Manufacturer defect – California Lemon Law blog

Volvo Cars has decided that there may be a safety defect affecting a small number of 2025 Volvo EX30 vehicles. The potential issue involved the high-voltage battery. Although there have been no reported incidents, warranty claims, or service reports in the United States, the company is taking precautionary steps to reduce any possible safety risk while a permanent repair is developed.

The concern centers on the vehicle’s high-voltage battery cells. According to Volvo, a manufacturing process deviation may result in the formation of lithium plating growth inside certain battery cells. Over time, this condition can increase the risk of an internal short circuit, which in rare circumstances could cause the battery to overheat.

If such a short circuit were to occur, it could lead to a thermal event, meaning excessive heat and, in extreme cases, the possibility of fire. While this scenario is considered unlikely, Volvo determined the issue warranted a safety recall out of an abundance of caution.

Drivers may receive a warning if a problem develops. In affected vehicles, a battery overheating message would appear in the Driver Information Module, alerting the driver to the condition.

Volvo first became aware of the issue in July 2025, after receiving a report of potential high-voltage battery cell overheating outside the United States. The company launched an internal investigation, which was later escalated to its Critical Concern Action Process. After technical analysis and risk assessment by the Critical Concern Management Team, Volvo concluded that the issue could present an increased risk to motor vehicle safety. On December 26, 2025, the decision was made to issue a safety notification recall.

While the investigation continues, Volvo has issued interim guidance for affected owners. Customers are being advised to limit battery charging to a maximum of 70 percent state of charge and to avoid parking their vehicles indoors or near structures. These recommendations are intended to reduce battery stress and minimize potential risk until a final remedy is available.

Volvo is currently developing a permanent service solution. Future production has already been updated to include a new high-voltage battery variant designed to eliminate the condition. Owner notification letters are expected to be mailed beginning February 23, 2026, at which point dealers will provide further instructions.

This recall is identified by Volvo recall number R10355 and National Highway Traffic Safety Administration campaign number 26V-001.

If you own a 2025 Volvo EX30 and receive a recall notice, following the interim guidance and staying in contact with your dealer is the best course of action while the final repair is completed.

Subaru has decided that a safety defect could affect certain 2026 Subaru Forester vehicles. According to Subaru, some vehicles were built with an incorrect or improperly oriented rear gate stay bracket, which could cause the rear hatch support stay to suddenly detach — without any warning to the driver or passengers.

What Is the Defect?

The problem involves the rear gate stay bracket, a component that helps support the rear hatch when it is open. Affected vehicles may have:

An incorrect rear gate stay bracket, or
A bracket that was installed in the wrong orientation

Either condition can cause the rear gate stay to detach unexpectedly during use.

Why This Is Dangerous

If the rear gate stay detaches without warning, the rear hatch can suddenly lose support. This creates a serious risk of:

Head and upper-body injuries
Crush injuries to hands or arms
Potential injuries to children, passengers, or anyone loading cargo

How Subaru Discovered the Problem

October 28, 2025: During in-process inspection, Subaru found a vehicle built with an incorrect rear gate stay bracket.
Additional inspections revealed more vehicles with either:
- Incorrect brackets, or
- Brackets installed backwards or in the wrong orientation.
October 29 – December 10, 2025: Subaru launched a formal investigation and conducted repeated open/close cycle testing.
While initial tests did not show failures, Subaru concluded that longer-term real-world use could lead to stay detachment without warning.
December 11, 2025: Out of caution, Subaru decided to issue a safety recall.

Subaru admitted the root cause was a faulty work instruction process that failed to ensure the correct bracket was installed in the proper orientation.

Vehicles Affected

Model: 2026 Subaru Forester
Recall Number: WRG-25
NHTSA Campaign Number: 25V-889
Owner Notification Letters: Expected to be mailed February 16, 2026

What Will Dealers Do?

Subaru dealerships will:

Inspect the rear hatch support bracket
Replace the rear gate stay and support bracket if any defect or mis-installation is found

Repairs are expected to be performed at no cost to owners.

What This Means for Lemon Law Claims

Even though Subaru says no injuries have occurred, this defect involves a safety-critical system and was serious enough to justify a federal recall.

You may have a valid Lemon Law claim if:

Your vehicle experiences repeat repair attempts
The rear hatch detaches or becomes unsafe
Your vehicle is out of service for an extended period
The defect substantially impairs the use, value, or safety of your Forester

Lemon laws protect consumers when manufacturers are unable to permanently fix serious safety defects within a reasonable number of attempts.

