23S27 – Under Hood Fire – 2020-2023 Ford Escape, 2022-2023 Maverick, & 2021-2023 Lincoln Corsair

May 26, 2023 NHTSA CAMPAIGN NUMBER: 23V380000

Engine Failure May Cause Fire

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
Corsair2021-2023LouisvilleOctober 24, 2019 through May 11, 2023
Escape2020-2023January 09, 2019 through May 23, 2023
Maverick2022-2023HermosilloFebruary 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

MAKEMODELYEAR
FORDESCAPE2020-2023
FORDMAVERICK2022-2023
LINCOLNCORSAIR2021-2023

 


4 Associated Documents

Defect Notice 573 Report

RCLRPT-23V380-2876.PDF 216.269KB

 


Miscellaneous Document – Chronology

RMISC-23V380-7289.pdf 54.009KB

 


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

RCMN-23V380-2733.pdf 45.44KB

 


Recall Acknowledgement

RCAK-23V380-9304.pdf 723.281KB

 


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