Tag Archives: manufacturing defect

Loss Of Drive Power From Fuel Pump Failure

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Hyundai is taking action to address a fuel pump issue in certain 2021-2022 Genesis vehicles. This problem came to Hyundai’s attention in September 2022 when they received their first warranty claim related to a 2022 Genesis GV70 vehicle experiencing a stall / hesitation problem. As more warranty claims started pouring in, Hyundai launched an investigation to pinpoint the root cause of the issue.

The vehicles affected include:

  • 2021-2022 Genesis G80
  • 2022 Genesis GV70
  • 2021-2022 Genesis GV80

In June 2023, Hyundai successfully replicated the problem. Their investigation, which included a dimensional tolerance CT scan, revealed a potential problem: interference between the impeller (a key component of the fuel pump) and its housing, causing an obstruction. Hyundai collaborated with the supplier and identified a specific production lot of fuel pump assemblies that lacked sufficient impeller material. This issue potentially affected vehicles manufactured between June 2021 and December 2021. Consequently, Hyundai made the decision to initiate a recall.

The issue lies with the low-pressure fuel pump assemblies in these vehicles. Some of these assemblies may contain impellers that do not meet the required material specifications, which can lead to deformations. This deformation can result in the impeller interfering with the fuel pump housing, creating mechanical resistance that can cause the fuel pump to shut down.

A fuel pump shutdown can severely restrict the flow of fuel to the engine, potentially causing a sudden reduction or complete loss of power while driving. This poses an increased risk of accidents.

As of the latest available data up to August 22, 2023, Hyundai has received reports of 879 unique incidents related to this defect condition in the United States, spanning from July 1, 2021. Fortunately, there have been no confirmed crashes, fires, or injuries linked to this fuel pump issue.

To rectify the problem, authorized Hyundai dealers will replace the affected fuel pumps. The recall associated with this issue is identified by Hyundai as number 016G, and it has been assigned the NHTSA campaign number 23V-630. Additionally, the NHTSA has designated a specific campaign number for the fuel pump recall, which is 23E-068.

In summary, Hyundai is addressing a fuel pump problem in certain 2021-2022 Genesis vehicles to ensure the safety and reliability of these vehicles on the road. If you own one of these vehicles, it is important to receive the necessary replacement to avoid potential issues related to the fuel pump.

Battery Fire Risk in Certain Lincoln Aviator and Ford Explorer Vehicles

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Ford Motor Company (Ford) is taking action to address a safety concern with specific 2020-2022 Lincoln Aviator and 2020-2022 Ford Explorer vehicles that are equipped with 3.0L PHEV (Plug-in Hybrid Electric Vehicle) engines. These vehicles may have a manufacturing defect in one or more of the high voltage battery cells, which could lead to an internal short circuit and a potential battery fire.

Discovery of the Issue

Ford became aware of this issue in June 2023 when they received a report regarding thermal venting problems with the PHEV battery used in these vehicles. The report highlighted a 2021 model year Transit Custom in France experiencing PHEV battery thermal venting. Subsequent analysis, conducted by the battery cell supplier, revealed an internal short circuit in the vehicle’s high voltage battery pack, partly due to the presence of a folded anode tab, which occurred during the cell manufacturing process.

Ongoing Investigation

The supplier’s investigation indicated that another, as yet unidentified, factor is necessary for the folded anode tab condition to lead to battery thermal venting. The supplier is actively conducting component-level testing to pinpoint this second factor. While this factor remains unknown, the Ford Critical Concern Review Group (CCRG) has been working to identify the group of vehicles that may potentially have the cell folded anode tab condition.

Additional Incidents

Ford was aware of three more instances of cells with folded anode tabs in the field. These incidents involved a 2020 model year Aviator in the United States, resulting in PHEV battery thermal venting, another 2020 model year Aviator in the United States resulting in a Malfunction Indicator Light (MIL) but no battery thermal venting, and a 2020 model year Aviator in Canada, also resulting in an MIL but no battery thermal venting.

Preventive Measures

To address this issue, Ford has reviewed the cell supplier’s manufacturing process and made improvements during cell production to reduce the occurrence of the folded anode tab condition. The timing of these process enhancements has been used by the CCRG to determine the affected population of vehicles.

Recall Procedure

Owners of the affected vehicles will be notified and requested to visit their authorized Ford dealers for a Battery Energy Control Module (BECM) diagnostic test. If the test identifies a battery problem, the high voltage battery pack will be replaced at no cost to the owner. To check if your vehicle is part of this recall, refer to Ford’s recall number 23S53 and the NHTSA campaign number 23V-626.

2024 Chevrolet Silverado and GMC Sierra Steering Fracture

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When it comes to your safety on the road, a reliable and functional steering system is paramount. Unfortunately, General Motors, LLC (GM) has recently issued a recall for certain 2024 Chevrolet Silverado and GMC Sierra vehicles due to a potential steering gear shaft defect that could pose serious risks. In this article, we’ll delve into the details of this recall, GM’s response, and how a Lemon Law lawyer can help if you’re affected by this issue.

GM has identified a critical concern in some 2024 Chevrolet Silverado 2500, 3500, and 2024 GMC Sierra 2500, 3500 vehicles. The issue revolves around the steering gear shaft, which has the potential to fracture and disconnect from the steering arm. This alarming discovery was brought to light in June 2023 during an alignment operation, when a GM quality engineer stumbled upon a fractured steering gear shaft on a 2024 model year Chevrolet Silverado HD truck. GM’s thorough investigation traced the root cause to the use of out-of-specification materials combined with improper heat treatment. This unfortunate combination can result in steering gear shaft parts with material properties that fall outside acceptable specifications, ultimately leading to the fracture of the shaft.

