
In an era where vehicle safety remains paramount, a series of urgent recall alerts from Ford Motor Company has brought critical attention to potential fire risks in some of its popular hybrid models. These recalls, affecting certain Ford Escape, Lincoln Corsair, and Ford Maverick vehicles equipped with 2.5L HEV or PHEV engines, underscore significant safety concerns that consumers need to understand thoroughly. For owners of these vehicles, awareness and prompt action are not just recommended, but essential for their safety and peace of mind.
Our commitment at Consumer Reports is to provide clear, unbiased, and actionable information, empowering you to make informed decisions about your vehicle. The gravity of these recalls cannot be overstated, as they involve serious defects that could, in the worst-case scenarios, lead to engine compartment fires. With multiple recalls issued in quick succession, it is crucial to dissect the specifics of each alert, understand the underlying causes, and grasp the potential ramifications for drivers and passengers alike.
This in-depth article aims to serve as your authoritative guide through the complexities of Ford’s hybrid vehicle recalls. We will break down the latest information from the National Highway Traffic Safety Administration (NHTSA) and Ford’s own investigations, providing comprehensive details on which vehicles are affected, what causes these dangerous issues, and what immediate risks you face. Our goal is to equip you with the knowledge necessary to navigate these safety concerns effectively and ensure your vehicle’s integrity.

1. **The Latest Alert: May 2025 Recall for Incorrect Repairs (NHTSA 25V345000)**Ford Motor Company has issued a new recall in May 2025, identified by NHTSA Recall No. 25V345000, which specifically targets vehicles that were previously repaired incorrectly under an earlier recall, 23V380. This latest alert is particularly concerning because it highlights a failure in the initial remedial process, leaving a subset of vehicles still vulnerable to serious safety hazards. The recall indicates that the intended software update from the prior repair was not successfully uploaded to the affected vehicles, essentially leaving the underlying problem unresolved.
This recall encompasses an additional 1,797 2020-2023 Escape, 2021-2023 Corsair, and 2022-2023 Maverick vehicles. The critical detail here is that these are not newly discovered issues but rather previously identified problems where the attempted fix failed to address the defect. Ford states, “The dealer instructions to complete the recall instruct the technician to upload the latest software using the service tool, which downloads the latest software from Ford for installation on the vehicle. For these vehicles, the software tool did not upload the correct software to the vehicle.” This oversight means that the protective measures intended to mitigate the risk were never properly implemented.
The consequence of these incorrect repairs is severe. The original defect that recall 23V380 aimed to address involved a potential for engine failure, which could lead to engine oil and fuel vapor being released into the engine compartment. When these flammable substances accumulate near hot engine or exhaust components, they create a significant risk of an engine compartment fire. For the 1,797 vehicle owners included in this May 2025 recall, the danger persists, demanding immediate attention to ensure proper remediation.
This new recall from May 2025 serves as a stark reminder of the importance of verifying that recall repairs are completed accurately. It underscores the need for vehicle owners to remain vigilant and ensure their vehicles receive the correct and effective updates. Ford has indicated that recall letters will be mailed between June 23 and June 30, 2025, instructing dealers to correctly update the powertrain control module software to finally resolve the issue.

2. **January 2025 Recall: High-Voltage Battery Defects (NHTSA 22V484000)**Prior to the May 2025 alert, Ford initiated another significant recall in January 2025, affecting 20,484 hybrid crossover SUVs. This recall, identified as NHTSA Recall No. 22V484000, centers on potential defects within the high-voltage battery cells themselves. Unlike the May recall which focused on incorrect repairs, this earlier alert addresses a fundamental manufacturing flaw in a critical component of the hybrid system.
The primary concern with this battery defect is the risk of an internal short circuit within the high-voltage battery cells. Such an event can lead to catastrophic battery failure, including thermal events. According to the National Highway Traffic Safety Administration (NHTSA), “the issue arises from a manufacturing flaw in the high-voltage battery cells, which could cause an internal short circuit, leading to battery failure and, in some cases, fire risk.”
This recall targets a substantial number of vehicles, encompassing certain 2020-2024 Ford Escape and 2021-2024 Lincoln Corsair models. The sheer volume of affected vehicles highlights the widespread nature of this manufacturing defect. Owners of these specific models were notified about this recall between January 20, 2025, and January 24, 2025, urging them to take action.
While Ford has proposed a remedy involving a software update to the battery energy control module (BECM) and, if necessary, a replacement of the high-voltage battery pack, the underlying issue points to a critical flaw in component quality. Understanding the scope and nature of this battery recall is vital for owners to recognize the specific risks their vehicle might face and to ensure they receive the appropriate corrective actions from their dealership.

3. **Specific Models Impacted by the May 2025 Recall**The May 2025 recall (NHTSA Recall No. 25V345000), which addresses vehicles incorrectly repaired under recall 23V380, specifically includes models equipped with 2.5L HEV or PHEV engines. This precise engine configuration is central to the defect, as it dictates the components and systems where the initial engine failure risk originated. The models covered are the 2020-2023 Ford Escape, the 2021-2023 Lincoln Corsair, and the 2022-2023 Ford Maverick.
It is crucial for owners of these model years to recognize that this recall applies to vehicles that were supposed to have been fixed previously. This implies a double layer of concern: first, the original defect, and second, the failure of the initial repair to adequately resolve it. The fact that the issue stems from an incorrect software upload during the prior recall means that the protective measures against engine failure were not activated, leaving these vehicles vulnerable.
