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Ford's Recall Woes Deepen with New Batch of Corrective Actions
June 4, 2024 — Ford Motor Company has issued a new set of five safety recalls, underscoring a persistent challenge for the automaker: getting the fix right the first time. In a significant admission of prior failures, four of these five new campaigns are direct re-dos of previous recalls where the initial repairs were ineffective or incorrectly applied. The latest actions, filed with the National Highway Traffic Safety Administration (NHTSA), collectively affect a substantial number of vehicles and highlight the growing complexity—and potential pitfalls—of software-dependent repairs in modern automobiles.
The most problematic trend in this latest announcement is the recurrence of issues thought to be resolved. The largest of these "re-recall" campaigns targets 91,198 F-150 pickup trucks from the 2018-2020 model years. The problem involves daytime running lights that fail to dim properly when the headlight switch is moved from "Auto" to "On," remaining at full brightness instead. This not only creates a potential glare hazard for other drivers but, more critically, signifies a failure to comply with federal motor vehicle safety standards. Owners of these trucks had already taken them in for a software update to the body control module to address this, but Ford now states that update was not performed correctly, necessitating another dealer visit.
Software glitches are the common thread running through these corrective re-dos. A separate recall involves 10,742 2018 F-150s for an issue where quickly moving the gear shifter can cause the gear indicator on the instrument cluster to disappear and may lead to the momentary selection of an unintended gear, such as Reverse or Neutral. The root cause was previously identified as a software flaw in the powertrain control module (PCM). However, the software patch applied during the initial recall did not fully resolve the problem, requiring a second, corrected update.
The issue extends to passenger cars as well. Ford is recalling 5,252 Ford Focus (2015-2018) and Fusion (2013-2016) sedans for a risk of transmission clutch fracture that could lead to fluid leakage and a fire hazard. This campaign is specifically for vehicles that were "repaired incorrectly" under two prior recall actions, as they did not receive the proper software update. Ford estimates 100% of the vehicles involved in this new notice are affected due to the previous repair error.
Even occupant safety features are not immune. Approximately 18,124 2017 Ford Escape crossovers are being called back because their power windows may exert excessive force and fail to reverse automatically when they detect an obstruction, posing a pinching or injury risk. This, too, is a failure of a prior recall fix. The automatic reversal system, which is mandated for safety, relies on software that was not updated properly the first time, requiring yet another software flash.
A New, Standalone Hazard: Explorer Rollaway Risk
Amidst the re-runs, Ford introduced one entirely new recall concerning a potentially serious rollaway risk in its popular Explorer SUV. The recall affects certain 2024 Explorer models equipped with the 2.3-liter EcoBoost engine. According to Ford's filing, these vehicles can experience an unintentional reset of the Powertrain Control Module while driving.
The technical explanation points to a "Diagnostic Identifier" data packet that is too large for the PCM's memory to handle, causing a buffer overflow that forces a system reset. If this reset occurs while the vehicle is in motion, it can damage the parking system. The critical failure is that this damage may prevent the driver from shifting the transmission into Park. Even more alarming, the reset event itself can cause the transmission to shift into Park automatically while the vehicle is still moving, which could lead to a sudden stop or drivetrain damage, followed by a rollaway once the vehicle is stopped if Park is not securely engaged.
Ford stated it became aware of the issue in May 2024 and has identified 27 warranty claims that may be related. Fortunately, the company reports no accidents or injuries linked to the defect to date. The remedy requires dealers to inspect the parking system for damage and replace any faulty components, in addition to performing a software update to prevent the unintended resets.
Expert Insight: The "Re-Recall" Phenomenon and Consumer Trust
This latest batch from Ford puts a spotlight on a growing concern in the industry: the efficacy of recall repairs, especially as they become more software-centric. "Re-recalls are a significant red flag for quality control in the repair process," notes automotive quality analyst, Dr. Evelyn Reed. "It erodes consumer confidence and suggests either a flaw in the initial diagnostic, the repair procedure, or the parts supplied to dealers. For software issues, it often means the patch wasn't thoroughly validated across all vehicle configurations."
Data from the Center for Automotive Safety indicates that while recall volumes are high across the industry, instances of "recall rework" have been climbing at a faster rate over the past five years, correlating with the increased software content in vehicles. For consumers, it means a single recall notice may turn into multiple time-consuming dealer visits for the same problem, a frustrating experience that can impact brand loyalty.
What Affected Owners Should Do
Owners of the affected Ford F-150, Focus, Fusion, Escape, and Explorer models will be notified by mail by Ford, likely starting in late June 2024. The repairs for all software-related issues will be performed at Ford dealerships at no cost to the owner. For the Explorer rollaway recall, owners are advised to use their parking brake diligently every time they park as an interim safety measure until the repair is completed.
Vehicle owners can check if their specific car or truck is included in any open recall by visiting the NHTSA website (nhtsa.gov/recalls) and entering their 17-character Vehicle Identification Number (VIN). Proactive checking is recommended, as mail notifications can be delayed or lost.
