Safety Recall 22S21 Right-Hand Engine Oil Separator Inspection – 2020-2022 Ford Escape & 2021-2022 Bronco Sport

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March 25, 2022 NHTSA CAMPAIGN NUMBER: 22V191000

Engine Oil Leak

An oil leak in the presence of an ignition source such as hot engine or exhaust components, can increase the risk of a fire.

 

NHTSA Campaign Number: 22V191

Manufacturer Ford Motor Company

Components ENGINE AND ENGINE COOLING

Potential Number of Units Affected 345,451

 

Summary

Ford Motor Company (Ford) is recalling certain 2020-2022 Escape and 2021-2022 Bronco Sport vehicles equipped with 1.5L engines. The engine oil separator housing may crack and develop an oil leak.

 

Remedy

Dealers will inspect the oil separator for damage or oil leaks, and replace the oil separator and seals, as necessary, free of charge. Owner notification letters were mailed April 18, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 22S21.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Vehicle has a Recall

 


March 30, 2022

NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 22S21
Certain 2021-2022 Model Year Bronco Sport and 2020-2022 Model Year Escape
Vehicles with a 1.5L GTDI Engine
Right-Hand Engine Oil Separator Inspection

 

AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
Bronco Sport 2021-2022 Hermosillo February 5, 2020 through March 4, 2022
Escape 2020-2022 Louisville November 19, 2018 through March 1, 2022

Affected vehicles are identified in OASIS and FSA VIN Lists.

 

REASON FOR THIS SAFETY RECALL

In some of the affected vehicles, the right-hand engine oil separator may have been damaged prior to engine assembly. A damaged oil separator may leak oil, and the customer may smell oil smoke, may see oil smoke emanating from the underhood area, or may observe oil leaks on or under the engine. In some cases, if sufficient oil accumulates and migrates to an ignition source, an underhood fire may occur, increasing the risk of injury.

 

SERVICE ACTION

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to inspect the right-hand engine oil separator for evidence of oil leaks and/or damage. If leaks and/or damage is found, dealers are to replace the right-hand engine oil separator. This service must be performed on all affected vehicles at no charge to the vehicle owner.

 

OWNER NOTIFICATION AND MAILING SCHEDULE

Owner letters are expected to be mailed the week of April 18, 2022. Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

PLEASE NOTE:

Federal law requires dealers to complete this recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $21,000 per vehicle. Correct all vehicles in your new vehicle inventory before delivery.

 

SOLD VEHICLES

  • Ford has not issued instructions to stop selling/delivering or driving used vehicles under this safety recall. Owners should contact their dealer for an appointment to have their vehicles remedied as soon as practicable. Owners can continue to safely drive their vehicle, if they do not see or smell evidence of engine oil smoke.
  • Immediately contact any of your affected customers whose vehicles are not on your VIN list but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date.
  • Correct other affected vehicles identified in OASIS which are brought to your dealership.
  • Dealers are to prioritize repairs of customer vehicles over repairs of new and used vehicle inventory.

 

STOCK VEHICLES

  • Correct all affected units in your new vehicle inventory before delivery.
  • Use OASIS to identify any affected vehicles in your used vehicle inventory.

 

DEALER-OPERATED RENTAL VEHICLES

The Fixing America’s Surface Transportation (FAST) Act law effective June 2016 prohibits a rental company from selling, renting or leasing vehicles subject to a safety or compliance recall. Please consult your legal counsel for legal advice.

 

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this recall.

 

OWNER REFUNDS

This safety recall must still be performed, even if the owner has paid for a previous repair. Claiming a refund will not close the recall on the vehicle.

  • Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. Owners are directed to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 481216251.
  • Dealers are also pre-approved to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed.
  • Refunds will only be provided for the cost associated with a damaged or leaking oil separator.

 

RENTAL VEHICLES

Dealers are pre-approved for up to one day for a comparable rental vehicle. Follow Extended Service Plan (ESP) guidelines for dollar amounts. Rentals will only be reimbursed for the day the vehicle is at the dealership for part replacement. Prior approval for more than one rental day is required from the SSSC. Contact the SSSC via the SSSC Web Contact Site for consideration and approval if appropriate.

