manufacturing error – California Lemon Law blog

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.

If you drive a 2025-2026 Ford Escape or Lincoln Corsair, it is time to check your mailbox and your rear seats. Ford has issued a safety recall affecting these popular SUVs due to a critical issue with the rear seat belt retractors. While safety technology has evolved rapidly, the seat belt remains your primary line of defense in an accident. Here is everything you need to know about the problem and the warning signs.

The Problem: Loose Retractors

The core of the issue lies in the left and right rear passenger seat belt retractors. According to the defect report, the bolts securing these retractors may not have been properly tightened during assembly. If the retractor isn’t securely fastened to the vehicle’s body (specifically the D-Pillar), it cannot do its job properly. In the event of a crash, a loose retractor may fail to adequately restrain the passenger, significantly increasing the risk of injury.

How Did This Happen?

Ford’s investigation traced the issue back to the Louisville Assembly Plant. It wasn’t a failure of the main assembly line, but rather an error that occurred at off-line repair stations. Vehicles that were pulled aside for unrelated repairs may not have had their retractor bolts properly secured upon completion. This procedural lapse resulted in the potential for loose hardware in the final customer vehicles.

Warning Signs: What to Listen For

Unlike some mechanical issues that remain silent until they fail, this defect often gives an auditory warning. Owners should look out for:

Rattling Noises: You may hear a metallic rattle coming from the rear pillar area while driving.
Seat Belt Binding: The seat belt may feel like it is “sticking,” making it difficult to pull out or retract smoothly.

The Timeline

Nov 6, 2025: Team members at the assembly plant noticed 5 warranty claims related to noisy or binding rear seat belts on vehicles with low mileage.
Nov 12, 2025: Ford’s Critical Concern Review Group (CCRG) opened a formal investigation.
Dec 5, 2025: A field action (recall) was approved.

As of December 8, 2025, Ford is not aware of any accidents or injuries related to this condition. The recall is proactive to ensure it stays that way.

What Should Owners Do?

If you receive a notice for your 2025-2026 Lincoln Corsair or Ford Escape, do not ignore this recall.

The Fix:
Dealers will inspect the seat belt retractor bolts. If they are loose, they will be properly secured. If the bolts or assembly are damaged, the dealer will replace the seat belt retractor entirely.

Important Details:

Owner Notification Date: Ford expects to mail letters to affected owners starting December 19, 2025.
Ford Recall Number: 25C68
NHTSA Campaign Number: 25V-862

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.

Recall Reference: VW Campaign 93EV / NHTSA Campaign 25V-836

If you are the owner of a 2023 or 2024 Volkswagen ID.4, please take a moment to review this critical safety warning. Volkswagen has issued a recall for specific vehicles in this model range due to a high-voltage battery defect that could lead to a vehicle fire.

Because the risk involves the potential for a thermal event (fire) while the car is parked or driving, Volkswagen has issued specific “Park Outside” instructions while they prepare the remedy.

The Issue With The VW ID.4 Battery

The problem lies within the High Voltage (HV) battery. According to the defect report, a production deviation at a battery supplier resulted in misaligned electrodes within certain battery cell modules. Specifically, the cathode inside the battery cell may have shifted. When these electrodes are not aligned correctly, it increases the risk of a short circuit inside the cell, which can lead to a fire.

Warning Signs

While a battery fire can happen suddenly, there are performance indicators you should watch for. If your vehicle has this defect, you may experience:

A noticeable loss of driving range.
A reduction in vehicle performance.

If you notice these issues, contact an authorized Volkswagen dealer immediately for diagnosis.

Critical Safety Instructions for Owners

Until the recall repair is performed, Volkswagen is advising owners of affected vehicles to follow these strict precautions to minimize risk:

Park Outside: Park the vehicle away from structures and other cars immediately after charging.
No Overnight Indoor Charging: Do not leave the vehicle charging indoors overnight.
Limit Charge to 80%: Adjust your charging settings to stop at an 80% state of charge.
Avoid Fast Charging: Do not use Level 3 DC Fast Chargers.

