Ford F-150 Unintended Activation of Electric Parking Brake

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Ford has been monitoring certain 2021-2023 Ford F-150 trucks equipped with single exhaust systems due to potential issues with the electric parking brake. Reports have surfaced indicating an unexpected activation of the parking brake, sparking concern among owners and the automaker alike. In response, Ford’s Critical Concern Review Group (CCRG) launched an investigation to assess the problem’s magnitude and potential root causes.

The initial investigation began after Ford received troubling reports of unintended parking brake application on a 2021 model year F-150 truck. Warranty and field reports revealed signs of damage to the wiring harness housing the rear electric parking brake circuits. Such damage raised red flags, necessitating a closer look to ensure the safety and reliability of these vehicles.

Looking deeper into the issue, Ford’s team of experts discovered that the damaged wiring was a component of the rear axle wiring harness assembly. This particular harness assembly not only houses wires for the rear electric parking brakes but also serves other essential electrical components. The investigation highlighted that, in certain scenarios, the rear axle wiring harness bundle could make contact with the rear axle housing, leading to chafing of the wiring bundle.

Over time, this chafing effect could wear through the abrasion-resistant tape and circuit insulation, ultimately exposing the underlying copper wiring. The consequence of this exposure could be the grounding of circuits on the rear axle housing, which in turn could cause unintended activation of the electric parking brake. Adding to the complexity, corrosion on the rear axle housing could accelerate the abrasion process, compounding the problem.

Ford’s engineering team took the investigation further by conducting comprehensive vehicle-level testing and data analysis. The goal was to understand the implications of damaged circuits within the wiring harness bundle. They discovered that if the low side electric parking brake motor circuit experienced a short to ground, it could trigger the unintended activation of the electric parking brake, potentially leading to hazardous situations.

Ford are initiating a recall to resolve this issue. Owners of affected vehicles will receive official notices instructing them to take their vehicles to authorized Ford or Lincoln dealers for thorough inspections of the rear axle wiring harness.

During the inspection, if the technicians observe any wear on the abrasion tape covering the wire bundle, the suspect harness will be replaced with a new service harness. In cases where the abrasion tape shows no signs of wear, the dealer will take preventive measures by installing a protective tie strap and tape wrap, ensuring the wiring remains secure and safeguarded against future issues.

Ford is aware of 918 warranty and three field reports in North America for the wire chafing condition. Of these reports, 299 indicated that the electric parking brake had unintended activation, of which nineteen (19) allege electric parking brake application while driving. Ford has assigned a recall number to this campaign, which is 23S35. Additionally, the National Highway Traffic Safety Administration (NHTSA) has designated the campaign as number 23V-509.

Ford Fusion PHEV Battery Problem
Risk Of Stall Or Fire

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Ford Fusion with smoke from trunk

Certain Ford Fusion PHEV vehicles may experience damage to their Battery Energy Control Module (BECM) due to excessive voltage and current flow. This issue can lead to a loss of motive power and pose safety risks such as the possibility of a crash or a localized fire around the BECM. Ford is currently working on a fix for this safety issue.

Problem was first discovered in July 2022, when Ford’s Trend and Early Warning Support (TEWS) team alerted the Critical Concern Review Group (CCRG) about five fire reports involving 2019 Fusion PHEV vehicles equipped with 30Ah high voltage batteries. These fires occurred while the vehicles were at dealerships during a replacement BECM service to address various issues like voltage sense Diagnostic Trouble Codes (DTCs), check engine light, no start, or loss of motive power concerns. Ford’s High Voltage Battery Systems Team conducted an analysis and determined that the fires originated from the BECM. Further examination by the supplier revealed that the Current Interrupt Device (CID) had been activated in the high voltage battery cells of the affected units, though the reason behind this activation remains unknown. Due to the rate and severity of the concern, Ford’s CCRG initiated an investigation.

In February 2023, Ford published a Technical Service Bulletin (TSB) that advises replacing the high voltage battery if vehicles come in for service with one or more voltage sense DTCs, instead of just replacing the BECM. This measure aims to address the underlying issue and prevent further damage.

