Tag Archives: manufacturing error

Steering Wheel Could Unexpectedly Turn

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The secondary steering torque sensor may not be properly calibrated on certain 2018-2023 Ford Mustang, 2018-2020 Ford F-150, 2018-2021 Ford Expedition, and 2018-2021 Lincoln Navigator vehicles. These vehicles are equipped with electronic power assist steering (EPAS) gears, which were installed as replacement service parts and are now found to have potential calibration issues.

This issue came to light when Ford’s Critical Concern Review Group (CCRG) was alerted by the supplier about an assembly problem affecting certain steering gears. To thoroughly understand the extent of this problem, Ford’s CCRG conducted a detailed review that included examining supplier maintenance records, warranty reports, and vehicle testing data. The findings prompted Ford’s Field Review Committee to decide on issuing a recall to address the defect.

The defect report indicates that the electronic Power Assist Steering (EPAS) gears, which were sold as service parts, may have an incorrectly calibrated secondary digital torque sensor in the steering gear. Specifically, the polarity of this sensor may be inverted. If the primary steering torque sensor fails or develops a fault, and the secondary digital torque sensor’s polarity is inverted, the steering wheel could start oscillating without warning. This means the steering wheel might alternate between clockwise and counterclockwise movements when the driver attempts to steer, leading to unintended steering assist from the electronic power steering gear.

This oscillation poses a significant safety risk as it can make steering unpredictable and difficult to control, potentially leading to accidents. Recognizing the severity of this issue, Ford has taken measures to address it.

Ford dealers will update the Power Steering Control Module (PSCM) software in the affected vehicles to correct the calibration issue. This update is intended to ensure the proper functioning of the secondary torque sensor, thereby preventing the unintended steering oscillation.

Owner notification letters were mailed on August 5, 2024, to inform vehicle owners about the recall and the necessary steps to have their vehicles repaired. Ford has assigned this recall the number 24S45, and it is also registered under the National Highway Traffic Safety Administration (NHTSA) campaign number 24E-055.

Rear View Camera Issue Prompts FCA Recall of Over One Million Vehicles

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blank-dashboard-displayChrysler (FCA US, LLC) is taking steps to address an issue affecting the rear view cameras in over a million of its vehicles. On October 23, 2023, the FCA Technical Safety and Regulatory Compliance (TSRC) organization was alerted to a potential problem where rear view cameras were not displaying images in certain Dodge, Chrysler, Jeep, and Ram models. This issue potentially violates the Federal Motor Vehicle Safety Standards (FMVSS) for rear visibility.

An investigation revealed that a software glitch in the radio system of these vehicles could cause the rear view camera to fail to display the required image when the vehicle is put into reverse. This noncompliance with FMVSS No. 111, which mandates that rear visibility systems must default to showing the rear view image and adhere to specific field of view and image size requirements at the start of each backing event, regardless of any prior modifications made by the driver.

The issue, affecting 1,033,433 units, was identified during a thorough investigation. By June 2024, FCA US’s Vehicle Regulations Committee determined that a voluntary safety recall was necessary to rectify the problem.

The vehicles affected include:

2021-2023 Chrysler Pacifica
2021-2022 Dodge Durango
2022-2023 Jeep Compass
2021-2023 Jeep Grand Cherokee
2022-2023 Jeep Grand Wagoneer
2022-2023 Jeep Wagoneer
2022 RAM 1500
2022 RAM 2500
2022 RAM 3500
2022-2023 RAM Promaster

NOTE: Owners of these vehicles will notice that the rear view image does not appear when the vehicle is placed into reverse.

To resolve this issue, dealers will update the radio software in the affected vehicles. Owner notification letters are scheduled to be mailed out by August 2, 2024. FCA has designated this recall with the number 66B, and it corresponds to the National Highway Traffic Safety Administration (NHTSA) campaign number 24V-436.

Improperly Secured Clutch Pressure Line

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Ford Issues Recall for Certain 2024 Mustang Models Due to Under Hood Fire Risk

Ford Motor Company (Ford) have identified a problem that could potentially lead to under hood fires in certain 2024 Mustang vehicles. Owners of the affected vehicles will receive notification letters with detailed instructions on how to get the necessary repairs. These letters are expected to be mailed by June 17th, 2024.

