loss of engine power – California Lemon Law blog

Ford Motor Company has announced a safety campaign addressing a software glitch in replacement Battery Energy Control Modules (BECMs) used in Mustang Mach-E vehicles with Lithium Iron Phosphate (LFP) batteries. The fix applies to both individual service components (NHTSA Equipment ID: 26E-063) and affected vehicles in the field (NHTSA Vehicle ID: 26V-582 / Ford Reference: 26S70).

The issue stems from replacement BECMs running uncalibrated software, which miscalculates long-term battery health and can result in sudden power loss or cell degradation. Here is a breakdown of what went wrong and the associated risks.

Understanding the Glitch

When a Mustang Mach-E receives a new BECM during service, the replacement module is designed to inherit the battery’s true historical State of Health (SOH). Instead, a software defect caused newly installed service parts (numbers PZ98-10B687-K* and PZ98-14C197-K*) to default to a 100% SOH reading.

This automatic reset creates a blind spot where onboard systems assume the battery is factory-fresh regardless of its actual age or condition.

The Safety Risks

An artificially inflated health metric introduces two primary hazards:

Unexpected Loss of Drive Power: Because onboard systems overestimate true energy reserves, the instrument cluster displays more remaining range than the battery possesses. Drivers face sudden power caps or complete stalls while driving, elevating collision risks.
Elevated Fire Risk: Incorrect health data throws off high-voltage charging limits. Over repeated DC Fast Charging (DCFC) sessions, this improper regulation promotes lithium plating inside the battery cells. Advanced lithium plating risks thermal venting, which can trigger a high-voltage battery fire.

Dashboard Warning Indicators

If the onboard computer detects severe power limits related to this mismatch, drivers will see specific dashboard alerts:

Wrench Icon (Service Vehicle Soon)
Turtle Icon (Reduced Power Mode)

Scope & Investigation Details

Ford’s Critical Concern Review Group launched a formal probe on July 7, 2026, after internal engineers flagged the default initialization flaw. Investigation teams confirmed the vulnerability spans spare BECM inventory used for warranty swaps and over-the-counter parts sales.

Impacted Units: A highly targeted group of approximately 83 vehicles.
Real-World Impact: Ford has recorded zero accidents, injuries, or fires associated with the flaw, along with zero field reports directly reporting SOH miscalculations.
Action Approved: Ford’s Field Review Committee authorized formal service actions on September 1, 2026.

The Service Fix

Technicians at Ford dealerships will reflash the BECM software to restore accurate SOH tracking and inheritance. Official owner notification letters go out beginning November 8, 2026.

Ford Motor Company recently identified a mechanical manufacturing defect affecting a small batch of 2026 Ford F-150 vehicles equipped with the max tow package. Documented under NHTSA Campaign Number 26V-576, this specific powertrain issue impacts an estimated 37 potential units.

While the number of affected trucks is limited, the potential safety risks make understanding the condition important for owners.

What Is the Defect?

The issue stems from an assembly oversight involving the rear axle tail bearings. Certain vehicles were built with an 8.8-inch axle tail bearing installed instead of the required 9.75-inch tail bearing.

Because the smaller 8.8-inch bearing lacks the adequate material hardness required for the heavier load conditions of the max tow package, it is not rated for long-term use in these specific trucks. Over an extended period in service, this component discrepancy can lead to bearing failure or full axle seizure.

Associated Safety Risks

If a rear axle tail bearing seizes, it can trigger severe operational issues while driving or parked:

Rear Wheel Lock-Up: A seized bearing can cause the rear wheels to lock suddenly, leading to a potential loss of vehicle control.
Driveshaft Separation & Power Loss: Bearing failure can lead to driveshaft separation, causing an immediate loss of motive power while driving.
Rollaway Hazard: If driveshaft separation occurs and the truck is parked without engaging the mechanical parking brake, unintended vehicle movement or rollaway can occur.

Each of these conditions significantly increases the risk of a crash or injury.

Early Warning Signs

As the incorrect bearing wears down over time, drivers may notice an increase in noise coming from the rear axle area. Sound levels and grinding noises will typically worsen as the condition progresses.

