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Why do Ford hybrid batteries and power cables keep getting recalled?
Two problems dominate Ford's electrical recalls. The first is high-voltage battery cells in hybrids and plug-in hybrids: 2020-2026 Escape and 2021-2026 Lincoln Corsair appear again and again, joined by 2020-2022 Explorer and Aviator PHEVs and the 2019-2020 Fusion PHEV. The defects are internal cell short circuits, insufficient welds, or a damaged battery energy control module, and they cause sudden loss of drive power or fire. The second is loose or wrong hardware on battery, starter and alternator cables — 2018 Edge and MKX, 2019 Flex and MKT, 2019-2020 F-150 — which arcs and overheats. Smaller campaigns cover a chafing 2020 Explorer wiring harness, trailer brake software on 2021-2022 trucks, and overheating engine block heaters.
Warning signs to watch for
- Sudden loss of drive power with no warning, especially in Escape, Corsair, Explorer and Aviator hybrids
- On 2019-2020 F-150: instrument panel display problems, loss of brake and steering assist, or an engine stall
- Smoke, burning smell or signs of arcing around the starter, alternator or positive battery terminal
- A towed trailer with electric or electric-over-hydraulic brakes does not brake, so stopping distances get much longer
- An engine block heater that overheats while the vehicle is parked and plugged in
Is it safe to keep driving?
None of these recalls carries a stop-driving or park-outside order. Ford does restrict charging: owners of 2019-2020 Fusion PHEVs and of the 2020-2024 Escape and Corsair plug-in hybrids are told not to charge until the remedy is complete, and the newest Escape and Corsair PHEV notices tell owners to use only "Auto EV" mode and limit maximum charge as their letter instructs. If you tow, avoid using electric trailer brakes until the software update. Stop using the block heater on affected Escape, Corsair and Nautilus vehicles. Otherwise, keep driving while you wait.
What the free repair involves
Repairs vary by campaign. Dealers inspect and properly secure or replace starter, alternator and battery cable hardware, retorque the positive battery terminal joint, add a tie strap to a rubbing harness, update integrated trailer brake control or BECM and HPCM software, and replace high-voltage battery packs or block heater elements as needed. For the Fusion PHEV, Ford also offered to repurchase the vehicle. All of it is free.
Severity at a glance
| Severity | Recalls |
|---|---|
| critical | 11 |
| high | 13 |
| medium | 15 |
Models affected most
Every recall in this group
Common questions
My Escape hybrid drives fine. Do I still need the battery recall done?
Yes. Ford's notices say the high-voltage battery can fail suddenly and cut drive power with no warning, and in several of these campaigns can short internally and catch fire. Book the free repair and follow any charging limits in your letter.
Can I keep charging my plug-in hybrid while I wait for the repair?
Not on the 2019-2020 Fusion PHEV or the 2020-2024 Escape and Corsair plug-in hybrids — Ford tells those owners not to charge until the remedy is complete. Newer Escape and Corsair PHEV notices instead say use Auto EV mode and limit maximum charge.
How do I find out whether my F-150 or Edge is included?
Check your VIN on NHTSA's recall lookup, or call Ford customer service at 1-866-436-7332 with the recall number from your letter. A Ford or Lincoln dealer can confirm the same thing and schedule the free inspection.
A recall applies only to specific vehicles. Check your 17-character VIN at nhtsa.gov/recalls.