Discovery of the Problem

Ford became aware of the issue in April 2024 after receiving two reports of under hood fire allegations in 2024 Mustang models equipped with manual transmissions. Upon receiving these reports, Ford’s Critical Concern Review Group (CCRG) promptly conducted inspections of both vehicles to determine the root cause of the fires. Following their investigation, the company decided to issue a recall to address the identified defect.

Details of the Defect

The defect report indicates that the vehicle’s clutch pressure line may not be properly secured to the vehicle’s firewall stud. An improperly retained clutch pressure line can come into contact with hot exhaust components and potentially melt, leading to brake fluid leakage. Although this leakage does not affect the brake system’s fluid volume or functionality, it can significantly impact the clutch system. Specifically, the defect can result in an inability to change gears, and in certain situations, the engine may stall when the throttle is released. Moreover, if the leaked brake fluid accumulates near a hot surface, there is a risk of smoke and an under hood fire, posing a serious safety hazard.

Recall Details and Repair Process

To address this issue, Ford dealers will inspect the clutch pressure line and perform necessary repairs to ensure it is properly retained. The recall has been assigned Ford’s internal number 24S36, and the National Highway Traffic Safety Administration (NHTSA) campaign number is 24V-394.

What Should Owners Do?

If you own a 2024 Mustang, especially one with a manual transmission, it is crucial to stay informed about this recall. Keep an eye out for the notification letter from Ford, which will provide specific instructions on how to proceed with the necessary repairs. In the meantime, if you experience any issues with your vehicle’s clutch or observe any unusual smoke from under the hood , contact your local Ford dealer for repairs, immediately.

Could Your Vehicle Be A Lemon?

The Lemon Law is a consumer protection statute designed to provide relief to car buyers who purchase vehicles that fail to meet quality and performance standards. It ensures that consumers can seek recourse if their new car has serious defects that the manufacturer cannot fix within a reasonable number of attempts. An essential aspect of leveraging the Lemon Law is maintaining accurate and detailed paperwork whenever your vehicle undergoes repairs. This documentation includes repair orders, work performed, dates, and technician notes. Accurate records are crucial because they serve as evidence of the recurring issues and the attempts made to resolve them, which can substantiate a Lemon Law claim. Without proper documentation, proving that your vehicle qualifies as a “lemon” can be challenging, potentially hindering your ability to receive a replacement, refund, or compensation.

Airbag Issue Affects Certain 2024 Jeep Grand Cherokee Models

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A recent discovery by FCA Technical Safety and Regulatory Compliance (TSRC) has led to a voluntary safety recall of certain 2024 Jeep Grand Cherokee vehicles. The issue affects a small number of vehicles that may be missing an important part in the front bumper. This missing piece could compromise the proper deployment of the front airbags.

The affected vehicles fail to comply with the Federal Motor Vehicle Safety Standards (FMVSS) for Occupant Crash Protection. FMVSS No. 208 specifies vehicle crash worthiness requirements and equipment requirements for active and passive restraint systems. In the event of a frontal collision, the missing energy absorbing foam could lead to a non-deployment or improper deployment of the front airbags, potentially increasing the risk of injury or harm to occupants.

According to FCA US, an analysis of vehicle production history revealed that some Jeep Grand Cherokee vehicles may have been built without a front fascia energy absorbing foam. This condition can lead to a non-compliance with FMVSS No. 208, as it compromises the intended load distribution or energy management, potentially jeopardizing proper crash sensing and airbag deployment.

The suspect period for affected vehicles began on December 6, 2023, and ended on December 9, 2023, when vehicle production processes were corrected. During this time, some Jeep Grand Cherokee vehicles may have been manufactured without the crucial foam, which is designed to absorb energy and help protect occupants in the event of a crash.

Dealers will inspect the affected vehicles and install the missing foam as necessary to ensure compliance with safety standards. This recall is intended to minimize any potential risks associated with this airbag issue and maintain the high standards of quality and safety that customers expect from Jeep vehicles.

Owners with affected vehicles will receive owner notification letters providing them with details on the recall and next steps to take. It is essential that vehicle owners take immediate action to address this issue and have their vehicles inspected and repaired as necessary to ensure their safety on the road.