The specific mention of 2.5L HEV or PHEV engines narrows down the affected population, but it is important to check the precise model year and engine type. These vehicles, designed for fuel efficiency and reduced emissions, unfortunately carry a significant latent safety concern due to this unresolved software issue. The consequence of this oversight is that the fire hazard associated with engine failure persists for these specific vehicles.
Ford has identified nearly 300 of these Ford hybrid vehicles recalled are in Canada, alongside the affected units in the U.S. This broadens the geographical scope of the problem. Owners should be particularly diligent in responding to the recall notices that will be mailed between June 23 and June 30, 2025, to ensure their vehicle finally receives the correct and necessary powertrain control module software update. This update is critical to eliminate the risk that should have been addressed during the earlier repair attempt.
Car Model Information: 2023 Ford Escape ST-Line
Name: Ford Escape
Caption: 2021 Escape Hybrid (US)
Manufacturer: Ford Motor Company
Aka: Unbulleted list
Production: 2000–present
ModelYears: 2001–present
Class: Compact crossover SUV
BodyStyle: SUV
Layout: Unbulleted list
Predecessor: Nissan Terrano II
Successor: Ford Territory (China)
Categories: 2010s cars, 2020s cars, All-wheel-drive vehicles, All Wikipedia articles written in American English, All articles with dead external links
Summary: The Ford Escape is a compact crossover SUV manufactured and marketed by the Ford Motor Company since the 2001 model year. The first Ford SUV derived from a car platform, the Escape fell below the Ford Explorer in size; the Escape was sized between the Ford EcoSport and Ford Edge. The 2005 model year Ford Escape Hybrid was the first hybrid-electric vehicle from Ford, and the first hybrid produced as an SUV.
The first two generations of the Escape used the Ford CD2 platform (jointly developed with Mazda), leading to the release of the rebadged variants, the Mazda Tribute and Mercury Mariner; as with the Escape, both the Tribute and Mariner were marketed in North America (the Mariner was never marketed in Canada). In Europe, the Escape was initially branded as the Ford Maverick from 2001 to 2008 (replacing a Nissan-produced SUV).
Under the mid-2000s “One Ford” globalization strategy, the third and fourth-generation designs of the Escape have been unified with the Ford Kuga, designed by Ford of Europe. Sharing a common body and chassis underpinnings (and several engines), the Escape and Kuga are manufactured in their home markets. As with previous generations, the fourth-generation Escape is offered with gasoline, hybrid, and plug-in hybrid options. Outside of North America, the Ford Escape is marketed in Australia, China, and Taiwan.
In August 2025, it was announced that Ford will be discontinuing the Escape after the 2026 model year.
Get more information about: Ford Escape
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Brand: Ford Model: Escape
Price: $20,790 Mileage: 49,987 mi.
Read more about: Critical Safety Alert: Over Half a Million Ford Edge and Lincoln MKX SUVs Recalled for Brake Fluid Leak Risk

4. **Models Covered by the January 2025 Battery Recall**The January 2025 Ford hybrid Battery Recall (NHTSA Recall No. 22V484000) targets a distinct set of vehicles, focusing on certain hybrid and plug-in hybrid models where battery cell defects have been identified. Specifically, this recall includes the 2020-2024 Ford Escape Plug-In Hybrid and the 2021-2024 Lincoln Corsair Grand Touring. These models are susceptible due to a manufacturing flaw in their high-voltage battery cells, which presents a significant risk.
This recall is distinct from the May 2025 recall and past engine fire recalls, as its root cause lies specifically within the battery components rather than engine failure leading to fuel/oil vapor release. The “20,484 hybrid crossover SUVs” mentioned in the initial January 2025 recall statement encompass these specific Escape and Corsair variants, emphasizing the scale of the battery-related issue. These are vehicles where the core power source itself carries a potential defect.
While the main list for the January 2025 battery recall explicitly names the Escape Plug-In Hybrid and Corsair Grand Touring, Ford’s broader context also mentions specific production date ranges for various models affected by hybrid recalls in general. However, for the January 2025 battery recall, the focus remains primarily on these plug-in hybrid models from the specified years, where the suspect battery cells from Samsung SDI were incorporated during manufacturing.
Owners of these particular Ford Escape Plug-In Hybrid and Lincoln Corsair Grand Touring models should pay close attention to the recall notifications they received between January 20 and January 24, 2025. The remedy for this recall involves a software update to the battery energy control module (BECM) and, if deemed necessary by the software’s diagnosis, a full replacement of the high-voltage battery pack. This proactive measure aims to mitigate the risk of internal short circuits and potential battery fires, ensuring the long-term safety and reliability of these electrified vehicles.
Car Model Information: 2023 Ford Escape ST-Line
Name: Ford Escape
Caption: 2021 Escape Hybrid (US)
Manufacturer: Ford Motor Company
Aka: Unbulleted list
Production: 2000–present
ModelYears: 2001–present
Class: Compact crossover SUV
BodyStyle: SUV
Layout: Unbulleted list
Predecessor: Nissan Terrano II
Successor: Ford Territory (China)
Categories: 2010s cars, 2020s cars, All-wheel-drive vehicles, All Wikipedia articles written in American English, All articles with dead external links
Summary: The Ford Escape is a compact crossover SUV manufactured and marketed by the Ford Motor Company since the 2001 model year. The first Ford SUV derived from a car platform, the Escape fell below the Ford Explorer in size; the Escape was sized between the Ford EcoSport and Ford Edge. The 2005 model year Ford Escape Hybrid was the first hybrid-electric vehicle from Ford, and the first hybrid produced as an SUV.