 

PARTS REQUIREMENTS

Part Number  Description Order Quantity
HX7Z-6A785-A Right-Hand Engine Oil Separator (only required if leaking and/or damaged) 1
JX6Z-6758-E PCV Line (only required on 2021-2022 MY vehicles when replacing the oil separator) 1 if required

 


CERTAIN 2021-2022 MODEL YEAR BRONCO SPORT AND 2020-2022 MODEL YEAR ESCAPE VEHICLES WITH A 1.5L GTDI  — RIGHT HAND ENGINE OIL SEPARATOR INSPECTION

 

SERVICE PROCEDURE

1. If equipped, remove the engine appearance cover. See Figure 1.

 

2. Locate the Right Hand (RH) Cylinder Head Crankcase Vent Oil Separator. See Figure 2.

 

3. Using an inspection mirror and a flashlight, inspect the RH cylinder head crankcase vent oil separator housing and mating surface for evidence of an oil leak and inspect the RH cylinder head crankcase vent oil separator housing for seal exposure, cracks or damage. See Figures 3 and 4.

 

4. Does the RH cylinder head crankcase vent oil separator housing have evidence of an oil leak, seal exposure, cracks or damage? See Figures 4 and 5.

Yes – Does NOT Pass Inspection – Proceed to Step 5.

No – Passes Inspection – Reassemble the vehicle. FSA is complete.

 

5. Photo submission is required.  Open the driver’s side front door.  Take a picture of the Vehicle Identification Number (VIN) sticker on the lower-A-pillar, and a picture of the suspect RH cylinder head crankcase vent oil separator oil leak, seal exposure, cracks or damage utilizing the inspection mirror for the picture submission. Similar to the photos in Figure 4.

Submit the pictures to the Special Service Support Center (SSSC) for  further review, and part request, showing the reason why the separator is being replaced (damaged separator or evidence of oil leaking).

NOTE: Photos taken for SSSC submission need to have proper lighting, be clear, and have a 50kb or higher file size, to allow decision for parts replacement. Photos that are blurry or that are too dark may be rejected.

NOTE: The RH cylinder head crankcase vent oil separator housing shown out of vehicle for clarity.

 

NOTE: 2020 MY vehicles utilize a PCV tube that has a releasable style of connector, allowing for reuse. All other MY vehicles in this FSA require the PCV connector to be destroyed in order to remove from the oil separator. See Figure 6.

6. Inspect the PCV tube. Is the PCV tube equipped with a quick release connection at both ends? See Figure 6.

Yes – The PCV is equipped with a quick disconnect at both ends. Disconnect the quick release coupling from the RH cylinder head crankcase vent oil separator. Please follow Workshop Manual (WSM) Procedures in Section 310-00A.

No – The PCV is NOT equipped with a quick disconnect at both ends. The tube will need to be replaced. Break the connection at the CAC tube, as the tube and the oil separator are getting replaced.

 

7. Disconnect the electrical connectors and detach the push pin retainers as shown in Figures 7, 8 and 9.    Position aside the wire harness.

 

8. Position aside the engine insulator. See Figures 10 and 11.

NOTICE: Take extra care not to damage the engine insulator.

 

9. Remove the RH cylinder head crankcase vent oil separator. See Figure 12.

 

10. Install a new RH cylinder head crankcase vent oil separator. To install, reverse the removal procedure.

  • Torque: 89 lb.in (10 Nm).

11. Reverse the removal procedure to reassemble the vehicle.

IMPORTANT NOTE: Federal law prohibits selling motor vehicle parts or components that are under safety, compliance, or emissions recall. Unless a part is requested to be returned to Ford, all parts replaced under this FSA must be scrapped in accordance with all applicable local, state and federal environmental protection and hazardous material regulations. Refer to the Parts Retention, Return, & Scrapping section of the FSA dealer bulletin for further information.

 


22S21 Chronology
Ford Motor Company
Date of Submission: March 25, 2022
FSA Number: 22S21
Title: 2020-2022 Escape, 2021-2022 Bronco Sport, 1.5L Engine Oil Separator Leak

On July 19, 2021, NHTSA informed Ford’s Critical Concern Review Group (CCRG) of a Vehicle Owner Questionnaire pertaining to a 2021 Bronco Sport underhood fire.

