Dearborn, Mich., January 4, 2019 – Ford Motor Company recently issued a recall for some 2019 EcoSport Vehicles. According to a Ford press release, some of the vehicles from this model year possess a weak weld holding the front seats in place.

This recall is relatively small in scale, affecting fewer than 100 of the crossovers throughout North America. With approximately 87 EcoSport vehicles affected in total, 63 are located in the U.S. and its federalized territories, while 13 are in Canada. The recall’s internal Ford reference number is 18C08.

The Defect

The weld between two parts of these vehicles’ front seats, the A-bracket and the side member, has been declared too weak in the affected crossovers. An insufficient seat weld may increase the risk of motorists being injured or killed in a collision. The Ford vehicles are thus in violation of the National Highway Traffic Safety Administration’s Federal Motor Vehicle Safety Standards 207 and 210, which pertain to the strength of seat backs.

Timeline of Events

As the vehicles affected by the recent recall are from a recent model year, the discovery of the defect and the recall process have played out over a short period of time. Ford announced the recall in early January, along with a separate recall regarding the ongoing process of taking potentially dangerous Takata airbag inflators off the market.

Ford did not indicate how the company realized its 2019 EcoSport crossovers were in violation of FMVSS regulations, or whether the report came from the NHTSA or internal inspections. It did note that thus far no accidents or injuries related to the defect have been reported to Ford.

The Solution

Owners of affected vehicles should go to their Ford dealers to receive repairs. Though the problem with the vehicles is associated with a single weld, the entire front seats of the EcoSport crossovers are compromised. Instead of making a smaller change, the dealers are ordered to replace the front seats of affected cars completely to bring them back into compliance with FMVSS.

Laguna Hills, CA – December 20, 2018 – Ford Motor Company (Ford) is recalling certain 2016-2018 Ford Focus vehicles equipped with a 1.0L Fox GTDI engine and a 6-speed manual transmission due to potential clutch fracture. The potential number of units affected is 2,828.

The Defect

According to the NHTSA Recall Safety Report, affected vehicles are equipped with the 1.0L Fox GTDI engine and B6 manual transmission and may experience clutch slip, potentially resulting in elevated system operating temperatures. Repeated high-energy clutch slip input can lead to premature clutch lining wear, and this can subsequently cause a reduction in the mechanical properties of pressure plate material. After repeated cyclic heating and cooling events, cracks may develop around the outer edge of the pressure plate.

The torque capacity reduction that occurs due to clutch lining wear can cause additional slippage and introduce excessive energy and heat into the pressure plate. Eventually, a structural failure or fracture of the pressure plate may occur, leading to clutch cover and transmission housing breaches, which can potentially cause a leak of transmission fluid. A transmission fluid leak in the presence of an ignition source such as hot engine or exhaust components can increase the risk of a fire in the engine compartment.

Vehicle operators may notice clutch odor and smoke, and reduced vehicle performance, which are indications of a potential clutch slip condition prior to pressure plate fracture.

Timeline of Events

As part of an earlier recall, Ford’s Field Review Committee approved field action 18S07 (18V169) March 5, 2018. Between April and August 2018, Ford of Europe continued to monitor field data related to the subject vehicles, and between September and October 2018, a review of field data identified two reports of clutch pressure plate damage on European vehicles. Of these, one vehicle was equipped with a 1.5L and one equipped with a 1.0L engine and B6 manual transmission. Both were built after the timeframe for the previous field action.

Additional engineering investigation and testing identified a wider suspect population of vehicles built with clutch pressure plates manufactured after the field action but prior to a February 2018 material change to the clutch pressure plate. Ford of Europe’s Critical Concern Review Group reviewed this issue on October 10, 2018.

Analysis of field data for U.S. vehicles equipped with the B6 manual transmission identified no reports of pressure plate damage on vehicles built after the timeframe for the previous field action, but on November 19, 2018, Ford’s Field Review Committee reviewed the concern and approved an incremental population of 2,828 vehicles to 18S07 due to two reports of underhood fire on vehicles with similar transmissions in Europe – although no reports have been made in the U.S. for any similar problems.

The Solution

Ford will notify owners, and dealers will update vehicles with software that detects and prevents prolonged clutch slip, and will replace the clutch, as necessary, free of charge. The recall is expected to begin January 7, 2019. Owners may contact Ford at 1-866-436-7332. Ford’s number for this recall is 18S07. Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-845, and this recall is an expansion of recall 18V-169.

Laguna Hills, CA – November 29, 2018 – Ford Motor Company (Ford) is recalling certain 2018 Ford Explorer vehicles equipped with 2.3L or 3.5L GTDI engine for a potential fuel leak. The potential number of units affected is 114.