The first two generations of the Escape used the Ford CD2 platform (jointly developed with Mazda), leading to the release of the rebadged variants, the Mazda Tribute and Mercury Mariner; as with the Escape, both the Tribute and Mariner were marketed in North America (the Mariner was never marketed in Canada). In Europe, the Escape was initially branded as the Ford Maverick from 2001 to 2008 (replacing a Nissan-produced SUV).
Under the mid-2000s “One Ford” globalization strategy, the third and fourth-generation designs of the Escape have been unified with the Ford Kuga, designed by Ford of Europe. Sharing a common body and chassis underpinnings (and several engines), the Escape and Kuga are manufactured in their home markets. As with previous generations, the fourth-generation Escape is offered with gasoline, hybrid, and plug-in hybrid options. Outside of North America, the Ford Escape is marketed in Australia, China, and Taiwan.
In August 2025, it was announced that Ford will be discontinuing the Escape after the 2026 model year.
Get more information about: Ford Escape
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Brand: Ford Model: Escape
Price: $20,790 Mileage: 49,987 mi.
Read more about: A Costly Lesson Learned: 15 New Cars Buyers Would “Unbuy” to Escape Terrible Fuel Economy

5. **The Critical Danger: Understanding Engine Compartment Fire Risk**At the core of several of Ford’s recent hybrid recalls is the alarming potential for an engine compartment fire, a hazard that poses severe risks to vehicle occupants and surrounding property. This danger arises from a specific sequence of events triggered by engine failure in affected vehicles. When a 2.5L hybrid or plug-in hybrid engine malfunctions, it can lead to the release of highly flammable substances into the engine bay.
According to Ford, “In the event of an engine failure, engine oil and fuel vapor may be released into the engine compartment.” These substances, once airborne or spread within the confines of the engine bay, become extremely dangerous. They do not need an external spark to ignite; rather, the internal conditions of a running or recently run engine provide ample opportunity for combustion.
The real peril materializes when these released oil and fuel vapors “accumulate near ignition sources such as hot engine or exhaust components.” The extreme temperatures generated by the engine and exhaust system during normal operation, and even shortly after shutdown, are more than sufficient to ignite these volatile liquids and gases. This proximity creates a highly combustible environment, rapidly escalating the risk.
The result is “possibly resulting in an engine compartment fire.” Such fires are not only destructive to the vehicle but, critically, “greatly increases the likelihood of injury” to anyone in or around the vehicle. The rapid spread of fire, toxic smoke, and potential for explosions make this a profoundly serious safety concern. Ford has explicitly advised owners who notice “abnormal noise from the engines or if their vehicles experience reductions in power. And seeing smoke coming from under the hood is a definite sign” to immediately park and shut off their hybrid engines, emphasizing the immediate and severe nature of this particular defect.

6. **The Root Cause of Battery Defects: Samsung SDI Cells**The manufacturing flaw behind the January 2025 recall concerning high-voltage battery defects has been directly traced to specific components supplied by Samsung SDI. Ford’s investigation identified that the affected vehicles were equipped with “suspect battery cells from Samsung SDI.” This pinpointing of the supplier and the specific component highlights a critical issue in the supply chain and quality control processes.
Ford began its investigation into these battery concerns in September 2024. This action was prompted by a series of concerning incidents: the company had received “three reports of battery thermal venting incidents in Europe, which occurred between April and August 2024.” These events, though occurring abroad, were significant enough to initiate a thorough internal review of the battery systems and their components used in Ford’s hybrid vehicles.
Through rigorous analysis and data collection, Ford was able to identify the precise nature and origin of the problem. “After further analysis, the root cause of the issue was identified in December 2024.” This timeline indicates a focused effort to determine why these battery cells were failing, leading to the conclusion that a manufacturing flaw was at play. The process of isolating such a root cause involves complex engineering and forensic examination of the components.
The identification of Samsung SDI as the source of the suspect battery cells is crucial for accountability and for ensuring future prevention. It implies that the inconsistencies or weaknesses are inherent to the production of these specific cells. This discovery informed Ford’s decision to issue the recall, emphasizing the severity of a defect that could compromise the integrity of the vehicle’s high-voltage power system and lead to potential fire hazards. The problem is not simply a design flaw on Ford’s part, but a manufacturing irregularity within a key outsourced component.

7. **Deeper Dive into the Battery Fault: Separator Layer Vulnerability**The technical specifics of the high-voltage battery defect, which prompted the January 2025 recall, point to a critical vulnerability within the battery cells themselves. The core issue lies in the structural integrity of the “separator layer between the anode and cathode.” This separator is a vital component in any lithium-ion battery, designed to prevent direct contact between the positive and negative electrodes, thus averting short circuits.
Ford’s analysis revealed that “this separator layer is vulnerable to damage, which can result from inconsistencies in the production process of Samsung SDI’s battery cells.” Such inconsistencies are often minute, perhaps microscopic, but they can have profound effects over time and under varying operating conditions. These manufacturing variances can manifest as small defects, weaknesses, or localized stresses within the separator material.
