manufacturing error – California Lemon Law blog

If you are driving a recent-model Jeep Grand Cherokee, you will want to pay close attention to your mail this fall. Fiat Chrysler Automobiles (FCA US, LLC) has announced a safety defect impacting 328,381 vehicles. A potential design defect could cause a rear coil spring to detach while the vehicle is in motion.

This problem isn’t just a routine fix—it supersedes two previous recalls on the same issue. Even if you already had your Grand Cherokee serviced under a previous campaign, you will need to take your vehicle back to the dealer for an updated fix.

What Is the Issue?

The recall centers on the vehicle’s rear suspension system. According to safety documents, the rear coil springs may have been incorrectly installed during manufacturing. As a result, the springs can detach from the vehicle while driving.

Why Is This Dangerous?

A coil spring detaching while you are driving poses severe safety hazards:

Loss of Vehicle Control: Sudden failure or loss of a rear suspension component impairs handling and stability, increasing the risk of a crash.
Road Hazard: A detached heavy steel spring becoming a high-speed projectile on the highway poses an immediate danger to drivers following behind you.

Affected Vehicles

The recall affects specific model years of the Grand Cherokee lineup equipped with rear coil springs:

2021–2023 Jeep Grand Cherokee L
2022–2023 Jeep Grand Cherokee
Jeep Grand Cherokee 4xe (Plug-in Hybrid)

Note: Models equipped with the air suspension system use air bags rather than traditional coil springs and are not part of this specific structural spring defect.

Key Recall Identifiers

NHTSA Campaign Number: 26V-562 (replaces previous recall numbers 26V-051 and 23V-413)
FCA Recall Number: 89D
Total Affected Units: 328,381 vehicles

The Repair

To resolve the defect, authorized Jeep dealership service departments will replace the rear coil spring lower isolators to ensure the springs remain properly seated and securely positioned.

Important Note for Previously Repaired Vehicles

Because this recall replaces two earlier campaigns (23V-413 and 26V-051), prior repairs are no longer considered sufficient. If you took your Jeep in for a spring fix under either of those earlier notices, you will still need to have this new final remedy performed.

Timeline & Next Steps

Interim Notifications: FCA expects to begin mailing interim notification letters to registered owners starting September 29, 2026. These letters will outline the safety risk.
Remedy Notifications: A second letter will be mailed as soon as the final remedy parts are fully available at local dealerships to schedule your service appointment.

If you hear unusual clunking noises coming from the rear suspension or notice an uneven ride height in the rear of your Jeep, contact an authorized service center immediately to have the vehicle inspected. Be sure to check all invoices for accuracy upon completion and keep detailed records of all repairs made to your vehicle. Maintaining accurate documentation creates an official paper trail that proves repeated repair attempts, establishes vehicle downtime, and protects your rights under warranty and lemon laws should the issue persist.

Certain 2026 Honda Pilot and 2026 Honda Passport SUVs could have a manufacturing issue that could affect the rear suspension. The defect involves improperly tightened rear subframe bolts, which could compromise vehicle stability and increase the risk of a crash. The recall affects approximately 3,933 vehicles in the United States.

What Is the Problem?

According to Honda, the rear subframe bolts may not have been tightened to the correct specification during vehicle assembly. The rear subframe is a critical structural component that supports parts of the suspension system and helps maintain proper handling and stability. If the bolts loosen over time due to normal driving loads or an impact, the subframe can begin to move out of position. In severe cases, the rear subframe could partially or completely detach from the vehicle, significantly increasing the risk of a collision.

What Caused the Issue?

Honda traced the problem to changes made on the production line.

A new rear subframe pallet was introduced during manufacturing, but the torque settings used to tighten the subframe bolts were not properly evaluated before production began. The investigation also found several additional factors that reduced the effectiveness of the tightening process, including:

Incorrect torque specifications applied during assembly
Inadequate grease application on the tightening equipment
Improper gearbox adjustments
An incorrectly adjusted subframe pallet clamp

Together, these issues resulted in some vehicles leaving the factory with rear subframe bolts that were not tightened sufficiently.

Warning Signs Owners May Notice

Owners of affected vehicles may experience:

Abnormal noises coming from the rear of the vehicle.
Reduced vehicle stability while driving.

If either symptom develops, owners should have the vehicle inspected as soon as possible.

How Honda Discovered the Problem

Unlike many recalls that begin with customer complaints, this issue was identified during Honda’s own quality control process.