Timeline & Discovery

Ford’s internal quality controls caught the issue at the manufacturing level before widespread distribution:

May 26, 2026: Plant personnel at the Sterling Axle Plant noticed the incorrect 8.8-inch bearings being installed into max tow package axles during production.
May 28 – June 3, 2026: Quality teams tracked outbound shipments to the Dearborn Truck Plant and issued a “Stop Ship” order. Inspectors determined that only 38 total vehicles had left plant control, with 37 destined for the U.S. market.
June – September 2026: Ford’s Critical Concern Review Group and Field Review Committee evaluated the safety impact and approved a formal field service action.

As of the investigation’s conclusion, Ford confirmed zero reports of accidents or injuries related to this condition.

The Remedy

To resolve this defect, authorized Ford dealership service departments will replace the affected rear axle components with the properly rated 9.75-inch tail bearing assembly. Owner notification letters are expected to be mailed September 21, 2026. Ford’s number for this recall is 26S63 and the NHTSA campaign number is 26V-576.

The National Highway Traffic Safety Administration (NHTSA) has launched an investigation into certain Ford Bronco and Maverick vehicles due to concerns with their electrical systems. The Office of Defects Investigation (ODI) opened a Preliminary Evaluation in January 2024 to investigate allegations of loss of motive power in model year 2021 Ford Bronco Sport vehicles.

What’s Happening?

In April 2024, Ford issued a safety recall (24V-267) covering 456,565 model year 2021-2024 Ford Bronco Sport and model year 2022-2023 Ford Maverick vehicles. The recall addressed occurrences of loss of motive power resulting from sudden degradation of the 12V battery during the drive cycle. When the battery failure occurs, consumers may experience a complete loss of engine power without the ability to restart, accompanied by the loss of 12V accessories, including hazard lights.

The Remedy

The recall remedy consists of software updates to the body control module and powertrain control module, which were designed to provide improved detection of the 12V battery state of charge during the drive cycle and provide warning to consumers if the battery is degraded.

New Concerns Arise

Despite the recall, the ODI has since received 15 reports from vehicle owners describing loss of motive power incidents for model year 2021 Ford Bronco Sport vehicles that received the 24V-267 recall remedy. Consumers describe that prior to the loss of motive power, there were no warnings related to the 12V battery or vehicle electrical system. Additionally, multiple consumers reported that after the vehicle was towed to the dealership following the loss of motive power, the event was diagnosed to the 12V battery, and a battery replacement was the only required repair.

What’s Being Done About It?

The NHTSA has opened an investigation (RQ24014) to further examine this issue. The agency will review the data and determine if additional action is necessary to ensure public safety.

What to Do Next

If you own one of these vehicles and have experienced a loss of motive power, it’s crucial to:

File a report : Share your experience with the NHTSA by submitting a complaint on their website.
Stay informed : Keep an eye on this investigation and any updates from the manufacturer or the NHTSA.

Your safety is paramount, and staying proactive can help prevent potential electrical system failures and keep you safe on the road.

Key Facts

Affected Vehicles: Certain Ford Bronco and Maverick models (2021-2024 Ford Bronco Sport and 2022-2023 Ford Maverick)
Component: Electrical System
NHTSA Action Number: RQ24014
Opened From: November 15, 2024–Present

Low Oil Pressure Warning Ford 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.

The 2021 Nissan Rogue, one of Nissan’s popular compact SUVs, is currently under investigation by the Office of Defects Investigation (ODI) due to reports of safety defects. Two major concerns have emerged—one involving inner tie rod failures that could lead to a loss of steering control, and the other concerning engine failures that could result in a complete loss of motive power. These issues raise significant safety risks for drivers and passengers, and Nissan is facing increasing scrutiny as the investigations unfold.

Inner Tie Rod Failures: Loss of Steering Control

Nissan Rogue Tie Rod Failure One of the top issues reported is inner tie rod failures, which can lead to a sudden and complete loss of steering control. The ODI received reports from owners and early warning data indicating that these failures can occur on either the driver’s or passenger’s side of the vehicle. In several instances, the vehicles had to be towed for repairs.