What Owners Should Do Now

Watch for Subaru’s recall letter in mid-February 2026
Schedule your inspection as soon as possible
Keep all repair orders and service records
If problems continue after repair, contact a Lemon Law attorney immediately

Final Thoughts

The 2026 Subaru Forester rear hatch recall highlights how even a small manufacturing error can create a serious safety hazard. A rear gate stay that detaches without warning is not a minor inconvenience — it is a potential injury-causing defect.

If your Forester has this issue and Subaru cannot repair it properly, your vehicle may qualify as a lemon.

Owners of certain 2016–2020 Acura ILX vehicles may be experiencing an unsettling brake issue that develops quietly over time. While it does not always appear suddenly or trigger warning lights, the condition can reduce brake effectiveness during everyday driving—particularly during gentle or slow brake applications. For drivers, any issue involving braking deserves close attention.

What Is the Brake Problem?

The issue centers on the brake master cylinder, a critical component responsible for converting pedal pressure into braking force. In the affected vehicles, a material used in the brake fluid reservoir hose can release excess plasticizer into the brake fluid.

Over time, this contamination causes a seal inside the master cylinder (known as the secondary cup seal) to swell and deform. Heat from the engine can make the problem worse.

When this happens:

Brake fluid can bypass the seal instead of building proper pressure
The brake pedal may feel softer or less firm
Stopping distances may increase, especially during light or gradual braking

In real-world driving, this means the vehicle may not slow down as expected—raising the risk of a crash or injury.

Why Did This Happen?

The root cause traces back to manufacturing timing. The brake reservoir hose was installed too soon after production, before excess plasticizer had time to dissipate. That plasticizer leached into the brake fluid, which was then absorbed by the master cylinder seal.

As the seal absorbed the contaminant and expanded:

Its shape and flexibility changed
It could no longer maintain a proper seal under certain braking conditions
Brake fluid was allowed to leak back into the reservoir

The result is reduced hydraulic pressure when the driver presses the brake pedal slowly.

A Long Investigation Timeline

Honda and Acura engineers spent nearly a decade analyzing this issue:

2015–2021: Initial complaints of intermittent brake pedal pressure loss
2022–2024: Extensive testing confirmed chemical contamination and seal swelling
2025: A clear link was found between hose storage timing, material curing, and seal deformation

By late 2025, the manufacturer determined that this condition posed a motor vehicle safety defect and initiated corrective action.

As of December 2025, there were 192 warranty claims associated with the issue. Fortunately, no injuries or fatalities have been reported.

What Is Being Done to Fix It?

Owners of affected vehicles will be notified by mail and instructed to visit an authorized Acura dealer. The repair involves:

Replacing the brake master cylinder
Installing an improved sealing cup made from a different material
Restoring proper brake fluid sealing and pedal feel

This updated design is intended to eliminate the contamination-related swelling entirely.

Why This Matters for Lemon Law Claims

Even if a manufacturer offers a fix, brake-related defects can still be relevant under Lemon Law statutes, especially if:

The problem existed during the warranty period.
You experienced repeated brake complaints or repairs.
The issue affected vehicle safety, drivability, or value.

Stellantis has determined that a safety defect could affect certain 2024 Dodge Hornet and Alfa Romeo Tonale Plug-In Hybrid Electric (PHEV) vehicles. The automaker has confirmed that the brake pedal arm in these vehicles may collapse, leading to a sudden and dangerous loss of braking ability.

If you own or lease one of these vehicles, here is everything you need to know about the defect, the remedy, and your potential rights under the Lemon Law.

The Problem: Brake Pedal Collapse

According to filings with the National Highway Traffic Safety Administration (NHTSA), the specific defect involves the brake pedal assembly. In affected vehicles, the pedal arm is susceptible to collapsing under the pressure of braking. If the pedal collapses, the driver may lose the ability to activate the service brakes. As stated in the safety report, “The inability to activate the service brakes while driving can cause a vehicle crash without prior warning.”

This recall (NHTSA Campaign Number 25V-846) is an expansion of a previous recall (24V-752) issued in October 2024. Despite earlier efforts, Stellantis Europe Control Tower received new field complaints in late 2025 regarding collapsed pedals in both North America and Europe, prompting this new, expanded campaign.

Accident Reports and Investigation

October & November 2025: Field complaints were received regarding pedals collapsing during normal driving.
November 24, 2025: Stellantis identified one warranty claim and one customer assistance record related to the issue.
Safety Risk: As of late November 2025, the automaker is aware of one accident related to this defect. Fortunately, zero injuries have been reported so far.

