Ford expands Takata airbag inflator recall

Dearborn, Mich., January 4, 2019 – Ford Motor Company recently increased the scope of its recall of vehicles including airbag inflator components provided by Takata, according to a company press release. Airbags containing Takata parts have been associated with several other waves of recalls over the past few years, encompassing multiple automakers.

The latest extension of the Ford recall, the Michigan-based automaker’s fourth, targets 2010 Ford Edge and Lincoln MKX, 2010-2011 Ford Ranger, 2010-2012 Ford Fusion, 2010-2012 Ford Fusion, 2010-2012 Lincoln MKZ, 2010-2011 Mercury Milan and 2010-2014 Ford Mustang. The number of units affected is approximately 953,000 vehicles across the U.S. and Canada.

The Defect

Airbag inflators manufactured by Takata may be defective, which could make the airbag’s components explode instead of deploying properly in the event of a collision. The current wave of the Ford recall centers around the aforementioned vehicles’ front passenger-side airbags. Since Takata provided so many components to such a wide variety of auto manufacturers, the recall has taken place in multiple phases,  targeting various components of vehicles made by multiple manufacturers.

A crash in which an airbag explosion occurred could cause serious injury or death to motorists, adding urgency to the multi-stage recall. Ford did note in its press release that there haven’t yet been any injuries or deaths directly linked to the kinds of passenger-side inflators included in this round of the recall expansion.

Timeline of Events

The latest expansion of the Takata recall is part of a rolling schedule implemented by the National Highway Traffic Safety Administration. The agency noted that since the recall includes “tens of millions” of vehicles, beginning with the riskiest types of cars, mostly vehicles produced in 2006 and earlier. The order of the recall is based on both year of manufacture and the relative heat and humidity of regions – hot, humid conditions exacerbate the problems with airbags and increase risk. The entire schedule began in November 2015, according to the NHTSA, and is intended to conclude at the end of 2019.

The vehicles included in the latest Ford recall were manufactured between 2008 and 2012. The potential fault in these airbags has been known since the early days of the overall Takata recall, but due to the logistical need to handle the repairs in waves, they are only being serviced now.

The Solution

Owners of affected Ford vehicles – or any other cars involved in the Takata recall thus far – should go to a local dealership, where the frontal passenger-side airbag inflator or airbag module will be replaced, with the manufacturer paying for the repairs. The reference number assigned to this latest recall by Ford is 19S01.

Sean ReyesFord expands Takata airbag inflator recall

Ford Motor Company Recalls Nearly 1 Million Ford F-Series Trucks

Ford Motor Company is recalling 874,082 F-150 and Super Duty trucks due to an engine block heater cable that has created a fire concern.

The recall applies to Ford F-150 and F-Series Super Duty trucks in North America, where an engine block heater is used by truck owners to help keep engines warm and start more efficiently on cold winter days. The cable hangs off of the truck and is often attached to an extension cord plugged into a house or garage.

The defect: water and other contaminants may enter the block heater cable’s splice connector causing corrosion and damage. When the heater is plugged in, prolonged corrosion can cause a resistive short and increase the risk of overheating, melting wires, and potential fire…Read more on FordAuthority.com

Sean ReyesFord Motor Company Recalls Nearly 1 Million Ford F-Series Trucks

Ford Recalls Nearly 3,000 Focus Vehicles Due To Potential Clutch Fracture

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.

Sean ReyesFord Recalls Nearly 3,000 Focus Vehicles Due To Potential Clutch Fracture

2019 Lincoln Nautilus Recalled Over Driver Airbag Issue

2019 Lincoln Nautilus Recalled Over Driver Airbag Issue

Ford Motor Company is recalling certain units of the 2019 Lincoln Nautilus crossover SUVs over an issue with the driver’s airbag.

The defect: the plastic cover on the driver frontal air bag module may detach during air bag deployment.

The hazards: if the airbag cover separates during deployment, it can increase the risk of injury in the event of a crash.

Components: service: air bags.

Affected vehicles: 2019 Lincoln Nautilus not equipped with Adaptive Front Steering. The Nautilus replaces the Lincoln MKX starting with the 2019 model year.

