Ford Motor Company is poised to exceed 150 vehicle recalls before the end of 2025, currently standing at 143 with two new campaigns adding to the total. These issues span from critical powertrain defects in electric vans to improperly secured seat belts in newer models, raising concerns about quality control and potential safety risks.
E-Transit Rollaway Risk: A Powertrain Defect
The first recall affects 32,160 Ford E-Transit vans manufactured between 2022 and 2025. The issue stems from a flaw in the powertrain where the left rear half shafts may not be fully secured into the primary drive unit. This can lead to premature wear, insufficient spline engagement, and ultimately, loss of drive power or even a rollaway situation – even when parked.
The problem surfaced during a durability test in May 2024, revealing a leak in the rear axle. Ford’s subsequent investigation found that assembly process specifications were inadequate, failing to ensure proper shaft insertion. While only four warranty claims and no accidents have been reported so far, the company estimates 5% of recalled vans are affected.
Notably, there is no immediate fix available. Owners will be notified and informed when a remedy is developed, with an estimated timeline of March 2026. The delay highlights the complexity of rectifying such a fundamental mechanical flaw.
Seat Belt Retractor Failure in Escape and Corsair Models
The second recall involves 780 Ford Escape and Lincoln Corsair vehicles from the 2025 and 2026 model years. The issue centers on rear seat belt retractors that were not properly secured during assembly. The problem originated at an off-line repair station within the Louisville Assembly Plant, where incomplete or improper repairs left the retractors inadequately fastened.
Five warranty claims involving binding or noisy seat belt mechanisms alerted Ford to the issue. Investigation confirmed that the retractors were not securely attached to the vehicle’s D-pillar.
The fix is straightforward: dealers will inspect and either secure or replace the faulty bolts. Owner notifications are expected to begin later this week.
These recalls underscore ongoing quality control challenges within Ford’s manufacturing processes. The increasing number of recalls not only impacts consumer trust but also raises questions about the effectiveness of current testing and assembly procedures. The automaker’s ability to address these issues swiftly and reliably will be critical in restoring confidence among buyers.
