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).

Lilburn, Georgia – Sept. 10, 2018 – Ford Motor Company is recalling almost 2 million F150 Regular Cab and SuperCrew Cab vehicles equipped with driver and front passenger seat belt pretensioners capable of creating “excessive” sparks, which could lead to a fire, according to a Ford company press release.

Affected vehicles include:

• 2015-18 Ford F-150 vehicles built at Dearborn Assembly Plant, March 12, 2014 through Aug. 23, 2018
• 2015-18 Ford F-150 vehicles built at Kansas City Assembly Plant, Aug. 20, 2014 through Aug. 23, 2018

Of the nearly 2 million affected vehicles, over 1.6 million are located in the U.S., with the rest registered across Canada and Mexico.

The Defect

Seat belt pretensioners, like many other vehicle safety devices (such as airbags), are triggered by a tiny explosive that allow only a split second to elapse between a collision and deployment of the safety feature. The explosive itself is set off by a crash, and in the case of seat belt pretensioners, the feature design allows the seat belt to instantly tighten to provide more protection for the seat occupant. The seat belts work in tandem with the airbags to reduce the likelihood of injury, securing the driver and passenger in position and limiting excessive movement.

However, Ford’s investigation found that some front seat belt pretensioners in specific F150 Regular Cab and SuperCrew Cab vehicles can generate excessive sparks when they deploy. If sufficient sparks are present, it is possible for gases exhausted inside the lower portion of the B-pillar by the pretensioners to ignite. Once the gas ignites, components behind the B-pillar (including insulation and carpet) can subsequently catch fire and may lead to the destruction of the entire vehicle.

Timeline of Events

As Consumer Reports noted in early August, the NHTSA opened an investigation into the F150 after five consumer complaints about fires were filed with the agency. It was reported that the fires began inside the pillar housing the seat belt mechanism. All five vehicles had been involved in a crash immediately preceding the start of the fires. Four incidents included airbag deployment, and three of the trucks were a total loss.

Ford claims there have been 17 reports of smoke or fire in the U.S. and six in Canada, although the manufacturer says they are not aware of any injuries or additional accidents associated with the defect. It is unusual for a recall to be issued after so few reports, but the ramifications of each incident are significant enough to trigger a recall.

The Solution

According to Ford, all repairs will be provided at no cost to customers. Dealers have been instructed to remove insulation material from the B-pillar trim, remove remnants of wiring harness tape in the B-pillar area, and apply heat-resistant tape to the carpet and its insulation. Dealers have also been instructed to modify the back interior panels of Regular Cab vehicles.

F-150 owners should not stop using their seat belts, according to the automotive safety engineer at Consumer Reports, as all major incidents have occurred only after a crash, and most after a crash severe enough to deploy the airbag in the vehicle. The risk of injury from not wearing a seat belt is deemed much higher than that of a potential fire following a severe crash.

There are approximately 1,995,776 vehicles in North America affected by this recall. Of these, 1,619,112 vehicles have been identified as being registered in the U.S. and its federalized territories. An additional 339,884 are currently in Canada and 36,780 in Mexico.

Owners may contact Ford customer service at 1-866-436-7332. The Ford reference number for this recall is 18S27. Owners may also connect with the National Highway Transportation Safety Administration through the agency’s toll-free Vehicle Safety Hotline at (888) 327-4236 The NHTSA campaign number for this recall is 18V568000. The recall is expected to begin Sept. 24, 2018. Ford had no additional comment beyond their press release.

Dearborn, Mich. – July 13, 2018 – Ford Motor Company has recalled more than 1,400 vehicles potentially equipped with defective brake components, according to documentation submitted to the National Highway Transportation Safety Administration.

The campaign affects 2018 Ford F-650 and F-750 Super Duty pickup trucks produced between Jan. 26, 2018, and March 13, 2018. The American automaker suspects all of the vehicles involved in the action contain the defective components.

The Defect

The affected models feature primary and secondary brake hose assemblies with ineffective corrosion coating. These fixtures, which are located near the master cylinder and hydraulic control unit, are susceptible to crippling oxidization as a result. In the event that this does occur, brake fluid leakage could occur, eventually resulting in drastically reduced braking functionality.

This defect increases the likelihood of an accident and therefore poses a serious safety hazard to occupants. However, Ford has yet to receive field reports connecting the defect to any accidents or injuries.

Timeline of Events

Members of the Ford Critical Concern Review Group received a report in March 2018 that referenced a vendor communication that seemed to indicate some vehicles had been equipped with defective brake hose assemblies.

The Mexican supplier Martinrea International had explained that numerous brake hoses had been shipped from its facility in Saltillo, Mexico to a Ford assembly site Avon Lake, Ohio without proper corrosion coating. The vendor had also informed Ford engineers that the hoses would lose 50 percent of their metal thickness over the course of 4.5 years.

The CCRG reviewed this information, along with internal test results from the Ford engineering group, and requested additional information. Throughout April and May 2018, engineers from both Ford and Martinrea International performed additional assessments and looked over production and shipment logs to determine the breadth of the problem.

The CCRG reconvened June 4, 2018, and decided that a voluntary safety recall was necessary.

Ford notified dealers of the impending action June 12, 2018.

The Solution

The automaker has directed dealers to replace the brake hose assemblies in affected vehicles free of charge, according to an NHTSA recall acknowledgement document. Ford will reach out to dealers via first-class mail between July 9, 2018, and July 13, 2018.

Owners in need of additional assistance can speak with Ford customer service personnel by calling (866) 436-7332. Callers should use the internal recall reference code 18S19. Owners may also connect with the NHTSA directly using the agency’s Vehicle Safety Hotline at (888) 327-4236.