An investigation means NHTSA has decided a pattern is worth examining. A
preliminary evaluation is often closed with no action; an engineering
analysis is the stage that usually precedes a recall.
Door Latch Failures
RQ19005
Closed recall query · opened December 19, 2019 · closed February 7, 2022 · led to recall 20V177000
the latches, locks and linkages, the body structure
In December 2019, the Office of Defects Investigation (ODI) opened this investigation based on 235 Vehicle Owner Questionnaires (VOQs) alleging doors failed to latch when closed, and/or inadvertently opened while driving, on model year (MY) 2012-2014 Ford Fiesta, and 2013-2014 Fusion and Lincoln MKZ. Some VOQs reported the failure occurred after the latch had been remedied under a prior recall which involved fracture of the latch pawl spring tab due to thermally induced cyclic fatigue. Other VOQs alleged a similar failure in vehicles not previously recalled. A latch with a fractured pawl spring tab typically results in a ?door will not close? condition, however in certain somewhat rare circumstances, may result in the door coming open while driving. In response to ODI?s investigation, Ford has announced three field actions, as discussed below.On March 23, 2020, Ford submitted Safety Recall 20V-177 (Ford 20S15), a regional recall campaign to address door latch failures in vehicles not previously recalled under Safety Recalls 15V-246, 16V-643 and 17V-210. The recall affects vehicles currently or ever registered in certain high ambient temperature states (see 20V-177 for affected states). As a remedy, Ford will replace all four door latches free of charge.On August 24, 2020, Ford issued a non-safety regional field action (Ford 20R01) to address door latch failures on the same model/MY vehicles not covered under 20V-177 (i.e., not currently/ever registered in affected states). According to Ford, spring tab failure rates for vehicles covered by this action are about half that of the 20V-177 vehicles. Under this action, dealers will replace all door latches, free of charge, if either; a) the vehicle exhibits a related latch concern, or b) if the vehicle owner expresses a concern about the latches in their vehicles. Details can be found under NHTSA TSB No. 10190990, a copy of which is available in this investigative file available at NHTSA.gov.On June 8, 2020, Ford submitted Safety Recall 20V-331 (Ford 20S30) addressing vehicles previously remedied under NHTSA Recalls 15V-246, 16V-643 and 17V-210, where the repair may not have been properly completed, specifically not all of the door latches were replaced, or replaced correctly. This recall involves an inspection of the latches, with the option for a consumer self-inspection; owners could view the date codes on their latches (and confirm child safety locks are present on the rear doors) and then submit the information to Ford?s mobile app or website. A dealership inspection option was also available. Any vehicle found to have unreplaced defective latches requires the replacement of all door latches as directed by Ford.Regarding the 4,494 reports cited above, 1,485 involve scope-related failures (with 13% alleging door opening), and the remaining 3,009 reports involving remedy concerns (with 18% alleging door opening - note ODI was unable to verify the allegations of door opening). The three ODI injuries were all relatively minor. Ford?s reported injury incidences include one (unconfirmed) report of an ejection, three minor injuries with the others involving undisclosed injuries. Ford?s crashes involved two (unconfirmed) crashes alleging the incident door contacted another vehicle and three involving doors striking other property.The recalled vehicles include MY 2011-2015 Ford Fiesta, 2013-2016 Ford Fusion and Lincoln MKZ, 2015 Ford Mustang and Lincoln MKC, 2013-2015 Ford Escape and Ford C-MAX, 2012-2015 Ford Focus and 2014-2016 Ford Transit Connect.Ford's actions address ODI's concerns at this time. ODI will take further action if warranted by new information. The reference (OD
Loss of Motive Power
PE18007
Closed preliminary evaluation · opened July 16, 2018 · closed December 27, 2024
the engine and its cooling
On July 16, 2018, the Office of Defects Investigation (ODI) opened this Preliminary Evaluation (PE) to investigate alleged instances of sudden stalling without warning on model year (MY) 2013 Ford Escape vehicles equipped with 1.6L GTDI turbocharged engines. Complaints alleged that vehicles stalled due to engine overheating, resulting in a delayed or no restart condition. When the investigation was opened, ODI had received 40 Vehicle Owner Questionnaires (VOQs). At this time, ODI has received 173 VOQs with five reported fires and no reported crashes. In investigating the incidents alleged in the VOQs, ODI revisited an apparently related recall that Ford had issued in November 2013 (Recall 13V-583). In Recall 13V-583, Ford recalled all MY 2013 Ford Escape vehicles equipped with the 1.6L engines, built from October 5, 2011, to June 2, 2013. This recall addressed potential engine compartment fires due to localized overheating of the engine cylinder head leading to cracks that can cause oil leaks onto a hot engine surface. The remedy was to provide several enhancements to the engine shielding, cooling and control systems, which involved recalibration of the powertrain calibration module and the instrument cluster system. The recalibration implemented a “Failure Mode Effects Management” (FMEM) strategy to alert the driver of a low coolant state and limit the power to the engine to prevent overheating to the point of cracking the cylinder head. The FMEM strategy includes a “Low Engine Coolant – Service Required” message in the instrument cluster when the coolant reaches a prescribed low level and the engine continues to perform normally, and a coolant level sensor that was incorporated such that if the coolant level is further reduced, the engine enters a reduced power mode (vehicle speed limited to about 40 mph). If