Tag Archives: Manufacturer defect

2025 Ford F-150 Lower Intermediate Shaft Fastener Problem

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F-150 Lower Steering Shaft

Ford Motor Company has issued a recall for certain 2025 model year F-150 vehicles due to a potential problem with the lower intermediate shaft fasteners. The issue affects the attachment of the lower intermediate shaft to the steering gear, which may not have been properly secured during the assembly process.

According to Ford, the problem was first identified on March 28, 2025, when a warranty claim was filed for a vehicle that exhibited “excessive steering play” during a pre-delivery inspection. Upon investigation, it was discovered that a lower intermediate shaft fastener was missing. Although an initial yard campaign did not reveal any additional vehicles with loose or missing fasteners, further review by Ford’s Critical Concern Review Group (CCRG) determined that the assembly plant’s labor rebalance operation may have caused the error proofing process control to be misaligned with the assembly station tool.

As a result, the error proofing system may have recorded a successful joint secure for vehicles that did not actually have a properly secured fastener. This means that some affected vehicles may have been released from the factory with a loose or missing lower intermediate shaft fastener, which could lead to separation of steering system components and a loss of steering control.

If the fastener securing the lower intermediate shaft to the steering gear is loose or missing, drivers may hear a rattle noise coming from the steering system while driving or experience excessive steering play prior to separation. In the worst-case scenario, this could result in a crash. Fortunately, Ford has reported only one warranty claim related to this concern and is not aware of any accidents or injuries.

To address the issue, dealers will inspect and replace the lower intermediate shaft fasteners as necessary. Vehicle owners can identify their vehicle’s recall status by checking Ford’s website or contacting their local dealership. The recall number for this issue is 25S46, and the National Highway Traffic Safety Administration (NHTSA) campaign number is 25V-309.

Ford’s ability to trace lower intermediate shaft production to the specific vehicle in which it is installed has allowed the company to identify the affected population and take corrective action. By inspecting and replacing the lower intermediate shaft fasteners, Ford aims to prevent any potential accidents or injuries related to this concern.

Vehicle owners who receive a notice about their F-150’s safety should contact their local dealership to schedule an inspection and repair if necessary. With prompt attention, Ford can ensure that all affected vehicles are brought up to standard and provide safe and reliable transportation for drivers.

Audi Q5 Quattro Fire Risk: Improperly Tightened Cylinder Head Cover Screws

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Volkswagen Group of America, Inc. (Audi) has issued a recall for certain 2022-2024 Audi Q5 Quattro and Q5 Sportback Quattro vehicles due to a potential problem with the cylinder head cover screws. The screws may have been improperly tightened, which can cause them to loosen over time, leading to engine oil leaks from the cylinder head cover screw holes.

According to the defect report, the issue is attributed to varying tightening torques during the screwing process of the cylinder head cover, resulting in a potentially insecure screw connection and compromised sealing of the cylinder head cover. If engine oil comes into contact with hot parts of the engine, it can cause a fire. Owners are advised to be vigilant for signs of smoke in the engine compartment and to safely park their vehicle immediately if they notice any unusual odors or smoke.

The recall was prompted by customer complaints received by Audi in May 2023, which reported oil leaking from cylinder head covers of Audi Q5 2.0 TFSI vehicles. An investigation was launched, and a root cause analysis suggested that screws with burrs caused during the manufacturing process may have damaged the cylinder head cover surface, leading to oil leakage and potential torque reduction over time.

Despite implementing manufacturing improvements, Audi continued to monitor the field and recognized an increase in oil leak claims in early 2024. In response, the company issued a Technical Service Bulletin instructing dealers to inspect the cylinder head cover screws and replace any loose screws. Further analysis by the engine plant revealed the potential for improperly torqued cylinder head cover screws, leading Audi to review the screwing process with its supplier and implement changes.

However, despite these efforts, the U.S. market reported an increase in field claims of oil leakage and thermal event incidents between November and December 2024. Audi inspected and analyzed these cases, evaluating potential root causes and contributing factors. The company’s Product Safety Committee ultimately decided to conduct a safety recall for the affected vehicles on April 30, 2025.

To date, Audi has received 2,539 potentially related warranty claims of oil leaks in the U.S. and eleven thermal event cases. Early engine oil leaks can be difficult to detect, but advanced cases may be accompanied by an unpleasant odor or smoke in the engine compartment when the engine is hot.

