Urgent Safety Alert: Ford Recalls 133,000 Lincoln Aviator SUVs Over Detaching Trim Components

Ford Motor Co. has issued a significant safety recall affecting approximately 133,000 Lincoln Aviator SUVs from model years 2020 to 2025. This recall addresses a critical defect where exterior trim pieces, specifically the C-pillar appliques and rear door window division bars, may detach from the vehicle while in motion. The potential detachment of these components poses an undeniable safety risk, as they can become hazardous road debris, endangering other vehicles, pedestrians, and cyclists.

The Dearborn, Michigan-based automaker has traced the root cause of this issue to insufficient adhesive bonding during the assembly process at its Chicago Assembly Plant. This manufacturing flaw increases the likelihood that these trim components could loosen or completely fall off, particularly at higher speeds. While Ford states it is not aware of any accidents or injuries directly related to this specific defect, the National Highway Traffic Safety Administration (NHTSA) emphasizes that detaching parts can elevate the risk of crashes and damage for other road users.

This in-depth look will meticulously detail the various facets of this urgent recall, providing crucial information for affected owners and the public. We will explore the precise nature of the defect, its safety implications, Ford’s extensive history of monitoring and response, and the comprehensive repair plan put forth by the manufacturer. Understanding these elements is paramount for ensuring vehicle safety and adherence to regulatory standards.

1. **Scope of the Lincoln Aviator Trim Recall**The recall initiated by Ford encompasses approximately 133,000 Lincoln Aviator SUVs, specifically targeting models from the 2020 through 2025 model years. This broad scope highlights the extensive number of vehicles potentially impacted by the trim detachment issue, underscoring the necessity of prompt action for owners. The official recall identifies these vehicles as having been produced between October 19, 2018, and May 30, 2025, which marks the period during which the problematic parts were utilized in assembly.

The magnitude of this recall, covering a five-year production span, indicates a persistent manufacturing concern that has now culminated in a widespread safety alert. While the total number of recalled vehicles stands at roughly 133,000, it is notable that Ford estimates only 3.2%, or approximately 4,256 of these vehicles, actually involve the safety defect. This distinction, however, does not diminish the importance of the recall for all potentially affected owners.

This particular recall is officially identified under Ford Recall Number 25S66. For reference and additional information, the National Highway Traffic Safety Administration (NHTSA) has also documented this campaign with report numbers RCAK‑25V407‑6048 and RCLRPT‑25V407‑8066. These identifiers are crucial for owners seeking to verify if their specific vehicle is included in the recall and for accessing official documentation from regulatory bodies regarding the defect and its resolution.

Fender Flares and C-Pillar Design — BMW E90 3 Series Widebody M3 Conversion for Non M3. Hood, … | Flickr, Photo by staticflickr.com, is licensed under CC BY-SA 4.0

2. **The Specific Components Involved**At the heart of this recall are two distinct but related exterior trim components: the C-pillar appliques and the rear door window division bars. These parts are integral to the aesthetic and structural finish of the Lincoln Aviator’s rear door assembly. The C-pillar applique is typically a decorative trim piece located on the C-pillar, the vehicle’s rearmost roof support, while the window division bars are positioned within the rear door window frame.

Ford’s official statements and recall reports specifically name these two components as being susceptible to detachment. The problem arises because these parts, intended to be securely bonded, may loosen or separate entirely from the vehicle’s body. This issue is more than just a cosmetic flaw; it directly contributes to the safety concerns that necessitated the recall.

The fact that these are exterior components makes their potential detachment a direct road hazard. Unlike an internal defect, a piece of trim separating from the vehicle immediately becomes uncontrolled debris. This physical separation is what transforms a manufacturing error into a significant safety issue, capable of impacting other road users.