When the separator layer sustains damage, even on a microscopic level, its ability to insulate the anode and cathode is compromised. “If the separator becomes damaged, it could trigger an internal short circuit.” An internal short circuit is a dangerous event where electrical current bypasses the normal circuit, generating excessive heat rapidly. This thermal event can lead to a cascade of failures within the battery cell.
The ultimate consequence of this damaged separator and subsequent internal short circuit is dire: it could lead to “potentially leading to a system shutdown.” More alarmingly, “In the worst-case scenario, this could result in a dangerous battery fire.” Such fires in high-voltage battery packs are extremely challenging to extinguish and pose significant safety risks. Despite the severity of the potential outcome, Ford has thankfully stated, “Fortunately, Ford has not reported any incidents of accidents or injuries related to this issue” concerning this specific battery defect, which offers some reassurance to affected owners while highlighting the preventative nature of the recall.

8. **Historical Context: The June 2023 Recall (NHTSA 23V380) and Its Aftermath**The May 2025 recall for incorrect repairs is not an isolated incident but rather a direct consequence of a preceding major recall: the June 2023 alert, identified as NHTSA Recall No. 23V380. This significant recall encompassed over 150,000 Ford vehicles, including specific 2020-2023 Ford Escape, 2022-2023 Ford Maverick, and 2021-2023 Lincoln Corsair models. The common thread among these vehicles was their equipment with 2.5L hybrid or plug-in hybrid engines, which were at the heart of the safety concern.
The core issue addressed by the June 2023 recall was a defect that could precipitate engine failure. Ford’s analysis indicated that such a failure could lead to the unwelcome release of engine oil and fuel vapor directly into the engine compartment. This scenario created an inherently hazardous environment, as these flammable substances could then accumulate in close proximity to the highly heated engine or exhaust components, which serve as potential ignition sources.
The inherent danger associated with this defect was considerable. The accumulation of these volatile substances under the hood carried a significant risk of sparking an engine compartment fire. As Ford explicitly warned, such a fire “greatly increases the likelihood of injury” to vehicle occupants and anyone nearby. This risk assessment underscores the critical importance of ensuring that any remedial actions taken were both comprehensive and effective in addressing the underlying engine fault.
The unfortunate reality revealed by the May 2025 recall is that for a subset of these vehicles, the intended repairs from the June 2023 recall were not successfully implemented. Dealers, despite recording the vehicles as successfully repaired, failed to upload the correct powertrain control module software. This lapse meant that the critical software updates designed to mitigate the engine failure and subsequent fire risk were absent, leaving owners unknowingly vulnerable to the very danger the original recall sought to prevent.
Car Model Information: 2023 Ford Escape ST-Line
Name: Ford Escape
Caption: 2021 Escape Hybrid (US)
Manufacturer: Ford Motor Company
Aka: Unbulleted list
Production: 2000–present
ModelYears: 2001–present
Class: Compact crossover SUV
BodyStyle: SUV
Layout: Unbulleted list
Predecessor: Nissan Terrano II
Successor: Ford Territory (China)
Categories: 2010s cars, 2020s cars, All-wheel-drive vehicles, All Wikipedia articles written in American English, All articles with dead external links
Summary: The Ford Escape is a compact crossover SUV manufactured and marketed by the Ford Motor Company since the 2001 model year. The first Ford SUV derived from a car platform, the Escape fell below the Ford Explorer in size; the Escape was sized between the Ford EcoSport and Ford Edge. The 2005 model year Ford Escape Hybrid was the first hybrid-electric vehicle from Ford, and the first hybrid produced as an SUV.
The first two generations of the Escape used the Ford CD2 platform (jointly developed with Mazda), leading to the release of the rebadged variants, the Mazda Tribute and Mercury Mariner; as with the Escape, both the Tribute and Mariner were marketed in North America (the Mariner was never marketed in Canada). In Europe, the Escape was initially branded as the Ford Maverick from 2001 to 2008 (replacing a Nissan-produced SUV).
Under the mid-2000s “One Ford” globalization strategy, the third and fourth-generation designs of the Escape have been unified with the Ford Kuga, designed by Ford of Europe. Sharing a common body and chassis underpinnings (and several engines), the Escape and Kuga are manufactured in their home markets. As with previous generations, the fourth-generation Escape is offered with gasoline, hybrid, and plug-in hybrid options. Outside of North America, the Ford Escape is marketed in Australia, China, and Taiwan.
In August 2025, it was announced that Ford will be discontinuing the Escape after the 2026 model year.
Get more information about: Ford Escape
Buying a high-performing used car >>>
Brand: Ford Model: Escape
Price: $20,790 Mileage: 49,987 mi.

9. **Further Historical Recalls: The July 2022 Engine Fire Warning**Before the widespread June 2023 recall, Ford had already issued an earlier, significant safety alert in July 2022, highlighting a recurring pattern of engine fire concerns in its hybrid lineup. This recall specifically involved 2020-2022 Ford Escape SUVs, Ford Maverick pickup trucks, and Lincoln Corsair SUV hybrids, all powered by the identical 2.5-liter hybrid powertrain. This earlier action showcased a consistent challenge Ford faced in ensuring the integrity of these advanced engine systems.
