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Ford recalls over 2 million vehicles for brake and door latches issues

The 2.4 million cars include the F-150, Fiesta, Focus, Fusion and Escape.

Kyle Hyatt Former news and features editor
Kyle Hyatt (he/him/his) hails originally from the Pacific Northwest, but has long called Los Angeles home. He's had a lifelong obsession with cars and motorcycles (both old and new).
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Kyle Hyatt
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2016 Ford Fusion
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2016 Ford Fusion

The 2016 Ford Fusion is one of the models affected by a faulty door latch mechanism, and is being recalled a second time for the issue.

 Ford

Recalls are a big deal for manufacturers, so they generally try to get things right the first time around when designing a fix for the issues that spawn them. That doesn't always go to plan though -- look at all the fix-on-a-fix stuff that happened with the Takata airbag recalls -- and it's in this situation that finds itself currently, with one of two recalls announced Wednesday.

Specifically, Ford is recalling a huge variety of models, from many factories, produced over extended periods because a faulty door latch that was recalled previously may have been incorrectly installed or is also defective. These vehicles are:

  • 2011-14 Ford Fiesta vehicles built at Cuautitlán Assembly Plant, January 26, 2010, to Oct. 31, 2013
  • 2012-15 Ford Focus vehicles built at Michigan Assembly Plant, October 4, 2010, to Jan. 31, 2015
  • 2013-14 Ford Fusion vehicles built at Hermosillo Assembly Plant, May 11, 2012, to Oct. 31, 2013
  • 2013-14 Lincoln MKZ vehicles built at Hermosillo Assembly Plant, July 19, 2012, to Oct. 31, 2013
  • 2013-15 Ford Escape vehicles built at Louisville Assembly Plant, December 23, 2011, to Jan. 31, 2015
  • 2013-15 Ford C-MAX vehicles built at Michigan Assembly Plant, February 2, 2012, to Jan. 31, 2015
  • 2014 Ford Fusion vehicles built at Flat Rock Assembly Plant, June 18, 2013, to Oct. 31, 2013
  • 2014-16 Ford Transit Connect vehicles built at Valencia Body and Assembly Plant, from Aug. 9, 2013, to Feb. 1, 2016
  • 2015 Ford Mustang vehicles built at Flat Rock Assembly Plant, Feb. 14, 2014, to April 30, 2015
  • 2015 Lincoln MKC vehicles built at Louisville Assembly Plant, Nov. 18, 2013, to Jan. 31, 2015

The specific issue involves the door latch pawl spring tab, which helps the pawl hold the door closed when latched. In hotter and sunnier climates, the spring tab can become brittle with use and crack. This can lead to a situation where the door may not latch fully and can open when the car is in motion.

Ford is setting up a system that will allow owners of potentially affected vehicles to submit the date codes on their latches to a website, which will tell them if they need to take the process further and get them replaced at the dealership. Total, the automaker says 2.15 million cars are affected.

2017 Ford F-150 hero

The F-150 EcoBoost is having its own problems, this time with a leaky front wheel circuit on its brake master cylinder.

 Emme Hall/Roadshow

Ford is also issuing a separate recall for 2014-2017 F-150s with the 3.5-liter EcoBoost engine. This recall stems from an issue with the brake master cylinder that can cause brake fluid to leak into the brake booster. This means that you may experience reduced brake effectiveness even though you don't see anything leaking on the ground.

The fault is with the front wheel circuit in the master cylinder and necessitates the replacement of the master cylinder. If the master cylinder is found to be leaking, the brake booster will be replaced as well.

Ford estimates that this recall affects 292,311 vehicles in total, and has reports of seven incidents that stem from the fault, including two that resulted in injury.

Ford didn't immediately respond to Roadshow's request for comment.

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First published June 10.