The Defect

According to the NHTSA Recall Safety Report, some fuel pressure sensors were produced by a supplier with over-size male threads resulting in a gap between the fuel pressure sensor and the mating saddle port with the o-ring not fully seated. Potentially, some Explorer vehicles built within the suspect date range may have a fuel pressure sensor that was not properly assembled. An improperly assembled fuel pressure sensor can result in a fuel leak. Fuel leaks in the presence of an ignition source can increase the risk of a fire.

Timeline of Events

On July 30, 2018, Ford’s Chicago Assembly Plant (CAP) discovered an Explorer with a 2.3L engine in the yard with fuel underneath it on the ground. The fuel leak was determined to originate from the fuel pressure sensor joint in the fuel line assembly on the top of fuel tank. CAP issued a Stop Ship on August 1, 2018, to contain all vehicles at the plant and in transit for inspection.

Ford’s Critical Concern Review Group (CCRG) subsequently reviewed this issue, beginning by inspecting held vehicles built during the month of July 2018, and initiated a Design of Experiments (DOE) to help determine the cause. The vehicle inspections identified no fuel leaks in the more than 9,000 vehicles being held; however, four sensors that were not properly assembled were identified. The four vehicles were built within a three day period between July 29, 2018, through July 31, 2018, and it was determined that the cause was over-size threads on the sensor.

Using the supplier’s records, Ford’s investigation of vehicle production records determined that 144 vehicles built at CAP during a specified three day period when incorrect parts were available were delivered to dealerships before the inspection could be completed and may or may not actually contain incorrect parts. On November 5, 2018, Ford’s Field Review Committee reviewed the concern and approved a recall, being unaware of any reports of accident, injury or fire related to this condition.

The Solution

Owners will be notified by mail and instructed to take their vehicle to a Ford or Lincoln dealer to have the fuel line assembly replaced. There will be no charge for this service. The recall is expected to begin December 3, 2018. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 18S35. Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-807.

Laguna Hills, CA – October 30, 2018 – Ford Motor Company (Ford) is recalling certain 2012-2018 Ford Focus vehicles with a 2.0L GDI or 2.0L GTDI engine due to an issue with the fuel vapor management system. This recall affects 1, 282,586 vehicles.

The Defect

According to the NHTSA Recall Safety Report, this safety recall involves affected vehicles equipped with 2.0L GDI and 2.0L GTDI engines may experience a malfunctioning Canister Purge Valve (CPV) and malfunctioning Powertrain Control Module (PCM) software. If the CPV sticks in “open” position, and the PCM software does not adequately detect the stuck-open CPV. the result can be excessive vacuum in the fuel vapor management system, potentially deforming the fuel tank.

If the vehicle is affected, the customer may observe a Malfunction Indicator Light (MIL), inaccurate or erratic fuel gauge indication, drivability concerns or loss of motive power, but may have no warning at all in case of simultaneous malfunction. An engine stall while driving without warning or without the ability to restart, can increase the risk of a crash.

Timeline of Events

NHTSA contacted Ford on May 29, 2018 regarding consumer complaints alleging loss of motive power on 2012-2014 model year Ford Focus vehicles. Ford reviewed the complaints and associated internal data and discovered information indicating canister purge valve malfunction that could cause excessive vacuum within the fuel system during evaporative emissions monitoring.

Consumer complaints included MIL illumination, fuel gauge inaccuracy, drivability issues, loss of motive power, or costly repairs. An investigative overview of the Focus fuel system operation and reviews of Ford’s data commenced, and on October 15, 2018, Ford’s Field Review Committee approved a field action. Ford is not aware of any reports of accident or injury related to this issue.

The Solution

Owners will be notified by mail and instructed to take their vehicle to a Ford or Lincoln dealer to have the Powertrain Control Module (PCM) reprogrammed with new software that will detect a malfunctioning CPV and prevent a potential excessive fuel vapor system vacuum condition from occurring. Dealers will check for Diagnostic Trouble Codes (DTC) and replace the CPV as necessary. If the CPV is replaced, dealers will inspect and replace the carbon canister, fuel tank and fuel delivery module as necessary. There will be no charge for this service.

Until the vehicle is serviced for this concern customers are advised to maintain at least 1/2 tank of fuel. The recall is expected to begin December 10, 2018. Owners may contact Ford Customer service at 1-866-436-7332. Ford’s number for this recall is 18S32. Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V- 735.

Laguna Hills, CA – October 18, 2018 – Ford Motor Company (Ford) is recalling certain 2017-2018 Ford GT vehicles due to a hydraulic fluid leak that increases the risk of fire. The potential number of units affected by this recall is 176.