While a permanent remedy is under development, Ford urges owners not to charge their vehicles until the remedy is implemented. To ensure owners are aware of the safety risk, interim letters have been sent to them as of July 14, 2023. Second letters will follow once the remedy becomes available. This recall is identified as 23S33 by Ford, and the NHTSA campaign number is 23V-440.

Nissan Leaf EV Unintended Acceleration

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Nissan North America, Inc. (Nissan) is taking action to address a safety matter related to certain 2018-2023 LEAF EVs. These Electric Vehicles could experience unintended acceleration. This issue came to Nissan’s attention during internal testing in December 2021 when a trial vehicle showed a motor torque deceleration delay following the deactivation of Intelligent Cruise Control.

To tackle this problem, Nissan conducted computer simulations, analyzing data from the test vehicle, in an effort to replicate the condition. After several tests, they identified a specific sequence of actions that could potentially lead to the reported phenomenon, although they were unable to recreate the issue on an actual vehicle.

To ensure the safety of their customers, Nissan continued their efforts to replicate the phenomenon under real-world conditions. After extensive computer simulation and on-track testing, they determined that the following sequence of actions must be completed in under eight (8) seconds for the unintended acceleration to occur:

1. Disengage Cruise Control, Intelligent Cruise Control, or ProPILOT Assist.
2. Immediately after disengagement, shift drive modes from ‘D’ to ‘B’ or ‘ECO’, or activate e-Pedal ‘ON’.
3. Press the accelerator pedal and then release it.

Nissan’s evaluation of the risk associated with this issue in real-world driving conditions is very low, as it has not occurred outside of controlled track or simulated test environments. However, taking a cautious approach, Nissan decided to conduct a recall campaign to reprogram the Vehicle Control Module (VCM) as a preventive measure.
For clarification, the ‘B’ mode engages the regenerative braking system more aggressively on downhill slopes, reducing the need for excessive brake use. This mode is manually selected by shifting from ‘D’ to ‘B’ using the shift lever.

To address the issue, Nissan dealers will reprogram the Vehicle Control Module (VCM). You can refer to Nissan’s recall number for this action, which is R23A6, and the corresponding NHTSA campaign number, which is 23V-494.

Toyota and Lexus Airbag Problem

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AirbagToyota and Lexus have announced that they will be reaching out to owners of specific vehicle models due to a critical problem related to the electrical connection inside the steering column. This issue has the potential to disable the driver’s side airbag, leading to non-compliance with Federal Motor Vehicle Safety Standards for Occupant Crash Protection.

The problem first came to Toyota’s attention in May 2023 when they were contacted by the spiral cable assembly supplier. The supplier informed Toyota about an ongoing investigation into the manufacturing process, which revealed contamination in the washing station for specific spiral cable components. As a consequence, a poor welding condition could occur between the Flexible Flat Cable (FFC) and the bus bar, which affects connectivity to various controls on the steering wheel. Extensive testing conducted by the supplier between late-May and late-June indicated that the FFC might detach from the bus bar at the weak weld connection area.

As per the defect report, the steering column assembly in the affected vehicles contains electrical connections to the driver’s airbag module housed within a spiral cable assembly, including the FFC. In cases where the FFC is inadequately welded to the spiral cable’s bus bar, there is a risk of the FFC separating, resulting in one or more open circuits linked through the FFC. This separation specifically impacts the circuit responsible for connecting the driver’s airbag module. If connectivity is lost, the SRS warning light will activate, and the driver’s airbag may be deactivated, failing to deploy in a crash scenario that necessitates its activation. Consequently, this raises the likelihood of driver injury in the event of a crash.

 

The vehicles affected include:

2023-2024 Lexus NX Hybrid
2023-2024 Lexus NX250
2023-2024 Lexus NX350
2023 Lexus RX Hybrid
2023 Lexus RX350
2023 Lexus RX500H
2023 Toyota Corolla
2023 Toyota Corolla Cross
2023 Toyota Corolla Cross Hybrid
2023 Toyota Highlander
2023 Toyota Highlander Hybrid
2023 Toyota Tacoma

Dealers will inspect and replace the spiral cable assembly as necessary. Toyota’s number for this recall is 23TA08, Lexus’ number for this recall is 23LA02 and the NHTSA campaign number is 23V-480.

