Recall Scale
After a brief pause, Ford returns to active actions with its 115th recall this year. This campaign covers 59,006 vehicles that may short-circuit and potentially ignite.
Affected Models
The recall involves a range of different models, including the 2021-2024 Bronco and Bronco Sport, as well as the 2020-2022 Escape and 2022-2024 Maverick. Added to the list are the 2019-2020 Fusion, 2019-2024 Ranger, and some 2016-2018 and 2020-2023 Explorer models. As this is a family affair, the company is also recalling the 2020-2022 Lincoln Corsair and 2016-2019 MKC.
Cause of Fire Hazard
The National Highway Traffic Safety Administration reports that the vehicles may be equipped with an engine block heater that can leak through the contact pins. This problem increases the risk of a fire in the engine compartment, especially when the engine block heater is plugged into an outlet without ground fault protection.
In more detail, the government notes that the heater’s soldered connections may crack near the base of the element, allowing coolant to penetrate the interface between the heater block and the cord.
When the coolant evaporates, it leaves behind conductive salt deposits. These deposits accumulate over time and can eventually corrode electrical connections or form a “salt bridge.” If this happens, a resistive short circuit may occur.
Symptoms and Prevalence of the Problem
Engine block heaters are relatively rare in non-diesel vehicles in the United States, and it is believed that only 1% of the recalled vehicles have the defect. Customers may notice the problem if they see coolant stains on their driveway or in their garage.
Other symptoms include overheating, loss of cabin heat, low coolant level warnings, or smoke coming from the heater block wiring.
Investigation and Identified Cases
Ford learned of the problem in January after a series of fires. They began an investigation and quickly discovered that “coolant could seep into the cord pocket, potentially leading to a short circuit when plugged into a 110V power source.”
As part of the investigation, they conducted radiography and computed tomography of the faulty components, which revealed voids and cracks in the soldered joint. However, the root cause of these issues was never determined.
As of September, Ford was aware of 46 vehicles that were reported to have caught fire. The automaker also received six customer complaints, 30 “legal claims,” and 21 reports from Transport Canada.
Given the prevalence of engine block heaters north of the border, it is not surprising that most problems occurred in Canada.
Consequences and Recommendations
The recall has led to a stop-sale order, as usual, and existing owners are recommended not to use the engine block heater until it is replaced. Unfortunately, this will happen closer to the end of winter, as the remedy is not expected to be available until February 2026.
This recall underscores the importance of thorough testing even for secondary components, especially in regions with harsh climate conditions. The fact that resolving the issue will take over a year indicates the complexity of finding a reliable replacement for the defective part. Owners of affected vehicles are advised to watch for any signs of coolant leakage and contact a dealer immediately if problems are detected.