The primary concern articulated in the July 2022 recall was remarkably similar to subsequent alerts: a potential for engine failure that could result in the release of oil and/or fuel vapor. This release, in turn, posed a direct threat of an under-hood fire, presenting an immediate safety hazard for vehicle occupants. The consistent appearance of this specific risk across multiple recall iterations underscores the deep-seated nature of the problem within certain hybrid engine configurations.
Investigations into this particular recall traced the problem back to “isolated manufacturing issues with hybrid and plug-in hybrid models.” More specifically, the root cause was identified as “a breach in the engine block or oil pan.” Such a breach would allow highly flammable fluids to escape and come into contact with hot engine components, creating a dangerous condition conducive to fire. This indicated a fundamental structural vulnerability in certain production runs.
This July 2022 recall affected a substantial number of vehicles, with a total of 100,689 units in the U.S. being included in the alert. At the time of this initial announcement, Ford reported that it was “not aware of any crashes or injuries related to this problem,” providing a degree of reassurance, although the potential for serious incidents remained. Owners of the affected vehicles were duly notified in early August, with Ford acknowledging that this recall was later expanded and eventually replaced by subsequent actions, indicating an evolving understanding and response to the ongoing safety challenges.
Car Model Information: 2023 Ford Escape ST-Line
Name: Ford Escape
Caption: 2021 Escape Hybrid (US)
Manufacturer: Ford Motor Company
Aka: Unbulleted list
Production: 2000–present
ModelYears: 2001–present
Class: Compact crossover SUV
BodyStyle: SUV
Layout: Unbulleted list
Predecessor: Nissan Terrano II
Successor: Ford Territory (China)
Categories: 2010s cars, 2020s cars, All-wheel-drive vehicles, All Wikipedia articles written in American English, All articles with dead external links
Summary: The Ford Escape is a compact crossover SUV manufactured and marketed by the Ford Motor Company since the 2001 model year. The first Ford SUV derived from a car platform, the Escape fell below the Ford Explorer in size; the Escape was sized between the Ford EcoSport and Ford Edge. The 2005 model year Ford Escape Hybrid was the first hybrid-electric vehicle from Ford, and the first hybrid produced as an SUV.
The first two generations of the Escape used the Ford CD2 platform (jointly developed with Mazda), leading to the release of the rebadged variants, the Mazda Tribute and Mercury Mariner; as with the Escape, both the Tribute and Mariner were marketed in North America (the Mariner was never marketed in Canada). In Europe, the Escape was initially branded as the Ford Maverick from 2001 to 2008 (replacing a Nissan-produced SUV).
Under the mid-2000s “One Ford” globalization strategy, the third and fourth-generation designs of the Escape have been unified with the Ford Kuga, designed by Ford of Europe. Sharing a common body and chassis underpinnings (and several engines), the Escape and Kuga are manufactured in their home markets. As with previous generations, the fourth-generation Escape is offered with gasoline, hybrid, and plug-in hybrid options. Outside of North America, the Ford Escape is marketed in Australia, China, and Taiwan.
In August 2025, it was announced that Ford will be discontinuing the Escape after the 2026 model year.
Get more information about: Ford Escape
Buying a high-performing used car >>>
Brand: Ford Model: Escape
Price: $20,790 Mileage: 49,987 mi.

10. **Comprehensive Remedies for the January 2025 High-Voltage Battery Recall**Addressing the critical concerns raised by the January 2025 recall (NHTSA Recall No. 22V484000) regarding high-voltage battery defects, Ford has outlined a comprehensive remediation strategy. This recall specifically targets the manufacturing flaw in suspect battery cells from Samsung SDI, which poses a risk of internal short circuits and potential battery fires. Ford’s proposed remedy is multi-faceted, designed to both detect and prevent the escalation of these dangerous battery cell irregularities.
The primary component of the resolution involves a crucial software update to the battery energy control module (BECM). This update is engineered to enhance the vehicle’s diagnostic capabilities, allowing it to “detect any anomalies in the battery cells.” The BECM plays a vital role in monitoring and managing the performance and health of the high-voltage battery pack, making this software enhancement a critical first line of defense against potential failures.
Should the updated software identify a condition indicative of separator damage—the root cause identified in the Samsung SDI cells—Ford has committed to a more extensive corrective action. In such instances, dealers will proceed with “a replacement of the high-voltage battery pack.” This measure ensures that vehicles with confirmed battery cell degradation or vulnerability are equipped with a new, fully functional battery, completely mitigating the risk associated with the manufacturing flaw.
It is crucial for affected owners to understand that all recall-related repairs, including the BECM software update and any necessary battery pack replacements, will be performed “at no cost to the customer.” This commitment from Ford ensures that owners are not financially burdened by manufacturing defects. Owners were notified between January 20 and January 24, 2025, emphasizing the urgency of scheduling these vital, preventative repairs to maintain vehicle safety and integrity.
Read more about: Navigating New Car Warranties: Spotting the Best, Understanding Manufacturer Challenges, and Avoiding Costly Pitfalls

11. **Ford’s Corrective Actions for the May 2025 Incorrect Repair Recall**In response to the concerning discovery that approximately 1,797 vehicles affected by the June 2023 recall (23V380) were not properly repaired, Ford has taken swift action with the May 2025 recall (NHTSA Recall No. 25V345000). This recall specifically addresses the oversight where dealer technicians failed to upload the correct powertrain control module (PCM) software, leaving a critical safety vulnerability unresolved in these 2020-2023 Escape, 2021-2023 Corsair, and 2022-2023 Maverick models equipped with 2.5L HEV or PHEV engines.
