Tag Archives: PHEV Battery Failure

Battery Cell Problems In Ford Escape & Lincoln Corsair Plug-In Hybrids

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Ford has decided that a safety defect exists involving the high-voltage battery packs inside certain plug-in hybrid vehicles—specifically the 2020–2024 Ford Escape PHEV and 2021–2024 Lincoln Corsair PHEV.  At the center of the issue is a manufacturing defect inside one or more battery cells, which can lead to an internal short circuit and, in the worst cases, battery thermal venting or vehicle shutdown.

This problem originally surfaced years ago, was addressed by a previous recall, and now—based on new field data—Ford has determined that the prior fix may not have been enough.

What’s Causing the Problem?

Inside the high-voltage battery pack, each cell has a separator layer that keeps the cathode and anode apart. If this thin separator layer becomes damaged, the cell can short internally.  Ford, its engineering teams, and the battery cell supplier have all pointed to variability in the supplier’s production process as the likely cause. This inconsistency may lead to small imperfections or weaknesses in the separator layer.

When the separator is compromised, the result can be:

  • Internal short circuits
  • Loss of propulsion power
  • Battery overheating
  • Thermal venting
  • Potential vehicle fire

Ford has not yet identified the complete root cause. Tear down investigations are still ongoing.

Safety Risks: What Can Happen

If a battery cell shorts internally:

1. Loss of Motive Power While Driving

The vehicle may suddenly shut down its propulsion system.
A red “Stop Safely Now” warning appears on the instrument cluster.

Although steering, braking, and lights still work, a sudden loss of acceleration dramatically increases crash and injury risk.

2. Battery Thermal Venting / Fire Risk

A shorted cell can overheat and vent hot gas, which can ignite surrounding components.
This is a significant safety hazard, particularly if venting occurs during or after charging.

To date, Ford reports no injuries or accidents connected to this defect.

A Look Back: The 24V-954 / 24S79 Recall

Ford already attempted to fix this issue once.

In December 2024, Ford approved recall 24V-954 (Ford) / 24S79 (Lincoln), which rolled out the following remedy:

  • Updated Battery Energy Control Module (BECM) software
  • Added enhanced detection of battery cell anomalies
  • Stopped battery charging automatically if anomalies were detected
  • Alerted owners through messages in the instrument cluster

This fix was intended to catch separator-layer damage before it caused a short circuit.  However, new field reports show this strategy was not always effective.

The Turning Point: New Thermal Venting Cases in 2025

July–August 2025

Three European Ford Kuga PHEV vehicles (the Kuga is the European variant of the Escape PHEV) experienced battery thermal venting even AFTER receiving the recall software update.

September 2025

Two more cases surfaced.

August–October 2025 Investigation

Ford’s Critical Concern Review Group (CCRG) opened a formal investigation on August 27, 2025.
Recovered battery packs and control modules showed:

  • No detectable anomalies before venting
  • Significant thermal damage making root-cause confirmation difficult
  • The updated software did NOT trigger any warnings prior to failure

Meanwhile, tear down analysis from other replaced battery packs (those that were flagged by the software and did not vent) has not yet identified a definitive cause.

As of November 5, 2025

Ford reports:

  • 7 total venting incidents, all from European Kuga PHEV vehicles
  • All had already received the 24V-954 software update
  • No injuries or accidents

November 7, 2025

Ford approved a new field action—leading to today’s recall.

The New Recall: 25SC4 (Ford) / 25V-789 (NHTSA)

Because of the new cases, Ford has issued a new recall to replace the old one.

Affected Vehicles:

  • 2020–2024 Ford Escape Plug-In Hybrid
  • 2021–2024 Lincoln Corsair Plug-In Hybrid
    (These vehicles were previously included in recall 24V-954.)

Ford’s New Instructions to Owners

Until the final fix is ready, Ford advises:

  • Only use Auto EV mode
  • Limit the maximum charge of the high-voltage battery
  • Wait for mailed instructions and further updates

Interim owner letters are scheduled to go out December 1, 2025, detailing the safety risks and how to limit battery charging.  A second letter will follow once a permanent remedy is available.

The Final Remedy Is Still Under Development

Ford has not yet determined what the permanent fix will look like—likely because the underlying defect is still not fully understood.

