The contact owns a 2020 Ford Escape. The contact stated that after entering the vehicle, the front driver's side door made an abnormal popping sound while closing. The vehicle was taken to the dealer, where the front driver's side door check arm and welds had fractured while the contact was closing the door. The dealer towed the…
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The contact owns a 2020 Ford Escape. The contact stated that after entering the vehicle, the front driver's side door made an abnormal popping sound while closing. The vehicle was taken to the dealer, where the front driver's side door check arm and welds had fractured while the contact was closing the door. The dealer towed the vehicle to the collision center, where it was determined that the front driver's side fender and the front driver's side door needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and a case was opened. The failure mileage was approximately 56,000.
NHTSA ODI #11554327
Mileage unknown · Nov 2, 2023
StructureUnknown Or Other
My vehicle is exhibiting the issues described in SSM 50150. The driver's side door spot welds have failed on my 2020 Ford Escape hybrid. The issue began as a creaking sound as I opened and closed my driver's side front door. The door was also stiff and difficult to operate. 2 days later the door became even more difficult to ope…
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My vehicle is exhibiting the issues described in SSM 50150. The driver's side door spot welds have failed on my 2020 Ford Escape hybrid. The issue began as a creaking sound as I opened and closed my driver's side front door. The door was also stiff and difficult to operate. 2 days later the door became even more difficult to open and close. A day after that the door welds failed. After the weld failure the door moved freely except the door catch would jam due to it floating. To allow proper door operation of the door the catch had to be unbolted at the body. After the failure I noticed the door panel around the area of the welds is pushed outward and no longer flush with the door along the edges. Also, since the issue began, the window strains whenever I try to raise and lower it and the window cannot be lowered all the way. My assumption is that the catch is tied to the window track. The window track and door catch appear to be associated with the broken welds. I brought the matter to the Ford dealership's attention, citing SSM 50150. They advised me that the vehicle was out of warranty, that the repair was not part of any mandatory recall and that the estimated repair cost was $2,083.14. They noted the possibility of Ford contributing a couple hundred dollars to defray the repair costs.
NHTSA ODI #11553203
Mileage unknown · Oct 25, 2023
Structure
1.) Faulty welding of front left door hinge causes loud popping noise when door is in motion. Door would not close. Forced the door to close, which caused the door bracket to break off inside the door. Now the window will not roll down. 2.) Faulty welding of front right door hinge causes loud popping noise when door in motion. …
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1.) Faulty welding of front left door hinge causes loud popping noise when door is in motion. Door would not close. Forced the door to close, which caused the door bracket to break off inside the door. Now the window will not roll down. 2.) Faulty welding of front right door hinge causes loud popping noise when door in motion. Hinge hasn't broken yet.
NHTSA ODI #11551791
Mileage unknown · Oct 24, 2023
Structure
2020 Ford Escape Hybrid drivers door retainer support spot welds broken out. Ford will not support repairs. Unable to close door until retainer arm is disconnected. Unable to use window.
NHTSA ODI #11551650
Mileage unknown · Oct 18, 2023
Structure
My driver side door is breaking at the welded spots. It started making a popping noise and you can see where the weld spots are failing. I have taken it to the dealership for diagnosis and it is doing the same thing that is under investigation currently. My car it out of warranty due to mileage so it is not a covered repair. At …
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My driver side door is breaking at the welded spots. It started making a popping noise and you can see where the weld spots are failing. I have taken it to the dealership for diagnosis and it is doing the same thing that is under investigation currently. My car it out of warranty due to mileage so it is not a covered repair. At this time I have not had it pop open yet because I am limiting opening that door by crawling in the other side but in the couple weeks since it has started the noise has gotten worse from the times I’ve had to open it.
NHTSA ODI #11550715
Mileage unknown · Oct 16, 2023
StructureUnknown Or Other
Driver’s Door Check Bracket is being stressed. It sounds like it is breaking. Situation has one on very quickly this past week.
NHTSA ODI #11550113
41,000 miles · Oct 6, 2023
Structure
The contact owns a 2020 Ford Escape Hybrid. The contact stated that after he opened the front driver’s side door, he heard a clicking sound upon closing the door. The contact then stated that he noticed that the front driver’s side door hinge had detached from the door and the door welds had fractured. Additionally, the contact …
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The contact owns a 2020 Ford Escape Hybrid. The contact stated that after he opened the front driver’s side door, he heard a clicking sound upon closing the door. The contact then stated that he noticed that the front driver’s side door hinge had detached from the door and the door welds had fractured. Additionally, the contact stated that he had to hold the front driver’s side door while driving to his residence. The contact then stated that he had to dismantle the front driver’s side door to be able to safely drive the vehicle. The vehicle was taken to the dealer where it was diagnosed that the door needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and the contact was informed that the vehicle mileage was over the warrant and provided a case number. The failure mileage was approximately 41,000. The VIN was unavailable.
NHTSA ODI #11548584
Mileage unknown · Oct 3, 2023
Structure
The driver door spot welds for the support arm broke. The door would not close. The dealer said it is not covered by Ford. I called Ford customer satisfaction. Case CAS45401361. Have an appointment for October 9th. Can you help?
NHTSA ODI #11548104
Mileage unknown · Sep 28, 2023
Structure
The drivers side front door developed a loud clunking sound upon opening and closing. My car sees somewhat higher mileage than typical and my mileage is at 79K miles currently. Upon inspecting the issue, I determined that the door closing indent mechanism that stops the door from swinging open all the way was jumping around and …
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The drivers side front door developed a loud clunking sound upon opening and closing. My car sees somewhat higher mileage than typical and my mileage is at 79K miles currently. Upon inspecting the issue, I determined that the door closing indent mechanism that stops the door from swinging open all the way was jumping around and making the loud thunking noise. Upon further looking I noticed all the spot welds were ripped out of the door body. Those welds hold a bracket on the inside of the door that holds the closing mechanism. I did a bit of online research and determined there was a service bulletin from Ford on this issue. I call the service rep I was working with on another issue and left a message about the door and the service bulletin number and asked for a call back. No Call back received. Meanwhile I have to drive my vehicle so I have been driving it. Opening the door causes loud thumping noises and ocassionally the window will no longer operate. I was going to live with it as didnt really think it was a safety issue. But the other day I stopped quickly on a downhill letft leaning slope and asTher I went to get out the weight of the door pulled me out of the car and I feel next to the car. The car started to roll forward and then slammed into park before the car ran over me. e is a failsafe on my car (hybrid with rotary shift know on console) that disengages the car from drive to park when you open the door. It did work but the 1ish second delay nearly allowed the car to run over me. Fortnunaely I was not injured except for a few bruises from the fall. Ford should make repairs to this car for driver safety issues. From what I read, the repair involves replacing the entire door and can cost thousands of dollars after bumper to bumper warranty is done. It is an obvious manufacturing issue and seems to be developing on many cars as their mileage, and therefore the number of cycles of door opening and closing taking place. Doors flying open should not happen.
NHTSA ODI #11547107
Mileage unknown · Sep 26, 2023
Structure
Front left door (driver side door) load popping noise and window wont go down.
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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