Ford’s remedy for this particular alert is straightforward but essential: dealers are instructed to correctly update the powertrain control module software. The official statement from Ford clarified the initial failure, stating, “The dealer instructions to complete the recall instruct the technician to upload the latest software using the service tool, which downloads the latest software from Ford for installation on the vehicle. For these vehicles, the software tool did not upload the correct software to the vehicle.” This new recall ensures the proper, intended software is finally installed.
The successful installation of this updated software is paramount to resolve the underlying engine fire risk. This update is designed to activate the protective measures that were initially intended to mitigate the danger of engine failure and the subsequent release of flammable oil and fuel vapors into the engine compartment. Without the correct software, the vehicles remained vulnerable to the severe risks of an engine compartment fire, which can lead to significant injury.
Owners of the affected vehicles should anticipate receiving recall letters directly from Ford, which are scheduled to be mailed between June 23 and June 30, 2025. These letters will provide explicit instructions on how to proceed with scheduling the necessary software update at their local Ford dealership. This final corrective action is critical to fully address the safety hazard that has persisted due to the initial incorrect repair, restoring confidence in the vehicle’s safety systems.
Car Model Information: 2023 Honda Accord LX
Name: Ford Maverick
Caption: United States
Manufacturer: Ford Motor Company
ModelCode: P758
Production: 2021–present
ModelYears: 2022–present
Assembly: Hermosillo
Designer: Unbulleted list
Class: Pickup_truck#Compact_pickup_truck
BodyStyle: pickup truck
Layout: Unbulleted list
Platform: Ford C2 platform
Chassis: Unibody
Related: Unbulleted list
Engine: Unbulleted list
Motor: 88 kW
Abbr: on (Tremor)
Powerout: cvt
Transmission: Unbulleted list
Drivetrain: Parallel hybrid
Battery: Lithium-ion battery
Wheelbase: 121.1 in
Length: 199.7 in
Width: 72.6 in
Height: 68.7 in
Weight: convert,convert
Sp: us
Categories: All-wheel-drive vehicles, All Wikipedia articles written in American English, All articles lacking reliable references, All articles needing additional references, Articles lacking reliable references from June 2022
Summary: The Ford Maverick is a four-door, compact pickup truck manufactured and marketed by the Ford Motor Company. It was unveiled on June 8, 2021, as Ford’s smallest truck, slotted below the mid-size Ford Ranger.
Using a front-wheel drive-based unibody platform shared with the Ford Escape and Bronco Sport, the pickup’s power train offerings include a gasoline hybrid engine or a turbocharged gasoline engine, the latter available with all-wheel drive. The truck is exclusively offered in a 4-door crew cab configuration with a short bed.
The Maverick went on sale in late 2021 for the 2022 model year. The truck saw strong demand from consumers, with Ford unable to fulfill all orders it received for the 2022 model year, and only accepting orders for the 2023 model year for one week. The truck has been successful in attracting new customers, with Ford reporting that nearly 60% of Maverick buyers are new to the brand.
Demand remains strong through mid 2025, with 48,041 trucks sold during the second quarter alone, an increase of 26.3% year over year. In contrast, sales of its primary competitor, the Hyundai Santa Cruz, dropped by 21%.
Get more information about: Ford Maverick (2022)
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Brand: Ford Model: Escape, Corsair, Maverick
Price: $25,677 Mileage: 15,933 mi.
Read more about: Beyond the Blink: How a Ford Camera Glitch Uncovers Systemic Engineering Failures and the Lingering Shadows of Automotive Design Mistakes

12. **Essential Actionable Steps for Owners Experiencing 2.5L Hybrid Engine Issues**For owners of Ford Escape, Lincoln Corsair, and Ford Maverick hybrid models, especially those equipped with the 2.5L hybrid engine, understanding and implementing specific actionable steps is paramount if any issues arise. Given the history of recalls concerning engine fire risks, vigilance and prompt action are crucial for safety. Following a clear protocol can help prevent further damage, ensure proper diagnosis, and facilitate timely repairs.
The immediate and most critical advice is to “Stop Driving” the vehicle if any unusual behavior is noticed. This includes symptoms such as engine hesitation, unexpected stalling, or a noticeable loss of power. Continuing to operate a vehicle under these conditions could exacerbate the underlying problem, potentially leading to more severe damage or, more gravely, increasing the risk of an engine compartment fire, as outlined in the various recalls.
Concurrently, owners should always “Check for Warning Lights” on their dashboard. Specifically, pay close attention to the check engine light or any dedicated hybrid system warning light. These indicators are designed to provide early alerts about potential malfunctions within the vehicle’s complex systems. Consulting the vehicle’s owner’s manual can also offer valuable guidance on troubleshooting specific error codes or initial steps to take before seeking professional assistance.
If concerns persist, or if warning lights illuminate, it is imperative to “Contact Your Dealership or Mechanic” without delay to schedule a diagnostic inspection. A certified Ford dealer or an experienced mechanic specializing in hybrid systems can accurately assess the issue. Furthermore, owners should proactively “Check for Recalls” by visiting the National Highway Traffic Safety Administration (NHTSA) website and entering their vehicle’s VIN, or by contacting their dealer directly to ascertain if their car is included in any active recall campaigns related to engine or battery issues.