the vehicle is driven farther and coolant is not added to the vehicle, the vehicle enters a further reduced power mode and audible and visual alerts will appear and sound, and the engine will be limited to operation at idle speeds. ODI sent Ford an information request letter in August 2018, and, in April 2021, additionally required that Ford provide an update of its field and warranty data. In response, Ford provided 4,047 customer complaints, field reports, and legal claims, consisting of 3,865 unique VINs, and 47,214 warranty claims, consisting of 33,684 unique VINs. Having had repeated discussions with ODI, Ford eventually binned all 4,047 post-recall reports and all 47,214 warranty claims to those that relate to loss of motive power due to coolant loss. Having so binned these reports and claims, Ford reported that the relevant number dropped to 227 reports with 222 unique VINs and 2,774 warranty claims with 1,875 unique VINs. In analyzing its own responsive data, Ford maintained that the remedy for Recall 13V-583 adequately addresses the risk of loss of motive power resulting from an engine overheat due to low coolant by providing clear warnings and progressive reduced power FMEM strategies. Ford further maintained that some complaints imply that the vehicles properly displayed the advanced and progressive warnings and reduced engine power modes, but that complainants ignored them. Ford, therefore, reported that it has not identified any further defect in the coolant system and that it believes the rate of complaints of reduced motive power (which some customers perceive reduced power as vehicle stalls) due to low coolant is low for the subject vehicles. Ford further states it believes that it has not identified any other related unreasonable risk to motor vehicle safety due to loss of motive power due to coolant loss or engine overheat. In addition to analyzing the vast amount of responsive data provided by Ford, ODI worked with NHTSA’s Vehicle Research and Test Center to review 1,462 VOQs with 1,347 unique VINs that were potentially related to this investigation. ODI found that 997 VOQs were relevant post-recall complaints. Of these, 161 VOQs included instances of stalling, sometimes preceded by warnings (low engine coolant message, audible/beeping sound, engine malfunction indicator lamp (MIL) illumination, etc.) and/or drivability issues (reduced power, vehicle jerking or shuddering, etc.). The other categories of complaints/failures were less severe or unrelated/undetermined: 73 related limp mode, nine related stall while vehicle stationary, 21 stalls unknown if related, 271 coolant failure without allegation of stalling, 64 engine MIL with no allegation of stalling, 267 not related to this investigation, 116 unknown if related, and 15 fires (including the initial 5 reports) that were ultimately determined to not be related to this investigation. ODI found that a relatively small percentage of the post-recall complaints involved loss of motive power (161 out of 997 VOQs; and 222 out of 3,865 Ford reports), while the remaining complaints involved vehicles in the early stages of FMEM mode, or were unrelated or undetermined if related to this investigation. ODI has further found that the number of complaints has declined significantly since mid-2021. Based on the analysis of the failure data indicating a declining trend of VOQs of loss of motive power, and in consideration of the remedy for Recall 13V-583 and NHTSA’s ongoing consent order with Ford, ODI is closing this Preliminary Evaluation. The agency will continue to monitor this issue under the heightened oversight pursuant to the consent order and the agency reserves the right to take additional action if warranted. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
Door Latch Failure
PE16001
Closed preliminary evaluation · opened January 16, 2016 · closed October 29, 2016 · led to recall 16V643000
the latches, locks and linkages
In January, the Office of Defects Investigation (ODI) opened this Preliminary Evaluation based on consumers' allegations of doors failing to latch and/or inadvertently opening on model year (MY) 2012-2013 Ford Focus vehicles (subject vehicles).ODI has received 464 unique reports related to the alleged problem, with over 200 claiming that the door(s) opened inadvertently while the vehicle was in motion.One consumer alleged an injury that occurred while driving when a door inadvertently opened and then closed on a child's arm.Another alleged that a door that inadvertently opened struck a parked vehicle.In response to ODI's information request, Ford Motor Company (Ford) provided 500 unique reports related to the alleged problem on the subject vehicles.Ford reported no injury or accident claims.Ford also submitted 1,513 warranty claims related to door latch failures.Many customers indicated that the affected door could not be latched at all and some of them decided to restrain the door by other means in order to operate the vehicle.Some customers also reported door latch failures occurring on multiple doors and at different times.Additionally, Ford stated that MY 2014-2015 Ford Focus, 2013-2015 Ford Escape, 2013-2015 Ford C-Max, 2014-2016 Ford Transit Connect, 2015 Ford Mustang, and 2015 Lincoln MKC, all use the same door latch as the 2012-2013 Ford Focus.On September 6, 2016, Ford notified ODI that it would conduct a safety recall (16V-643) to remedy the door latches in the MY 2012-2015 Ford Focus and other Ford models mentioned above (total of approximately 2 million vehicles).According to Ford, a component within the door latch may break preventing the door from latching.Ford dealers will replace all four door latches in the recalled vehicles with a new more robust latch design that is currently in production.The recall action initiated by the manufacturer appears to address the safety risks.Accordingly, this investigation is closed.The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the identification (ODI) numbers found in the attached list.