To address the issue, dealers will inspect and replace the screws as necessary. Owner notification letters are expected to be mailed on July 8, 2025. The recall is identified by Audi’s number 15ZK and the NHTSA campaign number 25V-294. Owners of affected vehicles are advised to contact their local dealership for further information and to schedule an inspection and repair if necessary.

Braking Safety Concern In 2025 Nissan And Infiniti Vehicles

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Nissan has issued a recall for certain 2025 model year Murano, Pathfinder, and Infiniti QX60 vehicles due to a potential braking safety issue. The problem affects the front brake caliper assemblies, which may have reduced strength and could break, leading to reduced braking performance.

The issue was discovered in January 2025 during a routine production brake test on a 2025 Nissan Pathfinder. A technician reported a failure of the front right-hand brake caliper assembly, prompting Nissan to quarantine the defective part and launch an investigation. Further analysis revealed that the suspect brake caliper had been produced with a common supplier production lot code (51A), which was found to have an inadvertent modification to an internal parameter setting. This modification reduced the material’s strength, making it more prone to failure.

The supplier’s investigation confirmed that a total of 3,115 caliper castings were produced in the affected lot and shipped to Nissan for assembly into vehicles. Through traceability records, Nissan identified 2,341 vehicles that may have received a potentially affected brake caliper. Of these vehicles, 711 were held for inspection, while 200 had been exported and 1,430 had previously been shipped to the US.

According to Nissan, if one or both of the front brake calipers fail, it can result in reduced braking performance and may not comply with certain performance requirements of Federal Motor Vehicle Safety Standard (FMVSS) 135. This could increase the risk of a crash, particularly if drivers are unable to stop their vehicles in time. Affected customers may notice uneven braking performance, and the “Low Brake Fluid” warning light may illuminate in certain cases.

To address the issue, Nissan will be recalling affected vehicles and asking owners to return to their dealerships for an inspection and replacement of the front brake caliper assemblies as necessary. Owner notification letters are expected to be mailed on May 9, 2025. The recall is identified as Nissan’s numbers PD137 and PD138, and the NHTSA campaign number is 25V-173. This issue highlights the importance of rigorous testing and quality control measures in ensuring the safety of vehicles on the road.

Ford and Lincoln Transmission Valve Failure

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A critical issue affecting the transmission valve body of certain Ford Bronco, Explorer, F-150, Mustang, Ranger, and Lincoln Aviator vehicles can cause reverse gear failure or unexpected forward movement while in reverse or neutral gear. This problem could be a significant safety risk to drivers and passengers.

According to Ford, the issue is attributed to an incorrectly machined transmission valve body, specifically the Outer Valve Body (OVB) of the transmission main control. The machining tool used during production did not maintain proper specifications, resulting in out-of-specification dimensions that can prevent the vehicle from entering reverse gear when commanded by the gear shift module.

Symptoms of the problem include no reverse motion when the gear selector is in reverse, and in some cases, the vehicle may move forward with the gear selector in either reverse or neutral position. The Malfunction Indicator Light (MIL) and Wrench light will illuminate on the dashboard when this malfunction occurs.

The recall affects vehicles, including:

  • 2024-2025 Ford Bronco
  • 2025 Ford Explorer
  • 2024-2025 Ford F-150
  • 2025 Ford Mustang
  • 2024 Ford Ranger
  • 2025 Lincoln Aviator

Ford’s investigation into the matter began in February 2025, after a transmission failure was reported on a 2025 Mustang at the Flat Rock Assembly Plant. The company subsequently issued a Stop Ship order for affected models and launched an analysis of the suspect transmissions.

Using advanced data analytics, including Machine Integrated Learning and Optimization (MILO) modeling, Ford identified individual Outer Valve Body units that were likely to experience this condition. The company then conducted evaluations of vehicles equipped with suspect parts and confirmed the symptoms reported by customers.

As of February 21, 2025, Ford had received five warranty reports related to this issue. On March 7, 2025, the company’s Field Review Committee approved a field action, which includes replacing the transmission main control valve body.

Ford has notified owners of affected vehicles and has begun repairing the transmissions. The recall is identified as Ford’s number 25S19 and NHTSA Campaign Number 25V-164.

This recall highlights the importance of rigorous quality control measures in the automotive manufacturing process. The issue serves as a reminder that even minor defects can have significant consequences on vehicle safety and performance.