Car Model Information: 2023 Lincoln Aviator Reserve AWD
Name: Lincoln Aviator
Caption: 2020 Lincoln Aviator
Manufacturer: The Lincoln Motor Company
Production: unbulleted list
ModelYears: unbulleted list
Class: unbulleted list
BodyStyle: Sport utility vehicle
Layout: unbulleted list
Categories: 2010s cars, 2020s cars, All Wikipedia articles written in American English, Articles with short description, Cars introduced in 2002
Summary: The Lincoln Aviator is a mid-size, three-row luxury SUV manufactured and marketed under the Lincoln brand of Ford Motor Company — and now in its second generation, with a hiatus from 2006 to 2020. The first generation Aviator was manufactured for 2003–2005 model years as a rebadged variant of the third generation Ford Explorer — and assembled at the now-closed St. Louis Assembly in Hazelwood, Missouri, alongside the Explorer and Mountaineer. For the 2020 model year, Lincoln reintroduced the Aviator as a badge engineered variant of the sixth generation Ford Explorer manufactured at Chicago Assembly and offered with a plug-in hybrid variant.

Get more information about: Lincoln Aviator

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“Lamborghini Countach, Diablo SV and Murciélago” by exfordy is licensed under CC BY 2.0

3. **Root Cause of the Detachment Issue**The core reason behind the Lincoln Aviator trim detachment recall is identified as insufficient adhesive bonding. Ford and NHTSA reports consistently point to this manufacturing deficiency as the direct cause of the problem. During the assembly process, the adhesive used to secure the C-pillar appliques and rear door window division bars was not applied with adequate pressure or quantity, leading to a compromised bond.

Specifically, Ford states that “The components may detach due to inadequate application pressure of the components during assembly at the supplier facility that results in insufficient adhesive retention.” This highlights a breakdown in the manufacturing quality control, where the critical step of bonding these trim pieces was not performed to standard specifications, leaving them vulnerable to loosening over time and during vehicle operation.

This inadequate adhesive retention means that the bond intended to hold these components firmly in place is weaker than designed. As vehicles are exposed to varying driving conditions, including vibrations, wind pressure, and environmental factors, this weak bond can fail, allowing the trim pieces to separate. This fundamental issue at the point of manufacture is what underpins the entire recall effort.

brown wooden smoking pipe on white surface — Photo by Tingey Injury Law Firm on Unsplash

4. **The Identified Safety Hazards**The detachment of the C-pillar appliques and rear door window division bars presents several serious safety hazards. Primarily, these loose trim pieces can become projectiles on the roadway. At highway speeds, such debris can strike nearby vehicles, potentially damaging windshields or other body parts, and in extreme cases, causing drivers to swerve unexpectedly, leading to a loss of control and potential accidents.

Beyond damage to other vehicles, there is a clear risk to vulnerable road users. In more populated areas, such as city streets or residential neighborhoods, detached trim could directly injure pedestrians or cyclists. Even if direct impact is avoided, these pieces of debris lying on the roadway can lead to other drivers running them over, resulting in tire damage or creating further accident scenarios as drivers attempt to avoid them.

Furthermore, Ford highlights potential legal and liability concerns for vehicle owners. If a detached component causes an accident, the vehicle owner might be held responsible, even if they were unaware of the defect. This adds a significant layer of concern beyond the immediate physical dangers. While primarily a safety issue, the trim also contributes to a vehicle’s structural finish and aerodynamics, with detachment potentially leading to increased wind noise or water intrusion, affecting overall integrity and comfort.

“1934 Ford V8 coupe” by sv1ambo is licensed under CC BY 2.0

5. **Ford’s Initial Monitoring and Assessment**Ford’s awareness of this trim detachment issue dates back more than three years, with the company monitoring the problem since June 2020. During this period, between June 17, 2020, and April 14, 2025, Ford received a substantial number of reports concerning the defect, totaling 1,105 warranty claims globally regarding trim pieces falling off Lincoln Aviator models. This long-standing accumulation of claims indicates a consistent, albeit initially underestimated, problem.

An initial investigation into the concern was conducted by Ford’s Critical Concern Review Group between April 2022 and May 2023. At that time, after reviewing the available data and characteristics of the detached parts, the group concluded that the problem “did not pose a significant safety risk.” This determination was based on the assessment that the Aviator parts “did not represent a significant risk while falling to the ground or while in the roadway due to low masses and narrow profiles with no sharp protrusions.”