On July 26, 2021, NHTSA informed Ford’s Critical Concern Review Group (CCRG) of a Vehicle Owner Questionnaire pertaining to a 2021 Escape underhood fire.

From July-October 2021, CCRG investigated the underhood fire reports. Ford Design Analysis Engineering inspected the two VOQ vehicles that experienced underhood fires and observed extensive fire damage to the engine compartment. Although there was no conclusive evidence of a cause for either fire, there was evidence of oil and severe heat damage at the upper rear of the engine. Based on these facts, CCRG opened an investigation into potential leaks at the engine oil separator which was a possible source of oil and is located in the upper rear of the engine. CCRG and Engineering searched for any other reports of 1.5L underhood fires that occurred prior to the July 19, 2021, report. Based upon these reviews, CCRG identified five other cases of underhood fire in 2020-2021 Escape vehicles where leaks at the oil separator may have initiated the fires. Additionally, CCRG and Engineering identified twelve warranty claims for vehicles where the oil separator was replaced for an external oil leak and described a crack in the separator housing. CCRG and Engineering understood underhood fire claims and warranty part replacements were occurring at low time in service and at low vehicle mileage based upon studied reports.

In October 2021 Ford’s supplier Bruss NA and Ford manufacturing implemented visual inspections to ensure there is no damage present for each oil separator shipped from the supplier manufacturing facility, at the engine assembly plant, and at the vehicle assembly plants where completed engines are shipped to.

From November – December 2021 the CCRG worked with the supplier and departments within Ford to understand the potential root cause of oil separator damage and determine if there was a population of vehicles in the field at risk. Ford did not identify any new related claims that occurred during this period. CCRG determined the probability of a damaged oil separator to be low. Additionally, at this time, CCRG determined that due to low time in service of the known failures, and the nature of the symptoms associated with an oil leak, including oil smoke or smell, all damaged separators in the field would have already been identified by owners and repaired.

In January 2022, CCRG placed the investigation into a monitoring period with the understanding that all damaged separators had been remedied under warranty.

On February 16, 2022, Ford met with NHTSA and shared the investigation findings and plan to monitor. NHTSA requested a follow up discussion.

On February 25, 2022 CCRG received a report of a 2021 Escape vehicle that experienced an underhood fire where a leak at the oil separator was suspected as a contributor to the fire.

On March 3, 2022 Ford met with NHTSA and shared the results of the additional vehicle fire identified on February 25.

On March 9, 2022 Ford’s Technical Review Group reviewed the CCRG’s investigation findings.

On March 16, Ford met with NHTSA and shared the plan to present a recommendation to Ford’s Field review Committee.

On March 18, 2022, Ford’s Field Review Committee reviewed the concern and approved a field action.

As of February 23, 2022, there are approximately 14 warranty claims and 1 field report describing leaks from the oil separator. The earliest warranty report describing a leak from the oil separator is May 20, 2021.

Ford is not aware of any reports of accident or injury related to this condition.

 


5 Affected Products

Vehicles

MAKE MODEL YEAR
FORD BRONCO SPORT 2021-2022
FORD ESCAPE 2020-2022

 


8 Associated Documents

Defect Notice 573 Report

RCLRPT-22V191-3103.PDF 213.842KB

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Miscellaneous Document – Chronology

RMISC-22V191-2655.pdf 263.617KB

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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 22S21 Certain 2021-2022 Model Year Bronco Sport and 2020-2022 Model Year Escape Vehicles with a 1.5L GTDI Engine Right-Hand Engine Oil Separator Inspection

RCMN-22V191-6536.pdf 1771.131KB

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Recall Acknowledgement

RCAK-22V191-7458.pdf 645.248KB

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Recall Quarterly Report #1, 2022-2

RCLQRT-22V191-1505.PDF 211.128KB

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ISSUED Renotification Notice

RCRN-22V191-0126.pdf 549.603KB

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Recall Quarterly Report #2, 2022-3

RCLQRT-22V191-3417.PDF 211.228KB

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Recall Quarterly Report #3, 2022-4

RCLQRT-22V191-3999.PDF 211.319KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V191&docType=RCL

 


 

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