20 Major Malfunctions Ford Tried To Bury

The auto industry in the U.S. may not be having a very good year. But that doesn’t mean that a significant number of cars aren’t being driven off a lot. In fact, Ford has been making some sales despite the downward shift in overall consumer purchase. This is perhaps because the carmaker makes exactly what car buyers want today: SUVs and pickup trucks.

According to Statista, the American carmaker managed to capture 14 percent of the U.S. market in 2018. And perhaps, it would have captured more if only one of its auto parts suppliers, Meridian Magnesium, did not experience factory fire back in May 2018.

In recent years, Ford has definitely shown that it can hold its own against any type of competition. However, that doesn’t mean that its cars have not been plagued by malfunctions in the past.

Let’s take a look back at some of these major issues:

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20 Faulty passenger side curtain airbag

via whichcar.com.au

According to the National Highway Traffic Safety Administration’s recall information (NHTSA) concerning the 2013 Ford Fiesta, “An occupant in the right rear seating position will not have coverage from the side curtain air bag in a side impact collision when the front passenger seat is empty, increasing the risk of injury to the right rear occupant.”

19 Faulty second-row head restraint

via motortrend.com

According to a Noncompliance Notice regarding the 2012 Ford Expedition, “An investigation of the head restraint on this vehicle was conducted and it was determined the head restraint guide sleeve had inadequate weld penetration to the seat back frame to fully secure the head restraint A further investigation was conducted that included review of warranty reports, inspection of vehicles at the assembly plant, supplier process reports, dimensional analysis of seat component parts, and supplier capability. It was determined that one of two weld fixtures used to locate the head restraint guide sleeves to the seat back frame had loose components.”

18 Stuck canister purge valve

via whatsyourrush.net

As a Defect Notice issued by Ford regarding the 2012 Focus revealed, “A CPV that is stuck open in these vehicles can cause excessive vacuum in the fuel vapor management system, potentially deforming the fuel tank. If this occurs, the customer may observe a Malfunction Indicator Light (MIL), inaccurate or erratic fuel gauge indication, drivability concerns or loss of motive power.”

17 Doors opening unexpectedly

via speednik.com

According to a press release issued by Ford, “In the affected vehicles, the pawl spring tab in the side door latch could break. A door latch with a fractured pawl spring tab typically results in a “door-will-not-close” condition.” Affected vehicles include the 2012 to 2015 Focus, 2015 Mustang, 2013 to 2015 Ford C-Max, 2015 Lincoln MKC and 2014 to 2015 Ford Transit Connect.

16 Fuel pump malfunction

via youtube.com, Steve Cronin channel

As Ford explained in a press release, “In the affected vehicles, the fuel pump control module could fail, which may cause an engine to not start or stall. In some cases, the engine could stall without warning while driving and without the ability to restart, increasing the risk of a crash.” As many as 88,151 vehicles in the U.S. were said to be affected, including the 2013 to 2015 Ford Police Interceptor sedan.

15 Faulty hub unit bearing

via youtube.com, DannyDoItAll channel

According to Ford’s Defect Notice, “If a drive axle hub is installed on the rear non-drive axle of a FWD vehicle, the absence of a halfshaft retaining nut will result in the hub having excessive looseness when driven. This may result in grinding or rubbing noise from the brake rotor noise and vibration, wheel wobbling while driving, and/or an ABS

malfunction light. If the vehicle continues to be driven in this condition and the

caliper or caliper bolts break, the rear wheel could separate from the vehicle.”

14 Unexpected transmission downshift

via youtube.com, rwmgd2 channel

According to the Safety Recall Report filed with the NHTSA regarding the 2011 F-150, “Depending on the vehicle speed at the time of an intermittent OSS failure, an abrupt transmission downshift to first gear could occur. A downshift to first gear without warning could result in a loss of vehicle control, increasing the risk of a crash.”

13 Windshield bubbles

via f150forum.com

Regarding the issue, Ford explained in a report, “Certain manufacturing conditions at the supplier may have allowed air particles to be trapped between the layers of glass. When the windshield is exposed to high temperatures, such as when the vehicle is parked in the sun with the windows closed in ambient temperatures greater than 80° Fahrenheit, bubbles may develop.” Affected models include the 2011 E-150, E-250, E-350, and E-450.

12 Shattering roof hatch glass

via cargurus.com

According to Ford’s Defect Notice regarding the 2018 Transit, “Hot/cold and vibration/shock can create stress concentrations at these edge defects that may result in fracture and failure of the tempered glass if edge damage is present.” Furthermore, records from the NHTSA indicate that the 2019 model is also affected by this issue.