2025 Chrysler Pacifica PHEVs – Insufficient Bolt Torque on Front Brake Caliper Bracket

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A potential safety issue has been identified in some 2025 Chrysler Pacifica Plug-In Hybrid Electric Vehicles (PHEVs) that may have been produced with insufficient bolt torque on the front brake caliper bracket. The problem, which affects vehicles produced on December 19, 2024, can lead to a range of serious consequences, including reduced steering control, brake fluid leakage, and diminished front braking performance.

According to FCA US LLC (FCA US), the issue was first identified on February 20, 2025, when the Technical Safety and Regulatory Compliance (TSRC) organization opened an investigation into the matter. The company worked with its engineering team and supplier to understand the potential consequences of the problem and determine if any vehicles with suspect front brake caliper brackets had left the factory.

As of March 13, 2025, FCA US is aware of one warranty claim related to this issue, which was received on January 8, 2025. However, there have been no field reports of accidents or injuries resulting from the problem.

The suspect vehicles were produced with front brake caliper bracket bolts that were not properly torqued, which can cause the bracket to separate from the steering knuckle. This can lead to a range of serious safety issues, including reduced steering control and diminished braking performance. In certain crashes, this can increase the risk of injury to occupants of the vehicle.

To address the issue, FCA US will be conducting a recall of affected vehicles. Dealers will inspect and replace the front brake caliper brackets and bolts as necessary, free of charge. Owner notification letters are expected to be mailed on April 24, 2025. The recall is identified as FCA’s number 27C and the NHTSA campaign number is 25V-191.

Vehicle owners who receive a notification letter should contact their local Chrysler dealer to schedule an appointment for the inspection and repair. It is essential to have the issue addressed promptly to ensure the safety of the vehicle’s occupants and other road users. The recall highlights the importance of regular maintenance and inspections to identify potential safety issues before they become major problems. FCA US’s prompt action in addressing the issue demonstrates its commitment to ensuring the safety and quality of its vehicles.

If you own a 2025 Chrysler Pacifica PHEV, it is essential to be aware of this potential issue and take immediate action if you receive a notification letter. By doing so, you can help ensure your safety and the safety of others on the road.

NHTSA Investigates Engine Failure in GM Trucks And SUVs

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A shocking number of complaints has prompted the National Highway Traffic Safety Administration (NHTSA) to launch a safety probe into engine failure reports affecting approximately 870,000 Chevrolet, GMC, and Cadillac models manufactured by General Motors (GM). The Office of Defects Investigation (ODI) has received a staggering 39 complaints, accompanied by numerous Early Warning Reporting (EWR) Field Reports, all pointing to engine failure in vehicles equipped with the L87 V8 engine.

Which Vehicles Are Affected?

The following models are under scrutiny:

  • 2019-2024 Chevrolet Silverado 1500
  • 2019-2024 GMC Sierra 1500
  • 2021-2024 Chevrolet Tahoe
  • 2021-2024 Chevrolet Suburban
  • 2021-2024 GMC Yukon
  • 2021-2024 Cadillac Escalade

The Alarming Reality of Engine Failure

Complainants have reported a disturbing trend: a bearing failure can trigger either engine seizure or a catastrophic breach of the engine block by the connecting rod. In many cases, there are no warning signs before the failure occurs, resulting in a sudden and unexpected loss of power. This increases the risk of a crash, which can lead to devastating consequences, including injuries and property damage.

NHTSA Takes Action

In response to these disturbing reports, the ODI has initiated a Preliminary Evaluation (PE) to determine the scope and severity of the potential problem. The investigation aims to assess the safety-related issues associated with engine failure and identify any necessary corrective actions to prevent future incidents.

What California Drivers Need to Know

If you’re behind the wheel of one of these affected vehicles, it’s crucial to be aware of this potential issue. Engine failure can be a significant safety concern, especially when driving at high speeds. Don’t wait until it’s too late – stay informed and take proactive steps to protect yourself and your loved ones.

Seeking Help from a California Lemon Law Expert

If you’re experiencing engine problems or other issues with your Chevy, GMC, or Cadillac vehicle, don’t hesitate to reach out to our experienced California Lemon Law attorneys. Our team is dedicated to helping you navigate the complex process and determine if you’re eligible for compensation or relief under the law. If you have concerns about your vehicle or would like to report an incident, consult with a California Lemon Law attorney for expert guidance and support.

