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.

Dearborn, Mich. – July 11, 2018 – Ford Motor Company has recalled more than 5,600 vehicles potentially equipped with defective fuel pump assemblies, according to documentation submitted to the National Highway Transportation Safety Administration. The campaign affects models across multiple brands, including:

• 2018 Ford Expedition sport utility vehicles produced between March 14, 2018, and April 12, 2018.
• 2018 Ford F-150 pickup trucks produced between March 14, 2018, and April 24, 2018.
• 2018 Lincoln Navigator sport utility vehicles produced between Feb. 20, 2018, and May 6, 2018.

The American automaker is unsure how many of the recalled vehicles actually contain defective components.

The Defect

Affected vehicles contain high-pressure fuel pump assemblies with potentially problematic welds connecting pump housings and mounting flanges. These joints may experience high-cycle fatigue and eventually crack. In the event that such separation occurs, the sealing integrity of nearby cam covers may be compromised, resulting in oil spillage and increasing the likelihood of engine fire. The defect therefore poses a serious hazard to occupants. However, Ford has yet to receive reports connecting the defective fuel pump assemblies to any accidents or injuries.

Timeline of Events

Members of the Ford Critical Concern Review Group convened in May 2018 to discuss an internal quality assurance report that detailed multiple instances in which high-pressure fuel pumps were welded with misaligned lasers, resulting in problematic welds joining the pump housings and mounting flanges. Pump supplier Robert Bosch had spotted the issue and informed QA personnel, who then brought the issue to the attention of the CCR.

Following the CCR meeting, Ford initiated tests to determine the engineering impact of the potentially defective parts. This inquiry revealed that weld breakage and subsequent oil spillage were possible. A computer simulation confirmed this finding. The Ford Field Review Committee took up the issue June 4, 2018, and decided that a voluntary safety recall was necessary.

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

The Solution

The car manufacturer will replace the high-pressure fuel pumps in affected vehicles free of charge, according to an NHTSA recall acknowledgment document. Ford intends to reach out to owners via first-class mail between July 16, 2018, and July 20, 2018. Owners in need of assistance prior to the start of the campaign can connect with Ford customer service personnel by calling (866) 436-7332. Callers should use the internal recall reference code 18S17. Individuals in possession of the recalled vehicles also contact the NHTSA directly using the agency’s Vehicle Safety Hotline at (888) 327-4236.

Dearborn, Mich. – Feb. 21, 2018 – Ford Motor Company has recalled 92 vehicles potentially equipped with defective brake jounce hoses, according to an organizational press release. The campaign affects 2018 Ford Escape and Lincoln MKZ sport utility vehicles. According to the American automaker, 88 of the recalled vehicles originated from dealerships in the U.S. while four came from dealers in Canada.

The Defect

Affected vehicles may feature out-of-specification brake jounce hoses that collide with surrounding vehicle components during operation. Due to this constant contact, the likelihood of hose wear and, eventually, brake fluid leakage increases. This poses a serious safety hazard to occupants, as the loss of break fluid could inhibit the braking system. That said, Ford has yet to receive reports connecting the defective brake jounce hoses to any accidents or injuries.

Timeline of Events

The car company has not released details into the investigation that uncovered the defect. However, Ford did announce the the vehicles included in the recall were produced at the Louisville Assembly Plant in Louisville, Kentucky between Oct. 29, 2017 and Oct. 30, 2017.

The Solution

Ford will direct dealers to inspect and, if necessary, replace the brake jounce hoses in the recalled models free of charge. The automaker has not yet announced a timetable for the recall action. Owners in need of assistance can contact Ford customer service personnel at (800) 392-3673. Callers should use the internal recall identification code 18S04. Owners can also reach out to the National Highway Transportation Safety Administration through its Vehicle Safety Hotline at (888) 327-4236.

Dearborn, Mich. – Feb. 5, 2018 – Ford Motor Company has recalled approximately 363 sport utility vehicles potentially equipped with defective second-row window electronic control modules, according to a company press release.

The campaign affects 2018 Ford Expedition and Lincoln Navigator SUVs assembled between Nov. 27, 2017, and Dec. 9, 2017 at the automaker’s Kentucky Truck Plant in Louisville. Ford estimates half of the models referenced in the action actually contain the defective parts.

The Defect

Affected vehicles may contain second-row window electronic control modules that were manufactured incorrectly and are therefore prone to malfunction, according to documentation submitted to the National Highway Transportation Safety Administration. Under certain conditions, the electronic modules in question may reach their thermal protection thresholds, inhibiting the automatic reverse function – a safety feature that goes into action when an obstruction is present. This poses a serious safety risk to occupants. However, Ford has yet to receive reports connecting the defective electronic modules to any accidents or injuries.

The defective part also violates Federal Motor Vehicle Safety Standard 118 Section 5, which requires vehicles of 10,000 pounds or more to contain power window systems that “minimize the risk of injury or death from their accidental operation,” according to The Federal Register.

Engineers for the automobile company have learned that occupants can move second-row windows without active automatic reverse functionality 500 millimeters at a time using the manual control switches on the doors. Additionally, the condition automatically resolves itself when electronic control modules fall below their thermal protection thresholds.

Timeline of Events

In December 2017, engineers conducting end-of-line vehicles review processes at the Kentucky Truck Plant discovered two models with defective second-row windows. These personnel suspected there was an issue with the electronic control modules in these fixtures and asked the supplier, Kostal of America, to investigate the components it delivered to Ford for installation. The parts provider found that the electronic control modules were improperly assembled. Laboratory tests confirmed that the misconstructed features reached their thermal protection thresholds in “high window load” scenarios, leading to operational issues. These initial findings were sent to the Critical Concern Group for further review.

On Jan. 5, 2018, Ford conducted further tests to determine if the fixtures met the requirements of FMVSS 118, which they did not.

The Field Review Committee reviewed the matter Jan. 8 and ultimately decided to launch a voluntary safety recall. Ford notified dealers Jan. 17.

The Solution

Ford has directed dealers to inspect the second-row window electronic control modules installed in affected models and, if necessary, replace them free of charge, according to a recall acknowledgment document from the NHTSA. The automaker intends to notify owners via first-class mail between Feb. 5 and Feb. 9. Those in need of more immediate assistance can contact Ford customer service at (866) 436-7332. Callers should use the internal recall identification code 18C01. Concerned owners can also reach out the NHTSA directly using its Vehicle Safety Hotline at (888) 327-4236.