Tag Archives: manufacturing error

Hyundai Palisade Electric Oil Pump Issue

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Hyundai Motor America has announced a safety recall affecting a limited number of 2025 Hyundai Palisade vehicles due to a potential problem with the controller for the electric oil pump (EOP). The issue, which may cause an electrical short and increase the risk of a vehicle fire, is attributed to an insufficient seal on the EOP controller housing.

According to Hyundai, the problem was first identified in March 2025, when the company was notified of a potential issue involving the electric oil pump installed on a model year 2025 Palisade produced in Ulsan. An investigation revealed that a damaged spring in the tooling used during manufacturing may have compromised the hermetic sealing of the EOP controller housing, allowing moisture to accumulate on the printed circuit board and increasing the risk of electrical shorting.

The National Highway Traffic Safety Administration (NHTSA) was informed of the issue, and after reviewing the findings, Hyundai decided to conduct a safety recall of all affected model year 2025 Hyundai Palisade vehicles in the U.S. The recall aims to replace the EOP controller and associated wiring harness, if necessary, to prevent any potential fires.

Symptoms and Precautions

Drivers of affected vehicles may notice a burning or melting odor or an illumination of the Malfunction Indicator Light. While owners can continue driving their vehicles, Hyundai recommends parking them outside and away from structures until the recall remedy is completed as a precautionary measure.

Recall Remedy and Notification

Hyundai will notify all owners of the subject vehicles by first-class mail, instructing them to bring their vehicles to a Hyundai dealer for replacement of the EOP controller. The recall remedy is expected to begin on July 4, 2025. Owners can contact Hyundai’s customer service or visit the NHTSA website for more information on the recall.

The recall number assigned by Hyundai is 278, and the NHTSA campaign number is 25V-291. Affected owners are encouraged to follow the instructions provided in the notification letter to ensure their vehicle is repaired promptly and safely.

In conclusion, while the electric oil pump issue affects only a small number of 2025 Hyundai Palisade vehicles, it is essential for owners to be aware of the potential problem and take necessary precautions to prevent any accidents. By following the recommended steps and cooperating with Hyundai’s recall efforts, owners can ensure their vehicle is safe to drive and minimize any risks associated with this issue.

Engine Failure Problem Affects Certain GM Vehicles

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General Motors LLC (GM) has determined that certain 2021-2024 GM vehicles equipped with a 6.2L V8 gas engines could experience engine failure problems. The issue is caused by manufacturing defects in the connecting rod and/or crankshaft engine components, which can lead to engine damage and failure.

Affected Vehicles

The following GM vehicles are affected by this recall:

  • Cadillac Escalade (2021-2024)
  • Cadillac Escalade ESV (2021-2024)
  • Chevrolet Silverado 1500 (2021-2024)
  • Chevrolet Suburban (2021-2024)
  • Chevrolet Tahoe (2021-2024)
  • GMC Sierra 1500 (2021-2024)
  • GMC Yukon (2021-2024)
  • GMC Yukon XL (2021-2024)

The Problem

GM’s investigation found that the connecting rod and/or crankshaft engine components in these vehicles may have manufacturing defects, including:

  1. Rod-bearing damage from sediment on connecting rods and crankshaft-oil galleries
  2. Out of specification crankshaft dimensions and surface finish

These issues can cause or contribute to bearing damage, leading to loss of propulsion and engine failure.

Warning Signs

Drivers may be alerted to the condition prior to failure by:

  • Unusual engine noises (knocking, banging, etc.)
  • Illumination of the check engine light
  • Engine-performance issues, including:
    • Hesitation
    • High RPMs
    • Abnormal shifting
    • Reduced propulsion
    • No-start condition

Consequences of Engine Failure

If the engine fails during vehicle operation, the vehicle will lose propulsion, increasing the risk of a crash. In fact, GM has identified 12 potentially related alleged crashes and 12 potentially related alleged injuries in the U.S.

Recall Repair

Dealers will inspect the engine and, as necessary, repair or replace it. For vehicles that pass inspection, dealers will:

  • Add higher viscosity oil
  • Install a new oil fill cap
  • Replace the oil filter
  • Update the owner’s manual

Recall Details

  • GM’s recall number: N252494000
  • NHTSA campaign number: 25V-274
  • Owner notification letters are expected to be mailed on June 9, 2025

If you receive a notice saying your vehicle is affected, it is essential to take immediate action and contact your local dealer to schedule a repair. Remember to always monitor your vehicle’s performance and watch for any warning signs of engine failure.

Braking Safety Concern In 2025 Nissan And Infiniti Vehicles

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Nissan has issued a recall for certain 2025 model year Murano, Pathfinder, and Infiniti QX60 vehicles due to a potential braking safety issue. The problem affects the front brake caliper assemblies, which may have reduced strength and could break, leading to reduced braking performance.