Jeep Grand Cherokee Front Seat Side Airbag May Not Deploy

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If you own a 2022-2024 Jeep Grand Cherokee or a 2021-2024 Jeep Grand Cherokee L , it’s crucial to be aware of a recent safety recall. A small number of these vehicles may have an improperly secured connector for the front seat side airbags (SAB), which could prevent the airbags from deploying in case of a crash. This issue compromises compliance with Federal Motor Vehicle Safety Standards (FMVSS) for side impact protection.

Discovery and Investigation

On April 25, 2023, FCA US LLC’s Technical Safety and Regulatory Compliance (TSRC) organization was notified of a potential safety issue involving improperly secured seat wiring connectors in certain 2022-2024 Jeep Grand Cherokee and 2021-2024 Jeep Grand Cherokee L vehicles .

From May 2023 to October 2023, the TSRC organization conducted a thorough review of warranty data, vehicle production records, field reports, and customer assistance records. This comprehensive analysis aimed to understand the potential impact on customers.

Regular meetings were held from October 2023 to September 2024 between FCA US TSRC, Engineering, and Supplier Quality teams. These discussions focused on identifying all possible failure modes of the issue and determining which vehicles were at risk.

On October 9, 2024, the TSRC organization officially recognized that a front seat SAB squib connector problem existed in certain vehicles due to improperly secured connectors. This defect could result in non-compliance with FMVSS No. 214, which governs side impact protection.

Recall Announcement

On November 21, 2024, FCA US decided through the Vehicle Regulations Committee to conduct a voluntary safety recall of the affected vehicles. This proactive step ensures that owners are aware of and can address this critical safety concern.

Identifying Affected Vehicles

If your vehicle is affected by this issue, you may notice an illuminated airbag warning light on the dashboard. This light indicates a potential problem with the front seat side airbags.

Owner notification letters are expected to be mailed on December 19, 2024. These letters will provide detailed instructions on how to proceed with the recall process.

Owners will be instructed to take their vehicles to a Jeep dealership. There, technicians will secure the improperly connected front seat side airbag connectors free of charge.

Recall Details

  • FCA US Recall Number : B3B
  • NHTSA Campaign Number : 24V-897

Ensuring your vehicle complies with federal safety standards is essential for protecting yourself and others on the road. By staying informed about recalls like this one, you can take necessary actions to maintain your vehicle’s safety features.

Audi Announces High-Voltage Battery Issue In Certain PHEV Models

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Audi has announced a safety defect affecting certain high-voltage battery modules in its 2022-2023 Q5 Plug-in Hybrid Electric Vehicle (PHEV) and A7 PHEV models. The recall is necessary due to the risk of thermal events, which may cause smoke or even fires.

According to Audi, the root cause of the issue is still under investigation, but current analysis suggests that manufacturing deviations at a supplier of battery modules may be to blame. The company has been working closely with its supplier, Samsung SDI, and conducting comprehensive analyses of affected batteries to determine the conditions and circumstances that trigger thermal events.

The recall affects approximately 50 high-voltage batteries from non-U.S. markets, as well as an additional batch of batteries collected from field incidents in the United States. Audi has also received reports of other vehicles outside of these specific models, which are also under investigation.

To mitigate the risk, Audi plans to install advanced onboard diagnostic software, which will detect potential issues with battery module performance and alert the driver before problems may occur. The software is expected to be available in the second quarter of 2025.

In addition to the software update, Audi will offer two interim remedies for vehicles affected by this recall:

  1. Vehicles with online data: Affected modules or high-voltage batteries must be replaced.
  2. Vehicles without online data: Customers will be instructed not to charge their vehicle from external sources or via the combustion engine until the new software becomes available.

To date, Audi reports no injuries, crashes, or fires related to this issue in the United States market. Interim letters notifying owners of the safety risk will be mailed on January 24, 2025, with a second notice to follow once the final remedy is available.

Vehicles Affected:

  • 2022-2023 Audi Q5 PHEV
  • 2022 Audi A7 PHEV

Recall Numbers:

  • Volkswagen’s number: 93AA
  • NHTSA campaign number: 24V-898

Interim Remedies:

  1. Vehicles with online data: Replacement of affected modules or high-voltage batteries.
  2. Vehicles without online data: Instructed not to charge vehicle from external sources or via combustion engine until new software becomes available.