Ford Recalls 2019-2020 Fusion PHEVs for Fires

Ford Motor Company (Ford) is recalling 2019-2020 Fusion Plug In Hybrid (PHEV) vehicles because the battery energy control module (BECM) may become damaged resulting in sudden loss of power or fires This is according to the National Highway Traffic Safety Administration (NHTSA), which today publicly released the relevant safety defect documents that Ford filed last month. Ford Dealers have been told Do Not Demonstrate or Deliver any new in-stock vehicles involved in this safety recall. (AutoInformed: More Ford Recalls Published – Millions of Vehicles Involved)

All of the so-called incidents occurred between March and May 2022 – more than one year ago. The fires occurred while the vehicles (built in Hermosillo Mexico between 6 December 2017 through 27 July) were at dealerships during a replacement Battery Energy Control Module (BECM) service to fix one or more voltage sense Diagnostic Trouble Codes (DTCs), a check engine light, no start, or loss of motive power defect.

Owners are now advised not to charge their vehicles until the remedy that is currently under development because Ford is uncertain – at least publicly – of the root cause. Interim letters notifying owners of the safety risk are expected to be mailed 10 July 2023. Second letters will be sent once the remedy is available. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 23S33. 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 about NHTSA recall 23V440.

Chronology

• On 17 July 2022, Ford’s Trend and Early Warning Support (TEWS) team informed the Critical Concern Review
• Group (CCRG) of five reports of fire allegations that occurred in the trunk area on 2019 Fusion PHEV vehicles in North America equipped with 30Ah high voltage batteries.
• Analysis of the vehicles by Ford’s High Voltage Battery Systems Team identified the fires originated in the BECM. The high voltage batteries were sent to the supplier for analysis.
• The un-named supplier confirmed the Current Interrupt Device (CID) was activated in high voltage battery cells from the suspect units, but the root cause of the CID activation is unknown.
• On 16 August 2022, Ford’s CCRG placed the investigation on “monitor” based on the rate and severity of what Ford calls a “concern”, but we call a safety defect.
• On 8 February 2023, a Technical Service Bulletin (TSB) was published providing direction to replace the high voltage battery if vehicles came in for service with one or more voltage sense DTCs rather than only replacing the BECM.