Honda and Acura Potential Brake Issues

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Honda and Acura have identified a potential issue related to the tie rod fastener in certain vehicle models. This manufacturing concern could lead to the separation of the brake master cylinder from the booster assembly, compromising brake function and potentially increasing the risk of accidents.

The following Honda and Acura vehicle models have been identified as being potentially affected by this recall:

2020-2021 Honda Civic
2020-2023 Honda Ridgeline
2021-2023 Honda Passport
2021-2022 Honda Pilot
2020 Acura MDX

Honda first became aware of the problem in December 2020 when a missing nut was discovered in the brake booster tie rods. The company notified the component part supplier and initiated an investigation to identify the root cause. The investigation revealed that the brake master cylinder may have been improperly fastened to the brake booster assembly during the manufacturing process, resulting in the presence of loose or missing tie rod nuts. This assembly flaw could potentially lead to the breakage of tie rod studs, causing the brake master cylinder to separate from the brake booster assembly.

Potential Consequences and Safety Concerns: In the event of a separation between the brake master cylinder and the brake booster assembly, drivers may experience diminished or complete loss of brake function. This compromised braking capability significantly increases the risk of accidents and injuries. Recognizing the seriousness of the situation, Honda has taken immediate action to address the issue and ensure the safety of its customers.

Recall and Repair Process: As a proactive measure, Honda has issued a recall for the affected vehicles. Authorized dealerships will inspect the brake booster assembly and perform the necessary repairs to rectify any potential issues. To facilitate the recall process, Honda has assigned the following identification numbers: VEU, AEV, and ZET. Additionally, the National Highway Traffic Safety Administration (NHTSA) has assigned the campaign number 23V-458 to this recall.

Ford Escape, Ford Maverick And Lincoln Corsair Engine Failure

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Ford Motor Company (Ford) has recently announced a crucial safety recall for specific models of Ford Escape, Ford Maverick, and Lincoln Corsair vehicles. The recall aims to address a potential issue that could lead to a vehicle fire, urging affected owners to promptly visit their dealers for necessary repairs and precautions.

The vehicles affected by this recall include those equipped with 2.5L HEV/PHEV engines, manufactured during the specified time frames. The identified problem revolves around the premature failure of these engines, which can have severe consequences. When an engine fails, there is a risk of significant quantities of engine oil and/or fuel vapor being released under the vehicle’s hood. These substances may then migrate to and accumulate near potential ignition sources, posing a potential fire hazard. In addition to the risk of fire, localized melting of components or the emission of smoke may also occur.

The specific models affected by this recall are the 2020-2023 Ford Escape, the 2022-2023 Ford Maverick, and the 2021-2023 Lincoln Corsair. Ford has identified isolated engine manufacturing issues as the root cause of the 2.5L HEV/PHEV engine failures that result in engine block or oil pan breaches. Despite the breach, the HEV/PHEV system continues to propel the vehicle, allowing the driver to continue operating it. Unfortunately, this means that as the driver continues to drive after a block breach, oil and/or fuel vapor continues to be expelled and accumulate near ignition sources, exacerbating the risk.

Owners of the affected vehicles should be aware of the signs indicating engine failure. These signs include loud noises such as a metal-to-metal clank, which will be audible to the vehicle’s occupants. Additionally, an engine failure will lead to a reduction in engine torque. If drivers notice any unexpected engine noises, experience an unexpected torque reduction, or observe smoke emanating from the engine compartment, they are strongly advised to safely park the vehicle and promptly shut off the engine.

Ford is actively working on developing the remedy for this issue. In the meantime, interim letters have been sent out to notify owners of the safety risk. These letters were mailed on June 23, 2023, to inform owners about the importance of addressing the issue. Once the remedy is available, a second round of letters will be sent out to inform owners and provide instructions for getting the necessary repairs. It’s important to note that this recall, identified by Ford as recall number 23S27, expands and replaces the previous recall number 22V-484. Therefore, even if the vehicles have been previously repaired under recall number 22V-484, owners will still need to have the new remedy completed to ensure their safety.