What to Do If Your Brakes Fail

Stellantis has provided specific emergency instructions for drivers who experience a brake pedal collapse while driving. If your pedal hits the floor or snaps and you cannot stop the car:

Use the Electronic Park Brake: Located on the center console, this switch can be pulled up and held while driving. This will override the failure and slow the vehicle to a controlled stop.
Automatic Emergency Braking (AEB): If your AEB system is active (not manually deactivated), it is designed to intervene automatically if it detects an imminent collision, even if the brake pedal is broken.

Recall Details and Remedy

Owners of affected vehicles should contact their dealerships immediately.

NHTSA Campaign Number: 25V-846
FCA US Recall Number: D0C
Notification Date: Owner notification letters are expected to be mailed by January 13, 2026.
The Fix: Dealers will reinforce the brake pedal arm to prevent collapse.

Can I File a Lemon Law Claim?

The Lemon Law is designed to protect consumers who have purchased defective vehicles. If your car has a substantial safety defect that the manufacturer has failed to fix within a reasonable number of attempts or a reasonable amount of time, you could be eligible for:

A vehicle repurchase (buyback).
A replacement vehicle.
Cash compensation.
Payment of your attorney’s fees.

Do not wait until an accident happens. If you are unsafe in your vehicle, contact us today for a free consultation regarding your rights.

If you own a model year 2024 or 2025 Hyundai Santa Fe or Santa Fe Hybrid, you need to be aware of a significant safety recall affecting your vehicle’s backup camera system.

Hyundai Motor America has determined that a defect exists in certain vehicles where the rear view camera image may fail to display when the vehicle is placed in reverse. This issue has triggered a noncompliance recall because the affected vehicles fail to meet the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 111 regarding “Rear Visibility.”

Here is everything owners need to know about why the cameras are failing, the safety risks involved, and how Hyundai plans to fix the problem.

What is Causing the Santa Fe Camera Failure?

It is frustrating when a new car feature stops working. In this case, the problem isn’t necessarily a defective camera lens, but rather how the camera system was installed at the factory.

According to investigations by Hyundai’s Safety Test and Investigation Laboratory (STIL), the root cause stems from improper installation of the rear view camera wiring harness.

During the manufacturing process, variations in how the “end-of-line” wire harnesses were packaged allowed for inconsistencies in cable routing. In some vehicles, the camera wiring harnesses were installed with a “twist.” This twisting creates increased tension on the wires.

Over time, this tension can cause physical damage to the wiring, including solder cracks near terminal connections and damage to the wire’s shield line. Once these wires are compromised, the connection becomes unstable, leading to a flickering image or a completely blank screen on your dashboard display.

Why This Is a Safety Issue

A functional rear view camera is vital for safe reversing. It helps drivers spot pedestrians, obstacles, and other vehicles in their blind spots.

When the camera fails to display an image, the driver loses this critical view. This noncompliance with FMVSS No. 111 increases the risk of a crash or backup collision.

The Investigation Timeline

Hyundai began looking into this issue between March and June 2025 after routine monitoring of warranty claims showed a spike in inoperative cameras. They analyzed 21 different camera assemblies, discovering the solder cracks and wiring damage. Following extensive review with the supplier and Hyundai’s North America Safety Decision Authority in November 2025, the decision was made to issue a recall.

The Fix: What Hyundai Will Do

Replace the rear view camera assembly entirely.
Reposition the wiring harness correctly to ensure there is no tension causing damage to the new unit.

Important Dates and Next Steps for Owners

If you own a 2024-2025 Santa Fe or Santa Fe Hybrid, keep an eye on your mail.

Owner Notification: Hyundai expects to mail notification letters to affected owners beginning January 19, 2026.

If your camera is currently not working, you do not need to wait for the letter to contact your dealer.

Essential Recall Reference Numbers

When speaking with your dealer or searching the NHTSA database, use these reference numbers to identify this specific issue:

Hyundai Recall Number: 288
NHTSA Campaign Number: 25V-808

Certain model-year 2020-2025 Jeep Wrangler 4xe and 2022-2026 Jeep Grand Cherokee 4xe vehicles were manufactured with high-voltage (HV) battery packs that may contain defective cells. The defect can lead the battery to internally fail and potentially cause a vehicle fire – whether the vehicle is parked or driving.

What’s the problem?