One notable case involved a 2021 Nissan Rogue owner who experienced a sudden and severe steering malfunction while pulling out of a parking lot. According to the owner, the steering wheel suddenly pulled to the right, causing the front passenger tire to become misaligned. The vehicle became undrivable, multiple warning lights illuminated, and it had to be towed to a dealership. Although the dealership diagnosed a bent tie rod and performed a repair, the steering wheel did not return to its normal position. The owner reported no impact that could have caused the damage, yet the manufacturer declined to cover the repair under warranty. This incident occurred with just over 16,600 miles on the vehicle, raising concerns about the durability and safety of the Rogue’s steering system.

This ongoing investigation into tie rod failures has raised serious concerns about the overall safety of the vehicle, as a sudden loss of steering control could lead to catastrophic accidents.

Engine Failures: Loss of Motive Power

In addition to the tie rod issue, the 2021 Nissan Rogue is also under investigation for engine failures that could lead to a complete loss of motive power. The ODI has identified multiple reports of engine knock, strange noises, and metal chunks or shavings found in the oil pan of vehicles equipped with Nissan’s KR15DDT and KR20DDET engines. The KR15DDT, a 1.5-liter 3-cylinder engine, is found in the Rogue, while the KR20DDET, a 2.0-liter 4-cylinder engine, powers other models such as the Altima, QX50, and QX55.

The variable compression ratio engines, designed to deliver both high power and fuel efficiency, have shown an elevated failure rate. These engine issues have been linked to bearing and L-link damage, which could lead to total engine failure, leaving drivers stranded or worse, in a dangerous situation while driving. Nissan has made manufacturing changes in an attempt to address these issues, but the investigation is still open as the company works to find a more permanent solution.

Alongside these investigations, the 2021 Nissan Rogue has been the subject of several recalls, addressing a variety of safety concerns:

Missing Internal Bushing in Brake Calipers – This defect could lead to brake fluid loss, reducing braking performance and increasing the risk of a crash.
Rear View Camera Malfunctions – The rearview camera display may become inoperative, reducing rear visibility and raising the risk of an accident.
Seat Belt Retraction Issues – Some seat belts may not retract properly, making them difficult to use, which could increase the risk of injury in a crash.
Fuel Pump Overheating – An overheated fuel pump can cause the engine to stall unexpectedly, posing a serious safety risk.
Second Row Seatback Welding Issues – Improperly welded seatbacks may fail to secure a child seat, increasing the risk of injury in the event of a sudden stop or crash.
Wheel Separation Risk – Incorrectly fitted wheel nuts could cause the wheel assembly to separate from the vehicle, which could result in a loss of vehicle control.
Fuel Hose Detachment – A poorly secured fuel hose can disconnect, causing a fuel leak or engine stall, both of which increase the risk of fire or crash.

With ongoing investigations into tie rod and engine failures, as well as several recalls addressing safety concerns, the 2021 Nissan Rogue has been thrust into the spotlight for potential safety risks. Drivers should stay informed about any updates from Nissan and take immediate action if their vehicle is affected by any recalls or investigations. Safety should always be a top priority, and these investigations aim to ensure that any defects are properly addressed to protect drivers on the road.

Fiat Chrysler Automobiles (FCA) USA will be contacting the owners of certain 2022 Ram trucks because their vehicles may have a manufacturing defect within the Engine Control Module (ECM) that could affect vehicle safety. This defect affects vehicles equipped with Cummins 6.7L turbo diesel engines and could result in an unexpected engine stall.

The RAM trucks affected by this defect include:

2022 Ram 2500
2022 Ram 3500
2022 Ram 3500 Cab Chassis
2022 Ram 4500 Cab Chassis
2022 Ram 5500 Cab Chassis

The FCA Technical Safety and Regulatory Compliance (TSRC) organization became aware of the problem in August 2022 when they were contacted by the RAM truck assembly plant regarding suspect ECMs manufactured with a defective component. According to the NHTSA safety report, some ECMs may have been manufactured with a misaligned capacitor that could short-circuit and create an internal loss of communication. This internal loss of communication could result in a loss of motive power and an increased chance of an accident.