The timeline of the investigation includes:

May 15, 2026: Honda identified insufficiently torqued rear subframe bolts during a production line sampling inspection.
May 20, 2026: All vehicles remaining in inventory were inspected.
June 8, 2026: Honda completed an investigation to identify the affected vehicle population.
June 25, 2026: Honda determined a safety defect existed and initiated a voluntary recall.

As of June 25, 2026, Honda reported no warranty claims, crashes, injuries, or fatalities related to this issue in the United States.

Recall Remedy

Honda dealers will:

Inspect the rear subframe bolts
Replace the bolts if necessary

Owner notification letters are expected to be mailed beginning August 24, 2026.

Recall Information

Manufacturer: Honda (American Honda Motor Co.)
Affected Vehicles: Certain 2026 Honda Pilot and 2026 Honda Passport models
Recall Number: OOY
NHTSA Campaign Number: 26V-424

What Owners Should Do

If you own a 2026 Honda Pilot or Passport, watch for a recall notification from Honda. Although Honda has not received any reports of crashes or injuries related to this issue, prompt inspection and repair will help ensure the rear suspension remains securely attached and your vehicle continues to operate safely.

Owners of certain 2025-2026 Chevrolet Express and GMC Savana vans should be aware of a newly announced safety defect involving a potentially dangerous steering problem that could result in a loss of vehicle control.

What Is the Problem?

General Motors has recalled approximately 26,541 vehicles after discovering that some steering gear assemblies may contain a critical fastening nut that was not properly tightened during manufacturing. According to the manufacturer, a malfunctioning parts sensor at a supplier’s facility allowed certain steering gear assemblies to pass inspection even though the retaining nut had only been hand-tightened instead of being properly torqued to specification. If that nut loosens or separates from the steering gear while the vehicle is being driven, the driver could experience a sudden loss of steering control, significantly increasing the risk of a serious collision.

Warning Signs Drivers May Notice

Before a complete failure occurs, some drivers may notice changes in how the vehicle steers, including:

Reduced steering precision
A steering wheel that is noticeably off-center while driving straight
Steering that feels abnormal or inconsistent

Drivers experiencing any of these symptoms should have their vehicle inspected immediately and avoid delaying repairs.

How the Defect Was Discovered

The investigation began after a dealership reported finding a loose steering gear nut on a 2025 Chevrolet Express. On May 28, 2026, a GM quality manager submitted the concern through the company’s internal Speak Up For Safety (SUFS) reporting program.

GM formally opened an investigation on June 2, 2026. The supplier later determined that a malfunctioning inspection sensor had allowed improperly assembled steering gear units to leave the production line. By reviewing manufacturing torque records, the supplier was able to identify the potentially affected steering gear assemblies.

In addition to the original report, GM identified nine field incidents that may have been related to the defect. Fortunately, the company reported that none of those incidents resulted in injuries or crashes.

On June 18, 2026, GM’s Safety Field Action Decision Authority approved a formal safety recall.

What Is the Remedy?

GM dealerships will inspect the steering gear assembly and replace it if necessary. Owner notification letters are expected to be mailed beginning August 10, 2026.

The recall information is:

GM Recall Number: N262563570
NHTSA Campaign Number: 26V-399

What Should Owners Do?

If you own a 2025 or 2026 Chevrolet Express or GMC Savana, watch for your recall notice to see whether your vehicle is included. Even if your vehicle appears to be operating normally, steering system defects can become dangerous with little warning. Prompt inspection and repair are the best way to reduce the risk of a steering-related accident.

If you have already experienced steering problems, or if you were involved in a collision that may have been caused by this defect, it is important to preserve any repair records and seek legal advice regarding your rights. A manufacturer’s safety recall does not automatically compensate drivers for injuries or property damage that may have occurred before the recall was issued.

Owners of certain Jeep Wrangler and Jeep Gladiator vehicles should be aware of a significant safety defect affecting more than one million vehicles across North America. Chrysler (FCA US LLC) has announced Recall 21D (NHTSA Campaign Number 26V-363) involving certain 2021-2025 Jeep Wrangler and Jeep Gladiator models due to a defect in the electric hydraulic power steering pump (EHPSP) wiring system that could potentially lead to a vehicle fire.

What Is the Problem?

According to FCA US, under certain conditions, high-resistance electrical activity can occur at the connection point of the Electric Hydraulic Power Steering Pump (EHPSP). This increased electrical resistance can generate excessive heat, causing nearby combustible materials to overheat and potentially ignite. What makes this defect particularly concerning is that a fire could occur even when the vehicle is parked and the ignition is turned off.

The issue originates from the electrical connection between the EHPSP and its wiring harness. Investigators discovered that some EHPSP components were manufactured outside specified tolerances, which could result in poor electrical contact. Over time, this can create excessive resistance, heat buildup, melting of the connector, and in rare cases, a vehicle fire.