Conclusion

Ford’s latest recall highlights an unresolved and potentially serious defect in the high-voltage battery cells used in its Escape and Corsair plug-in hybrid models. The original software-based solution from 2024 was not enough to catch every instance of cell separator damage, and new thermal-venting cases have forced Ford to develop a more comprehensive fix.  Until that final remedy is completed, owners must limit charging, follow Ford’s interim instructions, and watch for important recall notices.

Lincoln Aviator Battery Short

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According to Ford’s records, certain 2020-2021 Aviator vehicles were recorded as having the repair successfully completed, but may still be at risk due to the incorrect software installation. If the correct software update remedy is not installed on the vehicle, the manufacturing defect can cause a lower capacity cell to develop an internal short circuit, leading to a battery power off and potentially resulting in a vehicle fire.

The issue was first brought to Ford’s attention in November 2024, when an audit revealed insufficient data to confirm correct software application across all field service actions (FSAs) using the FDRS service tool. A team was formed to investigate further and created templates to track software lineage part numbers. In December 2024, Ford informed the National Highway Traffic Safety Administration (NHTSA) of the concern and discussed a plan to address the mismatched vehicles. After conducting an audit, it was found that 99.3% of the repairs conducted under recall 23S53 had the correct software installed. However, they identified specific vehicles that were recorded as receiving the remedy but still had software that did not address the safety risk.

To rectify the situation, Ford has approved a field action and will update the Battery Energy Control Module software for the affected vehicles. The company is not aware of any reports of accidents or injuries related to this condition. Dealers will correct the problem by updating the software with the correct version.

The recall number for this issue is 25S58, and the NHTSA campaign number is 25V-349. If you own a 2020-2021 Lincoln Aviator vehicle equipped with a 3.0L PHEV engine, and you receive a recall notice, contact your dealer for repairs to ensure your safety on the road.

Volkswagen ID.4 SUV: Common Problems and Navigating Lemon Law Protections

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The Volkswagen ID.4 SUV represents the German automaker’s entrance into the growing electric vehicle (EV) market. Launched with the promise of combining the brand’s legendary driving dynamics with cutting-edge EV technology, the ID.4 aims to provide a sustainable yet practical driving experience. However, as with many new models, especially those pioneering new technologies, the ID.4 has faced its share of teething troubles. This article will delve into the common problems reported by ID.4 owners and explain how these issues could potentially classify your vehicle as a lemon under the California Lemon Law. We’ll also highlight the importance of seeking assistance from a lemon law attorney if you find yourself grappling with persistent vehicle issues.

Common Volkswagen ID.4 Problems

1. Charging Issues

Many ID.4 owners have reported difficulties with charging their vehicles. Problems range from slow charging speeds to the car not charging at all. Some users have encountered issues with the compatibility of their ID.4 with various public charging stations, leading to inconvenience and frustration.

2. Software Glitches

The ID.4’s infotainment system and other software-driven features have been a source of concern for some drivers. Complaints include unresponsive touchscreens, malfunctioning navigation systems, and intermittent connectivity issues with smartphones. These software bugs can detract from the overall user experience and disrupt daily usage.

3. Battery Performance

Some ID.4 owners have reported inconsistent battery performance, including unexpected drops in range and inaccurate range estimates. Such issues can severely impact the reliability of the vehicle, especially for long-distance travel.

4. Build Quality

Although Volkswagen is renowned for its build quality, some ID.4 owners have experienced issues with fit and finish. Reports include problems with door alignment, rattling noises from the cabin, and malfunctioning interior components. These issues, while sometimes minor, can affect overall satisfaction with the vehicle.

5. Electrical System Faults

Electrical system faults have also been reported, with owners experiencing warning lights and system errors. These faults can be unsettling and sometimes necessitate multiple visits to the dealership for resolution.

When Is Your Vehicle a Lemon?

A vehicle is generally considered a “lemon” if it has significant defects that affect its use, value, or safety, and these defects persist despite multiple repair attempts. Under California law, a vehicle is presumed to be a lemon if:

  • The manufacturer has made at least two attempts to repair a warranty problem that could result in death or serious injury if the vehicle is driven.
  • The manufacturer has made at least four attempts to fix the same warranty problem.
  • The vehicle has been out of service for more than 30 days (not necessarily consecutive) for warranty issues.

