September 8, 2023 NHTSA CAMPAIGN NUMBER: 23V626000
High Voltage Battery May Short Circuit
Battery failure can cause a loss of drive power, increasing the risk of a crash. Battery failure can also increase the risk of a fire.
NHTSA Campaign Number: 23V626
Manufacturer Ford
Motor Company
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 2,954
Summary
Ford Motor Company (Ford) is recalling certain 2020-2022 Lincoln Aviator and Ford Explorer vehicles equipped with 3.0L PHEV engines. A manufacturing defect in one or more of the high voltage battery cells may result in an internal short circuit and battery failure.
Remedy
Dealers will perform a Battery Energy Control Module (BECM) diagnostic test and replace the high voltage battery pack, as necessary, free of charge. Owner notification letters are expected to be mailed October 2, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford Motor Company’s number for this recall is 23S53.
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
September 13, 2023
NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice – Safety Recall 23S53
Certain 2020-2022 Model Year Aviator and Explorer Plug-in Hybrid Electric Vehicles
(PHEV) – High Voltage Battery Diagnostic Inspection
AFFECTED VEHICLES
| Vehicle | Model Year | Assembly Plant | Build Dates |
| Aviator | 2020-2021 | Chicago Assembly | June 28, 2019 through September 26, 2020 |
| 2021-2022 | Chicago SHO Center | September 14, 2020 through May 23, 2022 | |
| Explorer | 2020 | Chicago Assembly | July 09, 2019 through September 24, 2020 |
| 2021-2022 | Chicago SHO Center | September 14, 2020 through March 16, 2022 |
US population of affected vehicles: 2,952.
Affected vehicles are identified in OASIS and FSA VIN Lists.
REASON FOR THIS SAFETY RECALL
In some of the affected vehicles, a manufacturing defect in one or more of the vehicle’s high voltage battery cells may result in a cell with lower capacity. In certain cases, the low-capacity cell will develop an internal short circuit.
Customers will experience a Malfunction Indicator Light (MIL) in the event of a high voltage battery cell internal short. Customers may also experience a loss of motive power, increasing the risk of a crash. Customers will continue to have 12-volt (V) accessories, steering, and braking control.
Customer may also experience battery thermal venting potentially resulting in a vehicle fire, increasing the risk of injury.
NOTE: Certain vehicles were determined to not be at risk due to battery cell capacity information available through connected vehicle data and therefore removed from the recall population.
SERVICE ACTION
DO NOT DEMONSTRATE OR DELIVER any new in-stock vehicles involved in this safety recall. For new vehicle storage guidelines, refer to EFC13033. A complete Dealer Bulletin will be provided to dealers in the 4th quarter of 2023 when it is anticipated that software 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 repair instructions and parts ordering information have been provided to dealers.
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.
Date of Submission: 9/8/2023
FSA 23S53 – Certain 2020 – 2022 Ford Explorer, and Lincoln Aviator PHEV Vehicles – Potential Battery Vent
Chronology
On June 28, 2023, an issue pertaining to PHEV battery thermal venting was brought to Ford’s Critical Concern Review Group (CCRG) for review. Ford received a report describing a 2021 model year Transit Custom experiencing PHEV battery thermal venting in France on January 19, 2023. Teardown analysis performed by the battery cell supplier was completed in May 2023 and identified an internal short of a cell in the vehicle’s high voltage battery pack due in part to the presence of a folded anode tab. The supplier determined the folded anode tab was introduced during the cell manufacturing process.
July – August 2023
Supplier investigation and analysis indicated an additional, still undetermined, factor must be present for the cell folded anode tab condition to propagate to battery thermal venting. Supplier component level testing is ongoing to identify this second factor. With this second factor unknown, the CCRG focused on identifying the population of vehicles that may potentially have the cell folded anode tab condition.
Ford’s review of cell supplier process identified cell manufacturing process improvements over the course of cell production to reduce instances of the folded anode tab condition. CCRG used the timing of introduction of these process improvements to determine the affected population.
Ford determined a low cell capacity relative to average capacity of all cells in a battery pack can be used as an indicator of folded anode tab condition. On vehicles where connected vehicle data sharing is enabled by the customer, cell capacity information was reviewed to rule out potential presence of folded anode tab condition.
As of August 11, 2023, Ford was aware of three additional instances of cells with folded anode tabs in the field. One of these instances involved a 2020 model year Aviator in the United States and resulted in PHEV battery thermal venting. The other instances involved a 2020 model year Aviator in the United States resulting in a MIL but no battery thermal venting, and a 2020 model year Aviator in Canada also resulting in a MIL but no battery thermal venting.
On September 01, 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.