The issue was discovered in January 2025 during a routine production brake test on a 2025 Nissan Pathfinder. A technician reported a failure of the front right-hand brake caliper assembly, prompting Nissan to quarantine the defective part and launch an investigation. Further analysis revealed that the suspect brake caliper had been produced with a common supplier production lot code (51A), which was found to have an inadvertent modification to an internal parameter setting. This modification reduced the material’s strength, making it more prone to failure.

The supplier’s investigation confirmed that a total of 3,115 caliper castings were produced in the affected lot and shipped to Nissan for assembly into vehicles. Through traceability records, Nissan identified 2,341 vehicles that may have received a potentially affected brake caliper. Of these vehicles, 711 were held for inspection, while 200 had been exported and 1,430 had previously been shipped to the US.

According to Nissan, if one or both of the front brake calipers fail, it can result in reduced braking performance and may not comply with certain performance requirements of Federal Motor Vehicle Safety Standard (FMVSS) 135. This could increase the risk of a crash, particularly if drivers are unable to stop their vehicles in time. Affected customers may notice uneven braking performance, and the “Low Brake Fluid” warning light may illuminate in certain cases.

To address the issue, Nissan will be recalling affected vehicles and asking owners to return to their dealerships for an inspection and replacement of the front brake caliper assemblies as necessary. Owner notification letters are expected to be mailed on May 9, 2025. The recall is identified as Nissan’s numbers PD137 and PD138, and the NHTSA campaign number is 25V-173. This issue highlights the importance of rigorous testing and quality control measures in ensuring the safety of vehicles on the road.

Ford and Lincoln Transmission Valve Failure

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A critical issue affecting the transmission valve body of certain Ford Bronco, Explorer, F-150, Mustang, Ranger, and Lincoln Aviator vehicles can cause reverse gear failure or unexpected forward movement while in reverse or neutral gear. This problem could be a significant safety risk to drivers and passengers.

According to Ford, the issue is attributed to an incorrectly machined transmission valve body, specifically the Outer Valve Body (OVB) of the transmission main control. The machining tool used during production did not maintain proper specifications, resulting in out-of-specification dimensions that can prevent the vehicle from entering reverse gear when commanded by the gear shift module.

Symptoms of the problem include no reverse motion when the gear selector is in reverse, and in some cases, the vehicle may move forward with the gear selector in either reverse or neutral position. The Malfunction Indicator Light (MIL) and Wrench light will illuminate on the dashboard when this malfunction occurs.

The recall affects vehicles, including:

  • 2024-2025 Ford Bronco
  • 2025 Ford Explorer
  • 2024-2025 Ford F-150
  • 2025 Ford Mustang
  • 2024 Ford Ranger
  • 2025 Lincoln Aviator

Ford’s investigation into the matter began in February 2025, after a transmission failure was reported on a 2025 Mustang at the Flat Rock Assembly Plant. The company subsequently issued a Stop Ship order for affected models and launched an analysis of the suspect transmissions.

Using advanced data analytics, including Machine Integrated Learning and Optimization (MILO) modeling, Ford identified individual Outer Valve Body units that were likely to experience this condition. The company then conducted evaluations of vehicles equipped with suspect parts and confirmed the symptoms reported by customers.

As of February 21, 2025, Ford had received five warranty reports related to this issue. On March 7, 2025, the company’s Field Review Committee approved a field action, which includes replacing the transmission main control valve body.

Ford has notified owners of affected vehicles and has begun repairing the transmissions. The recall is identified as Ford’s number 25S19 and NHTSA Campaign Number 25V-164.

This recall highlights the importance of rigorous quality control measures in the automotive manufacturing process. The issue serves as a reminder that even minor defects can have significant consequences on vehicle safety and performance.

2025 Chrysler Pacifica PHEVs – Insufficient Bolt Torque on Front Brake Caliper Bracket

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A potential safety issue has been identified in some 2025 Chrysler Pacifica Plug-In Hybrid Electric Vehicles (PHEVs) that may have been produced with insufficient bolt torque on the front brake caliper bracket. The problem, which affects vehicles produced on December 19, 2024, can lead to a range of serious consequences, including reduced steering control, brake fluid leakage, and diminished front braking performance.

According to FCA US LLC (FCA US), the issue was first identified on February 20, 2025, when the Technical Safety and Regulatory Compliance (TSRC) organization opened an investigation into the matter. The company worked with its engineering team and supplier to understand the potential consequences of the problem and determine if any vehicles with suspect front brake caliper brackets had left the factory.

As of March 13, 2025, FCA US is aware of one warranty claim related to this issue, which was received on January 8, 2025. However, there have been no field reports of accidents or injuries resulting from the problem.

The suspect vehicles were produced with front brake caliper bracket bolts that were not properly torqued, which can cause the bracket to separate from the steering knuckle. This can lead to a range of serious safety issues, including reduced steering control and diminished braking performance. In certain crashes, this can increase the risk of injury to occupants of the vehicle.

To address the issue, FCA US will be conducting a recall of affected vehicles. Dealers will inspect and replace the front brake caliper brackets and bolts as necessary, free of charge. Owner notification letters are expected to be mailed on April 24, 2025. The recall is identified as FCA’s number 27C and the NHTSA campaign number is 25V-191.