2024 Cadillac XT5 Air Bag Could Tear

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General Motors (GM) has announced a safety recall affecting a small number of its 2024 Cadillac XT5 vehicles. This recall addresses a potential defect with the driver front airbag. This defect may pose a risk to vehicle safety.

The issue was identified when GM’s airbag module supplier observed a tear in the airbag cushion during a routine lot-acceptance test. This incident, which occurred in February 2024, prompted a thorough investigation by GM. The supplier was able to isolate the affected batch and performed additional tests on these airbags across various temperature settings to assess their reliability and safety.

The tests revealed that the airbag cushions could tear during deployment due to a recent design change in the airbag modules. Following these findings, GM’s Safety Field Action Decision Authority (SFADA) made the decision to issue a recall for all vehicles equipped with airbag modules from the affected production lot, manufactured the day before the problematic batch.

It is important for consumers to understand that a tear in the airbag cushion during deployment can significantly impair the airbag’s performance in the event of a crash, thereby increasing the risk of injury to the occupants.

To address this safety concern, GM is taking proactive steps. The company will replace the driver’s front airbag module at no cost to vehicle owners. GM plans to begin notifying affected Cadillac XT5 owners through formal letters, which are scheduled to be sent out on June 17, 2024. The recall has been officially recorded under GM’s number N232439241 and the National Highway Traffic Safety Administration (NHTSA) campaign number 24V-311. GM has confirmed that there have been no field incidents or injuries reported in relation to this defect.

2021-2023 Mini Cooper SE Vehicle Stall And Potential Battery Fire

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Mini CooperA manufacturing issue was identified in a small batch of 2021-2023 Mini Hardtop 2 Door Cooper SE vehicles. These electric cars were found to have a high voltage battery housing that did not meet the company’s assembly specifications. This discovery came to light after a concerning incident in the U.S. in October 2023, where one such vehicle experienced what is known as a thermal event—a significant overheating.

Following this incident, BMW initiated a thorough engineering analysis to pinpoint the cause. It was found that during certain production periods, there was a flaw in how the battery housing was sealed. Specifically, an inadequate amount of sealing compound was applied between the two halves of the battery module’s housing. This oversight made it possible for water to seep into the battery enclosure.

Water entering the high voltage battery compartment can trigger what is called an isolation fault. This type of fault compromises the battery’s integrity, leading to performance issues and safety concerns. Initially, such water ingress prompts the vehicle to display a warning message, alerting the driver of the fault and advising them to have the vehicle checked at a MINI service center.

Should the water exposure continue, the situation can escalate. The accumulation of moisture can cause multiple isolation faults, potentially causing the vehicle to stall. In more severe cases, particularly after long periods of inactivity, these faults could cause the battery to overheat significantly. Such overheating, while rare, could lead to a thermal event, even if the car is not in use.

To address this issue, BMW is recalling affected vehicles to inspect, and if necessary, repair the sealing of the battery housing. This includes a thorough leak test to ensure the integrity of the battery enclosure. Owners of the affected Mini Cooper SE models will be notified by mail with instructions to visit their dealer. Notification letters are scheduled to be sent out on June 21, 2024. The recall has been officially recorded under the NHTSA campaign number 24V-302.

Vehicle owners are encouraged to respond to the recall notice promptly to ensure their safety and the proper functioning of their vehicle.

The Steering Knuckle And Strut May Be Loose In Certain 2023 Ford Explorer Vehicles

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In a recent announcement, Ford has highlighted a critical concern affecting a specific subset of its 2023 Ford Explorer vehicles. The issue revolves around the right-front lower fastener connecting the steering knuckle and strut, which may either be loose or missing altogether. This problem can have significant repercussions on the vehicle’s performance and safety.

A loose or missing connection between the knuckle and strut can lead to improper tire alignment, potentially causing steering pulls or requiring increased steering effort. Moreover, the proximity of the brake hose to the tire in this compromised setup poses an additional risk. If the hose comes into contact with the tire, it may sustain damage resulting in a brake fluid leak, ultimately leading to a loss of braking ability. These circumstances significantly elevate the likelihood of a crash, underscoring the severity of the situation.