6 Affected Products
Vehicles
4 Associated Documents
Defect Notice 573 Report
RCLRPT-23V626-5018.PDF 215.726KB
Miscellaneous Document – Chronology
RMISC-23V626-4749.pdf 33.045KB
Recall Acknowledgement
RCAK-23V626-7600.pdf 645.376KB
Manufacturer Notices(to Dealers,etc) – Advance Notice re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice – Safety Recall 23S53 Certain 2020-2022 Model Year Aviator and Explorer Plug-in Hybrid Electric Vehicles (PHEV) – High Voltage Battery Diagnostic Inspection
Latest Recalls Documents
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-626 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Ford Motor Company Submission Date : SEP 08, 2023 NHTSA Recall No. : 23V-626 Manufacturer Recall No. : 23S53 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 : 2,954 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2020-2022 Lincoln Aviator Vehicle Type : LIGHT VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC Descriptive Information : Ford’s team reviewed supplier process records to determine the population of affected parts. The Ford process is capable of tracing high voltage battery cell production to the vehicle in which the high voltage battery cell is installed. Affected vehicles are equipped w/ 3.0L PHEV engines and suspect high voltage battery cells 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. 2,941 Lincoln Aviator PHEV vehicles are affected. Production Dates : JUN 18, 2019 – MAY 23, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-626 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2020-2022 Ford Explorer Vehicle Type : LIGHT VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC Descriptive Information : Ford’s team reviewed supplier process records to determine the population of affected parts. The Ford process is capable of tracing high voltage battery cell production to the vehicle in which the high voltage battery cell is installed. Affected vehicles are equipped w/ 3.0L PHEV engines and suspect high voltage battery cells 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. 13 Ford Explorer PHEV vehicles are affected. Production Dates : DEC 01, 2019 – DEC 12, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : A manufacturing defect in one or more of the vehicle’s high voltage battery cells may result in a lower capacity cell. In certain cases, the low capacity cell will develop an internal short circuit. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : In the event of a high voltage battery cell internal short, customers may experience a battery power off. A battery power off will result in a loss of motive power with coasting, increasing the risk of crash. Customers will continue to have 12V accessories, steering, and braking control. If a second, still undetermined, factor is present with the folded tab, the customer may experience battery thermal venting potentially resulting in a vehicle fire, increasing the risk of injury. Description of the Cause : The root cause of this condition is partially due to the presence of a folded anode tab within a cell in the high voltage battery. The folded anode tab is introduced during the cell manufacturing process. A folded tab may result in a cell with lower capacity. In addition to the folded tab, a second factor must be present or induced for a cell internal short with thermal venting to result. This factor is still unknown and under investigation. Identification of Any Warning that can Occur : Customer will experience a Malfunction Indicator Light (MIL) in the event of a high voltage battery cell internal short. Part 573 Safety Recall Report 23V-626 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Involved Components : Component Name 1 : UNT ASY BAT H/V TRCT Component Description : High Voltage Battery Pack Component Part Number : L1M* 10B759 AP Supplier Identification : Component Manufacturer Name : LGES Address : 1 LG Way Holland 49423 Country : NR Chronology : Chronology is provided as an attachment. Description of Remedy : Description of Remedy Program : Owners will be notified by mail and instructed to take their vehicle to a Ford or Lincoln dealer to have a Battery Energy Control Module (BECM) diagnostic test performed. If a cell capacity anomaly, indicative of a folded anode tab introduced during cell manufacturing, is detected during the test, dealers will replace the high voltage battery pack. There will be no charge for this service. Ford provided the general reimbursement plan for the cost of remedies paid for by vehicle owners prior to notification of a safety recall in May 2023. The ending date for reimbursement eligibility is estimated to be December 14, 2023. Ford will forward a copy of the notification letters to dealers to the agency when available. How Remedy Component Differs from Recalled Component : Replacement high voltage battery packs will have cells that are produced post-supplier manufacturing process improvements. Part 573 Safety Recall Report 23V-626 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : Notification to dealers is expected to occur on September 13, 2023. Mailing of owner notification letters is expected to begin October 2, 2023, and is expected to be completed by October 6, 2023. Planned Dealer Notification Date : SEP 13, 2023 – SEP 13, 2023 Planned Owner Notification Date : OCT 02, 2023 – OCT 06, 2023 * NR – Not Reported
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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 September 13, 2023 TO: All U.S. Ford and Lincoln Dealers SUBJECT: NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice – Safety Recall 23S53 Certain 2020-2022 Model Year Aviator and Explorer Plug-in Hybrid Electric Vehicles (PHEV) – High Voltage Battery Diagnostic Inspection AFFECTED VEHICLES Vehicle Model Year Assembly Plant Build Dates Aviator PHEV 2020-2021 Chicago Assembly June 28, 2019 through September 26, 2020 2021-2022 Chicago SHO Center September 14, 2020 through May 23, 2022 Explorer PHEV 2020 Chicago Assembly July 09, 2019 through September 24, 2020 2021-2022 Chicago SHO Center September 14, 2020 through March 16, 2022 US population of affected vehicles: 2,952. Affected vehicles are identified in OASIS and FSA VIN Lists. REASON FOR THIS SAFETY RECALL In some of the affected vehicles, a manufacturing defect in one or more of the vehicle’s high voltage battery cells may result in a cell with lower capacity. In certain cases, the low-capacity cell will develop an internal short circuit. Customers will experience a Malfunction Indicator Light (MIL) in the event of a high voltage battery cell internal short. Customers may also experience a loss of motive power, increasing the risk of a crash. Customers will continue to have 12-volt (V) accessories, steering, and braking control. Customer may also experience battery thermal venting potentially resulting in a vehicle fire, increasing the risk of injury. NOTE: Certain vehicles were determined to not be at risk due to battery cell capacity information available through connected vehicle data and therefore removed from the recall population. Ó Copyright 2023 Ford Motor Company SERVICE ACTION DO NOT DEMONSTRATE OR DELIVER any new in-stock vehicles involved in this safety recall. For new vehicle storage guidelines, refer to EFC13033. A complete Dealer Bulletin will be provided to dealers in the 4th quarter of 2023 when it is anticipated that software 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 repair instructions and parts ordering information have been provided to dealers. 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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