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May 26, 2023 NHTSA CAMPAIGN NUMBER: 23V380000
An engine compartment fire increases the risk of injury.
NHTSA Campaign Number: 23V380
Manufacturer Ford
Motor Company
Components ENGINE
Potential Number of Units Affected 125,322
Summary
Ford Motor Company (Ford) is recalling certain 2020-2023 Escape, 2022-2023 Maverick, and 2021-2023 Corsair vehicles equipped with 2.5L HEV or PHEV engines. In the event of an engine failure, engine oil and fuel vapor may be released into the engine compartment and accumulate near ignition sources such as hot engine or exhaust components, possibly resulting in an engine compartment fire.
Remedy
Owners are advised to park and shut off the engine as quickly as possible if they hear unexpected engine noises, notice a reduction in vehicle power, or see smoke. The remedy is currently under development. Letters notifying owners of the safety risk are expected to be mailed June 12, 2023. Second letters will be mailed once the remedy is available. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 23S27. This recall expands and replaces recall number 22V-484. Vehicles previously repaired under 22V-484 will need to have the new remedy completed.
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
NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice – Safety Recall 23S27
Certain 2021-2023 Model Year Corsair, 2020-2023 Escape and 2022-2023 Maverick
Vehicles Equipped With 2.5L HEV/PHEV Engine
Under Hood Fire
AFFECTED VEHICLES
| Vehicle | Model Year | Assembly Plant | Build Dates |
| Corsair | 2021-2023 | Louisville | October 24, 2019 through May 11, 2023 |
| Escape | 2020-2023 | January 09, 2019 through May 23, 2023 | |
| Maverick | 2022-2023 | Hermosillo | February 3, 2021 through May 18, 2023 |
US population of affected vehicles: 124,739. Affected vehicles are identified in OASIS and FSA VIN Lists.
REASON FOR THIS SAFETY RECALL
Isolated engine manufacturing issues can cause the engine to fail prematurely. In the event of an engine failure, engine oil and/or fuel vapor may be released into the under-hood environment and may migrate to and/or accumulate near ignition sources, increasing the risk of fire and injury. Engine failure is expected to produce loud noises (example: metal-to-metal clank) audible to the vehicle’s occupants. An engine failure will also result in a reduction in available engine power.
In Owner Letters mailed to customers, Ford will advise customers to safely park and shut off the engine as promptly as possible upon hearing unexpected engine noises, after experiencing a reduction in available engine power, or if smoke is observed emanating from the engine compartment.
SERVICE ACTION
DO NOT DEMONSTRATE OR DELIVER any new in-stock vehicles involved in this safety recall. A complete Dealer Bulletin will be provided to dealers in the 4th quarter when it is anticipated that a remedy and repair instructions will be available to support this safety recall.
IMPORTANT: Dealers should open a Repair Order (RO) only when a full dealer bulletin is published. Opening an RO against an Awareness or Advance Notice will result in warranty rejections against a recall.
CUSTOMER NOTIFICATION
Owners of record will be notified via first-class mail after the remedy and repair instructions have been provided to dealers.
RENTAL VEHICLES
Ford has not issued instructions to stop driving vehicles under this safety recall. However, if a
customer contacts your dealership requesting a rental/loaner prior to recall remedy availability, please contact the SSSC for further direction.
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 $26,315 per vehicle. Correct all vehicles in your new vehicle inventory prior to delivery.
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.
23S27 CHRONOLOGY
June 2022: Ford’s Field Review Committee approved field action 22S47 to address the risk of an under hood fire after an engine block breach on certain 2020-2022 Escape/Corsair/Maverick HEV/PHEV vehicles equipped with 2.5L engines built on or before July 7, 2022 after Ford’s Critical Concern Review Group (CCRG) identified 23 reports globally of under hood fire or smoke after a suspected block or oil pan breach.