Ford offers explicit guidance for specific severe symptoms: “If vehicle owners observe any unusual engine sounds, experience a decrease in vehicle power, or see smoke, the manufacturer advises them to promptly park their vehicle and turn off the engine.” This directive underscores the immediate and serious nature of these warnings, urging owners not to delay. Taking timely action on these steps can significantly help in managing risks, securing necessary repairs under warranty or recall programs, and ultimately safeguarding occupant safety.
Car Model Information: 2023 Ford Escape ST-Line
Name: Ford Escape
Caption: 2021 Escape Hybrid (US)
Manufacturer: Ford Motor Company
Aka: Unbulleted list
Production: 2000–present
ModelYears: 2001–present
Class: Compact crossover SUV
BodyStyle: SUV
Layout: Unbulleted list
Predecessor: Nissan Terrano II
Successor: Ford Territory (China)
Categories: 2010s cars, 2020s cars, All-wheel-drive vehicles, All Wikipedia articles written in American English, All articles with dead external links
Summary: The Ford Escape is a compact crossover SUV manufactured and marketed by the Ford Motor Company since the 2001 model year. The first Ford SUV derived from a car platform, the Escape fell below the Ford Explorer in size; the Escape was sized between the Ford EcoSport and Ford Edge. The 2005 model year Ford Escape Hybrid was the first hybrid-electric vehicle from Ford, and the first hybrid produced as an SUV.
The first two generations of the Escape used the Ford CD2 platform (jointly developed with Mazda), leading to the release of the rebadged variants, the Mazda Tribute and Mercury Mariner; as with the Escape, both the Tribute and Mariner were marketed in North America (the Mariner was never marketed in Canada). In Europe, the Escape was initially branded as the Ford Maverick from 2001 to 2008 (replacing a Nissan-produced SUV).
Under the mid-2000s “One Ford” globalization strategy, the third and fourth-generation designs of the Escape have been unified with the Ford Kuga, designed by Ford of Europe. Sharing a common body and chassis underpinnings (and several engines), the Escape and Kuga are manufactured in their home markets. As with previous generations, the fourth-generation Escape is offered with gasoline, hybrid, and plug-in hybrid options. Outside of North America, the Ford Escape is marketed in Australia, China, and Taiwan.
In August 2025, it was announced that Ford will be discontinuing the Escape after the 2026 model year.
Get more information about: Ford Escape
Buying a high-performing used car >>>
Brand: Ford Model: Escape
Price: $20,790 Mileage: 49,987 mi.

13. **Navigating Recalls: How to Check Your Vehicle and Stay Informed**In the intricate landscape of vehicle safety, knowing how to verify if your Ford hybrid is affected by a recall is an empowering piece of information for every owner. With multiple, sometimes overlapping, recalls issued for the Escape, Corsair, and Maverick hybrid models, it’s more important than ever to possess the tools to independently confirm your vehicle’s status. The process is designed to be straightforward, ensuring critical safety information reaches those who need it most.
The most authoritative and direct method for determining if your specific vehicle is included in any active recall campaign is to utilize the “NHTSA’s site using your car’s VIN number.” The Vehicle Identification Number (VIN) is a unique, 17-character alphanumeric code that acts as your car’s fingerprint, providing access to a comprehensive history of recalls and safety alerts pertinent to that exact vehicle. This simple step can immediately clarify whether your vehicle requires attention.
Beyond checking the NHTSA database, affected vehicle owners should also be vigilant for official correspondence. Ford typically sends “recall letters” directly to registered owners. For instance, letters pertaining to the May 2025 recall for incorrect repairs are scheduled to be mailed between June 23 and June 30, 2025. These letters contain vital information regarding the nature of the defect, the potential risks, and the detailed steps required to schedule the necessary repairs at a dealership.
For those who have questions or seek additional clarification, Ford has established dedicated channels. Owners with concerns regarding the recent hybrid engine recalls can “call 866-436-7332 and refer to Ford hybrid recall number 25S54.” This direct line provides an opportunity to speak with a Ford representative who can offer personalized assistance and confirm details specific to your vehicle. Staying proactively informed through these channels is a critical aspect of vehicle ownership in the face of ongoing safety alerts.
Car Model Information: 2023 Ford Escape ST-Line
Name: Ford Escape
Caption: 2021 Escape Hybrid (US)
Manufacturer: Ford Motor Company
Aka: Unbulleted list
Production: 2000–present
ModelYears: 2001–present
Class: Compact crossover SUV
BodyStyle: SUV
Layout: Unbulleted list
Predecessor: Nissan Terrano II
Successor: Ford Territory (China)
Categories: 2010s cars, 2020s cars, All-wheel-drive vehicles, All Wikipedia articles written in American English, All articles with dead external links
Summary: The Ford Escape is a compact crossover SUV manufactured and marketed by the Ford Motor Company since the 2001 model year. The first Ford SUV derived from a car platform, the Escape fell below the Ford Explorer in size; the Escape was sized between the Ford EcoSport and Ford Edge. The 2005 model year Ford Escape Hybrid was the first hybrid-electric vehicle from Ford, and the first hybrid produced as an SUV.
