Ford Recalls Hybrid SUVs over Battery Defect

Ford has initiated the recall of approximately 20,484 plug-in hybrid SUVs, specifically certain model years of the Ford Escape and Lincoln Corsair vehicles produced between 2020 and 2024. The issue stems from a manufacturing defect in the high-voltage battery cells supplied by Samsung SDI. According to the company, the defect involves potential damage to the separator layer between the cathode and anode within the battery cells, which may result in an internal short circuit.

If an internal short occurs, it could lead to a sudden loss of propulsion, increasing the risk of accidents. Additionally, the defect raises concerns about thermal venting, which could cause the battery to overheat or even catch fire.

Ford stated that the defect triggers a “Stop Safely Now” warning on the instrument cluster, signaling potential issues with the high-voltage battery system. While no injuries or accidents have been reported, the automaker has received four reports of thermal venting incidents linked to the defect. Affected vehicles retain operational steering, braking, and lighting systems despite propulsion loss, but the sudden nature of the issue significantly elevates safety risks.

Lincoln Corsair PHEV. Credit: Ford Motor Co.

Remedies and next steps

Ford has outlined its plan to address the issue, including a software update for the Battery Energy Control Module (BECM) to enhance system monitoring and detection capabilities. For vehicles where the defect is detected, the high-voltage battery pack will be replaced at no cost to the owners.

Owners of the affected vehicles will be notified starting January 20, 2025. They are encouraged to visit authorized dealerships to perform the necessary software updates and battery inspections. Customers can contact Ford’s toll-free line at 1-866-436-7332 for additional information ([NHTSA Recall Report, 2024, https://static.nhtsa.gov/odi/rcl/2024/RCLRPT-24V954-5979.PDF]).

A broader challenge for EV safety

This recall underscores the critical importance of quality control in high-voltage battery manufacturing as automakers navigate the complexities of electrification. As hybrid and electric vehicle production scales, ensuring battery safety and reliability remains paramount. Ford’s proactive measures to address this defect reflect its commitment to maintaining high safety standards and customer satisfaction in an evolving automotive landscape.