The driver side door began making loud creaking sounds and would not close properly. The power window would not go down all the way. I was terrified that the door would come open when I was driving and it did once! The Ford dealer said it is a known issue with faulty welding, but there is no recall. I had to pay $1,250 for the r…
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The driver side door began making loud creaking sounds and would not close properly. The power window would not go down all the way. I was terrified that the door would come open when I was driving and it did once! The Ford dealer said it is a known issue with faulty welding, but there is no recall. I had to pay $1,250 for the repair and I was without my vehicle for a week!
NHTSA ODI #11567350
33,420 miles · Jan 22, 2024
Structure
The contact owns a 2020 Ford Escape. The contact stated that the front driver’s side door failed to open or close as needed. The vehicle was taken to an independent mechanic where it was discovered that the spot weld inside the door was defective, and the door needed to be replaced. The manufacturer was notified of the failure a…
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The contact owns a 2020 Ford Escape. The contact stated that the front driver’s side door failed to open or close as needed. The vehicle was taken to an independent mechanic where it was discovered that the spot weld inside the door was defective, and the door needed to be replaced. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The vehicle was not repaired. The failure mileage was 33,420.
NHTSA ODI #11567082
Mileage unknown · Jan 22, 2024
Structure
Driver's side door hinge/weld problem. That Ford is aware of and not fixing free of charge! These vehicles are 2020-21! Mileage should not matter, because actually high mileage on a new car should show the door is NOT being used very often, rather there are long journeys in between each use. It is problem, they are aware of …
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Driver's side door hinge/weld problem. That Ford is aware of and not fixing free of charge! These vehicles are 2020-21! Mileage should not matter, because actually high mileage on a new car should show the door is NOT being used very often, rather there are long journeys in between each use. It is problem, they are aware of it, and they are leaving it up to the customer to repair the vehicles. Also, I was told by Ford Dealership it was safe to drive, and further investigating, some of the doors have come off while moving! It is so unfortunate that a large company would have the consumer pay for their faulty/poor work. Let's get this problem on the news.
NHTSA ODI #11567017
Mileage unknown · Jan 15, 2024
Structure
drivers side front door. Welds are broken. Ford dealership says they are not equipped to repair
NHTSA ODI #11565578
79,000 miles · Jan 12, 2024
Structure
The contact owns a 2020 Ford Escape. The contact stated that upon entering the vehicle, there was an abnormal popping sound coming from the driver's side door. The contact stated that the failure persisted and ultimately resulted in the driver's side door not latching closed properly. The vehicle was taken to the dealer, who dia…
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The contact owns a 2020 Ford Escape. The contact stated that upon entering the vehicle, there was an abnormal popping sound coming from the driver's side door. The contact stated that the failure persisted and ultimately resulted in the driver's side door not latching closed properly. The vehicle was taken to the dealer, who diagnosed a failure with the door check arm attachment point. The vehicle was not repaired. After investigating the failure, the contact related the failure to NHTSA Action Number: PE23013 (Structure). The manufacturer was notified of the failure but referred the contact to the NHTSA Hotline for assistance. The failure mileage was 79,000.
NHTSA ODI #11565134
30,000 miles · Jan 11, 2024
Structure
The contact owns a 2020 Ford Escape. The contact stated that while entering the vehicle through the driver's side door, the door made an abnormal popping sound while being opened. The contact stated that the passenger’s side front door also made the abnormal popping sound while being opened. The contact had taken the vehicle to …
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The contact owns a 2020 Ford Escape. The contact stated that while entering the vehicle through the driver's side door, the door made an abnormal popping sound while being opened. The contact stated that the passenger’s side front door also made the abnormal popping sound while being opened. The contact had taken the vehicle to a local dealer, where it was diagnosed the door welds were fracturing. The dealer determined that the driver's and front passenger’s doors needed to be replaced. The vehicle was not repaired. The manufacturer was informed of the failure. The failure mileage was approximately 30,000.
NHTSA ODI #11564836
Mileage unknown · Jan 9, 2024
Structure
Driver door: spot welds inside door shell for hinge attachment have broken inside door; door difficult to close and open; unable to properly open/close window
NHTSA ODI #11564312
58,000 miles · Jan 4, 2024
Structure
The contact owns a 2020 Ford Escape. The contact stated that while opening the front driver's side door, the door made an abnormal popping sound. The contact determined that the front driver's side door spot welds had fractured. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was …
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The contact owns a 2020 Ford Escape. The contact stated that while opening the front driver's side door, the door made an abnormal popping sound. The contact determined that the front driver's side door spot welds had fractured. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was made aware of the failure, and a case was opened. The failure mileage was approximately 58,000.
