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The Essence of the Recall
Ford has announced a new large-scale recall affecting thousands of crossovers. This time, the recall involves plug-in hybrid SUVs Escape and Lincoln Corsair from model years 2023 through 2026. In total, the recall covers 24,690 vehicles equipped with a plug-in hybrid powertrain.
The Cause of the Problem and Its Danger
According to the National Highway Traffic Safety Administration, the high-voltage battery packs in these vehicles may have a manufacturing defect. It concerns one or more battery cells and can lead to an internal short circuit and complete battery failure.
If this occurs, the vehicle may suddenly lose propulsion or catch fire.
This is already the third recall related to the same issue, indicating its seriousness. The total number of vehicles involved in all campaigns due to this defect is approaching 61,526 units.
The Root of the Problem and the Supplier
The source of the problem is cited as “variability in the manufacturing process of the battery cell supplier.” This variability can lead to micro-defects in the cell cathode and localized stresses in its separator layer. The official report mentions that these damages can compromise the separator, leading to a short circuit. The batteries were manufactured by Samsung SDI. Despite the scale of the recall, it is believed that only about 1% of the total affected vehicles have the defect.
Lack of a Solution and Recommendations for Owners
The most alarming aspect of the situation is that Ford currently does not have a ready technical solution to fix the defect. While engineers are searching for a way out, the company is providing owners with temporary operating recommendations.
Owners are advised to use the “Auto EV” mode exclusively and limit battery charging to a maximum of 80% of its full capacity.
The first notifications to owners are planned to be sent out at the beginning of next month. The final solution and repair instructions will be sent later when they become available. There is no information yet on when exactly this might happen.
Consequences for New Vehicles
The situation also affects new vehicles at dealer lots. A stop-sale order has been placed on them, meaning these crossovers cannot be delivered to buyers or even demonstrated for test drives. This creates additional logistical and financial difficulties for the dealer network. This series of recalls highlights the complex challenges automakers face when scaling up production of complex electrified hybrid systems, where the reliability of every link in the supply chain, especially critical components like batteries, is crucial for safety and reputation.