Warning Signs Drivers May Notice

Before a failure occurs, some owners may experience symptoms related to the power steering system, including:

Loss of power steering assist
A “Service Power Steering” warning message
Diagnostic Trouble Codes (DTCs) related to the steering system

However, FCA notes that some incidents occurred without prior warning, which is one reason the recall was issued.

How the Investigation Unfolded

The road to this recall began in May 2023 when FCA US launched an investigation into reports of engine compartment fires in Jeep Wrangler and Gladiator vehicles. After reviewing available data through April 2024, the company initially closed the investigation, determining that the occurrence rate was low and did not represent an unreasonable safety risk.

That assessment changed in August 2024 when FCA began receiving an increased number of reports involving fires originating near the EHPSP electrical connection. Shortly afterward, on September 6, 2024, the National Highway Traffic Safety Administration (NHTSA) opened a formal investigation, designated PE24-024, into engine compartment fires involving 2021-2023 Jeep Wrangler and Gladiator vehicles.

Over the next 18 months, FCA and NHTSA worked extensively to determine the cause of the fires. Engineers analyzed field reports, inspected returned parts, conducted vehicle buybacks, performed CT scans and X-ray analysis, tested materials, and carried out extensive laboratory and vehicle testing.

In spring 2025, investigators identified manufacturing tolerance issues in the EHPSP connector assembly. These issues could cause excessive insertion forces during assembly, resulting in spread terminals, incomplete electrical connections, and elevated electrical resistance. FCA also identified a separate “terminal push-out” condition that could contribute to poor electrical contact.

Although engineers initially struggled to duplicate the exact failure mode, FCA confirmed in April 2026 that a loose EHPSP electrical connection could generate enough heat to melt the connector and potentially ignite surrounding materials.

By May 2026, FCA was aware of:

72 field reports related to the issue
63 customer assistance records
12 additional service records potentially related to the defect
1 reported injury potentially associated with the condition

No accidents related to the defect had been reported.

Based on the findings of the investigation, FCA’s Vehicle Regulations Committee formally determined on May 28, 2026, that a safety defect exists in affected vehicles.

What Should Owners Do?

FCA US is advising owners of affected vehicles to park their vehicle outside and away from structures, garages, and other vehicles until the recall repair has been completed. This recommendation reflects the possibility that an electrical overheating event could occur even when the vehicle is parked and turned off.

Dealers will inspect the EHPSP connection and replace affected components as necessary at no cost to vehicle owners.

Owner notification letters are expected to begin mailing on July 9, 2026.

Recall Information

FCA Recall Number: 21D.
NHTSA Campaign Number: 26V-363.
Vehicles Affected: Approximately 1,076,999.
Defect: EHPSP electrical connection overheating.
Risk: Potential vehicle fire, including while parked.
Remedy: Inspection and replacement of affected parts as necessary.

If you own a 2021-2025 Jeep Wrangler or Jeep Gladiator, it is important to monitor recall announcements and schedule the repair as soon as it becomes available. While the number of reported incidents remains relatively small compared to the number of vehicles on the road, the potential consequences of an under-hood fire make this a recall that should not be ignored.

Owners of several popular full-size GM SUVs may soon receive a recall notice tied to a potentially serious wheel hub safety issue. General Motors has announced a new safety recall affecting certain 2025–2026 luxury and SUV models equipped with 24-inch wheels after discovering that incorrect bolts may have been installed on the front wheel hubs.

The recall has been assigned NHTSA Campaign Number 26V-304 and impacts approximately 2,464 vehicles across the United States.

What Is the Problem?

According to GM, some affected vehicles may have been serviced using incorrect front wheel hub bolts. The issue specifically involves vehicles equipped with 24-inch wheels where dealers may have reused production-installed bolts during installation of an accessory brake package or while servicing front wheel hub bearings.

Over time, these incorrect bolts can loosen, deform, or potentially break.

If one bolt loosens or fails while driving, excessive stress can be transferred to the remaining bolts. In severe cases, this could lead to partial loss of vehicle control and increase the risk of a crash.

GM states that the problem originated from incorrect service information and accessory brake kit instructions that failed to specify unique fasteners required for vehicles equipped with 24-inch wheels.

Vehicles Included in Recall 26V-304

The following vehicles may be affected:

Cadillac Escalade
Cadillac Escalade ESV
Chevrolet Suburban 1500
Chevrolet Tahoe
GMC Yukon
GMC Yukon XL

Only certain vehicles equipped with 24-inch wheels are included in the recall population.

