Livonia, Mich. – March 28, 2017 – Roush CleanTech, an alternative fuel technology firm, has recalled 434 modified Ford vehicles equipped with faulty fuel control valves, according to documentation filed with the National Highway Transportation Safety Administration. The recall impacts propane-operated Ford E-450 cutaway trucks and vans, F-59 stepvans and F-650 and F-750 heavy duty diesel pickups manufactured between August 2015 and February 2017.

The Defect

Affected models include fuel control valves that exhibit over-current and short-to-ground performance. This increases engine temperatures capable of degrading the non conductive coverings that protect the solenoid wiring coils contained within the valves. When these fixtures fall apart, the valve closes, halting the flow propane to the engine and prompting complete shutdown. This poses serious risks to drivers, as the vehicles could cease operation suddenly and increase the likelihood of a crash.

Timeline of Events

Three separate owners reported incidents of solenoid failure in December 2016, two involving supply valve solenoids and one involving return valve solenoids. Roush contacted the fuel control valve supplier, Parker Hannifin Corporation based in New Britain, Connecticut, and explained the incidents. Soon after, Roush initiated an internal investigation to better understand the problem and identify a solution.

The firm evaluated fuel control valves in the Parker inventory, focusing on the state of the solenoid wiring coils. Roush discovered that, due to the placement of a small plastic bobbin, the coil wiring was slightly eschew. This failed to create enough distance between the wiring and the metal coil casting, leading to the over-current and short-to-ground performance. The parts had gone through the inspection process without being flagged.

Roush decided to issue a recall March 8, 2017, following its investigation. Dealers received notification of the recall March 14.

The Solution

The company has pledged to replace the defective parts, free of charge, according to the NHTSA. Owners should expect to receive notification between March 31 and April 30.

Dearborn, Mich. – Mar. 16, 2017 – Ford has recalled 8,000 trucks due to defective instrument clusters. The recall impacts F-150 models produced between October and November 2016, according to a company news release.

The Defect

Instrument clusters in the affected trucks can lose functionality in cool temperatures. For instance, the transmission gear indicator may not illuminate. Additionally, warning lights may shutdown unexpectedly. These occurrences poses serious risks to occupants, as key vehicle status indicators being unavailable can increase the likelihood of a crash. No injuries have been reported as a result of inoperable instrument clusters. A large majority of the impacted trucks are registered in the U.S., while just over 1,100 more are located in Canada and Mexico.

Timeline of Events

Ford began investigating the problem after receiving customer complaints. The car manufacturer eventually tied the issue to faulty quality control processes at fabrication facilities in Dearborn, as well as Kansas City, Missouri.

The Solution

The automaker has ordered dealers to reprogram instrument clusters in affected vehicles, free of charge. Owners can contact Ford customer service for more information.

Dearborn, Mich. – March 15, 2017 – Ford Motor Company has recalled 5,470 Mustang sports cars with defective interior door handles. The recall impacts models produced between Jan. 13 and Jan. 31 of this year, according to documentation filed with the National Highway Transportation Safety Administration.

The Defect

Affected models include left interior door handles equipped with misoriented spring mechanisms. This defect may cause the door to open when subjected to inertia loads of 30gs or more. Motorists involved in accidents that impact the driver side are likely to suffer serious injury due to the faulty door handle. However, there have been no reported injuries connected to the defect.

Timeline of Events

In early January, a tier-two supplier noticed a missing spring in the left-hand door latch assembly designated for the Mustang. The company began an internal investigation, notifying both Ford and the original OEM parts producer, Key Plastics of Felton, Pennsylvania. Key Plastics immediately froze shipments containing the component and started its own inquiry. At the same time, engineers at the Ford assembly plant in Flat Rock, Michigan, found one vehicle containing a left-hand door handle with loose springs. This lead to a widespread evaluation in which 843 vehicles were reviewed. Approximately 14 contained the defective door handle assembly.

In February, the Critical Concerns Review Group at Ford looked over the data collected and determined that the fixture may be in violation of one or more Federal Motor Vehicle Safety Standards. The body ordered tests to determine how the door handles performed with one loose or missing spring. Engineers conducted the trials in early March and determined that the fixture was a serious safety hazard, as it came unlatched when subjected to a 30g force.

The Field Review Committee looked over the test results and soon after recommended that vehicles containing the defective left-hand door assemblies be recalled. Dealers received notification March 14.

The Solution

Ford has ordered dealers to inspect affected models and replace door handle springs, if necessary, free of charge, according to the NHTSA. The car maker intends to notify impacted Mustang owners, via mail, April 24.

Dearborn, Mich. — Feb. 13, 2017 — As part of a joint recall announcement, Ford Motor Company recently explained an effort to correct an instrument cluster display problem. Affected vehicles could end up failing the Federal Motor Vehicles Safety Standard if the instrument clusters lose power.

