Ford and Lincoln Plug-In Hybrids Recalled Due to Fire Risk and Potential Shutdowns

Ford Motor Company is initiating a recall affecting over 20,000 plug-in hybrid vehicles due to a potential defect in the high-voltage battery cells that could lead to internal short-circuiting. This issue, previously addressed in an earlier recall, may still result in a loss of propulsion or a vehicle fire, posing a risk of crash and injury. The recall encompasses certain 2021-2024 Lincoln Corsair PHEV models and 2020-2024 Ford Escape PHEV models.

The defect involves the high-voltage battery cells, manufactured by Samsung SDI, which may experience internal short circuits. This condition can cause the vehicle’s propulsion system to shut down unexpectedly, increasing the risk of a crash. Additionally, a short circuit could lead to battery thermal venting, potentially resulting in a vehicle fire. While steering, braking, and lighting functions are not affected, the risk of losing motive power remains a significant concern. The root cause is believed to be related to variability in the battery cell supplier’s production process, potentially damaging the separator layer between the cathode and anode.

This recall supersedes a previous safety action, NHTSA recall 24V954/24S79, which aimed to mitigate this risk by updating the Battery Energy Control Module (BECM) software. The enhanced software was designed to detect cell anomalies indicative of short-circuiting conditions and, upon detection, stop battery charging and notify the customer. However, new information suggests that this software update may not detect these conditions in all instances.

Ford is aware of seven cases of battery cell venting on Kuga PHEV vehicles in Europe that occurred after the previous software remedy was applied. The company is not aware of any accidents or injuries directly related to this specific issue. A comprehensive investigation into the battery packs and control modules from vehicles that experienced venting is ongoing, but thermal damage has prevented a definitive root cause determination from recovered cells.

The remedy for this recall is currently under development. Vehicle owners will be notified by mail and instructed to take their vehicle to a Ford or Lincoln dealer for the remedy to be performed at no cost. In the interim, owners will receive instructions on how to limit the maximum state of charge of their vehicles through the vehicle’s infotainment system or a connected Ford/Lincoln application. They will also be advised to use only “Auto EV” mode until the permanent remedy is available. A guide for performing these interim actions will be provided by mail, and customers can seek assistance from their local dealer.

Owners of potentially affected vehicles can determine if their specific vehicle is part of this recall by contacting Ford’s toll-free line at 1-866-436-7332 or by visiting a local Ford or Lincoln dealer. Dealers can access the Ford On-line Automotive Service Information System (OASIS) database to provide specific information about vehicle applicability. Dealer notification is scheduled for November 18, 2025, with interim owner notifications expected to begin on December 1, 2025. The VIN search functionality is expected to be available on November 18, 2025.

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

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