Despite the numerous warranty claims, Ford also stated that it was not aware of any accidents or injuries reported to date directly linked to this specific trim detachment. This absence of reported incidents might have contributed to the initial conclusion that the risk was not significant enough to warrant a recall, highlighting a crucial point in the company’s decision-making process prior to the official recall approval.

Car Model Information: 2022 Lincoln Aviator Reserve AWD
Name: Lincoln Aviator
Caption: 2020 Lincoln Aviator
Manufacturer: The Lincoln Motor Company
Production: unbulleted list
ModelYears: unbulleted list
Class: unbulleted list
BodyStyle: Sport utility vehicle
Layout: unbulleted list
Categories: 2010s cars, 2020s cars, All Wikipedia articles written in American English, Articles with short description, Cars introduced in 2002
Summary: The Lincoln Aviator is a mid-size, three-row luxury SUV manufactured and marketed under the Lincoln brand of Ford Motor Company — and now in its second generation, with a hiatus from 2006 to 2020. The first generation Aviator was manufactured for 2003–2005 model years as a rebadged variant of the third generation Ford Explorer — and assembled at the now-closed St. Louis Assembly in Hazelwood, Missouri, alongside the Explorer and Mountaineer. For the 2020 model year, Lincoln reintroduced the Aviator as a badge engineered variant of the sixth generation Ford Explorer manufactured at Chicago Assembly and offered with a plug-in hybrid variant.

Get more information about: Lincoln Aviator

Buying a high-performing used car >>>
Brand: Lincoln Model: Aviator
Price: $47,950 Mileage: 27,533 mi.

“’79 Ford F-Series Pickup (4994863009)” by Michael Gil from Calgary, AB, Canada is licensed under CC BY 2.0

6. **The Catalyst for Renewed Investigation**A pivotal moment that shifted Ford’s stance on the trim detachment issue occurred in April 2025. On April 15, Ford’s Product Development Quality team identified a loose C-pillar applique on an internal test vehicle. This concrete finding on a company-owned vehicle served as a critical catalyst, prompting a renewed and more intensive investigation into the problem that had previously been deemed a non-significant safety risk.

Following this discovery, the concern was escalated to Ford’s Critical Concern Review Group on April 22, signaling the increased gravity with which the issue was now being treated. Throughout the month of May, Ford’s engineering team launched a dedicated effort to identify the definitive cause of the C-pillar applique detachments and division bar looseness, also referred to as “glass run channels” in some reports. This renewed analysis went beyond prior assessments.

The comprehensive re-investigation involved a thorough review of existing field and warranty data, including the potential for higher occurrences of detachment on higher mileage Aviator SUVs. Additionally, supplier process improvement actions were scrutinized by Ford’s Supplier Technical Assistance team to precisely determine the scope and nature of the underlying problem. These internal findings, combined with subsequent “discussions with NHTSA on the road hazard risks,” ultimately led to the official recall approval.

7. **Ford’s Official Response and Repair Plan**Following the renewed investigation and crucial discussions with the National Highway Traffic Safety Administration (NHTSA), Ford’s Field Review Committee officially approved the recall for the Lincoln Aviator trim detachment issue on June 6, 2025. This approval marked the formal commitment by the automaker to address the safety defect comprehensively and proactively, moving beyond its earlier assessment.

As part of the established remedy, Ford dealerships are authorized and instructed to repair or replace the affected C-pillar appliques and window division bars. Importantly, these repairs will be performed at no cost to the vehicle owner, ensuring that the burden of rectifying the manufacturing defect does not fall on the consumer. This commitment to free repairs is standard practice for safety recalls.

Ford has emphasized that the replacement parts will be “permanently secured to prevent future detachment.” This indicates a revised installation procedure or improved adhesive bonding method designed to eliminate the root cause of the problem. The repair solution aims to provide a definitive and lasting fix, restoring the integrity of the vehicle’s exterior trim. Owner notification will occur in two phases, with initial letters alerting owners to the recall, followed by a second letter once the repair solution and parts are readily available at dealerships.