Understanding the California Lemon Law

The California Lemon Law, officially known as the Song-Beverly Consumer Warranty Act, provides robust protections for consumers who purchase or lease new vehicles. The law mandates that if a manufacturer cannot repair a vehicle to conform to its warranty after a reasonable number of attempts, the manufacturer must either replace the vehicle or refund the purchase price, minus a usage fee.

Benefits of the California Lemon Law

  1. Consumer Protection: The law protects consumers from being stuck with a defective vehicle.
  2. Replacement or Refund: Consumers are entitled to a replacement vehicle or a refund, ensuring they receive the value they paid for.
  3. Legal Support: Consumers can recover legal fees if they prevail in a lemon law claim, making it financially feasible to pursue legitimate claims.

The Importance of a Lemon Law Attorney

Navigating the intricacies of the California Lemon Law can be challenging, and manufacturers often have significant legal resources at their disposal. Here’s why hiring a lemon law attorney is a smart move:

  1. Expertise: Lemon law attorneys have specialized knowledge of consumer protection laws and can effectively navigate the legal process.
  2. Maximized Compensation: An attorney can help ensure you receive the maximum compensation you are entitled to, including potential incidental and consequential damages.
  3. No Upfront Costs: Many lemon law attorneys work on a contingency basis, meaning they only get paid if you win your case.

Conclusion

The Volkswagen ID.4 SUV, while a promising entry into the electric vehicle market, has faced several common problems reported by owners. If you find yourself repeatedly dealing with these issues, your vehicle might qualify as a lemon under the California Lemon Law. Seeking the assistance of a lemon law attorney can provide the expertise and support needed to navigate this legal landscape and ensure you receive fair treatment. Remember, consumer protection laws are there to safeguard your rights and ensure you get the quality you paid for in your vehicle purchase.

Battery Problem – Jeep Wrangler PHEV

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In recent years, the automotive industry has witnessed a significant shift towards electric vehicles (EVs), with hybrid models like the Plug-In Hybrid Electric Vehicles (PHEVs) gaining popularity. However, this transition has not been without challenges, particularly concerning battery reliability and safety. A case in point is the recent issue with certain 2021-2023 model year Jeep Wrangler PHEVs.

The Core Issue

The heart of the problem lies in the high voltage (HV) battery of some Jeep Wrangler PHEVs, which have been reported to fail internally. This issue first came to light in May 2023 when the FCA Technical Safety and Regulatory Compliance (TSRC) organization received two field reports of 2021 Jeep Wrangler PHEVs catching fire due to the HV battery. Following these alarming reports, FCA bought back the vehicles for in-depth analysis. By November 2023, seven such incidents had been reported, prompting FCA US to initiate a voluntary safety recall of the affected vehicles.

Investigating the Cause

The root cause of these battery failures remains unidentified and under investigation. The suspect period for these faults began on September 18, 2020, with the issue being potentially linked to battery cells manufactured between January 21, 2021, and October 2, 2021. These dates were determined using supplier manufacturing records, indicating a specific window during which the faulty cells were produced.

Broader Challenges with EV Batteries

This situation with Jeep Wrangler PHEVs brings to light broader concerns in the EV industry regarding battery safety and reliability. Battery issues in electric vehicles can stem from various factors, including manufacturing defects, improper management of battery temperature, overcharging, or physical damage to the battery. Such problems can lead to reduced battery life, decreased performance, and in extreme cases, safety hazards like fires.

The recall of the Jeep Wrangler PHEVs underscores the importance of ongoing monitoring and quality control in the production of EV batteries. Manufacturers must implement stringent quality checks and improve battery technology to prevent such incidents. Furthermore, understanding and rectifying the root cause of these failures is crucial for the advancement and consumer confidence in EV technology.

Owners are advised not to recharge their vehicles, and to park outside and away from structures, until they are repaired. Dealers will update the high voltage battery pack software and replace the battery pack assembly if necessary. FCA US, LLC’s number for this recall is 89A and the NHTSA campaign number is 23V-787.

The case of the Jeep Wrangler PHEV batteries serves as a reminder of the complexities and challenges associated with the EV revolution. While the shift to electric mobility is imperative for sustainable transportation, it also demands heightened attention to the safety and reliability of EV components, especially batteries. As the industry evolves, continuous improvements and vigilance in battery technology and manufacturing processes will be key to ensuring the safety and satisfaction of EV users worldwide.