The service remedy for 22S47 modifies the under-engine shield and active grille shutters to redirect and/or purge the engine compartment of engine oil and/or fuel vapor from known ignition sources to reduce the opportunity for under hood fire. These corrective actions were implemented in production at Louisville Assembly Plant on June 13, 2022 and at Hermosillo Stamping and Assembly Plant on July 7, 2022.
July – August 2022: Ford’s Chihuahua Engine Plant continued to implement additional robustness actions to reduce engine failures and block breaches improving crankshaft machining/finishing operations and reducing contamination introduced during engine assembly. Ford launched the 22S47 service remedy in August 2022. Ford’s CCRG continued to monitor the field performance of these engines after the production actions were implemented and the recall was launched.
August 2022 – December 2022: Ford’s CCRG received three reports of under hood fires globally on vehicles that were included in the 22S47 population. Records indicated that all three vehicles had received the recall remedy. At this time, Ford did not have enough information to determine if the fires resulted from an engine block breach.
January 2023: Ford’s Design Analysis Engineering team reviewed photographs of the vehicle from one of the under hood fire reports received between August – December 2022 and confirmed a block breach and that the recall remedy was performed correctly on the vehicle. On January 31, 2023, the issue pertaining to under hood fires after the 22S47 recall remedy was brought to Ford’s CCRG for review.
February 2023 – May 2023: A Ford dealer in Europe inspected one of the previously identified vehicles that sustained an under hood fire and confirmed a block breach. Ford’s CCRG received two reports globally of under hood fire on vehicles produced after the 22S47 clean point. Ford’s inspection of these vehicles confirmed that a block breach is present.
After investigating the reported fires, the CCRG determined that the risk of block breach and fire is likely exacerbated by the PHEV/HEV system which allows the customer to continue to drive the vehicle following a bearing failure and loss of the gasoline engine torque.
Ford’s CCRG conducted analysis of engine warranty data including all engine failures resulting from a worn crankshaft bearing on these vehicles. The CCRG reviewed the rates of engine replacement attributed to a worn crankshaft bearing and compared it to engines produced with the robustness actions and concluded that engines produced before the robustness actions were fully implemented in August 2022 have elevated rates of engine replacement. There have been no reports of engine block breaches on engines built after September 1, 2022.
Based on occurrences of 2.5L HEV/PHEV under hood fires on vehicles that had 22S47 completed or were built with the containment actions, Ford’s CCRG and Technical Review Committee recommended a safety recall for vehicles that were built with engines manufactured on or before September 1, 2022, when the engine robustness actions were fully implemented.
On May 19, 2023, Ford’s Field Review Committee reviewed the concern and approved a field action.
Ford is not aware of any reports of accident or injury related to this condition.
9 Affected Products
Vehicles
4 Associated Documents
Defect Notice 573 Report
RCLRPT-23V380-2876.PDF 216.269KB
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Miscellaneous Document – Chronology
RMISC-23V380-7289.pdf 54.009KB
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Manufacturer Notices(to Dealers,etc) – Advance Notice re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice – Safety Recall 23S27 Certain 2021-2023 Model Year Corsair, 2020-2023 Escape and 2022-2023 Maverick Vehicles Equipped With 2.5L HEV/PHEV Engine Under Hood Fire
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Recall Acknowledgement
RCAK-23V380-9304.pdf 723.281KB
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SEOCONTENT-START
Ó Copyright 2023 Ford Motor Company Stacy L. Balzer Ford Motor Company Operating Director P. O. Box 1904 Service Engineering Operations Dearborn, Michigan 48121 Ford Customer Service Division May 31, 2023 TO: All U.S. Ford and Lincoln Dealers SUBJECT: NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice – Safety Recall 23S27 Certain 2021-2023 Model Year Corsair, 2020-2023 Escape and 2022-2023 Maverick Vehicles Equipped With 2.5L HEV/PHEV Engine Under Hood Fire AFFECTED VEHICLES Vehicle Model Year Assembly Plant Build Dates Corsair 2021-2023 Louisville October 24, 2019 through May 11, 2023 Escape 2020-2023 January 09, 2019 through May 23, 2023 Maverick 2022-2023 Hermosillo February 3, 2021 through May 18, 2023 