NHTSA ODI #11563550
Mileage unknown · Jan 3, 2024
Structure
bracket tack welds failed in drivers side front door at attachment of the door check to the door frame. Resulting loose end causes multi-part safety hazard. First, it jams door, randomly presenting it from closing and latching properly, which defeats the auto-lock safety features designed to maintain body integrity in the event …
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bracket tack welds failed in drivers side front door at attachment of the door check to the door frame. Resulting loose end causes multi-part safety hazard. First, it jams door, randomly presenting it from closing and latching properly, which defeats the auto-lock safety features designed to maintain body integrity in the event of an accident (hazard 1). It also binds now and then, preventing door from being opened for the driver of the car (hazard 2). Third, while flopping around inside the door, the part interferes with the opening of drivers side window (hazard 3). Hazard 2 and 3 in combination create a condition where safe egress from the vehicle in the event of an emergency is not assured for the driver. Dealer confirmed issue and issued quote to replace the door. Manufacturer thinks its not their problem unless its under warranty. Issue is well described in various locations on the web, so its not a one-off manufacturing issue, rather a systemic design/implementation problem.
NHTSA ODI #11563226
Mileage unknown · Dec 27, 2023
Structure
There is a spot weld failure inside my driver side door resulting in the door hinge being broken inside the door. The door does not open all the way and it makes loud popping and screeching noises. I can only roll my window down about 3 inches. I am concerned for my safety as I have seen other complaints regarding this issue wh…
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There is a spot weld failure inside my driver side door resulting in the door hinge being broken inside the door. The door does not open all the way and it makes loud popping and screeching noises. I can only roll my window down about 3 inches. I am concerned for my safety as I have seen other complaints regarding this issue where the door stopped latching completely. Also, windows are an emergency exit. In the case of an accident, I need to be able to open the window to exit if it is the only viable option. I took my vehicle to the local dealer on 10/27/23 and was told that this issue is not covered by my manufacturer warranty or the Ford Premium extended warranty that I purchased through Ford. I have been told that I will need a new door at my expense. The dealer did offer to reach out to Ford on my behalf but still no response after 2 months of waiting. This is my 4th Ford Escape and I have never had so many issues with a vehicle in the past. Ford is very aware of the hundreds of complaints about this very issue, but still will do nothing to help. It is extremely frustrating.
Ford Motor Company (Ford) is recalling certain 2022-2024 Maverick Hybrid and 2020 Escape Hybrid vehicles. The Hybrid Powertrain Control Module (HPCM) software may cause the vehicle to shift into neutral unexpectedly, causing a loss of drive power.
Consequence & remedy
Consequence: A loss of drive power increases the risk of a crash.
Remedy: Dealers will update the HPCM software, free of charge. Owner notification letters were mailed February 12, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S33. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning January 15, 2026. This is an expansion of Recalls 24V330 (24S33) and 25V133 (25S16).
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
2
PE23013 · Failed Door Check Arm Attachment Point
Opened Jul 7, 2023 · Closed Jan 24, 2024
Status: closed (inferred from source dates) · Structure:body:door ; Structure:body:door:hinge And Attachments
On July 7, 2023, the Office of Defects Investigation (ODI) opened PE23-013 to investigate instances of check arm bracket failure in the front doors in model year (MY) 2020-2021 Ford Escape vehicles. At the time of opening, ODI received 118 Vehicle Owner Questionnaires (VOQs) alleging this failure. To date, ODI has received 593 VOQs alleging this failure, with a variety of reported failure conditions. The most common reported failure condition was reduced door functionality (e.g. door was more difficult to open or close) and the least common was inadvertent door opening. Other reported failure conditions include inability to latch and inability to open. Three VOQs reported injuries, one of which requiring medical attention. ODI conducted a consumer survey which yielded an additional 44 injuries (although the VOQs did not indicate any injury), none of which requiring medical attention. All these injuries were bumps/bruises from the door closing on occupants’ arms and legs while entering and exiting the vehicle. The function of the check arm system is to provide hold-open assist at specific angles and to assist with door closing energy. It does not provide vertical support of the door and is independent of the latching mechanism. This failure is progressive and detectable by vehicle occupants. Consumers commonly report hearing a popping or snapping noise when opening and closing the door. This noise is caused by some of the welds between the bracket and door structure failing and detaching. There may also be visible damage present to the welds in the door structure. Continued use of the door may result in all welds separating and the bracket fully detaching from the door structure, which could lead to increased resistance in closing and opening the door, restrained window operation, and the door freely rotating when open. ODI inspected 3 consumer vehicles in the field, and 2 test vehicles at Ford’s testing facility. The test vehicles were retrofitted with the failed component. ODI observed an increased door closing resistance, however, was unable to reproduce an inadvertent open while parked or driving, or a failure to latch or open condition. Testing also verified this failure did not affect the door ajar warning system. This system provides an audible and visual warning in the event a door did not achieve primary latch position. Ford has provided details on a one-time-repair customer satisfaction program (23B56), stating that they will provide customers with a letter, currently targeted for March 2024, to bring their vehicle to a Ford dealership for a proactive repair. Dealers will inspect the door check arm welds for damage and will either provide a rivet plate to reinforce the existing door check arm or will provide a replacement door, depending on the level of damage present. Customers will be eligible for reimbursement if they previously paid to repair this issue. In view of the high detectability of failure, low potential hazard to drivers, and Ford’s customer satisfaction program to provide a proactive repair, this Preliminary Evaluation (PE) is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