11 Restraint system misclassification

via motortrend.com

According to a press release issued by Ford, “If the multicontour front passenger seat massage function is turned on and an adult is in that seat, the occupant classification system may incorrectly classify the adult as a child – suppressing the front passenger airbag and increasing the risk of injury in a crash.” This issue affected the 2016 F-150.

10 Cracking fuel tank

via cargurus.com

According to a press release issued by Ford, “The fuel tank might not have been manufactured properly and could crack in a crash, which is a compliance issue with FMVSS 301 regarding fuel system integrity. A fuel leak in the presence of an ignition source could lead to a fire.” Affected vehicles include the 2016 Ford Fusion and the 2016 Lincoln MKZ.

9 Cracked fuel line

via ford-trucks.com

According to Ford’s Defect Notice concerning the 2012 Ford Edge, “Fuel line pulse damper metal housings may crack as a result of an improper manufacturing process. Cracked fuel line pulse damper metal housings may result in a combination of fuel odor, weepage, or a continuous leak while the fuel system is pressurized.”

8 Loss of service brake pressure

via youtube.com, Cody Gaudlip channel

In a Defect Notice prepared by Ford regarding the 2011 E-350, the carmaker explained, “The rear sway bar frame mounting bolt threads may come in contact with the steel hydraulic brake line. If metal-to-metal abrasion occurs, the brake line may eventually rupture and cause a loss of hydraulic service brake pressure. If a loss of service brake pressure occurs a sudden brake failure may cause the vehicle to lose control and crash.”

7 PTO pressure switch oil leak

via phtruck.com

According to the recall information from NHTSA, “The leaking oil may soak into the thermal blanket covering the exhaust which when combined with heat from exhaust, may result in an increased risk of fire.” The affected models include the 2009 to 2013 F-350, F-450 and F-550 Super Duty chassis that were modified by PJ’s Truck Bodies & Equipment Co.

6 Parking brake failing to fully engage

via blog.consumerguide.com

According to a press release issued by Ford, “In these vehicles, the parking brake

might not engage fully, which is a compliance issue with FMVSS 135 regarding brake systems.” Affected models include the 2015 to 2016 Ford Explorer, 2015 Ford Taurus, 2015 Ford Flex, 2015 Lincoln MKS and certain Lincoln MKT units.

5 Halfshaft and linkshaft disengagement

via speednik.com

According to Ford’s Defect Notice, “In some of the affected vehicles, the halfshaft retention circlip may not have been fully engaged. If the circlip is not fully engaged, the splines between the linkshaft and halfshaft may move outward over time, which can result in noise and vibration, teeth shear and/or halfshaft disengagement from the linkshaft. If the two shafts fully disengage, the halfshaft will no longer transmit torque to the wheel and the customer can experience loss of drive function.” Affected vehicles include the 2013 to 2014 Ford Flex, Ford Taurus and Lincoln MKS models.

4 Possible steering wheel detachment

via motortrend.com

According to a press release issued by Ford, “In affected vehicles, the steering wheel bolt may not maintain torque, allowing the bolt to loosen over time, and if not serviced, a steering wheel could potentially detach and lead to a loss of steering control and increased risk of a crash.” Affected vehicles include the 2014 to 2017 Ford Fusion and 2014 to 2018 Lincoln MKZ.

3 Loss of power steering assist

via ford-trucks.com

According to a copy of the Owner Notification letter issued by Ford, “On your vehicle, the power steering system may revert to manual steering mode while driving due to a steering system sensor fault. If this condition should occur, a message will display in the Instrument Cluster Message Center, a chime will sound, and the steering effort may be greater at low speeds, which may increase the risk of accident.” Affected models include the 2011 to 2013 Explorer.

2 Engine continues to run unexpectedly

via youtube.com, SrKyAaTnE4162 channel

According to a press release issued by Ford, “It could be possible for the engine to continue to run after turning the ignition key to the “off” position and removing

the key, or after pressing the Engine Start/Stop button. This is a compliance issue with FMVSS 114 regarding theft protection and rollaway prevention.” Affected models include the 2015 Escape, C-MAX and Focus.

1 Engine shutdown

via youtube.com, Brandon Skifton channel

According to Ford’s press release, “The exhaust gas temperature sensors may not function properly, causing the vehicle to incorrectly identify a high temperature condition.” This would cause the car’s engine management system to shut down the car’s engine and even prevent a restart. Affected models include 2011 to 2015 Ford F-350, F-450, and F-550 pickup trucks.


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