with the vehicle’s floor pan, leading to the fastener becoming loose. If this occurs, the airbag may deploy late or not at all, which could significantly increase the risk of injury during a crash.

Upon learning about the problem, Nissan and the supplier conducted a thorough audit. They discovered that 531 affected parts had been shipped to Nissan’s Canton, MS Plant. Fortunately, 528 of these parts were identified and quarantined before they could be installed in vehicles. However, three parts had already been installed in 2024 Nissan Titan vehicles that had been shipped.

In June 2024, the supplier identified additional affected parts included in a service part kit, of which 41 were shipped to Nissan. Nissan was able to quarantine and scrap 37 of these parts, but four had already been installed in 2021 Nissan Titan vehicles during repairs.

On July 19, 2024, after further assessment, Nissan confirmed that the absence of the spacer could indeed cause interference with the floor pan, potentially leading to loose fasteners and compromised airbag deployment.

As a result of these findings, Nissan decided on July 29, 2024, to initiate a Voluntary Safety Recall for the seven affected vehicles—three from the 2024 model year and four from the 2021 model year. While there have been no reports of accidents or injuries related to this issue, Nissan is taking precautionary measures to ensure the safety of its customers.

Nissan will address the issue by replacing the ACU in the affected vehicles. Owners of these vehicles will receive notification letters starting September 19, 2024. The recall number assigned by Nissan is PD120, and the corresponding National Highway Traffic Safety Administration (NHTSA) campaign number is 24V-580.

Although the number of vehicles affected is small, this recall is a critical step to ensure the safety of Nissan Titan drivers and passengers. If you own a 2021 or 2024 Nissan Titan, keep an eye out for the notification letter and get the the necessary repairs.

2021 Jeep Wrangler and Gladiator PCM Software Update

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A select number of Jeep Wrangler and Jeep Gladiator vehicles that were previously repaired under NHTSA recall number 23V-116 are now slated for a crucial Powertrain Control Module (PCM) software update.

In February 2023, FCA US LLC’s Vehicle Regulations Committee launched a safety recall (19A) targeting specific 2018-2023 Jeep Wrangler and 2020-2023 Jeep Gladiator models with manual transmissions. This recall was triggered by reports of potential overheating of the clutch pressure plate due to friction. Such overheating could cause the pressure plate to fracture rapidly, leading to cracks or holes in the transmission case. This damage could result in the expulsion of heated debris from the transmission case, posing safety risks to vehicle occupants and other road users.

By June 2024, FCA’s Technical Safety and Regulatory Compliance (TSRC) organization received reports of vehicles stalling after undergoing the 19A recall remedy. An investigation focused on specific 2021 Jeep Wrangler and 2021 Jeep Gladiator vehicles with manual transmissions that had received the initial remedy under FCA US Recall ID 19A / NHTSA Recall 23V-116. The investigation found that these vehicles might encounter an issue with the Revolutions per Minute (RPM) reduction feature in the PCM software.

The issue was traced to a suspect software release that began on June 19, 2024. This software release introduced a malfunction affecting the RPM reduction feature. The release period ended on June 26, 2024, when the software was withdrawn from availability. Affected vehicles were identified using PCM scan data, ensuring precise identification of those needing further attention. It was confirmed that similar vehicles not included in the recall either lacked manual transmissions or were not updated with the problematic software version.

The remedy involves updating the PCM software in the affected vehicles to ensure the RPM reduction feature operates correctly. This update aims to eliminate the risk of stalling and enhance overall vehicle performance.

Owners of the affected Jeep Wrangler and Jeep Gladiator models will receive notification letters by August 15, 2024. These letters will provide detailed instructions on how to proceed with the necessary software update.

For reference, FCA US LLC has assigned the number 92B to this recall, and the NHTSA campaign number is 24V-572. It is crucial for vehicle owners who had previously completed repairs under recall 23V-116 to ensure this new remedy is completed to maintain vehicle safety and reliability.

Pacifica Plug-In Hybrid Battery Fire Warning

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Chrysler Pacifica Battery FireChrysler (FCA US, LLC) has found a problem with some 2019-2021 Pacifica Plug-In Hybrid Electric (PHEV) vehicles, as well as some 2017-2018 Pacifica PHEVs that got a software update under a previous recall (NHTSA recall number 22V-077). The issue is with the battery pack, which could cause a fire even when the car is parked and the ignition is off.

Chrysler first learned about this issue in February 2022 through the Vehicle Regulations Committee, which led them to start a voluntary safety recall on certain Pacifica PHEVs, known as recall Z11.

Since then, Chrysler and LG Energy Solution (LGES) have been working to figure out the root cause of the problem. They’ve analyzed field reports, bought back vehicles, looked at vehicle data, conducted thermal tests, and torn down battery packs to get to the bottom of it.

In November 2022, the Technical Safety and Regulatory Compliance (TSRC) team at Chrysler was informed about a battery fire in a Pacifica PHEV that had already been fixed under recall Z11.

From June 2023 to December 2023, TSRC learned about five more fires involving the HV battery in some Pacifica PHEVs that had the Z11 remedy. They tried to buy back these vehicles to analyze if the recall fix was working.

In April 2024, Chrysler received a Pacifica PHEV with a post-Z11 remedy fire in the battery pack. After analyzing the vehicle and battery pack, they sent the battery back to the supplier for further inspection. They found a torn anode tab in one of the cells, but couldn’t identify a second factor causing the fires. This confirmed that the Z11 remedy wasn’t effective.

A folded or torn anode tab can lead to lithium by-product build-up over time. This defect, combined with another unknown factor, can cause an internal short in the battery pack, potentially resulting in a vehicle fire.

Chrysler advises owners not to charge their vehicles and to park them outside and away from structures until repairs are made. Dealers will update the high voltage battery pack control module (BPCM) software, and if necessary, replace the battery pack assembly. The recall numbers are 72B and 73B, and the NHTSA campaign numbers are 24V-356 and 24V-358. Vehicles previously repaired under recall 22V-077 will need to have the new fix applied.