Upon receiving a report of a missing fastener,Ford’s Critical Concern Review Group (CCRG) initiated an investigation at the beginning of January 2024. The Plant Vehicle Team (PVT) at the Assembly Plant promptly identified the issue during a routine warranty claim review. Further analysis revealed that the primary double spindle fixture tool responsible for securing the right front knuckle-to-strut fasteners was offline for repairs during a specific period. This temporary setback affected a limited number of vehicles, with Ford confirming that out of 121 Explorer rotations, only one vehicle was found to have a missing fastener. Nonetheless, the company is taking proactive steps to address the concern.

While Ford has not identified any vehicle owner questionnaires (VOQs) related to this condition, it’s crucial for affected vehicle owners to remain vigilant. Signs of potential issues include a visually detectable tire leaning inward at the top or changes in steering effort or pull. Additionally, if there are any indications of tire contact with the strut or spring seat, such as abrasion damage or a burning smell, prompt action is necessary.

In response to this concern, Ford has announced a field action to have the affected vehicles inspected. Dealers will thoroughly examine the fasteners and take appropriate measures, such as tightening or installing them as needed, to rectify the issue. Affected vehicle owners can reference Ford’s recall number 24S04 and the corresponding NHTSA campaign number 24V-091 for further information and to schedule inspections.

Importance of Keeping Records for Lemon Vehicles:

Maintaining detailed records of repairs and maintenance for your vehicle is essential, especially if you suspect that your vehicle might be a lemon. Lemon laws vary by jurisdiction, but generally, they provide recourse for consumers who have purchased a defective vehicle that the manufacturer has failed to repair adequately within a reasonable number of attempts.

Keeping comprehensive records serves several purposes. Firstly, it provides documentation of the issues you’ve experienced and the attempts made to address them, which can be crucial evidence if you need to pursue legal action under lemon laws. Additionally, it helps establish a pattern of recurring problems, strengthening your case for a vehicle replacement or refund.

Furthermore, detailed records can expedite the repair process by providing technicians with essential information about past issues and repairs. This can help diagnose and resolve problems more efficiently, minimizing inconvenience for you as the owner.

In summary, maintaining thorough records of repairs and maintenance is not only good practice for vehicle ownership but can also be invaluable if you find yourself grappling with a lemon. By documenting issues and repairs diligently, you empower yourself to assert your rights as a consumer and seek appropriate recourse if necessary.

Driver Air Bag Could Deactivate In Ford Trucks

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Ford Motor Company is reaching out to owners of certain 2023 F-150 and Ford Super Duty vehicles, including the F250, F350, F450, F550, and F600 models. There is a concern with the driver’s frontal air bag not deploying during a crash.

The issue came to light in November 2023, when Ford’s main supplier, BCS Automotive Interface Solutions, alerted them about a potential problem. This was linked to airbag clock springs provided by American Furukawa, a sub-supplier to BCS. BCS discovered that some clock spring assemblies in the Steering Column Control Modules (SCCM) they supplied to Ford might have been tainted during production.

The problem lies in the SCCM of the affected vehicles, where the clock spring assembly might have a weak weld between the bus bar and the ribbon cable. This issue traces back to the manufacturing stage, where clock spring bus bars were washed in isopropyl alcohol mixed with glycerin. This mix could weaken the weld between the bus bar and ribbon cable in the clock spring assembly.

This ribbon cable is crucial as it connects to the driver’s airbag. A weak weld can cause the ribbon cable circuits to disconnect, leading to a loss of electrical connection to the driver’s front airbag. This malfunction would trigger the airbag warning light and prevent the airbag from deploying as needed. Ford, alongside BCS, has been investigating this issue. They’re reviewing production and shipping records to identify which Ford vehicles might be equipped with the affected clock springs.

As of December 6, 2023, Ford received 19 warranty reports dating from May 1 to November 10, 2023, which could be linked to this clock spring issue.

Drivers might notice problems like non-functional steering wheel switches (like radio controls), a silent horn, and an illuminated airbag warning lamp.

Affected owners will be contacted to bring their vehicles to Ford dealers for an inspection and, if necessary, a replacement of the air bag clock spring. Initial notifications to owners explaining the safety risk are planned for January 8, 2024. A follow-up notice will be sent once the replacement parts are ready, expected in the second quarter of 2024. This recall is officially listed under the NHTSA campaign number 23V-847.