On July 3, 2025, the manufacturer’s technical safety organization opened an investigation after reports of fires originating in the HV battery packs of these plug-in hybrid vehicles – including vehicles that had already undergone the earlier remedy under Recall ID 95B (NHTSA ID 24V-720).
The battery supplier Samsung SDI obtained a pack from a vehicle that had experienced a fire with cells manufactured outside the original recall’s scope. They found the fire was caused by the same defect identified under 95B and are working to identify additional causal factors.
As of October 13, 2025:
- 9 fires reported in vehicles which had already had the 95B software remedy applied.
- 10 fires reported in vehicles whose cells were outside the original 95B scope.
- 19 customer-assistance records, 0 warranty claims, and 19 field reports tied to this issue (dates from Jan 27 to Sept 2, 2025).
- 1 injury and no confirmed accidents tied to this issue.
On October 24, 2025, the manufacturer determined there is a defect affecting motor vehicle safety in all affected vehicles.
The manufacturer states that in rare cases, a battery pack may contain cells with separator damage which, combined with other complex interactions within the cell, may lead to a fire.
A key interim safety measure: risk is lower when the battery charge level is low or depleted, and higher when the battery is fully or highly charged.
Owner advice: refrain from recharging the vehicle, and park away from structures or other vehicles until the final remedy is available.
The recall campaign number is 68C (NHTSA campaign number 25V-741) and even vehicles previously recalled under 24V-720 or 23V-787 will need the new remedy.

Affected vehicles

Model year 2020-2025 Jeep Wrangler 4xe
Model year 2022-2026 Jeep Grand Cherokee 4xe

What should owners do now?

Minimize risk until fixed:
- Avoid charging the plug-in-hybrid battery.
- Park the vehicle outdoors or away from other vehicles/structures (such as garages) when practicable.
- Try to keep the battery’s state of charge as low as is reasonable for your use.
Wait for the remedy: The final repair or battery replacement is under development. Interim notification letters are expected to be mailed starting December 2, 2025, with additional letters once the remedy is ready.
Follow dealer instructions: Once the remedy is available, schedule service promptly. The remedy may include software updates to the battery management/control module plus potentially a full HV battery pack replacement.
Stay informed: Keep track of recall updates and announcements.

Why this matters: safety & resale considerations

A fire originating from a plug-in hybrid’s high-voltage battery is a rare but serious risk: it can pose danger to occupants, first-responders, and bystanders, and damage property.
Even if your vehicle hasn’t shown signs of the defect, being part of the recall means you should treat it as a potential risk and act accordingly.
From a resale/ownership value perspective, vehicles under open safety recalls can be harder to sell or may need disclosure depending on local laws. Completing the remedy promptly is beneficial for overall vehicle value and peace of mind.

Bottom line

If you own a 2020-2025 Jeep Wrangler 4xe or a 2022-2026 Jeep Grand Cherokee 4xe, this is a recall you cannot ignore. While the risk may only affect a minority of vehicles, the potential consequence is serious. Until the permanent fix is installed, follow the safety advice strictly: no recharging, park away from buildings, and monitor for dealer communications. Once the remedy becomes available, book the service as soon as possible. Your safety – and the safety of others around your vehicle – depends on it.

(Recall: SB-25-16-005 / NHTSA Campaign 25V-690)

If you own or are considering buying a 2025 Model 3 or 2026 Model Y from Tesla, there’s a safety issue you should know about. Certain vehicles built between early March and mid-August 2025 are affected by a battery pack contactor fault that may result in an unexpected loss of drive power. This article explains what the issue is, which vehicles are affected, what the risks are, and what owners should do next.

What is the issue?

Tesla has determined that certain 2025 Model 3 and 2026 Model Y vehicles are equipped with a battery pack contactor manufactured with an InTiCa solenoid that may have a poor coil termination connection.

If the contactor opens unexpectedly while the vehicle is in drive, the driver loses the ability to apply torque through the accelerator pedal, resulting in a loss of propulsion. This sudden loss of drive power could increase the risk of a collision.

There is no warning prior to the failure. However, when it occurs, the driver receives an immediate visual alert on the user interface instructing them to safely pull over.

Which vehicles are affected?

2025 Tesla Model 3 vehicles manufactured between March 8 and August 12, 2025.
2026 Tesla Model Y vehicles manufactured between March 15 and August 15, 2025.

Tesla estimates roughly 13,000 vehicles in total are affected, including around 5,000 Model 3s and nearly 8,000 Model Ys produced within those date ranges.

Timeline of Investigation & Recall

August 8, 2025: Tesla’s Field Reliability team began investigating service cases where vehicles were unable to enter drive and high coil resistance was detected in the pack contactor.
August 8 – September 26, 2025: Tesla collected contactors from the field and performed detailed failure analysis.
September 29 – October 2, 2025: Tesla reviewed the failure analysis results, along with repair and production records.
October 3, 2025: Tesla completed its investigation and determined the scope of affected vehicles, initiating a voluntary recall.
December 9, 2025: Owner notification letters are expected to be mailed to customers.

