In 2021, the driver's side door began to be difficult to open and close. It make a loud cracking or popping sound each time it was opened and closed. Eventually, I was unable to open or close the door at all, and had to enter and exit the vehicle through the passenger door. Ford repaired the door under warranty. In 2023, the…
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In 2021, the driver's side door began to be difficult to open and close. It make a loud cracking or popping sound each time it was opened and closed. Eventually, I was unable to open or close the door at all, and had to enter and exit the vehicle through the passenger door. Ford repaired the door under warranty. In 2023, the passenger's side door began to make the same noise and exhibit resistance to opening and closing. As the car is no longer under warranty, I will have to pay for the repair, but the issue is clearly a defective hinge or weld.
NHTSA ODI #11536072
Mileage unknown · Aug 2, 2023
Structure
After owning this car for 38 months we were out running errands and the driver's door began making a cracking noise when opened or closed. We visually inspected the door and found that it was related to the bracket that keeps the door from opening too far,. The bracket did not appear to be broken on the outside of the door but u…
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After owning this car for 38 months we were out running errands and the driver's door began making a cracking noise when opened or closed. We visually inspected the door and found that it was related to the bracket that keeps the door from opening too far,. The bracket did not appear to be broken on the outside of the door but upon further further review, we noticed that 3 spot welds that secured the bracket inside the door had failed. I have attached a picture of the failed welds taken by the body shop (circled in yellow). The assessment of the body shop was that the door needed to replaced due to a "design flaw" that was known by the manufacturer. When I spoke to the body shop manager he said that he had replaced several doors for the exact same reason in his shop. This car was never in an accident so this issue is just from normal opening and closing. We noticed that the other 3 doors did not have the same method for attaching the bracket to the inside of the door. The loaner car the dealer gave us was also a Escape model (2023) and the flaw had been corrected. Had the car ever been in an accident on the driver's side and those welds did not hold there could have been serious injuries or a fatality. I am requesting that a recall be issued for that model of Escape for 2020 to replace the driver's door.
NHTSA ODI #11536061
Mileage unknown · Jul 26, 2023
Structure
The left front door is making popping noises. Body shop has stated that the spot welds on the door have failed and the entire door will need to be replaced. Yes, it is available for inspection. Safety issue is that the door could open while driving threatening life of those in car and on highway if door were to pop open. The…
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The left front door is making popping noises. Body shop has stated that the spot welds on the door have failed and the entire door will need to be replaced. Yes, it is available for inspection. Safety issue is that the door could open while driving threatening life of those in car and on highway if door were to pop open. The problem has been confirmed by independent service center. Plan on bringing car to dealership for inspection. No warnings prior to failure, just started without warning.
NHTSA ODI #11534566
Mileage unknown · Jul 24, 2023
StructureUnknown Or Other
Dealer advised it is a bracket inside the door that has broken, possibly due to broken welds holding said bracket. The Dealer advised that this is an unfixable issue, and the entire door needs replaced. If it is not fixed, the dealer said it will cause other issues with the door, possibly leaving it inoperable. Dealer also co…
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Dealer advised it is a bracket inside the door that has broken, possibly due to broken welds holding said bracket. The Dealer advised that this is an unfixable issue, and the entire door needs replaced. If it is not fixed, the dealer said it will cause other issues with the door, possibly leaving it inoperable. Dealer also confirmed this is a very common issue with this model and that it is not covered. The Dealer said I will need to repair at my own expense, with an estimated cost of $2,000 or more.
NHTSA ODI #11534190
Mileage unknown · Jul 24, 2023
Structure
Driver side door kept clicking when opening or closing. At one point while opening, hinge where it is riveted in broke off and door will not close properly.
NHTSA ODI #11534099
Mileage unknown · Jul 23, 2023
EngineStructure
1 Engine Fire Safety Recall Dealer not able to fix the problem. 2 Driver's side door hinge broken window will not go down. Dealer told me this is not a manufacture problem.
NHTSA ODI #11533959
Mileage unknown · Jul 20, 2023
Structure
Drivers door check stop is creaking and snapping and exibiting all the behavior being investgated by your department as reported in the Reuters article https://www.reuters.com/business/autos-transportation/us-investigates-346000-ford-escape-suvs-over-door-issues-2023-07-11/
NHTSA ODI #11533446
Mileage unknown · Jul 12, 2023
Structure
The contact's company owns a 2020 Ford Escape. The contact stated that the hinge detached from the front driver’s side door. The contact took the vehicle to the local dealer, where it was diagnosed with needing the front driver’s side door to be replaced. The vehicle was repaired however, the failure recurred. The contact took t…
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The contact's company owns a 2020 Ford Escape. The contact stated that the hinge detached from the front driver’s side door. The contact took the vehicle to the local dealer, where it was diagnosed with needing the front driver’s side door to be replaced. The vehicle was repaired however, the failure recurred. The contact took the vehicle to the local dealer, where it was diagnosed with needing the front driver’s side door to be replaced. The vehicle was not repaired due to the parts not being available. The manufacturer had not been informed of the failure. The failure mileage was unknown. The contact stated the door was set to repaired again on 07/31/2023.
NHTSA ODI #11531776
Mileage unknown · Jul 11, 2023
Structure
The driver door made a loud noise when I opened it. I took it to my Ford dealer and they told me the door hinges had broken. Now my window will not go down and the Ford dealer suggested I take the car to a weld shop to fix.
NHTSA ODI #11531567
Mileage unknown · Jul 10, 2023
StructureUnknown Or Other
My front left drivers side door wouldnt close, I noticed the spot welds holding the door strap component in place had broke free and was now being pushed into the door shell. I took my car to the dealership and they said it is not covered. I have since looked on line, on how to repair this defect and see this is a known issue to…
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My front left drivers side door wouldnt close, I noticed the spot welds holding the door strap component in place had broke free and was now being pushed into the door shell. I took my car to the dealership and they said it is not covered. I have since looked on line, on how to repair this defect and see this is a known issue to the make and model year of my vehicle.
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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