Ford is recalling about 20,000 plug-in hybrid SUVs due to a manufacturing defect that could cause battery cells to short circuit.
The recall encompasses 2020-2024 Ford Escape Plug-In Hybrids and 2021-2024 Lincoln Corsair Grand Touring plug-in hybrids, with 16,480 Fords and 4,004 Lincolns affected. These vehicles may have battery packs with cells manufactured in such a way that the separator layer between the cathode and anode is susceptible to damage, according to the NHTSA.
2023 Lincoln Corsair
Damage to the separator layer could lead to a short circuit, causing a loss of propulsion and, potentially, a fire, the NHTSA said. Other functions like steering, braking, and lights won’t be affected by this type of short circuit, the safety agency noted, adding that drivers will see a “Stop Safely Now” message on the dashboard if a short circuit occurs.
Ford told the NHTSA that it is aware of four incidents of “battery thermal venting” related to this issue, the first three of which occurred on European-market vehicles, but is not aware of any related accidents or injuries. An investigation into these incidents led the automaker to conclude that changes in the cell manufacturing process allowed for small defects in the cathode and additional stress on the separator layer that led to damage.
2023 Ford Escape Plug-in Hybrid
Dealers will at first install a software update for the battery energy control module, but may replace battery packs if necessary. All work will be done free of charge. Ford expects to mail owner notification letters Jan. 20. Owners can also call the automaker’s customer service department at 1-866-436-7332. Ford’s reference number for this recall is 24S79.
The Escape and Corsair are closely related, and use similar plug-in hybrid powertrains incorporating a 2.5-liter inline-4 and 14.4-kwh battery pack. But the Ford is only available with front-wheel drive, while the Lincoln is offered with all-wheel drive exclusively, contributing to a 10-mile difference in EPA electric range, at 37 miles for the Escape and 27 miles for the Corsair. The latter is also Lincoln’s only model with a plug, following the discontinuation of the larger Aviator Grand Touring plug-in hybrid.
