Ford Recalls Over 105,000 Mustang Models Due to Water Intrusion Risk

According to a Part 573 Safety Recall Report submitted to the National Highway Traffic Safety Administration (NHTSA) by Ford Motor Company, a significant number of 2024-2025 Ford Mustang vehicles are being recalled due to a defect that could lead to water intrusion into the Body Control Module (BCM). This issue, stemming from improperly sealed body seams, has the potential to affect exterior lighting functions, increasing the risk of a crash. The recall affects approximately 105,441 vehicles produced between September 7, 2022, and July 14, 2025.

The problem originates from inconsistencies in how body seam sealers were applied at the cowl top and lower windshield corners during production. This inadequate sealing can allow water to enter the vehicle’s body structure and potentially reach the BCM. When water infiltrates the BCM, it can disrupt communication with exterior lighting components. This can result in critical lights, such as front and rear side marker lamps, taillamps, and license plate lamps, failing to activate when the low beams are engaged, as required by Federal Motor Vehicle Safety Standard (FMVSS) 108. Additionally, water intrusion may cause these lights to flicker or not remain steadily illuminated, further compromising vehicle visibility and compliance with safety standards.

The safety risk associated with this defect is a reduced ability for other drivers to see the vehicle, particularly at night or in adverse weather conditions, due to the inoperable or intermittently functioning signal lamps. This heightened risk could lead to accidents. Consumers might also observe flickering side marker and taillamps as a warning sign. In some instances, lights may remain activated even after the vehicle is turned off, leading to battery drain and a potential battery warning light appearing on the instrument panel.

Ford’s internal review process initiated an investigation in April 2025 after a durability test revealed headlamp lighting issues in a 2025 Mustang. The investigation escalated as warranty claims related to interior/exterior lighting and battery drain concerns, attributed to water intrusion into BCMs, began to rise in August 2024. Engineering teams conducted extensive vehicle tests between December 2024 and May 2025 to pinpoint the leak sources, identifying multiple points of failure due to improper sealer application. While containment actions were implemented, the investigation team continued to collaborate with BCM hardware specialists to understand the full scope of potential BCM water intrusion effects.

Initially, the investigation was closed in July 2025, with the assessment that vehicles met safety standards upon departure from the assembly plant and that the occurrence rate of water intrusion was low. However, the investigation was reopened in August 2025 following a review of new information concerning early-stage warranty claims. This further analysis indicated that the water intrusion issue could manifest more rapidly than initially thought, potentially impacting compliance with FMVSS standards at the time of sale. As of July 1, 2025, Ford had received 69 warranty claims and 17 field reports documenting water or corrosion at the BCM connectors. The company is not aware of any accidents or injuries linked to this specific condition.

Owners of affected 2024-2025 Ford Mustangs will be notified by mail and instructed to bring their vehicles to a Ford or Lincoln dealership for inspection and repair. The remedy involves verifying the sealing of potentially affected body seams and inspecting the BCM for any signs of water or corrosion. If water or corrosion is present in the BCM connectors, it will be replaced at no cost to the owner. The dealerships will also ensure that body seams are properly sealed to prevent future water intrusion. The remedy aims to provide a BCM free from water and corrosion and a vehicle body with properly sealed seams.

Notification to dealers is scheduled to commence on August 25, 2025, with interim owner notifications expected to be mailed between September 1 and September 5, 2025. The mailing of final remedy notification letters is planned from January 1 to March 31, 2026. Information regarding the applicability of this recall to specific vehicles will be accessible through Ford’s VIN lookup tool starting August 25, 2025. Vehicle owners can also obtain this information by contacting Ford’s toll-free line at 1-866-436-7332 or by visiting a local Ford or Lincoln dealer.

Article by Mel Anara, based upon information from Ford Motor Company

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