Owners of affected Lincoln Aviator SUVs are advised to understand the specific steps involved in the recall process to ensure their vehicle is properly addressed. Ford will initiate owner notifications through a two-phase mailing system. The initial notification letters are scheduled to be mailed beginning July 28, 2025, informing owners that their vehicle may be affected by the recall. This first communication will advise recipients to await further instructions before scheduling any dealership visits.

Following the initial alert, a second notification letter will be dispatched once the necessary repair parts and procedures become fully available. This subsequent letter will provide clear instructions on how owners can schedule a complimentary repair appointment at any authorized Ford or Lincoln dealership. It is crucial for owners to heed the advice to refrain from visiting a dealership for this recall service until they have received this second notification, confirming that repairs can be performed and the required parts are readily accessible.

Upon receiving the second letter, owners should promptly contact their local Ford or Lincoln dealer to schedule the free repair appointment. Ford has ensured that these repairs will be performed at no cost to the vehicle owner, covering the rectification of the manufacturing defect. For those who have already experienced trim parts detaching, it is recommended to report the issue directly to Ford Customer Service at 1-866-436-7332 or to the NHTSA at 1-888-327-4236. Additional information and resources are also available at www.nhtsa.gov. The official Ford Recall Number for this campaign is 25S66.

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“A Heavy Duty Tonneau Cover And Custom Headache Rack On A Ford Super Duty” by DiamondBack Truck Covers is licensed under CC BY-SA 2.0

8. **Owner Notification and Next Steps**Lincoln Aviator owners should be aware of a structured process designed by Ford to address the trim detachment recall. This process prioritizes timely communication and clear instructions to facilitate the necessary repairs without undue burden on the consumer. The initial outreach aims to inform, while the subsequent communication will empower owners to take action.

The first round of notification letters will commence mailing on July 28, 2025. These letters will serve as an alert that a specific Lincoln Aviator vehicle is potentially impacted by the safety recall concerning exterior trim detachment. Importantly, this initial letter will include a directive for owners to wait for a subsequent notification before attempting to schedule any service appointments at a dealership.

The second and definitive notification letter will be sent once Ford dealerships are fully equipped with both the necessary repair parts and the updated procedural guidelines to implement the fix. This letter will contain comprehensive instructions on how to proceed, including how to schedule the free repair. Owners are explicitly advised against visiting a dealership until they have received this second letter, as it confirms the availability of resources to complete the repair effectively.

Once the second notification is in hand, owners should contact their preferred local Ford or Lincoln dealership to arrange a service appointment. All repairs related to this recall, including the replacement or permanent securing of C-pillar appliques and window division bars, will be performed at no charge. For any immediate concerns or if trim parts have already detached, owners are encouraged to contact Ford Customer Service at 1-866-436-7332 or the NHTSA at 1-888-327-4236, or to visit www.nhtsa.gov for further assistance.

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Documents with Home Address — “Old document with nice stamp” by storebukkebruse is licensed under CC BY 2.0

9. **What to Do If the Trim Problem Returns After Repair**Should the trim detachment problem reoccur on a Lincoln Aviator that has already undergone the recall repair, specific steps are recommended to address the persistent issue. Owners are advised to contact the same dealership where the original recall repair was performed as soon as possible. It is important to clearly communicate that the trim problem has returned and to request a follow-up inspection.

When returning to the dealership, vehicle owners should bring all relevant documentation. This includes the service receipt from the initial recall repair, any recall notices received, and proof of vehicle ownership. Such documentation can assist the service technicians in understanding the previous work performed and expedite the diagnostic process.

Thorough documentation of the recurring issue is also vital. Owners should consider taking photos or videos of the detached or loose trim components. Additionally, noting the date, time, and specific driving conditions under which the problem reappeared can provide valuable information for the dealership’s assessment. Maintaining a detailed record of all communications with both the dealership and Ford Customer Service can be beneficial if the issue continues to be unresolved.