Number of vehicles affected: 268 (United States number)…Read more on FordAuthority.com

Sean Reyes2019 Lincoln Nautilus Recalled Over Driver Airbag Issue

Ford Recalls Nearly 35,000 Vehicles Due to Missing Seat Brackets

Laguna Hills, CA – November 30, 2018 – Ford Motor Company (Ford) is recalling certain 2018 Lincoln Navigator, and Ford Expedition vehicles due to missing brackets in the center row seating. The potential number of units affected is 34,946.

The Defect

According to the NHTSA Recall Safety Report, the second row center seat track assemblies may be missing one or both of the J-Channel reinforcement brackets, possibly allowing the seat to move in the event of a crash. In the event of a crash, a seat that moves may not properly restrain the seat occupant, increasing their risk of injury.

This recall includes all vehicles produced with this seat configuration (second row bench [40/20/40]), which was a new design for the 2018 model year. The second row bench center (20%) seat is adjustable and can be positioned 70mm further forward than the outboard seats. The owner’s manual states the seat should be adjusted to its rearward position when it is occupied by older children or adults, including children in booster seats.

Timeline of Events

On August 30, 2018, Ford’s Critical Concerns Review Group (CCRG) reviewed a concern regarding missing J-channel reinforcement brackets on certain 2018 model year Expedition and Navigator second row bench center (20%) seats. This seat track assembly design, which was new for 2018 models, contains two J-channel reinforcement brackets, one left-hand and one right-hand. CCRG requested an assessment of center seat structural integrity with one or both J-channel bracket reinforcements missing.

During September and October 2018, directional CAE analysis was conducted on a rigidified body sheet metal structure with the second row center seat in the full rear and full forward seating positions, and a more detailed analysis simulating actual body sheet metal structure was performed under crash conditions to determine if the missing brackets presented a risk.

The in-depth CAE analysis, simulating the production vehicle design, indicated that the seat track missing one or both J-channel reinforcement brackets may peel or tear when the seat is adjusted in the fully forward or near fully forward position. This could lead to increased risk of injury during a crash, particularly for children seated in the middle row seating.

CAE was able to confirm that a seat adjusted in the full rearward seating position did not present this concern. On November 5, 2018, Ford’s Field Review Committee reviewed the concern and approved a recall; at this time, Ford was 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 second row center (20%) seat inspected to determine if both J-channel brackets are installed. If one or both J-channel brackets are missing, dealers will replace the center seat frame assembly. There will be no charge for this service. Until the vehicle is serviced for this concern, customers are advised to adjust the center seat to its full rearward position. The recall is expected to begin December 17, 2018. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 18S37. 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-805.

Sean ReyesFord Recalls Nearly 35,000 Vehicles Due to Missing Seat Brackets

Ford Recalls Nearly 300 Nautilus Vehicles Due to Air Bag Issue

Laguna Hills, CA – November 29, 2018 – Ford Motor Company (Ford) is recalling certain 2019 Lincoln Nautilus vehicles that are not equipped with Adaptive Front Steering, due to a defect in an air bag cover. The potential number of units affected is 268.

The Defect

According to the NHTSA Recall Safety Report, the driver airbag modules installed in vehicles may contain a plastic cover that was improperly injection-molded at the sub-tier supplier. A driver airbag cover that has not been properly molded may detach during an airbag deployment. If the air bag cover separates during deployment, it can increase the risk of injury in the event of a crash.

Timeline of Events

On September 27, 2018, Autoliv, the non-AFS driver airbag module Tier 1 supplier, notified Ford of a test anomaly that had occurred during a lot acceptance test (LAT) at high temperature on that day. Autoliv subsequently contained all suspect parts from that lot, and began an investigation into the cause of the failure.

In October 2018, Autoliv’s ongoing investigation discovered that the potential root cause could be attributed to the presence of knit lines in the area of the tear seam on the airbag cover substrate, and it was also revealed that the Tier 3 supplier (DEMO) made several adjustments to the cover injection-molding process without notifying the Tier 2 supplier (Eissmann) of the adjustments. These adjustments had resulted in the improper forming of the knit lines in the area of the cover tear seam.

The investigation also revealed that the injection-molding process change had been used on covers that were built into airbag module assemblies which had previously passed LAT and were subsequently installed in vehicles; therefore, an analysis to identify the release status of these vehicles was initiated. On November 5, 2018, Ford’s Field Review Committee reviewed the concern and approved a recall.