Timeline: How the Defect Was Discovered

The investigation into this issue spanned nearly two years. Here is a summary of the events that led to this recall:

January 2024 (Illinois): Volkswagen was notified of the first thermal event involving a vehicle connected to a Level 3 DC charger. The battery was analyzed, confirming the fire started in the HV battery.
July & October 2024 (California): Two separate fires occurred in parked vehicles that were not charging. Inspections confirmed the origin was the HV battery, but initial analysis (including CT scans by the supplier in June 2025) failed to identify the root cause.
December 2024 (Utah): A fourth thermal event occurred while a vehicle was being driven.
Summer 2025: With CT scans appearing inconclusive, VW and the supplier investigated other potential causes outside the battery but found nothing. The focus returned to the battery.
August 2025 (Colorado): A fifth event occurred while a vehicle was using a DC fast charger.
September 2025 (The Breakthrough): The supplier performed a physical “tear-down” analysis of damaged cell modules. They discovered the “shifted” electrode condition. By comparing this physical evidence back to the previous CT images, they realized the defect was visible in the scans but had been previously unrecognized.
November 2025: The supplier identified the specific batch of bad modules, allowing VW to isolate which vehicles were affected. On November 26, VW officially decided to issue a recall.

The Remedy

Dealers will resolve this issue by replacing the high-voltage battery cell modules as necessary. Owner Notification: Notification letters are expected to be mailed by January 30, 2026.

Volkswagen Recall Number: 93EV
NHTSA Campaign Number: 25V-836

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

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.

If you drive a 2020 or 2021 Ford Super Duty F-250, F-350, or F-450, there’s a new recall you should know about. Ford has confirmed a steering defect that could cause you to suddenly lose control of your truck while driving.

And here’s the bigger issue: these trucks already have a long history of recalls. If your Super Duty keeps going back to the dealership for repairs, it may be more than just bad luck — your truck could be a lemon.

What’s the Problem?

The recall centers on the steering column upper shaft. In certain trucks, the part doesn’t meet Ford’s own strength requirements. That means it can actually separate while driving, causing you to lose the ability to steer.

Safety Risk: Loss of steering control makes a crash much more likely.
No Warning Signs: There are no dashboard messages or alerts — the failure can happen without warning.
Affected Trucks: Ford believes the defect affects trucks built at the Kentucky Truck Plant before October 1, 2020.

How Ford is Handling the Recall

Ford has issued recall number 25S94 (NHTSA 25V-626). Here’s what they’re telling owners:

Notices in the Mail: Letters started going out in October 2025 to warn owners.
Dealer Inspections: Dealers will check your steering column.
- If it fails inspection → the part will be replaced.
- If it passes → it will be modified to improve durability.
Final Fix: A long-term repair solution is expected by December 2025.

Ford Super Duty: Too Many Recalls?

Unfortunately, this isn’t the first time Super Duty owners have faced recalls. The 2020–2021 lineup has been hit with recalls for:

Driveshaft separations
Brake system problems
Electrical issues

When you add the steering shaft defect to the list, it paints a troubling picture. For owners, these repeated issues can mean frustration, downtime, and serious safety worries.

Could Your Truck Be a Lemon?

Here’s the bottom line: If you’ve had to bring your F-250, F-350, or F-450 back to the dealer again and again for serious repairs, you may not just have a bad truck — you may have a lemon.

Lemon Law Basics: If a defect affects your truck’s safety, value, or reliability, and the manufacturer can’t fix it after a reasonable number of tries, you may qualify for a buyback, replacement, or cash settlement.
Why Steering Defects Matter: Because steering is critical to safe driving, repeated failures or incomplete fixes could make your case even stronger.

What Should You Do Now?

Keep Records: Save every repair order, recall notice, and warranty claim. Documentation is key if you ever need to pursue a claim.
Pay Attention to Repeat Repairs: If you’ve had the same issue fixed more than once, or your truck keeps going back to the dealer, you may have lemon law rights.
Get Help if Needed: Don’t wait until you’re out of patience (or warranty). Talk to a lemon law professional if you suspect your Super Duty qualifies.

FAQ: Ford Super Duty Steering Recall & Lemon Law

Q: Is it safe to drive my truck before the repair?
A: Because there are no warning signs before the steering defect happens, it’s risky to keep driving an affected truck. Schedule a dealer inspection as soon as possible.

Q: What if the dealer already repaired my steering issue once, but the problem came back?
A: If the same issue keeps happening after repairs, that’s a red flag. Repeated failures may qualify your truck as a lemon under state or federal law.

Q: How many repairs does it take before my Ford is considered a lemon?
A: It depends on your state. In many states, two or more failed repair attempts for a serious safety issue (like steering) may be enough. In others, it may take three or four attempts.