While recall repairs are typically covered under warranty, the coverage for additional repairs stemming from a recurring problem may depend on whether the issue is attributed to faulty parts, improper installation during the initial recall service, or the elapsed time since the original repair. If the dealership’s response is unsatisfactory or the trim problem persists after multiple attempts at repair, owners can escalate the issue. This can be done by contacting Ford Customer Service directly at 1-866-436-7332. Furthermore, filing a formal complaint with the National Highway Traffic Safety Administration (NHTSA) through their website at nhtsa.gov/report-a-safety-problem provides an official avenue for reporting unresolved safety concerns.

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Close-up of hands holding jumper cables near a car engine, ready for repair. — Photo by Daniel @ bestjumpstarterreview.com on Pexels

10. **When to Speak with a Lemon Law Attorney About Your Lincoln**The recall concerning detaching exterior trim parts on Lincoln Aviators, including C-pillar appliques and rear door window division bars, highlights significant safety concerns that vehicle owners should take seriously. While Ford has committed to providing complimentary repairs aimed at permanently rectifying these manufacturing defects, some vehicles may unfortunately continue to experience issues even after the initial recall service has been completed. This persistence of problems can be a critical trigger for further action.

If a Lincoln Aviator has undergone repeated warranty repairs related to these trim problems, or other safety concerns, and these issues persist even after the prescribed recall repairs have been performed, owners may be entitled to pursue a Lemon Law claim. Lemon laws are designed to protect consumers who purchase vehicles that fail to meet reasonable standards of quality and performance after a reasonable number of repair attempts. Such persistent defects can significantly diminish the vehicle’s value and reliability.

Successfully filing a Lemon Law claim can offer substantial consumer protection. Notably, if a claim is successful, the vehicle manufacturer is typically responsible for paying the consumer’s legal fees and associated costs. This provision means that pursuing a Lemon Law claim often involves no out-of-pocket expenses for the consumer, making it a financially accessible decision for those dealing with unresolved vehicle issues.

Legal professionals specializing in Lemon Law, such as the Lemon Law Experts who have assisted vehicle owners since 2009, can provide crucial guidance. They help consumers hold manufacturers accountable when vehicles fail to meet established safety and quality standards, despite repair efforts. Owners dealing with ongoing issues in their Lincoln Aviator despite recall repairs are encouraged to contact such legal teams for a free consultation to understand their rights and available options to secure a resolution.

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11. **Manufacturing Origins of the Defective Parts**Understanding the manufacturing origins of the defective components is essential for comprehending the scope and cause of the Lincoln Aviator trim detachment recall. Ford’s investigation traced the root cause of the insufficient adhesive bonding to a specific part of its production chain. The affected Lincoln Aviator vehicles were assembled at Ford’s Chicago Assembly Plant, a key facility for the automaker.

The problematic exterior trim components, specifically the C-pillar appliques and rear door window division bars, were supplied by Cooper Standard Automotive. This Tier 1 supplier is located in Mexico, indicating that the manufacturing deficiency originated at an earlier stage in the supply chain before final vehicle assembly. The adhesive bonding issue points to a breakdown in quality control during the production of these parts.

Ford’s official statements, supported by NHTSA reports, confirm that the inadequate application pressure of the components during assembly at the supplier facility led to insufficient adhesive retention. This deficiency in the bonding process is the fundamental reason why these trim pieces may loosen or detach from the vehicle over time and during operation. The identification of the supplier and assembly location provides clarity on where quality improvements are specifically needed.

The collaboration between Ford and its suppliers is critical to ensuring that such manufacturing defects are identified and rectified promptly. This recall underscores the importance of stringent quality checks not only at the final assembly plants but also at every stage of the component supply chain. Addressing the issue at its origin point in Mexico by Cooper Standard Automotive is key to preventing similar issues in future vehicle production.

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“2021 Ford F-150 (fourteenth generation) front view 01” by Gold Pony is licensed under CC BY 3.0

12. **Ford’s Extensive Recall History**This specific recall for the Lincoln Aviator’s trim detachment issues occurs within a broader context of an extensive and increasing number of recalls issued by Ford Motor Co. In recent years, Ford has faced a notable surge in vehicle recalls, leading to significant scrutiny. According to reports, as of September 4, 2025, Ford had issued 109 recalls covering a staggering 7,871,344 vehicles in that year alone.