The Solution

Owners will be notified by mail and instructed to take their vehicle to a Ford or Lincoln dealer to have the driver airbag module replaced. There will be no charge for this service. The recall is expected to begin in November 2018. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 18S38. 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-806.

Sean ReyesFord Recalls Nearly 300 Nautilus Vehicles Due to Air Bag Issue

Ford Recalls 114 Explorers Over Potential Fuel Leak

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.

Sean ReyesFord Recalls 114 Explorers Over Potential Fuel Leak

Ford Recalls 215 Previously Recalled Vehicles for Potential Air Bag Malfunction

Laguna Hills, CA – November 27, 2018 – Ford Motor Company (Ford) is recalling certain 2010 Ford Fusion, Mercury Milan and 2010-2012 Lincoln MKZ vehicles that previously received a replacement passenger air bag under recalls 16V-384, 17V-024 or 18V-046. The potential number of units affected is 215.

The Defect

According to the NHTSA Recall Safety Report, in the event of a crash requiring deployment of the passenger air bag, the bracket that secures the air bag inflator to the module housing may deform, allowing the gas that inflates the air bag to leak out. If the air bag does not inflate properly, there is an increased risk of injury in the event of a crash. All affected vehicles were previously repaired under safety recalls using passenger airbag module service parts manufactured with stop brackets with an incorrect material thickness. Ford identified the affected vehicle population by monitoring warranty repairs using its warranty system to identify vehicles repaired with a specific part number that contained incorrect material thickness stop brackets, and issued the subsequent recall for those vehicles alone, as the issue had been fixed at manufacturing level for subsequent builds.

Timeline of Events

For production validation (PV) testing, the supplier used a stop plate component that did not follow the proper production part approval process (PPAP) and was thicker than the specified material thickness. This resulted in a “false positive” validation test. The specified material thickness utilized in production was inadequate to provide expected performance. On October 4, 2018, Joyson Safety Systems (JSS) reported a production validation test failure while validating parts on a new production line at their Monclova plant on an airbag module produced as a service part for the 2010 through 2012 model year Fusion/Milan/MKZ vehicles.

On October 8, 2018, JSS observed a Lot Acceptance Test (LAT) failure on the same part produced at their Torreon plant. Parts used for LAT testing were  also assembled using an incorrect gage thickness stop plate. JSS halted production of the affected airbag modules and quarantined stock in its control. Investigation of the test failures identified that a stop plate utilized in the module assembly provided insufficient support during airbag deployment. This defect was declared to be an issue, potentially resulting in inflation gas leakage and incomplete airbag cushion inflation in the event of a crash. The subsequent investigation of the PV and LAT test failures further identified that PV testing for the initial production line at the Torreon facility was performed using similar stop plates produced with an incorrect material thickness.

On October 16, 2018, the PV and LAT test failures were brought into Ford’s Critical Concerns Review Group, and on October 25, 2018, Ford’s Field Review Committee reviewed the concern and approved a field action.

The Solution

Ford will notify owners, and dealers will replace the passenger air bag module, free of charge. The recall is expected to begin in late November 2018. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 18S34. Owners will be notified by mail and instructed to take their vehicle to a Ford or Lincoln dealer to have the vehicle’s passenger airbag module replaced. There will be no charge for this service. 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-775.

Sean ReyesFord Recalls 215 Previously Recalled Vehicles for Potential Air Bag Malfunction

Ford Issues Safety Recall for Airbag Module in Select Fusion and Lincoln MKZ Vehicles

Ford Issues Safety Recall for Airbag Module in Select Fusion and Lincoln MKZ Vehicles

The Ford Motor Company announced a safety recall involving approximately 215 Ford Fusions made in 2010 and Lincoln MKZ vehicles made from 2010-2012. The issue involves a defect with the airbag modules that might cause the passenger airbags to fail to fully inflate.

In the statement released by Ford last Friday, Nov. 2, the vehicles in the scope of the recall may be equipped with a bracket that is to blame for the faulty airbags. This is the bracket that secures the airbag inflator to the module housing, and it has been identified as having the potential to deform and allow leaking of the gas that makes the airbag inflate when deployed…Read more on TheDrive.com

Sean ReyesFord Issues Safety Recall for Airbag Module in Select Fusion and Lincoln MKZ Vehicles

Ford Recalls More Than One Million Vehicles for Stalling Issues

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.

Sean ReyesFord Recalls More Than One Million Vehicles for Stalling Issues