manufacturing error – California Lemon Law blog

Ford Motor Company has announced a safety defect affecting certain 2024–2026 Ford Ranger vehicles. Some Rangers could experience a wiring issue that can, in rare cases, lead to smoke or fire inside the vehicle.

What’s the Problem?

The issue is tied to the wiring harness connected to the sun visor and headliner. In some vehicles, this wiring may have been installed incorrectly or wrapped with excessive protective tape. These conditions can cause the wiring to become pinched or damaged as it passes through metal openings near the A-pillar, which is the structural area along the windshield. If the wiring becomes damaged and contacts metal, it can create an electrical short. This short may generate heat or sparks, potentially leading to smoke, melting components, or even a fire in the A-pillar area. Any smoke or fire inside a vehicle increases the risk of injury or a crash. Even before a fire occurs, smoke or melting materials can distract the driver or reduce visibility.

While no accidents or injuries have been reported, there has been at least one case involving flames and several others showing signs of smoke or burn damage.

What Caused It?

Ford’s investigation found two main contributing factors. First, excessive tape thickness on the wiring harness can cause it to bind or become damaged when passing through tight metal openings. Second, insufficient controls during installation may allow the wiring to be routed incorrectly, increasing the chance of contact with metal edges.

Over time, damaged wiring can become exposed. Combined with repeated resets of the Body Control Module after a fault, this can lead to ongoing electrical arcing, soot buildup, and eventually a fire risk.

Warning Signs to Watch For

Drivers may notice early warning signs before a more serious issue develops. These include flickering or non-functioning sun visor mirror lights or overhead console lights. These symptoms may indicate a problem with the circuit and should not be ignored.

Timeline of the Investigation

Ford’s investigation began on October 31, 2025, after a fire was reported in the A-pillar area of a 2024 Ranger. Early findings pointed to an electrical short in the sun visor power circuit, confirmed by a diagnostic trouble code. The issue was escalated to Ford’s Critical Concern Review Group on November 6, 2025.

Over the following months, engineers reviewed supplier specifications and installation procedures, identifying risks related to wiring thickness and routing. Testing in early 2026 confirmed that materials were not inherently flammable, but electrical system behavior could still lead to fire over time.

By March 20, 2026, Ford had identified multiple reports tied to four vehicles, including one case involving flames. On April 7, 2026, the Field Review Committee approved a field service action.

What’s the Fix?

Ford dealers will inspect the wiring harness for damage, replace it if necessary, and update the Body Control Module software. he recall will be carried out in phases. Owners of 2025 model year vehicles will be notified the week of May 31, 2026. Owners of 2026 models will be notified the week of June 29, 2026, followed by 2024 model owners the week of July 27, 2026.

Interim letters informing owners of the safety risk are expected to be mailed starting April 27, 2026. Additional letters will be sent once the full repair remedy is available, anticipated in August 2026.

Ford has assigned recall number 26S29, and it is listed under NHTSA campaign number 26V-238.

Mercedes-Benz has determined that there is a safety defect affecting over 24,000 Mercedes-Benz vehicles. The problem is related to an issue with the drive shaft universal joint. This part plays a critical role in how power is delivered to your wheels, and when it fails, the consequences can be serious.

What Vehicles Are Affected?

This recall (NHTSA Campaign Number: 26V-216) applies to select 2018–2020 Mercedes-Benz 4MATIC models, including:

E-Class (Sedan, Wagon, Coupe, Cabriolet)
S-Class (Sedan, Coupe, Convertible)
Maybach S 560 4MATIC

Specifically, models like the E 400, E 450, S 450, S 560, and Maybach S 560 are included.

What’s the Problem?

Mercedes-Benz has identified that increased wear may occur in the universal joint (U-joint) on the drive shaft. This is due to insufficient production parameters from a supplier, which can lead to premature degradation over time.

The real issue begins when:

The U-joint loses lubrication.
Wear accelerates.
The joint can fracture under load.

At that point, the connection between the transfer case and front axle transmission may fail entirely.

Why This Matters (Safety Risk)

If the universal joint fails, the vehicle can experience a sudden loss of propulsion—meaning it may stop delivering power to the wheels without warning.

That creates a dangerous situation:

Loss of acceleration in traffic.
Reduced ability to maneuver.
Increased risk of a crash.

Mercedes-Benz notes that while some warning signs may appear, they are not guaranteed to be noticed before failure.

Warning Signs to Watch For

In some cases, drivers may notice early symptoms such as:

Unusual noises from underneath the vehicle.
Vibrations while driving, especially under acceleration.

However, these signs can be subtle—or completely absent—making this issue particularly concerning.

What Caused the Issue?

The root cause traces back to a supplier manufacturing process that did not meet optimal parameters. Over time, this can result in:

Improper wear patterns.
Reduced durability of the U-joint.
Increased likelihood of failure under normal driving conditions.

What Mercedes-Benz Will Do

Mercedes-Benz dealers will:

Inspect the drive shaft.
Replace it if necessary.
Perform all repairs free of charge.

This recall highlights how even a single component failure within the drivetrain can have major safety implications. If your vehicle is affected, it is worth addressing promptly—even if you have not noticed any symptoms. A quiet drivetrain today does not guarantee it will stay that way tomorrow. Owner notification letters are scheduled to be mailed beginning June 2, 2026.

If you own a newer Chevrolet Corvette, there’s an important safety defect you should be aware of. General Motors has issued a recall affecting nearly 33,000 vehicles over a software issue that could prevent drivers from being alerted when a rear turn signal fails.