Released in January, the statement has added timeliness because the issue is increasingly likely in cold conditions. The company noted that the recall involved around 8,000 vehicles, with 6,792 of them in the U.S. and the rest in Canada and Mexico.

The Defect

The Part 573 Safety Recall Report said that the panel cluster’s display could fail to show important indicators. These include some warning chimes and lights, as well as the transmission gear a driver has currently selected. The display could be affected for up to several minutes, leaving the driver confused and liable to make a critical mistake. This is a particular risk while driving in low temperatures, as this could cause the power supply to function incorrectly.

Timeline of Events

• Oct. 4, 2016: The earliest production date for the affected Ford F-150 vehicles.
• November 2016: Multiple display problems caused Ford to halt the F-150 from shipping, with the company undertaking an investigation based on initial observations.
• December 2016: Ford and the supplier, Visteon, continued looking into the matter as engineers discovered the link between the defect and cold temperatures. While Ford’s Critical Concern Review Group asked for more details, the engineering department investigated further.
• January 2017: The offending power supply chip was discovered, and the Ford’s Field Review Committee approved the recall after review, similar to another recall announced around the same time.

Resolution

The recall report said that owner notification would be finished by Feb. 13, 2017. The repair, covered by the affected vehicles’ original warranties, would reportedly involve reprogramming the instrument clusters as necessary, with no cost to the consumer.

Dearborn, Mich. — Feb. 10, 2017 — A shared defect has two different Ford models from 2016 included in a new recall. This action stems from structural issues within just 17 vehicles across these models, which had already prompted attention.

The Defect

The apron joints on the left side of floor pans in affected vehicles are, according to documents from the NHTSA, incorrectly welded in these autos. The 17 vehicles included in the recall are all in the U.S. and cover 2016 Ford Focus and C-Max vehicles from the company’s Michigan assembly plant. Both of the models were produced in the last full week of October last year.

As the source described, the improper welding means the fronts of these vehicles would be weakened, making them more susceptible to damage. In a Jan. 26 statement, Ford said that no accidents or injuries were yet connected to this problem.

Timeline of Events

• Oct. 25, 2016: The day before the first production for both of these brands. The joints were actually already repaired before the vehicles were originally released with rivets, but later tests showed possible dangerous errors in the process.
• Jan.  17, 2017: After two months of analysis, the manufacturer’s Field Review Committee approves the recall action, which is covered under the original vehicle warranties and will therefore be free of charge for owners. The decision only came after the Critical Concerns Review Group prompted analysis in an earlier response.

Resolution

To fix the issue, car owners will be instructed to take the vehicles to their dealer to get them fixed. This could involve inspecting the rivets and replacing as needed. While the original Part 573 Safety Recall Report said the dealer notification date was set for Jan. 25, owners are not slated for notification until the first full week of March.

Recall Masters – January 30, 2017

Ford Trucks Risk Fuel Leak

Ford has announced that it will recall two different types of light trucks due to a fuel systems leak that could result in a fire of not addressed.

The Defect
Ford will recall model year 2017 F-250 and F-350 trucks manufactured between Aug. 10, 2016 and Sept. 17, 2016, according to documents compiled by the National Highway Traffic Safety Administration. Some of these vehicles appear to have been built without a necessary frame reinforcement bracket attached to the front fuel tank strap. Without this component, regular wear and tear to the vehicle will eventually cause the fuel tank strap to separate from the frame, which could cause the tank itself to move and possibly hit the ground. Any resulting damage could lead to a fuel leak and possibly a fire…

Read the entire article on the Recall Masters website

Dearborn, Mich. – Jan. 30, 2017 – Ford has announced that it will recall two different types of light trucks due to a fuel systems leak that could result in a fire of not addressed.

The Defect

Ford will recall model year 2017 F-250 and F-350 trucks manufactured between Aug. 10, 2016 and Sept. 17, 2016, according to documents compiled by the National Highway Traffic Safety Administration. Some of these vehicles appear to have been built without a necessary frame reinforcement bracket attached to the front fuel tank strap. Without this component, regular wear and tear to the vehicle will eventually cause the fuel tank strap to separate from the frame, which could cause the tank itself to move and possibly hit the ground. Any resulting damage could lead to a fuel leak and possibly a fire.

Timeline of Events

• September 2016: A frame supplier notified Ford that a pickup frame had been manufactured without the necessary fuel tank strap reinforcement. Further inspection revealed that out of about 4,000 uninstalled frames, 58 were improperly built. At the time, it was not yet clear if any defective frames had been installed on vehicles and sold.
• October 2016: Further analysis allowed Ford to pinpoint the dates on which the defective frames were built. The manufacturer confirmed that some had indeed made it onto vehicles that were shipped.
• December 2016: Ford’s Field Review Committee approved a recall.

Resolution

Ford will notify affected owners by mail and will advise them to bring their vehicles to the nearest Ford or Lincoln dealers for inspection. If the trucks lack reinforcements brackets, replacements will be installed, free of charge.