Lincoln MKC Fire Risk While Parked

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Lincoln MKC under hood fire

Ford Motor Company has made a decision regarding a defect that poses a risk to motor vehicle safety in specific models of Lincoln MKC vehicles manufactured between 2015 and 2019. These vehicles, produced during the mentioned time frame, have been found to have a potential for under hood fire, even while the vehicle is parked and turned off.

In March 2023, Ford’s Critical Concern Review Group (CCRG) was made aware of the issue related to 18 reports of under hood fires involving 2015 to 2017 model year MKC vehicles in North America and China. It is noteworthy that all these incidents occurred when the vehicles were parked and not in use.

Ford’s CCRG initiated a thorough investigation that spanned throughout March, April, and May. The investigation encompassed various activities, such as comprehensive vehicle inspections, reviews of suppliers involved in the manufacturing process, assessments of product designs, detailed analysis of field data, and rigorous examination of components and subsystems in laboratory settings.

At present, the investigation has not been able to find the cause or origin of the fires. Nevertheless, it was observed that the fires seemed to originate in close proximity to the vehicles’ 12-volt batteries, which raised concerns regarding the potential link between the fires and the battery system.

As of May 2023, Ford’s CCRG has received information about 19 potentially related incidents of under hood fires, all of which occurred while the vehicles were parked and turned off.

Ford’s Field Review Committee thoroughly examined the matter and decided to undertake a field action to provide guidance to vehicle owners. As part of this field action, Ford advised owners to park their vehicles outside and away from any structures until the completion of the ongoing investigation. This precautionary measure aims to minimize the risk of potential fires until a conclusive resolution is reached.

For reference, customers and owners can refer to Ford’s designated number for this recall, which is 23S28, and the corresponding NHTSA campaign number, which is 23V-378.

Jeep Grand Cherokee Incorrectly Installed Rear Coil Springs

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Chrysler (FCA) has recently taken steps to address a potential safety issue that could pose a risk to owners of certain 2022-2023 Jeep Grand Cherokee and 2021-2023 Jeep Grand Cherokee L vehicles. The concern revolves around the rear coil springs, which may have been incorrectly installed during the manufacturing process. This misalignment could lead to the complete detachment of the coil spring while the vehicle is in motion, potentially increasing the likelihood of accidents.

In response to reports received in March 2023 about a 2023 Jeep Grand Cherokee experiencing a rear coil spring detachment while driving, FCA US Technical Safety and Regulatory Compliance (TSRC) launched an investigation. The aim was to thoroughly examine the situation, including the design and assembly process of the coil spring, as well as reviewing measurement data for both the part and the affected vehicles. Although no accidents or injuries have been reported thus far, FCA US has decided to initiate a safety recall for the impacted models as a proactive measure.

The defect report indicates that certain 2022-2023 Jeep Grand Cherokee and 2021-2023 Jeep Grand Cherokee L vehicles were built with rear coil springs that may not have been properly installed. This installation error could result in the coil spring shifting out of its intended position. If the rear coil spring becomes detached while the vehicle is in motion, it can pose a hazard not only to the occupants of the affected Jeep but also to operators and passengers of other vehicles sharing the road. The sudden detachment of the coil spring without any warning can potentially lead to accidents and cause injuries.

To address this issue, Chrysler authorized dealerships will conduct thorough inspections of the rear coil spring assemblies in the affected vehicles. If any problems are identified, the necessary repairs will be carried out promptly. It is crucial for owners of the impacted Jeep models to have their vehicles inspected to ensure that the rear coil springs are correctly installed, thereby mitigating the risk associated with this issue.

For reference, the safety recall associated with this concern has been assigned the identification number 64A by FCA. Additionally, the National Highway Traffic Safety Administration (NHTSA) has designated the corresponding campaign as number 23V-413.