Ford Recalls Improperly Fixed Explorer Recalls

Ford Motor Company (NYSE: F) is recalling more than 4000 2020-2022 model year Explorer vehicles previously repaired incorrectly under NHTSA recall numbers 23V-199 or 22V-255. The rear axle horizontal mounting bolt may fracture and cause the driveshaft to disconnect. This is another Ford Motor recall caused by software errors and its inability to ascertain if the prior recall was implemented correctly. (Read AutoInformed.com on: Ford Recalls Previous Bronco and Escape Fire Recalls)

“The Ford process is capable of determining which software part numbers have been installed in production and service. Affected vehicles do not contain the remedy Powertrain Control Module (PCM) software for recall 23S16 and/or 22S27. 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,” Ford said in the mandatory safety defect filing made by the National Highway Traffic Safety Administration this morning.

Dealers will update the powertrain control module (PCM) software, free of charge as required by safety regulations passed long ago by the U.S. Congress. Thus far they haven’t been revoked by executive order under the Trump mis-Administration. Owner notification letters are not expected to be mailed until 24 April 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 25S22. Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 888-327-4236 or go to nhtsa.gov about NHTSA recall 25V166 or 25V-166.

Chronology of Defect and Non-Compliance Determination

• On 26 November 2024, an issue pertaining to incomplete software recall remedies was brought to Ford’s Critical Concern Group (CCRG) for review. This issue was initially identified in a Quality Office forum, where an audit was requested for software part numbers applied to vehicles remedied under a sample of field service actions (FSAs). Initial review of three FSAs revealed insufficient data to confirm correct software application across all FSAs using the FDRS service tool. Further investigation was deemed necessary.
• In December 2024, a cross-functional team was formed to audit all software FSAs that used the FDRS service tool, with its first focus being on safety and compliance FSAs. Templates were created to track software lineage part numbers.
• On 19 December 2024, Ford informed NHTSA of this concern – the service tool data confirmed that the software state on the service tool at the time of installation matches the FSA software release for most vehicles. However, there are vehicles that do not have a match between the software state on the service tool and the FSA software release. Ford discussed with NHTSA its plan to address the mismatched vehicles.
• In January 2025, the cross-functional team created database records to store all software lineage part numbers for previously launched FSAs. The team then began auditing the current software level for every VIN repaired under several previously launched field service actions.
• On 27 February 2025, the cross-functional team completed the audit of 23S16 and 22S27 and brought the results to Ford’s CCRG for review, concluding that 94.1% of the repairs conducted under 23S16 and 86.1% of the repairs conducted under 22S27 had the correct software installed. The team identified the specific vehicles that were recorded as receiving the remedy but have software that does not remedy the safety defect.
• On 7 March 2025, 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.