manufacturing error – California Lemon Law blog

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.

If you’ve recently purchased a Tesla Cybertruck, you’re probably enjoying the attention it brings — but there’s something new owners need to be aware of. Tesla has issued a recall affecting about 46,000 2024-2025 Cybertrucks due to a faulty exterior trim panel that could detach while driving.

This isn’t just about aesthetics — it’s a real safety issue and could raise serious Lemon Law concerns here in California.

What’s the defect?

The problem lies in a trim piece along the windshield, called the cantrail panel. Tesla says it may have been attached using the wrong adhesive. As a result, the panel could come loose and separate from the vehicle while you’re on the road.

If you’ve already noticed unusual wind noise or seen Cybertruck owners post about missing trim — this might explain it.

What’s Tesla doing about it?

Tesla has already started performing repairs, which involve replacing the entire cantrail assembly. Owners aren’t expected to pay out of pocket for the fix, but the availability of parts — and service appointments — can vary widely.

Why Lemon Law applies here in California

Tesla has had a mixed track record when it comes to customer service and timely repairs. If this defect has left your vehicle in the shop for a long period, or if your Cybertruck has other unresolved issues, you could be protected under California’s Lemon Law.

You may qualify if:

You’ve experienced repeated or serious safety-related issues
Tesla can’t fix the defect within a reasonable number of attempts
Your vehicle has been out of service for 30+ total days under warranty

It doesn’t matter if your truck is new or leased — what matters is whether it’s safe, reliable, and performing the way it should.

What you can do right now:

Check your paperwork to see if you’ve already reported trim or body issues
Schedule your repair as soon as possible — and keep all documentation
If you’ve already had problems with build quality or multiple repair visits, it may be time to explore your legal options

Don’t assume you have to live with poor fit and finish. California law is on your side, and in most cases, you can pursue a Lemon Law claim without paying anything out of pocket. If your Cybertruck has already spent more time in the shop than on the road, let’s talk. You may be entitled to a replacement or refund — and we can walk you through what that looks like. Call Now for a FREE Case Review at 888-395-3666 or fill in the contact form at the top of the page. Our experienced team is here to help you navigate the process and ensure you receive the compensation you deserve. Don’t wait – take action today to protect your rights as a California consumer!

A major safety concern has been uncovered by Ford, affecting several of its 2024 and 2025 models, including the popular Bronco, Ranger, and electric F-150 Lightning. At the heart of the issue is a potentially faulty front upper control arm ball joint fastener, which may have been improperly secured or even missing altogether. This oversight could lead to a catastrophic failure, where the front upper control arm becomes detached from the knuckle assembly, compromising the vehicle’s stability and control.

The first reported incident involving the F-150 Lightning BEV occurred on March 6, 2025, when a customer’s vehicle suffered a right front wheel failure after just 634 miles on the road. Upon investigation, it was discovered that the upper control arm nut was missing, which had caused the control arm to separate from the knuckle assembly.

Further analysis revealed that the root cause of the problem lies in the manufacturing process, where inconsistencies in the alignment between the fastening tool and the fastener may have prevented the nut from being properly secured. As a result, the ball joint nut may not have been tightened to the correct torque specification, creating a risk of separation.

Drivers who experience this issue may initially notice unusual noises, such as clunks or rattles, when driving over bumps or uneven terrain. However, in more severe cases, the loss of directional control can occur without warning, significantly increasing the risk of an accident.

While the exact timeline for the discovery of this issue on the Bronco and Ranger models is not publicly available, it is imperative that owners of affected vehicles take immediate action to ensure their safety on the road. Ford dealers will inspect and repair the ball joint fastener as necessary, and owner notification letters were sent out on May 23, 2025.

The recall numbers for this issue are 25S45 (Ford’s internal number) and 25V-310 (NHTSA campaign number) for the Bronco and Ranger, and 25V-341 for the F-150 Lightning BEV. If you receive a notification regarding your vehicle, it is essential to contact your local Ford dealer promptly to schedule an appointment and have the necessary repairs carried out.

In conclusion, the safety of drivers and passengers is paramount, and it is crucial that owners of affected Ford vehicles take swift action to address this critical issue. By doing so, they can ensure a safe and reliable driving experience, and minimize the risk of accidents caused by this potentially hazardous fault.