What’s the Problem?

The issue centers around a software defect in the exterior lighting control module. In affected vehicles, a failed rear turn signal may not trigger a warning to the driver. This creates a compliance issue with Federal Motor Vehicle Safety Standard (FMVSS) No. 108, which requires that drivers be notified when exterior lighting, like turn signals, fail. Turn signals are critical for communication on the road. If a rear signal fails and the driver isn’t alerted, it increases the risk of miscommunication with other drivers, lane-change or turning accidents, and reduced overall safety.

Vehicles Affected

This recall applies to select 2025 and 2026 Corvette models, including:

2026 Corvette ZR1X Coupe and Convertible
2026 Corvette E-Ray Coupe and Convertible
2026 Corvette Coupe and Convertible
2025 Corvette E-Ray Coupe and Convertible
2025 Corvette Coupe and Convertible

What Caused the Issue?

The root cause traces back to a software change made in October 2024 by a supplier working on the rear lamp assembly. The update was intended to help technicians during a tire pressure monitoring system (TPMS) learning process, but it had an unintended side effect. It interfered with the system responsible for detecting rear turn signal failures, meaning that under certain conditions the system does not recognize when a signal is out. The issue was discovered during internal testing for the upcoming 2027 Corvette model.

Timeline of Events

The issue traces back to a software change introduced by a supplier in October 2024. It was not identified until December 9, 2025, when a GM employee reported the problem through the company’s internal safety system following validation testing. GM officially opened an investigation on January 27, 2026, which ultimately led to the recall being approved on March 26, 2026. Owner notification letters are scheduled to be mailed beginning May 18, 2026. GM has stated that there have been no known accidents or injuries related to this issue.

How the Problem Will Be Fixed

The solution is a software update to the exterior lighting control module. Owners have two options. Vehicles equipped with over-the-air capability can receive the update remotely if the owner has accepted GM’s update terms. Alternatively, all owners can have the update performed at an authorized GM dealership at no cost.

Recall Details

NHTSA Campaign Number: 26V-213
GM Recall Number: N252541250
Component: Exterior Lighting
Affected Units: 32,988

What Corvette Owners Should Do

If you own a 2025 or 2026 Corvette, watch for your official recall notice starting May 18, 2026. Check whether your vehicle supports over-the-air updates, and if not, schedule a visit with your dealer. Even if you have not noticed any issue, it is important to have the update completed.

Final Thoughts

This recall highlights how modern vehicles rely heavily on software systems. Even a small change can have unintended consequences for safety features.

Volkswagen has decided that a safety defect may exist in certain 2025–2026 Volkswagen Jetta vehicles. A potentially serious electrical defect may increase the risk of a vehicle fire.

The recall, identified as NHTSA Campaign Number 26V-138 and Volkswagen recall 97TC, impacts approximately 48,165 vehicles across the United States and Canada.

What Is the Problem?

According to the recall notice, the issue stems from a transmission ground wire that may not have been properly connected during vehicle assembly.

This seemingly small oversight can create a much bigger problem.

If the ground wire is not connected:

The electrical system may develop an open circuit.
This can lead to unexpected current flow.
Excessive current may cause overheating of components.

Ultimately, this increases the risk of an engine compartment fire.

Why This Defect Is Dangerous

Electrical grounding is critical for safely managing current flow in a vehicle. Without a proper ground:

Electrical energy has no safe path to dissipate.
Components may overload or melt.
Heat buildup can occur in wiring or connectors.

Volkswagen has confirmed that in some cases:

Wiring and connectors have melted.
Engine compartment fires have occurred.

While no injuries or fatalities have been reported, the risk is real and should not be ignored.

Real-World Incidents Reported

Volkswagen has identified:

6 confirmed cases (USA and Canada)
- 3 involved melted wires/connectors
- 3 involved engine compartment fires
1 additional unconfirmed report

All incidents were limited to vehicle damage, but the potential for more serious consequences exists.

What Causes the Issue?

The root cause has been identified as human error during the assembly process.

Specifically:

The transmission ground wire was not connected properly
This resulted in an open electrical circuit
The system may still partially ground through other components (such as the Oil Pressure Unit), creating unsafe current conditions.

Warning Signs? None.

One of the most concerning aspects of this recall is that: There are NO warning indicators for drivers

That means:

No dashboard lights
No error messages
No early symptoms

The issue can exist without any visible sign, making it especially important to address proactively.

Timeline of the Recall

December 2025: First field cases reported and investigated.
February 19, 2026: Volkswagen confirms fire risk due to open circuit.
February 26, 2026: Escalated to Product Safety Committee.
March 4, 2026: Official recall decision made.

What Should Owners Do?

Volkswagen dealers will:

Inspect the transmission ground wire.
Repair or properly connect it if necessary.

Owner notification letters are expected to be mailed on May 8, 2026.

If you own a 2025 or 2026 Volkswagen Jetta, you should:

Watch for your recall notice.
Contact your local Volkswagen dealer.
Schedule a free inspection and repair.

Your Rights Under Lemon Law

If your vehicle has experienced:

Electrical issues
Burning smells
Smoke or fire damage
Multiple repair attempts

You may be entitled to compensation under your state’s Lemon Law.

Final Thoughts

This recall highlights how even a small assembly error can lead to serious safety risks. With no warning signs and confirmed fire incidents, affected owners should take immediate action.

If you drive a 2025–2026 Volkswagen Jetta, do not delay—schedule your inspection as soon as possible after receiving your notification.

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