This volume of recalls included 26 “re-recalls,” meaning these were recalls issued for problems that Ford had previously attempted to address. The wide array of issues spanned numerous critical vehicle systems, from malfunctioning reverse cameras and parking light issues to more severe safety concerns like engine fires and airbag defects. This diversity of problems suggests a systemic challenge in various aspects of vehicle design and manufacturing quality control.

From January 1, 2025, the automaker had already issued over 80 recalls, impacting more than 4.2 million vehicles, as reported by the National Highway Traffic Safety Administration (NHTSA). This figure established Ford as having the highest number of recalls among major automakers in 2025. This total significantly surpassed the combined recall numbers of several prominent competitors.

Further analysis indicates that Ford’s recall volume in 2025 exceeded the collective total of General Motors, Stellantis, Toyota, Honda, Hyundai, Volkswagen, and Tesla. This extensive record of safety-related actions has drawn considerable attention to Ford’s manufacturing processes and its overall commitment to vehicle quality and consumer safety, highlighting a persistent challenge for the Dearborn-based automaker.

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13. **Industry Recall Comparisons**When evaluating Ford’s recall activity, a direct comparison with other major automakers reveals a distinct trend. As of September 4, 2025, Ford’s issuance of 109 recalls notably outpaced its industry counterparts. This figure positioned Ford significantly ahead in the volume of recalls during that period, indicating a considerable disparity in manufacturing and quality control issues compared to other manufacturers.

In stark contrast to Ford’s 109 recalls, the second position in the industry was held jointly by Forest River, an RV manufacturer, and Stellantis, each reporting 26 recalls. This difference highlights Ford’s disproportionately higher number of safety-related actions. The gap underscores a persistent challenge for the automaker in maintaining consistent quality across its diverse vehicle lineup.

Further down the list, Volkswagen had issued 19 recalls, while both General Motors and Mercedes-Benz reported 16 recalls each. These comparisons demonstrate that Ford’s recall activity was not merely slightly higher but represented a substantial outlier within the automotive sector. The data suggests that Ford faced unique or more widespread manufacturing and design challenges than its competitors during this period.

The cumulative impact of these extensive recalls and the comparative data against other major global automotive manufacturers place heightened scrutiny on Ford’s internal processes. The volume of recalls suggests systemic issues that extend beyond isolated incidents, necessitating comprehensive reviews and corrective actions to align with industry benchmarks for quality and reliability.

14. **Another Recent Lincoln Aviator Recall**Adding to the complexities for Lincoln Aviator owners, the trim detachment issue marks the second recall specifically affecting this model in June 2025. This underscores a broader period of multiple safety-related actions concerning the Aviator. The earlier recall in the same month addressed a separate but equally important defect involving second-row seat switch bezels.

This previous recall, impacting over 300,000 Aviator and Explorer SUVs from model years 2020 to 2025, focused on issues with the easy-entry second-row outer seats. The problem identified was that the switch for these seats might bind or stick. This binding could result in the seats inadvertently unlatching, folding, or sliding unexpectedly while the vehicle was in motion, posing a clear safety risk to occupants.

The remedy for this second-row seat switch recall involves dealerships inspecting the switch and, if necessary, replacing the bezel around it. Like the trim detachment recall, these repairs were also to be performed at no cost to the vehicle owner. Owner notifications for the seat switch issue were scheduled to begin on June 23, 2025, indicating that many Aviator owners might have received notifications for two distinct recalls in close succession.

The simultaneous issuance of two significant recalls for the same model within a single month highlights a challenging period for the Lincoln Aviator. It emphasizes the importance for owners to be vigilant about all recall notices related to their vehicle and to ensure all necessary repairs are completed to maintain safety and vehicle integrity. This situation also contributes to the broader narrative of Ford’s ongoing recall challenges across its product line.

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This comprehensive overview of the Lincoln Aviator recall, from its immediate details to its broader industry context and owner implications, serves as a critical resource for current and prospective owners. Ensuring the safety and reliability of vehicles remains paramount, and proactive engagement with recall notices and available remedies is essential for all drivers.