The first two generations of the Escape used the Ford CD2 platform (jointly developed with Mazda), leading to the release of the rebadged variants, the Mazda Tribute and Mercury Mariner; as with the Escape, both the Tribute and Mariner were marketed in North America (the Mariner was never marketed in Canada). In Europe, the Escape was initially branded as the Ford Maverick from 2001 to 2008 (replacing a Nissan-produced SUV).
Under the mid-2000s “One Ford” globalization strategy, the third and fourth-generation designs of the Escape have been unified with the Ford Kuga, designed by Ford of Europe. Sharing a common body and chassis underpinnings (and several engines), the Escape and Kuga are manufactured in their home markets. As with previous generations, the fourth-generation Escape is offered with gasoline, hybrid, and plug-in hybrid options. Outside of North America, the Ford Escape is marketed in Australia, China, and Taiwan.
In August 2025, it was announced that Ford will be discontinuing the Escape after the 2026 model year.
Get more information about: Ford Escape
Buying a high-performing used car >>>
Brand: Ford Model: Escape
Price: $20,790 Mileage: 49,987 mi.

14. **Empowering Consumers: Understanding Your Lemon Law Options**Beyond the immediate remedies offered through recalls, consumers facing persistent and unresolved issues with their Ford Escape or Lincoln Corsair hybrid vehicles have additional avenues for protection, notably under “Lemon Law provisions.” This vital piece of legislation is specifically designed to safeguard consumers who have purchased or leased vehicles that exhibit substantial manufacturing defects, which cannot be fixed after a reasonable number of repair attempts by the manufacturer or authorized dealership.
The “Lemon Law” essentially protects consumers from vehicles that consistently fail to meet safety and quality standards, which can certainly apply to critical defects like the potential battery failure or engine fire risk discussed in these Ford recalls. If your vehicle, despite recall repairs or multiple service attempts, continues to exhibit the same significant safety or operational problems, it may be deemed a “lemon” under state-specific statutes.
Should your Ford hybrid be classified as a “lemon” due to these persistent, safety-critical defects, you, as the consumer, may be entitled to significant recourse. This can include “a refund, replacement, or cash compensation.” A refund would entail the repurchase of your vehicle by the manufacturer, while a replacement would provide you with a new, comparable vehicle. Cash compensation might be offered if you choose to keep the vehicle but receive monetary damages for its diminished value and inconvenience.
Navigating the complexities of Lemon Law can be challenging, which is why organizations like the “Lemon Law Experts” exist to assist consumers. They offer to “work diligently to ensure you get the help and compensation you deserve, as quickly as possible.” If you are experiencing recurring issues with your Ford hybrid, particularly those related to the recent battery or engine recalls, and feel your vehicle might be a lemon, seeking a “free, no-obligation case analysis” is a proactive step toward understanding your legal rights and securing a resolution.
Car Model Information: 2023 Ford Escape ST-Line
Name: Ford Escape
Caption: 2021 Escape Hybrid (US)
Manufacturer: Ford Motor Company
Aka: Unbulleted list
Production: 2000–present
ModelYears: 2001–present
Class: Compact crossover SUV
BodyStyle: SUV
Layout: Unbulleted list
Predecessor: Nissan Terrano II
Successor: Ford Territory (China)
Categories: 2010s cars, 2020s cars, All-wheel-drive vehicles, All Wikipedia articles written in American English, All articles with dead external links
Summary: The Ford Escape is a compact crossover SUV manufactured and marketed by the Ford Motor Company since the 2001 model year. The first Ford SUV derived from a car platform, the Escape fell below the Ford Explorer in size; the Escape was sized between the Ford EcoSport and Ford Edge. The 2005 model year Ford Escape Hybrid was the first hybrid-electric vehicle from Ford, and the first hybrid produced as an SUV.
The first two generations of the Escape used the Ford CD2 platform (jointly developed with Mazda), leading to the release of the rebadged variants, the Mazda Tribute and Mercury Mariner; as with the Escape, both the Tribute and Mariner were marketed in North America (the Mariner was never marketed in Canada). In Europe, the Escape was initially branded as the Ford Maverick from 2001 to 2008 (replacing a Nissan-produced SUV).
Under the mid-2000s “One Ford” globalization strategy, the third and fourth-generation designs of the Escape have been unified with the Ford Kuga, designed by Ford of Europe. Sharing a common body and chassis underpinnings (and several engines), the Escape and Kuga are manufactured in their home markets. As with previous generations, the fourth-generation Escape is offered with gasoline, hybrid, and plug-in hybrid options. Outside of North America, the Ford Escape is marketed in Australia, China, and Taiwan.
In August 2025, it was announced that Ford will be discontinuing the Escape after the 2026 model year.
Get more information about: Ford Escape
Buying a high-performing used car >>>
Brand: Ford Model: Escape
Price: $20,790 Mileage: 49,987 mi.
The series of Ford recalls affecting Escape, Corsair, and Maverick hybrid models underscores a critical lesson for all vehicle owners: the journey to ensuring vehicle safety is often ongoing, requiring constant vigilance and informed action. From understanding the nuanced technical causes of engine failure and battery defects to recognizing the importance of correct recall repairs and knowing your rights under consumer protection laws, staying educated is your best defense. Ford’s commitment to addressing these issues, alongside the availability of robust consumer advocacy, empowers owners to navigate these challenges, ultimately fostering safer roads for everyone. We urge all affected vehicle owners to review their vehicle’s status, act promptly on recall notices, and leverage available resources to protect their investment and, more importantly, their safety.