Ford Motor Company has announced a recall affecting certain 2025 model-year vehicles, including the Transit, F-150, and Explorer, due to a manufacturing defect that may lead to engine failure and an increased risk of crashes. Affected vehicles were found to have mis-machined connecting rods, a critical engine component, potentially resulting in mechanical failure without warning.
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The recall impacts a total of 154 vehicles. Specifically, 15 units of the Ford Transit produced between March 7 and March 17, 2025, 135 units of the Ford F-150 produced from February 26 to March 10, 2025, and 4 units of the Ford Explorer produced on February 28, 2025, are included. The defect stems from a machining tool that was incorrectly installed, causing improper machining and insufficient bolt head clearance, which could lead to deformation or fatigue in the engine’s connecting rod assembly.
The problem was first identified on April 3, 2025, after defective parts were rejected during assembly at Ford’s Cleveland Engine Plant. Subsequent investigations traced the issue back to the Essex Engine Plant, where the tool installation error occurred during two production shifts in February. Although no accidents, injuries, or complaints have been reported, Ford’s Field Review Committee approved a field action on May 16, 2025, to address the problem.
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Owners of the affected vehicles will be notified by mail starting June 9, 2025. Ford advises consumers not to drive the impacted vehicles and to park them outside until repairs are completed. The remedy is currently under development, and repairs will be performed free of charge once available. Vehicle owners can contact their local Ford or Lincoln dealer or call Ford’s toll-free number for more information. VINs for the affected vehicles will be searchable starting May 27, 2025.
Article by multiple contributors, based upon information from Ford Motor Company press release.
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