Ford has issued a recall affecting approximately 20,000 of its hybrid crossover vehicles, specifically the plug-in hybrid (PHEV) variants of the Ford Escape and Lincoln Corsair. The recall addresses a potential manufacturing defect within the high voltage battery cells that could increase the risk of fire.
According to filings with the National Highway Traffic Safety Administration (NHTSA), the issue lies in the separator layer within the battery cells, which may be susceptible to damage during manufacturing. This defect, present in vehicles equipped with the 2.5-liter PHEV powertrain, could lead to battery pack degradation over time. While Ford estimates the defect rate to be around one percent of the recalled vehicles, the potential consequences include thermal runaway and subsequent battery fires.
Even in less severe cases, the defect could cause a short circuit, potentially disabling parts of the vehicle’s electrical system. Ford has reported four instances of “thermal venting,” a precursor to battery fires, though thankfully, no injuries or accidents have been linked to this issue. It’s important to note that while three of these incidents occurred in Europe, the recall is not geographically limited and affects vehicles in North America as well.
Ford’s Critical Concern Review Group initiated an investigation in November, collaborating with battery supplier Samsung SDI to develop a solution. The remedy involves a software update for the Battery Energy Control Module. This update is designed to provide early warnings of potential electrical problems and identify vehicles with already compromised batteries. Dealers will perform this software flash free of charge. If the software detects an issue, the entire high-voltage battery pack will be replaced at no cost to the owner.
Notifications to affected Ford Escape and Lincoln Corsair PHEV owners are scheduled to begin on January 20th. The recall specifically targets 2.5-liter plug-in hybrid models manufactured between July 10, 2019, and April 17, 2024. Owners who wish to check if their vehicle is affected before receiving notification can contact Ford directly at 866–436–7332 or use the NHTSA recall website (nhtsa.gov/recalls) with their Vehicle Identification Number (VIN).