The repercussions of this defect are both concerning and dangerous. The steering gear shaft, if compromised, may fracture and detach from the steering (pitman) arm. Such an occurrence renders the driver unable to steer the vehicle effectively, dramatically increasing the risk of a potential crash. It’s essential for vehicle owners to recognize the seriousness of this situation and take immediate action.

In response to this critical safety concern, GM’s Safety and Field Action Decision Authority acted swiftly. In July 2023, they decided to initiate a safety recall for the affected vehicles. If you own one of the affected models, GM will contact you with instructions on returning to your nearest dealership. There, your steering gear will be thoroughly inspected, and if necessary, replaced. To identify this recall, GM has assigned it the recall number N232414720, and it is also associated with the NHTSA campaign number 23V-549.

If you find yourself entangled in this recall, it’s crucial to understand your rights as a consumer. This is where a Lemon Law lawyer can make a significant difference. Lemon Laws are designed to protect consumers who have purchased faulty vehicles, ensuring that manufacturers rectify the situation. Your Lemon Law lawyer can guide you through the legal processes, helping you navigate the intricacies of the law to ensure you receive the compensation and resolution you deserve.

In light of GM’s recent recall of certain 2024 Chevrolet Silverado and GMC Sierra vehicles due to a steering gear shaft defect, prioritizing your safety on the road has never been more important. Stay informed, heed the manufacturer’s instructions, and if you encounter any challenges along the way, remember that a Lemon Law lawyer is here to safeguard your rights and help you achieve a fair resolution. Your safety and peace of mind are paramount, and by taking appropriate action, you can ensure a secure driving experience.

2022-2023 Jeep Wagoneer and Grand Wagoneer Airbag Safety

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airbagCertain 2022-2023 Jeep Wagoneer and Grand Wagoneer vehicles could experience a compromised side curtain air bag (SABIC) deployment due to an improperly seated upper B-pillar. These vehicles fail to comply with the requirement of the Federal Motor Vehicle Safety Standard for ejection mitigation.

Fiat Chrysler Automobiles (FCA) became aware of the problem in June 2022 when the FCA technical Safety and Regulatory Compliance (TSRC) organization was informed of a potential issue related to the upper B-pillar trim that could result in a compromised SABIC deployment in some 2022-2023 Jeep Wagoneer and Jeep Grand Wagoneer vehicles. FCA analyzed warranty claims, customer records and vehicle history to identify reports of improperly seated upper B-pillar trim. They held meetings with FCA Interior Engineering and Manufacturing to review the issue and understand the part design failure mode.

According to the defect report, when the ejection propulsion mechanism propels the ejection impactor into the impact target locations of each side daylight opening of a vehicle according to the test procedures specified in S5 of this standard, the most outboard surface of the ejection head form must not displace more than 100 millimeters beyond the zero displacement plane. Vehicles with the upper B-pillar trim not fully seated may have a compromised side airbag inflatable curtain deployment that may not meet this requirement. A compromised deployment of the SABIC can reduce occupant protection in the event of a crash, resulting in an increased risk of injury to vehicle occupants. If a vehicle has this problem, the driver may notice a loose fit and/or rattle in the B-pillar.

This recall is not related to a part defect but rather an assembly issue where the vehicle may have been built with an improperly seated upper B-pillar trim. The remedy will be to inspect and, if necessary, reseat or replace all loose or broken upper B-pillar interior trim pieces. FCA US, LLC’s number for this recall is 76A and the NHTSA campaign number is 23V-545.

Electric Oil Pump Failure May Cause Fire

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Hyundai Motor America (Hyundai) and Kia America, Inc. (Kia) are contacting owners of certain 2023-2024 vehicles because these vehicles are potentially affected by a critical issue related to the electric oil pump assembly. The problem could lead to a vehicle fire.

According to the defect report, the problem lies in a Multi-Layer Ceramic Capacitor (MLCC) located on the printed circuit board within the Idle Stop & Go (ISG) electric oil pump assembly for the transmission. During the manufacturing process, the MLCC may have incurred damage from the supplier. This damage can have severe consequences on the electrical operation of the pump, leading to heat damage to the electric oil pump circuit board, connector, and wiring harness.

The consequences of this heat damage are twofold. Firstly, it escalates the risk of a vehicle fire, which can pose a significant threat to both the occupants and the vehicle itself. Secondly, there is a potential for a Controller Area Network (CAN) communication disruption for multiple onboard controllers. This disruption could lead to operational issues and compromises in the vehicle’s performance.

A range of 2023-2024 Hyundai and Kia models have been identified as being susceptible to this issue. The affected vehicles include:

The vehicles affected include:

2023 Hyundai Elantra
2023 Hyundai Kona
2023-2024 Hyundai Palisade
2023 Hyundai Sonata
2023 Hyundai Tucson
2023-2024 Kia Seltos
2023 Kia Soul
2023 Kia Sportage

Drivers may notice smoke from the vehicle’s under-body, a burning or melting odor or an illuminated Malfunction Indicator Light and other system dashboard warning lamps.

To address this potential problem, Hyundai and Kia are taking immediate action by issuing a recall. Owners of the affected vehicles will be notified and requested to schedule an appointment with their nearest Hyundai or Kia dealerships. During the inspection process, the electric oil pump controller will be inspected, and if necessary, replaced to ensure optimal performance and safety.

As a precautionary measure until the recall repair is completed, owners are advised to park their vehicles outside and away from structures. This will minimize the potential risk of a vehicle fire and provide added safety for both the vehicle and surrounding property.

For reference, Hyundai has designated the recall with the number 246, and the corresponding NHTSA campaign number is 23V-526. Meanwhile, Kia has assigned the recall with the number SC275, and the associated NHTSA campaign number is 23V-531.

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.

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.