US population of affected vehicles: 124,739. Affected vehicles are identified in OASIS and FSA VIN Lists. REASON FOR THIS SAFETY RECALL Isolated engine manufacturing issues can cause the engine to fail prematurely. In the event of an engine failure, engine oil and/or fuel vapor may be released into the under-hood environment and may migrate to and/or accumulate near ignition sources, increasing the risk of fire and injury. Engine failure is expected to produce loud noises (example: metal-to-metal clank) audible to the vehicle’s occupants. An engine failure will also result in a reduction in available engine power. In Owner Letters mailed to customers, Ford will advise customers to safely park and shut off the engine as promptly as possible upon hearing unexpected engine noises, after experiencing a reduction in available engine power, or if smoke is observed emanating from the engine compartment. SERVICE ACTION DO NOT DEMONSTRATE OR DELIVER any new in-stock vehicles involved in this safety recall. A complete Dealer Bulletin will be provided to dealers in the 4th quarter when it is anticipated that a remedy and repair instructions will be available to support this safety recall. IMPORTANT: Dealers should open a Repair Order (RO) only when a full dealer bulletin is published. Opening an RO against an Awareness or Advance Notice will result in warranty rejections against a recall. CUSTOMER NOTIFICATION Owners of record will be notified via first-class mail after the remedy and repair instructions have been provided to dealers. Ó Copyright 2023 Ford Motor Company RENTAL VEHICLES Ford has not issued instructions to stop driving vehicles under this safety recall. However, if a customer contacts your dealership requesting a rental/loaner prior to recall remedy availability, please contact the SSSC for further direction. 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 $26,315 per vehicle. Correct all vehicles in your new vehicle inventory prior to delivery. 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. QUESTIONS & ASSISTANCE For questions and assistance, contact the Special Service Support Center (SSSC) via the SSSC Web Contact Site. The SSSC Web Contact Site can be accessed through the Professional Technician System (PTS) website using the SSSC link listed at the bottom of the OASIS VIN report screen or listed under the SSSC tab. Sincerely, Stacy L. Balzer
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-380 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Ford Motor Company Submission Date : MAY 26, 2023 NHTSA Recall No. : 23V-380 Manufacturer Recall No. : 23S27 Manufacturer Information : Manufacturer Name : Ford Motor Company Address : 330 Town Center Drive Suite 500 Dearborn MI 48126-2738 Company phone : 1-866-436-7332 Population : Number of potentially involved : 125,322 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2020-2023 Ford Escape Vehicle Type : LIGHT VEHICLES Body Style : Power Train : NR Descriptive Information : Ford’s team reviewed plant records to determine the population of affected parts. The Ford process is capable of tracing engine production to the vehicle in which the engine is installed. Affected vehicles are equipped with 2.5L HEV or PHEV engines. 86,656 Escape vehicles are affected. These vehicles are not produced in VIN order. Information as to the applicability of this action to specific vehicles can best be obtained by either calling Ford’s toll-free line (1-866-436-7332) or by contacting a local Ford or Lincoln dealer who can obtain specific information regarding the vehicles from the Ford On-line Automotive Service Information System (OASIS) database. Production Dates : JAN 01, 2019 – MAY 23, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-380 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2022-2023 Ford Maverick Vehicle Type : LIGHT VEHICLES Body Style : Power Train : NR Descriptive Information : Ford’s team reviewed plant records to determine the population of affected parts. The Ford process is capable of tracing engine production to the vehicle in which the engine is installed. Affected vehicles are equipped with 2.5L HEV engines. 35,501 Maverick vehicles are affected. These vehicles are not produced in VIN order. Information as to the applicability of this action to specific vehicles can best be obtained by either calling Ford’s toll-free line (1-866-436-7332) or by contacting a local Ford or Lincoln dealer who can obtain specific information regarding the vehicles from the Ford On-line Automotive Service Information System (OASIS) database. Production Dates : FEB 03, 2021 – MAY 18, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2021-2023 Lincoln Corsair Vehicle Type : LIGHT VEHICLES Body Style : Power Train : NR Descriptive Information : Ford’s team reviewed plant records to determine the population of affected parts. The Ford process is capable of tracing engine production to the vehicle in which the engine is installed. Affected vehicles are equipped with 2.5L PHEV engines. 