The Defect

According to the NHTSA Recall Safety Report, a seal failure in the rear wing valve block may result in leakage of hydraulic fluid onto the exhaust. A hydraulic fluid leak in the presence of an ignition source can increase the risk of a fire.

The subject component responsible for the risk was introduced into production in late December 2016, and the condition was remedied on all vehicles produced after July 31, 2018. All prior generation Ford GT vehicles are unaffected by this recall. Ford is aware of one vehicle fire report in Germany with no injuries.

Timeline of Events

On June 19, 2018, Ford’s Critical Concern Review Group (CCRG) reviewed a report of a vehicle fire that occurred in Germany on June 16, 2018. Subsequently, on June 25, 2018, Ford inspected the report vehicle in Germany. Ford was unable to identify the cause of the fire, and Ford’s CCRG subsequently conducted a review of field data and warranty claims, the vehicle inspection, and design and manufacturing process data, accompanies by an extensive engineering investigation, laboratory testing, and.

By the end of September 2018, the investigation found that seal specifications could be exceeded for hydraulic pressure in the rear wing valve block assembly, and on October 1, 2018, Ford’s Field Review Committee reviewed the concern and approved a field action, issuing a recall for affected vehicles. Ford is aware of one vehicle fire report in Germany with no injuries.

The Solution

Ford will notify owners, and dealers will perform a software update to the fully integrated vehicle controller, which eliminates the possibility of excessive pressure in the valve block assembly. Some vehicles will have a rear wing hydraulic check valve installed and will have the O-rings and the filter replaced, if needed. The repairs will be performed free of charge. The recall is expected to begin November 26, 2018. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 18S29.

Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-707.

Ford is issuing a recall for approximately 50,000 120-volt convenience charge cords originally provided with select 2012-15 Ford Focus Electric, 2013-15 Ford Fusion Energi and 2013-15 Ford CMAX Energi vehicles.

According to the FORD Media Center, affected vehicles include: 2012-15 Ford Focus Electric vehicles built at Michigan Assembly Plant, Sept. 15, 2011 through March 14, 2015 2013-15 Ford Fusion Energi vehicles built at Hermosillo Assembly Plant, Sept. 4, 2012 through March 5, 2015 2013-15 Ford C-MAX Energi vehicles built at Michigan Assembly Plant, April 13, 2012 through March 14, 2015.
There are approximately 50,524 vehicles in North America with accompanying charge cords relating to this concern, with 49,197 vehicles in the United States and its federalized territories and 1,327 in Canada.

The Defect

The 120V convenience charge cord originally provided with the affected vehicles, when used in combination with a home AC outlet that is not on a dedicated circuit or is damaged, worn or corroded, could become susceptible to increased contact resistance at the convenience charge cord plug and home AC outlet interface.

Timeline of Events

According to the NHTSA Safety Recall Report, in December 2013 and May 2017, Ford’s Critical Concern Review Group (CCRG) opened investigations on 120V convenience charge cord allegations of heat damage. However,m neither investigation was able to identify a manufacturing or quality defect. Subsequent to the CCRG investigation Ford inspected four fires alleged to involve C-Max vehicles, and although the exact cause of the fires was not determined, it was noted that in three of the four fires, extension cords between the wall outlet and convenience charge cords were identified.

In June 2018, in response to an NHTSA request,  Ford reviewed additional information and subsequently completed an additional comprehensive data review and analysis of vehicles that use the same or similar 120V Convenience charge cords.  An elevated rate of melting/ fire reports on 120V Convenience charge cords designed without a thermistor led to an equipment recall, which was upgraded to a vehicle recall in September 2018.

Ford is aware of some fire reports, and has identified an elevated rate of allegations of melting and fire involving the 120V convenience charge cord that did not include a thermistor. Ford’s investigation revealed that an increased resistance at the plug/outlet interface was resulting in some cases in increased temperature and could potentially lead to a fire. Incomplete or slow charge cycles, or inability to charge have been identified as early indicators, as well as visible melting damage of the area surrounding the charge cord plug and/or odor.

The Solution

Owners will be notified by mail and reminded of the requirements for adequate wall outlets, and that extension cords should not be used under any circumstance to charge their vehicles. They will be instructed to take their vehicle to a Ford dealer to have the factory-equipped 120-volt convenience charge cord replaced with the latest version of the 120-volt convenience cord that includes a thermistor, free of charge. The thermistor can identify over-temperature conditions at the plug/outlet interface and will discontinue charging until the temperature decreases to an appropriate level.

The Ford reference number for this recall is 18S24. Notification to dealers occurred in August 2018. Mailing of owner notification letters occurred in September 2018. Owners may contact Ford customer service at 1-866-436-7332. Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153).