Additional source detail variants (2)
Structure:body:door
On July 7, 2023, the Office of Defects Investigation (ODI) opened PE23-013 to investigate instances of check arm bracket failure in the front doors in model year (MY) 2020-2021 Ford Escape vehicles. At the time of opening, ODI received 118 Vehicle Owner Questionnaires (VOQs) alleging this failure. To date, ODI has received 593 VOQs alleging this failure, with a variety of reported failure conditions. The most common reported failure condition was reduced door functionality (e.g. door was more difficult to open or close) and the least common was inadvertent door opening. Other reported failure conditions include inability to latch and inability to open. Three VOQs reported injuries, one of which requiring medical attention. ODI conducted a consumer survey which yielded an additional 44 injuries (although the VOQs did not indicate any injury), none of which requiring medical attention. All these injuries were bumps/bruises from the door closing on occupants’ arms and legs while entering and exiting the vehicle. The function of the check arm system is to provide hold-open assist at specific angles and to assist with door closing energy. It does not provide vertical support of the door and is independent of the latching mechanism. This failure is progressive and detectable by vehicle occupants. Consumers commonly report hearing a popping or snapping noise when opening and closing the door. This noise is caused by some of the welds between the bracket and door structure failing and detaching. There may also be visible damage present to the welds in the door structure. Continued use of the door may result in all welds separating and the bracket fully detaching from the door structure, which could lead to increased resistance in closing and opening the door, restrained window operation, and the door freely rotating when open. ODI inspected 3 consumer vehicles in the field, and 2 test vehicles at Ford’s testing facility. The test vehicles were retrofitted with the failed component. ODI observed an increased door closing resistance, however, was unable to reproduce an inadvertent open while parked or driving, or a failure to latch or open condition. Testing also verified this failure did not affect the door ajar warning system. This system provides an audible and visual warning in the event a door did not achieve primary latch position. Ford has provided details on a one-time-repair customer satisfaction program (23B56), stating that they will provide customers with a letter, currently targeted for March 2024, to bring their vehicle to a Ford dealership for a proactive repair. Dealers will inspect the door check arm welds for damage and will either provide a rivet plate to reinforce the existing door check arm or will provide a replacement door, depending on the level of damage present. Customers will be eligible for reimbursement if they previously paid to repair this issue. In view of the high detectability of failure, low potential hazard to drivers, and Ford’s customer satisfaction program to provide a proactive repair, this Preliminary Evaluation (PE) is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
Structure:body:door:hinge And Attachments
On July 7, 2023, the Office of Defects Investigation (ODI) opened PE23-013 to investigate instances of check arm bracket failure in the front doors in model year (MY) 2020-2021 Ford Escape vehicles. At the time of opening, ODI received 118 Vehicle Owner Questionnaires (VOQs) alleging this failure. To date, ODI has received 593 VOQs alleging this failure, with a variety of reported failure conditions. The most common reported failure condition was reduced door functionality (e.g. door was more difficult to open or close) and the least common was inadvertent door opening. Other reported failure conditions include inability to latch and inability to open. Three VOQs reported injuries, one of which requiring medical attention. ODI conducted a consumer survey which yielded an additional 44 injuries (although the VOQs did not indicate any injury), none of which requiring medical attention. All these injuries were bumps/bruises from the door closing on occupants’ arms and legs while entering and exiting the vehicle. The function of the check arm system is to provide hold-open assist at specific angles and to assist with door closing energy. It does not provide vertical support of the door and is independent of the latching mechanism. This failure is progressive and detectable by vehicle occupants. Consumers commonly report hearing a popping or snapping noise when opening and closing the door. This noise is caused by some of the welds between the bracket and door structure failing and detaching. There may also be visible damage present to the welds in the door structure. Continued use of the door may result in all welds separating and the bracket fully detaching from the door structure, which could lead to increased resistance in closing and opening the door, restrained window operation, and the door freely rotating when open. ODI inspected 3 consumer vehicles in the field, and 2 test vehicles at Ford’s testing facility. The test vehicles were retrofitted with the failed component. ODI observed an increased door closing resistance, however, was unable to reproduce an inadvertent open while parked or driving, or a failure to latch or open condition. Testing also verified this failure did not affect the door ajar warning system. This system provides an audible and visual warning in the event a door did not achieve primary latch position. Ford has provided details on a one-time-repair customer satisfaction program (23B56), stating that they will provide customers with a letter, currently targeted for March 2024, to bring their vehicle to a Ford dealership for a proactive repair. Dealers will inspect the door check arm welds for damage and will either provide a rivet plate to reinforce the existing door check arm or will provide a replacement door, depending on the level of damage present. Customers will be eligible for reimbursement if they previously paid to repair this issue. In view of the high detectability of failure, low potential hazard to drivers, and Ford’s customer satisfaction program to provide a proactive repair, this Preliminary Evaluation (PE) is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
DP22005 · Pedestrian Alert Sounds
Opened Jan 27, 2023 · Closed Aug 7, 2023
Status: closed (inferred from source dates) · Electrical System:propulsion System
NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.
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