Ford Recalls Thousands of E-Series Vans Over Engine Cover Fire Risk

Dearborn, MI – Ford Motor Company is initiating a recall affecting 7,046 model year 2021 E-Series vehicles due to a potential fire hazard caused by improperly installed software related to a previous safety recall. According to a report submitted to the National Highway Traffic Safety Administration (NHTSA), these vehicles may still possess an engine cover with mispositioned insulation, which could lead to elevated temperatures on the passenger compartment surface of the engine cover. This condition is a continuation of the risk identified in Safety Recall 20S73 / 20V-795.

The defect stems from an issue where the remedy for Safety Recall 20S73 / 20V-795 was incorrectly recorded as completed when it may not have been. The underlying problem involves an engine cover insulation that did not fully extend to the perimeter as intended, due to insufficient manufacturing tolerances and a lack of comprehensive testing across all engine operating conditions. This can allow heat from the engine compartment to cause the passenger compartment side of the engine cover to become excessively hot. The safety risk associated with this condition, as previously identified, is the potential for direct and continuous contact with certain areas of the engine cover surface to cause burns to the skin of the driver or front seat passenger. Ford has indicated that warning signs may include a gradual increase in the surface temperature of engine cover corners near the driver or front passenger’s feet.

The issue was first brought to Ford’s attention on November 26, 2024, when an internal audit flagged potential discrepancies in software part numbers applied during service actions related to recall 20S73. A subsequent investigation involving a cross-functional team began in December 2024 to audit all software field service actions (FSAs) that utilized the FDRS service tool. This audit confirmed that while most vehicles received the correct software update, a significant number were recorded as repaired without actually having the necessary software installed. Ford officially informed NHTSA of this concern on December 19, 2024, outlining plans to address the affected vehicles.

By October 30, 2025, the audit of recall 20S73 was completed, revealing that approximately 69.71% of repairs had the correct software installed. The specific vehicles that did not receive the 20S73 software update, despite being marked as repaired, were identified. Following a review by Ford’s Field Review Committee on November 7, 2025, the company approved the current field action. Ford has stated that they are not aware of any accidents or injuries linked to this specific condition.

The remedy for this recall will involve installing the intended software update for 20S73 / 20V-795. Ford will notify dealers of the recall on December 22, 2025. Owners of affected vehicles are expected to receive notification letters beginning January 5, 2026, with the mailing process scheduled to conclude by January 9, 2026. Vehicle identification numbers (VINs) for affected vehicles will be searchable on the NHTSA website starting December 22, 2025, allowing owners to check their vehicle’s recall status. Ford will utilize its general reimbursement plan on file for any applicable expenses.

Owners with concerns can contact Ford’s toll-free customer service line at 1-866-436-7332 or a local Ford or Lincoln dealership. The dealership can access specific vehicle information through the Ford On-line Automotive Service Information System (OASIS) database.

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

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