The suspect period for these defective ECMS began on May 31, 2022, and ended on August 23, 2022, when the ECMs were quarantined. This time period was determined using supplier traceability and vehicle production records. Similar vehicles not included in the recall did not receive suspect ECMs or were repaired prior to release from the assembly plant control.

Owners who receive notices will be asked to return to their dealers to have ECMs in their trucks replaced. FCA US, LLC’s number for this recall is Z87 and the NHTSA campaign number is 22V-642.

A small number of 2021-2022 Chevrolet Corvette owners will be contacted by the manufacturer regarding a problem affecting the rear half shaft assemblies in their vehicles. According to the defect report, Some Corvettes may have a rear half-shaft assembly that is missing one or more ball bearings. If any ball bearings are missing, the half-shaft will eventually fail, resulting in a loss of propulsion.

In September 2021, a General Motors (GM) engineer carried out a warranty inspection of a rear half shaft recovered from a 2021 Chevrolet Corvette. The half shaft fractured and caused the vehicle to lose propulsion. Upon further inspection, it was found that the half shaft was missing two of six ball bearings. Follow-up, discussions with the supplier identified a potential failure in the inspection process that led to the miss-build. In October, the GM engineer submitted a report to GM’s Speak Up For Safety (SUFS) program and the supplier identified 19 vehicle identification numbers (VINs) containing half-shafts that may have been improperly inspected.

GM is not aware of any injuries or crashes related to this condition. In February, GM’s Safety and Field Action Decision Authority decided to conduct a safety recall for any 2021-2022 Chevrolet Corvette that may have received suspect rear half shaft assemblies.

Those receiving notices will be asked to return to their GM dealers to have the left and/or right rear half-shaft assemblies inspected and replaced as necessary. Owner notification letters are expected to be mailed in April. GM’s number for this recall is N212351320 and the NHTSA campaign number is 22V-091.

Do you think your Chevy Corvette could be a Lemon? Don’t live with a Lemon, especially if the problems you are having are safety-related. If you have any questions about your rights and the California Lemon Law, please call our office at 888-395-3666 for some great Lemon Law advice.

In August 2020, Volkswagen / Audi received an inquiry about a gateway control module failure in an Audi Q5 vehicle in China. An inspection of the situation found that the gateway control module had gone into fail safe mode because of liquid entering the module from a rear bench seat spill.

The gateway control module has been programmed to go into a fail-safe mode when an implausible signal is detected in the control unit. If an implausible signal is detected, the gateway switches off its function in order to avoid unwanted vehicle reactions. The vehicle remains steerable and the brake system will work, but the engine will go into emergency mode and remains in operation with reduced power.

Audi performed a safety assessment to evaluate the potential conditions and consequences that could result from a power shutdown of the gateway control module due to liquid ingress. Audi also conducted a risk assessment which indicated that the risk of a liquid spill leading to a failure of the gateway control module is very low and rare over the lifetime of the vehicle. At the time there were only isolated cases in the North American region and all of them happened after an outside influence, mostly after a beverage spill. Audi continued to monitor the problem.

In March 2021, Audi experienced an increase in customer reports related to gateway control module failures on Q5 vehicles after a liquid spill. Audi conducted additional testing and continued to investigate a potential solution to be implemented in production and in the field. Due to single field cases alleging the failure without a liquid spill, an additional investigation was initiated to rule out other root causes for liquid ingress. In August 2021 Audi identified a potential manufacturing issue in the factory in Mexico. “Due to a programming error of a glue bead robot, an underbody seam may not have been sealed sufficiently and therefore allow water ingress from underneath in very rare cases when driving through heavy rain or deep puddles.” The adjustment to the robot was implemented immediately and analysis continued regarding the impact of this additional potential cause for liquid ingress.

The Audi Safety Committee began to issue a service campaign in order to install a protective cover for the gateway control module and to seal the underbody in the area of the insufficient glue bead, but after a meeting with Transport Canada and the Defective Product Administrative Center in China, the Audi Product Safety Committee re-evaluated their decision and decided to conduct a voluntary recall to fix affected vehicles.

The Vehicles Affected Include:
2018-2022 Audi Q5 Sportback
2018-2022 Audi SQ5 Sportback

Tag Archives: loss of engine power

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