Vehicle owners who receive a notification letter should contact their local Chrysler dealer to schedule an appointment for the inspection and repair. It is essential to have the issue addressed promptly to ensure the safety of the vehicle’s occupants and other road users. The recall highlights the importance of regular maintenance and inspections to identify potential safety issues before they become major problems. FCA US’s prompt action in addressing the issue demonstrates its commitment to ensuring the safety and quality of its vehicles.

If you own a 2025 Chrysler Pacifica PHEV, it is essential to be aware of this potential issue and take immediate action if you receive a notification letter. By doing so, you can help ensure your safety and the safety of others on the road.

Certain 2022-2024 Ford F-150 Lightning BEVs May Have A Battery Defect

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A potential safety issue has been identified in a small number of 2022-2024 Ford F-150 Lightning Battery Electric Vehicles (BEVs). The problem affects the high voltage battery cells, which may have a manufacturing defect that can cause an internal short circuit. This defect is due to misaligned electrodes in the battery cells, which can occur over repeated charge and discharge cycles.

The issue was first brought to Ford’s attention in October 2024, when a fire was reported in a 2022 model year F-150 BEV. Further investigation revealed two additional fires in 2022 and 2023 model year vehicles, prompting Ford to launch a broader inquiry into the matter. Although no physical samples were initially available for analysis, Ford’s Field Review Committee authorized a program to collect and evaluate additional samples from the field.

The subsequent tear-down analysis of the returned battery arrays revealed evidence of misaligned electrodes in the high voltage battery cells. The supplier also found that eight stacker machines between two production lines had produced cells with cathode shift, which did not meet the design requirements. This manufacturing concern resulted in overlap that fell short of the required standards. Notably, some of the cells from vehicles that experienced fires were manufactured during this time frame.

On February 18, 2025, Ford learned of a fifth report of a vehicle fire and decided to approve a safety recall. The recall affects certain 2022-2024 Ford F-150 Lightning BEVs, and owners are advised to take precautions until the repair is completed. Specifically, owners should only charge their vehicles to a maximum of 80% battery capacity to minimize the risk of an internal short circuit.

To address this issue, dealers will inspect and replace the high voltage battery array as necessary. Owner notification letters are expected to be mailed on March 17, 2025. Ford’s recall number for this issue is 25S18, and the National Highway Traffic Safety Administration (NHTSA) has assigned a campaign number of 25V-131.

Fuel Leak: 2021-2023 Acura TLX

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The fuel filler neck and fuel tank junction in a small number of 2021-2023 Acura TLX vehicles may have an incomplete weld that could separate. An incomplete weld can cause separation, leading to a fuel leak while driving or parked. This defect poses a significant risk to vehicle occupants and bystanders, as fuel leaks can ignite and cause fires.

Background of the Issue

Honda first became aware of the issue in November 2023, when they received a warranty claim related to a fuel leak in an affected TLX vehicle. The company promptly launched an investigation, which revealed that a defect related to motor vehicle safety existed. As a result, Honda decided to conduct a safety recall to address the problem. To date, the company has received two warranty claims related to this issue, but fortunately, there have been no reports of injuries, fires, or deaths.

Cause of the Defect

The root cause of the defect lies in the production process of the fuel tank assembly. During manufacturing, the fuel filler neck was improperly loaded into the gripper fixture, resulting in a tilted position and uneven contact between the fuel tank and fuel filler neck during the weld procedure. Additionally, the fuel filler neck melt depth was incorrectly set for the weld equipment, leading to a shallow melt weld depth between the components. This combination of factors created an incomplete weld that can separate over time, allowing fuel to escape.

Symptoms of a Fuel Leak

If you own a 2021-2023 Acura TLX, it’s essential to be aware of the symptoms of a fuel leak. One of the most common signs is a strong gasoline odor wafting through the vehicle while driving. This can be caused by a variety of factors, including worn-out seals, cracked fuel lines, or faulty fuel system components. As cars age, the rubber components in their fuel systems can deteriorate, allowing gas to escape. Common culprits behind these leaks include the fuel pump, filter, and injectors, as well as parts of the emissions system.

Risks Associated with Fuel Leaks

A gasoline smell is not just a minor annoyance; it can also be a sign that your engine is burning more fuel than necessary, which can hit you in the pocketbook. More alarmingly, prolonged exposure to gas fumes can have serious health consequences, including respiratory damage. Given the potential risks to both your wallet and well-being, it’s crucial to address any issues causing a gasoline smell in your TLX promptly.

Recall Details

To rectify the issue, dealers will replace the fuel tank assembly. Owner notification letters are expected to be mailed on February 10, 2025. Acura’s number for this recall is JKX, and the NHTSA campaign number is 24V-950. If you receive a notice for this problem, it’s essential to schedule a service appointment as soon as possible to have the fuel tank assembly replaced.

Engine Cup Oil Leak In 2024-2025 Ford & Lincoln Vehicles

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Low Oil Pressure WarningFord 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.