Warning Signs Drivers May Notice

GM says drivers of affected vehicles could experience symptoms before a failure occurs, including:

Noise coming from the front wheel area
Vibration felt through the steering wheel or chassis
Unusual wheel hub movement or instability

Drivers noticing these symptoms should have their vehicle inspected immediately.

How GM Discovered the Issue

GM’s investigation began in April 2026 after a product investigator identified that accessory brake package kits (RPO 5JL) lacked separate instructions and special fasteners required for vehicles equipped with 24-inch wheels.

The automaker also discovered that its electronic parts catalog (EPC) failed to identify the proper replacement bolts during front hub bearing service procedures.

GM received seven field complaints potentially related to this condition between January 2025 and April 2026. Despite the complaints, GM reports that it is not aware of any crashes or injuries connected to the defect.

On May 7, 2026, GM’s Safety Field Action Decision Authority (SFADA) approved a formal safety recall.

What Dealers Will Do

To correct the issue, GM dealers will:

Inspect affected vehicles
Replace the front left and right wheel hub bolts with the correct parts

Owner notification letters are expected to begin mailing on June 29, 2026.

Recall Information

NHTSA Campaign Number: 26V-304
GM Recall Number: N262554630
Vehicles Potentially Affected: 2,464

General Motors has issued a serious safety recall and “Do Not Drive” warning affecting a small number of 4WD and AWD Cadillac, Chevrolet, and GMC vehicles after discovering a defect that could cause the front or rear wheels to lock up without warning while driving.

The issue centers around defective transfer case assemblies that may have been built without a critical oil pickup tube — a component necessary to properly lubricate internal bearings inside the transfer case. Without lubrication, the transfer case can fail suddenly, potentially causing wheel lock-up and increasing the risk of a crash.

Which GM Vehicles Are Affected?

The recall impacts certain:

2026 Cadillac Escalade
2026 Cadillac Escalade ESV
2026 Chevrolet Silverado 1500
2026 Chevrolet Suburban
2026 Chevrolet Tahoe
2026 GMC Sierra 1500
2026 GMC Yukon
2026 GMC Yukon XL

The recall also includes certain 2015–2020 model year:

Chevrolet Suburban
Chevrolet Tahoe
Cadillac Escalade
Cadillac Escalade ESV
GMC Yukon
GMC Yukon XL

Only vehicles equipped with four-wheel drive (4WD) or all-wheel drive (AWD) are affected. Rear-wheel-drive-only vehicles do not use the same transfer case and are not included in the recall.

What Is Causing the Wheel Lock-Up Problem?

According to GM’s defect report, the issue stems from manufacturing errors at a supplier facility during assembly line process changes.

GM says standardized assembly procedures and quality control protocols were not properly followed, allowing some transfer case assemblies to leave the factory without the oil pickup tube installed. Normally, built-in error-proofing systems would detect and reject incomplete assemblies, but those safeguards were bypassed.

Without the oil pickup tube:

Transfer case bearings may not receive proper lubrication.
Internal components can overheat or seize.
The transfer case can fail suddenly.
Front and/or rear wheels may lock up while driving.

Drivers May Hear Grinding Noises Before Failure

GM says some drivers may notice a grinding sound before the wheels lock up. However, the wheel lock-up could also occur with little or no warning. A sudden wheel lock-up at highway speeds could result in loss of vehicle control and significantly increase the risk of a crash.

How GM Discovered the Problem

The issue first came to light on April 14, 2026, when a GM engineer submitted a report through the company’s Speak Up For Safety (SUFS) program after reviewing a failed transfer case from a 2026 Chevrolet Silverado 1500 that experienced wheel lock-up in a parking lot.

A teardown inspection revealed the transfer case was missing the oil pickup tube entirely.

GM officially opened a product investigation on April 17, 2026.

Using supplier end-of-line torque testing data, GM identified:

68 suspect transfer case assemblies
46 assemblies installed in 2026 production vehicles
1 suspect service replacement transfer case shipped for repairs involving older 2015–2020 vehicles
54 dealerships that may have received the suspect replacement parts
21 vehicles that may have received defective replacement transfer cases during service repairs

GM’s investigation identified four field complaints potentially related to the defect. At this time, GM says it is not aware of any crashes or injuries linked to the issue. GM’s Safety Field Action Decision Authority approved the recall on April 30, 2026.

What Owners Should Do

GM is urging affected owners not to drive their vehicles until the recall inspection and repair have been completed. Owner notification letters are expected to begin mailing on June 22, 2026.

Recall Information

GM Recall Number: N262557620
NHTSA Campaign Number: 26V-289

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.