As of early October 2025, Tesla had identified 36 warranty claims and 26 field reports related to this issue, with no known injuries, collisions, or fatalities.

What is the remedy?

Tesla Service will correct the problem by replacing the high-voltage battery pack contactor. The updated parts do not include the defective InTiCa solenoid and have improved coil termination connections. The repair takes approximately one hour to complete, and Tesla will notify all affected owners by mail.

Why this matters

Safety risk

A sudden loss of propulsion without warning can be dangerous, especially when driving at highway speeds or in traffic. While no injuries have been reported, Tesla’s recall emphasizes the importance of addressing this issue promptly.

Financial and resale considerations

Unresolved recalls can affect resale value, financing, and insurance. Ensuring the recall repair is completed not only improves safety but also helps preserve the vehicle’s long-term value.

What owners should do if their Tesla vehicle is affected.

Schedule a service appointment through the Tesla app or by contacting your nearest Tesla Service Center.
Pay attention to alerts while driving. If a visual warning or loss of power occurs, pull over safely and contact Tesla support immediately.
Keep documentation of the recall repair for future reference or resale.
If buying used, confirm with the seller that any open recalls have been completed.

This recall serves as a reminder that even advanced electric vehicles like Tesla are not immune to hardware issues. While Tesla can often fix software defects through over-the-air updates, mechanical components such as contactors and solenoids require physical inspection and replacement.

Frequently Asked Questions

Q: Does this recall affect all 2025 Model 3 and 2026 Model Y vehicles?
A: No. Only vehicles built between March and August 2025 with the affected InTiCa solenoid contactor are included.

Q: My car feels fine — do I still need the repair?
A: Yes. The failure can occur without warning, so even if your car shows no symptoms, Tesla recommends completing the replacement.

Q: How long will the repair take?
A: The contactor replacement typically takes about one hour and is performed free of charge.

Q: Can I continue driving before the repair?
A: Tesla advises that owners continue driving normally but schedule service as soon as possible. If your vehicle shows a propulsion loss alert, pull over safely and contact Tesla.

Conclusion

If you drive a 2025 Tesla Model 3 or 2026 Model Y, this recall deserves your attention. The contactor defect can cause sudden loss of drive power, posing a potential safety risk. Tesla is replacing the affected parts at no cost to owners, with notifications beginning December 2025.

Ford Motor Company has issued a recall for certain 2025 Ford Ranger trucks due to a potential problem with the passenger airbag system. According to the automaker, a manufacturing error could prevent the airbag from deploying properly in the event of a collision, creating an increased risk of injury for passengers.

While the issue affects only a limited number of vehicles, Ford is taking immediate action to ensure compliance with federal safety standards and to protect customer safety.

The Issue: Faulty Instrument Panel Scoring

The concern originates from the instrument panel (IP) assembly—specifically the laser scoring process used on the underside of the IP topper. The scoring defines the precise way the airbag deploys through the dashboard surface.

Ford discovered that the supplier, Yanfeng (YF), had unintentionally altered the laser scoring parameters during production. This seemingly small change resulted in a deviation from the approved design, affecting the scoring pattern in certain 2025 Ford Ranger vehicles.

This flaw may cause the passenger airbag to deploy more slowly or not fully deploy at all, especially during cold-temperature conditions or low-output deployments. During internal safety testing, Ford observed that in some cases, the airbag cushion failed to completely exit the panel surface, creating a potential hazard and violating Federal Motor Vehicle Safety Standards (FMVSS) 208, which govern occupant crash protection performance.

Timeline of Events

The airbag concern was identified and escalated through Ford’s quality and safety review process over the course of several weeks:

September 10, 2025: Supplier Yanfeng notifies Ford of an unintended change to the laser scoring process.
September 18, 2025: Ford’s Critical Concern Review Group (CCRG) launches a detailed investigation into the issue.
September 9, 2025: The supplier revises the laser scoring process to match the original specifications and validates the fix.
October 3, 2025: Ford’s Field Review Committee reviews the findings, confirms non-compliance with FMVSS 208, and authorizes a field action.

Although Ford is not aware of any crashes, injuries, or customer complaints linked to the problem, the company has decided to act out of caution and replace affected components.

What Ford Owners Need to Know

Owners of affected 2025 Ford Ranger trucks will be contacted directly by Ford. Here’s what you should know about the recall:

Recall Number: 25C54
NHTSA Campaign ID: 25V-678
Remedy: Ford dealers will replace the instrument panel assembly.
Notification Schedule:
- Interim owner letters were mailed on October 24, 2025, to inform customers of the issue.
- Final remedy letters will be mailed once replacement parts are available and the repair process begins.