THE MANUFACTURER WELDS ON THE DOOR CHECK ARM FAILED. THIS PREVENTED THE DRIVER SIDE DOOR FROM CLOSING. INSPECTED BY DEALERSHIP AND THEY ACKNOWLEDGED THAT FORD WAS AWARE OF THE PROBLEM. THEY HAVE HAD MANY SIMILAR FAILURES ON BOTH THE ESCAPE AND EDGE VEHICLES. FORD HAS SAID THEY WILL NOT MAKE "OUT OF WARRANTY" REPAIRS. THE RE…
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THE MANUFACTURER WELDS ON THE DOOR CHECK ARM FAILED. THIS PREVENTED THE DRIVER SIDE DOOR FROM CLOSING. INSPECTED BY DEALERSHIP AND THEY ACKNOWLEDGED THAT FORD WAS AWARE OF THE PROBLEM. THEY HAVE HAD MANY SIMILAR FAILURES ON BOTH THE ESCAPE AND EDGE VEHICLES. FORD HAS SAID THEY WILL NOT MAKE "OUT OF WARRANTY" REPAIRS. THE REPAIRS ARE AT OWNERS OWN EXPENSE AND FORD WILL NOT ISSUE A RECALL FOR WHAT IS A MANUFACTURING DEFECT. FORD'S SOLUTION, REPLACE ENTIRE DOOR AND ASSEMBLY. MY OPINION, FACTORY WELDS SHOULD NOT FAIL.
NHTSA ODI #11529343
Mileage unknown · Jun 22, 2023
Structure
opened driver side door making a popping noise coming from stop arm. found that spot welds broken off and stop arm will not allow me to open door not allowing me access to get into driver side door. found ssm 50150 on the internet. this is a safety issue and needs to be a recall.
NHTSA ODI #11528280
40,000 miles · Jun 21, 2023
Structure
The contact owns a 2020 Ford Escape. The contact stated that while opening and closing the driver's side door, there was an abnormal crunching sound coming from the door. The contact stated that he observed that the welds on the door and the check arm were fractured. The contact stated that the driver's side window no longer rai…
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The contact owns a 2020 Ford Escape. The contact stated that while opening and closing the driver's side door, there was an abnormal crunching sound coming from the door. The contact stated that he observed that the welds on the door and the check arm were fractured. The contact stated that the driver's side window no longer raised or lowered as designed. The contact had taken the vehicle to a local dealer, where it was diagnosed and determined that the driver's side door needed to be replaced. The vehicle was repaired. The manufacturer had not been informed of the failure. The failure mileage was approximately 40,000.
NHTSA ODI #11528128
Mileage unknown · Jun 7, 2023
StructureVisibility
A panel under the moon roof that is used to deflect water in case water leaks through the moon roof suddenly fell down on the back seat of the car while we were driving with the moon roof open. Upon inspection we discovered that this panel is glued to some foam pads and apparently the adhesive had lost it's grip. We were able to…
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A panel under the moon roof that is used to deflect water in case water leaks through the moon roof suddenly fell down on the back seat of the car while we were driving with the moon roof open. Upon inspection we discovered that this panel is glued to some foam pads and apparently the adhesive had lost it's grip. We were able to put the panel back in place. But the next time we opened the moon roof it came down again this time bouncing off the back seat and hitting my wife (the passenger) in the head. Fortunately, she was not injured. Had it hit me (the driver) it could have caused an accident with unknown consequences. Ford's response when we addressed it with Dealer was to replace the panel and install it using the same method of adhesive and foam pads. I believe this is an engineering failure because it was not secured with screws or nuts & bolts. Pictures of the part number and part are attached.
NHTSA ODI #11525855
Mileage unknown · May 31, 2023
Structure
Broken weld points inside the front driver-side door. There was no accident or impact to the door. The door was used properly and never overextended or caught by the wind to my knowledge. I am the primary driver. My spouse occasionally drives the car and he doesn’t recall any such incidents either. I opened it to get in one day …
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Broken weld points inside the front driver-side door. There was no accident or impact to the door. The door was used properly and never overextended or caught by the wind to my knowledge. I am the primary driver. My spouse occasionally drives the car and he doesn’t recall any such incidents either. I opened it to get in one day and started hearing a popping sound. Immediately after the popping sound, I was not able to close the door. Ultimately, I was able to close the door but there are creaking and grinding noises every time I use the door.
NHTSA ODI #11524614
Mileage unknown · May 28, 2023
Structure
2020 Ford Escape drivers door had the check arm fail due to the inner reinforcement bracket breaking off of the outer door shell. The failure caused the check arm to lodge into the window track and the door would not close and the vehicle couldn’t be driven or secured. The door made a popping sound just 1 time before the failur…
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2020 Ford Escape drivers door had the check arm fail due to the inner reinforcement bracket breaking off of the outer door shell. The failure caused the check arm to lodge into the window track and the door would not close and the vehicle couldn’t be driven or secured. The door made a popping sound just 1 time before the failure. Ford states an issue with the check arm welds failing in SSM 51553 but doesn’t have a remedy other than replacing the door. I worry a new door will fail in the same way unless it’s been redesigned.
NHTSA ODI #11524178
Mileage unknown · May 25, 2023
Structure
The welds securing the check arm on driver's side door detached without prior warning during normal use, making the door nearly impossible to close fully, and keeping the window from going down more than about an inch. The dealer says they have seen multiple instances of this on the 2020 Escape, and there are many reports of th…
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The welds securing the check arm on driver's side door detached without prior warning during normal use, making the door nearly impossible to close fully, and keeping the window from going down more than about an inch. The dealer says they have seen multiple instances of this on the 2020 Escape, and there are many reports of the same thing on the internet. The body shop that repaired it has also seen it many times, always with the 2020 model. Ford appears to have strengthened it in subsequent model, but hasn't issued a recall and won't cover the cost the repair. Obviously, having a door (or even a window) that doesn't operate well, especially on the driver's side, is a safety issue. This detached check arm also allowed the door to swing out uncontrollably if caught by the wind or on a downhill slope, which could damage other cars in a parking lot.
NHTSA ODI #11523853
Mileage unknown · May 24, 2023
Structure
My driver’s side door top hinge the spot welds let go, I already had the door replaced by Ford under warranty back in 2021 my car is not under warranty anymore I have about 156,000 miles on it. I got a estimate at a body shop it will cost me about $1820 to replace the door.
NHTSA ODI #11523676
Mileage unknown · May 24, 2023
Structure
On the driver's side door are spot welds that are breaking away and preventing the window from coming down. As documented in SSM-50150.
NHTSA ODI #11523642
Mileage unknown · May 22, 2023
Structure
Welds holding driver's side door broke inside the door, door makes a crunching noise, is hard to close and window can't be rolled down. Door was not caught by wind or any other strain, no abnormal use. The car has 26,000 miles and the welds just gave out.
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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