3165 Corsair vehicles are affected. These vehicles are not produced in VIN order. Information as to the applicability of this action to specific vehicles can best be obtained by either calling Ford’s toll-free line (1-866-436-7332) or by contacting a local Ford or Lincoln dealer who can obtain specific information regarding the vehicles from the Ford On-line Automotive Service Information System (OASIS) database. Production Dates : OCT 24, 2019 – MAY 11, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-380 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Defect : Description of the Defect : Affected vehicles have 2.5L HEV/PHEV engines that could fail prematurely. In the event of an engine failure, significant quantities of engine oil and/or fuel vapor may be released into the under hood environment and may migrate to and/or accumulate near ignition sources resulting in potential under hood fire, localized melting of components, or smoke. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Engine oil and/or fuel vapor that accumulates near a sufficiently hot surface, below the combustion initiation flame speed, may ignite resulting in an under hood fire, and increasing the risk of injury. Description of the Cause : Isolated engine manufacturing issues have resulted in 2.5L HEV/PHEV engine failures involving engine block or oil pan breach. In the event of an engine block or oil pan breach, the HEV/PHEV system continues to propel the vehicle allowing the customer to continue to drive the vehicle. As the customer continues to drive after a block breach, oil and/or fuel vapor continues to be expelled and accumulates near ignition sources, primarily expected to be the exhaust system. Identification of Any Warning that can Occur : Engine failure is expected to produce loud noises (example: metal-to-metal clank) audible to the vehicle’s occupants. An engine failure will also result in a reduction in engine torque. In Owner Letters mailed to customers, Ford will advise customers to safely park and shut off the engine as promptly as possible upon hearing unexpected engine noises, after experiencing an unexpected torque reduction, or if smoke is observed emanating from the engine compartment. Involved Components : Component Name 1 : Engine Component Description : Engine bare Component Part Number : LX6Z-6006-A Supplier Identification : Component Manufacturer Name : Ford Motor Company Address : One American Road Part 573 Safety Recall Report 23V-380 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Dearborn Michigan 48126 Country : United States Chronology : Chronology is attached. Description of Remedy : Description of Remedy Program : The service remedy is currently being developed and expected to be available in the third quarter of 2023. Owners of vehicles will be notified by mail that Ford’s investigation is ongoing and they will be contacted when further information is available. In letters mailed to owners, Ford will also advise customers to safely park and shut off the engine as promptly as possible upon hearing unexpected engine noises, or after experiencing an unexpected torque reduction, or seeing smoke from the engine compartment. Ford will notify the Agency and update this defect notice when the repair is defined. Ford provided the general reimbursement plan for the cost of remedies paid for by vehicle owners prior to notification of a safety recall in June 2021. The ending date for reimbursement eligibility is expected to be June 30, 2024. Ford will forward a copy of the notification letters to dealers to the agency when available. How Remedy Component Differs from Recalled Component : The service remedy is currently being developed. Identify How/When Recall Condition was Corrected in Production : Robustness actions to reduce engine failures and block breaches, and therefore reduce the risk of fire, were implemented at the engine plant on or before September 1, 2022. Recall Schedule : Description of Recall Schedule : Notification to dealers is expected to occur on May 31, 2023. Mailing of owner notification letters is expected to begin June 12, 2023 and is expected to be completed by June 16, 2023 advising owners that a repair is anticipated to be available in the third quarter of 2023. Planned Dealer Notification Date : MAY 31, 2023 – MAY 31, 2023 Planned Owner Notification Date : JUN 12, 2023 – JUN 16, 2023 * NR – Not Reported
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