Q: Can I get a buyback or replacement if my truck is a lemon?
A: Yes. Lemon laws can entitle you to a buyback of your vehicle or a replacement truck, if the manufacturer can’t fix the defect after a reasonable number of tries.

Q: Do I need a lawyer to file a lemon law claim?
A: While not required, most lemon law cases are easier with legal help. Many lemon law attorneys work on a no-cost-to-you basis, since the law requires the manufacturer to pay legal fees if you win.

Final Thoughts

The 2020–2021 Ford Super Duty trucks are built to tackle tough jobs, but repeated recalls and a dangerous steering defect have many owners concerned. If your F-250, F-350, or F-450 is spending more time in the shop than on the road, don’t ignore it. Your truck may qualify as a lemon, and knowing your rights could help you get the compensation or replacement you deserve.

General Motors (GM) has announced a serious safety defect that may affect certain 2023–2026 Chevrolet Corvette vehicles. The issue is linked to models equipped with a left-side radiator and fan combination, which are found in Corvette Z06 and ZR1 models.

According to GM, excess fuel spilled into the fuel-filler pocket during refueling could leak onto hot radiator surfaces and potentially ignite. This dangerous condition raises the risk of a vehicle fire, even while the car is turned off.

What Is the Chevrolet Corvette Fire Risk Defect?

In the affected vehicles, the fuel-filler pipe and recessed pocket sit directly above the left-side radiator and cooling fan. If a refueling spill occurs—especially if a gas pump fails to shut off properly—the spilled fuel may leak onto the radiator.

When the fan is running, it can draw spilled fuel through the radiator, vaporize it into the engine compartment, and expose it to ignition sources. If ignited, this can result in a sudden vehicle fire.

GM’s investigation confirmed that at least four Corvette fire incidents were connected to this defect, two of which involved malfunctioning gas station pumps that failed to shut off properly.

Timeline of GM’s Safety Investigation

June 10, 2025 – GM received a report through its “Speak Up for Safety” system after a social media post claimed three Corvettes caught fire during fueling within 30 days.
June 12, 2025 – A GM-owned Corvette test vehicle caught fire while refueling.
June 17, 2025 – GM officially opened a product investigation.
June 20, 2025 – Engineers identified distinct burn patterns on the left-side radiator of the test vehicle.
July–August 2025 – Controlled fuel-spill simulations showed that fuel leaks in vehicles with a left-side radiator could ignite under specific conditions, replicating the burn damage seen in real-world fires. Vehicles without this radiator design did not ignite.
August 14, 2025 – GM’s Safety Field Action Decision Authority (SFADA) decided to launch a safety recall.

Models Affected by the Safety Recall

While the issue involves Corvettes from model years 2023 through 2026, GM confirmed the left-side radiator/fan combination is only used in:

Chevrolet Corvette Z06 (2023–2026)
Chevrolet Corvette ZR1 (2023–2026)

All confirmed fire incidents involved Corvettes equipped with this radiator design.

Risks to Drivers and Passengers

If fuel leaks during refueling and reaches an ignition source, the risks include:

Vehicle fire while stationary
Potential injuries or fatalities (two incidents reported minor injuries)
Damage to property and fueling stations

GM’s Recommended Precautions for Corvette Owners

Until repairs are completed, Corvette owners should take the following precautions:

Always ensure the fuel nozzle is fully inserted into the filler pipe.
Do not overfill the gas tank; stop after the pump clicks off once.
Always turn off the engine before refueling.
Be cautious at gas stations with malfunctioning or leaking pumps.

The Official Fix

GM has announced that dealers will:

Install a protective shield to divert spilled fuel away from hot components.
Begin mailing owner notification letters on October 6, 2025.
Send a second letter once permanent parts and remedies are available.

The National Highway Traffic Safety Administration (NHTSA) has assigned this defect campaign number 25V-536.

Can Lemon Law Help Corvette Owners?

If your 2023–2026 Chevrolet Corvette has experienced repeated problems, you may have rights under the California Lemon Law and other state lemon laws.

The law may entitle you to:

A repurchase (buyback) of your Corvette
A replacement vehicle
Or cash compensation if your car qualifies as a lemon

Since the defect involves a serious safety risk, owners should act quickly. Consulting with an experienced Lemon Law attorney can help determine if your Corvette qualifies for relief. If repeated safety issues, downtime, or repair delays affect your Corvette, you may qualify for protection under Lemon Law.