Ford Maverick Hybrid Engine Failure/Fire Update Recall Letter (Received 2/12/24)

[pigsareus]

Got my letter yesterday also.
Sounds like you know some facts about the cause of issue....and not some wild guess. Wild guesses do none of us any good. As a software developer, I can easily see a diagnostic error turn off an engine or fuel pump to stop a fire.

I got my first recall letter on this issue back in Sept and dealer keeps telling me parts are not available...but from your comment it may not be a need for parts, but more testing of oil analysis.

As a precaution I have two gas fire-extinguishers and know if I see a fire, do not raise the hood but release spray through the grill or crack in the hood.

Not worth posting but my Ford dealer service rep told me that Ford only knows of 4 or 5 fires out of the thousands of Hybrids they have in service.

Yep - this prob was reported quite a while ago and some reliable Ford sources identified the root problem and had specific metrics on the quantity of the flawed cranks, there were a couple/few fires and engine breakdowns that made them go looking for the root cause and eventually they identified it but the downside was that the flawed ones just made it into the mix of all of them and post production months later the incidents occurred so the old horse was out of the barn. Problem was exacerbated because of the lack of drain holes so if you have one and the engine starts smoking and spewing oil it just sort of sits there and (can) ignite, so it's a two fold problem and that's why they went the route of porting some holes to at least have the oil seep thru and help eliminate potential fire but that doesn't address who might have the ticking time bomb. So in the meantime it's just like they say if you see smoke pull over and shut it down. Your idea re fuel pump shutdown is reasonable with the cavaet that the elec engine should still be operational for a short while so you can safely pull over - just disabling both might be dangerous as if you're on the xway and you just shut down well that might be even more trouble. Fire exting is a good idea, no harm in it. I'd guess that if/when they do id the flawed engines they would likely drop a new engine in - can't see them just buying you out.

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[mcc63303]

Yep - this prob was reported quite a while ago and some reliable Ford sources identified the root problem and had specific metrics on the quantity of the flawed cranks, there were a couple/few fires and engine breakdowns that made them go looking for the root cause and eventually they identified it but the downside was that the flawed ones just made it into the mix of all of them and post production months later the incidents occurred so the old horse was out of the barn. Problem was exacerbated because of the lack of drain holes so if you have one and the engine starts smoking and spewing oil it just sort of sits there and (can) ignite, so it's a two fold problem and that's why they went the route of porting some holes to at least have the oil seep thru and help eliminate potential fire but that doesn't address who might have the ticking time bomb. So in the meantime it's just like they say if you see smoke pull over and shut it down. Your idea re fuel pump shutdown is reasonable with the cavaet that the elec engine should still be operational for a short while so you can safely pull over - just disabling both might be dangerous as if you're on the xway and you just shut down well that might be even more trouble. Fire exting is a good idea, no harm in it. I'd guess that if/when they do id the flawed engines they would likely drop a new engine in - can't see them just buying you out.

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Ford will most likely not be replacing any engines unless the problem occurs. What has happened in the past Ford will have a "special program" (not a recall) where Ford will extend the warranty for maybe 10 years and 150,000 miles. If an engine failure occurs in that time/mileage Ford will cover the repair. Any one that had a Focus with the transmission issue had a program like that. Same thing concerning other issues (Windstar rear axle rusting apart) have been done in that manor also. Just will be interesting to see what a reprogramming will do.

 

[pigsareus]

-
Ford will most likely not be replacing any engines unless the problem occurs. What has happened in the past Ford will have a "special program" (not a recall) where Ford will extend the warranty for maybe 10 years and 150,000 miles. If an engine failure occurs in that time/mileage Ford will cover the repair. Any one that had a Focus with the transmission issue had a program like that. Same thing concerning other issues (Windstar rear axle rusting apart) have been done in that manor also. Just will be interesting to see what a reprogramming will do.

maybe if they can truly isolate those with the flawed cranksharts via an oil analysis (or other method) they'd do something (just a few hundred involved) else they'd be driving around with a potential engine fire risk and that's a lot more troubling than just being stuck in 1st gear with a flawed trans. Guess we'll know later this year.....

 

[mamboman777]

It's exactly what they have tested. From the sounds of the report it's passed lab testing, now it needs field testing.


"May – November 2023: Ford’s Internal Combustion Powertrain and Powertrain Controls Engineering

teams tested several engines and analyzed historical calibration data to characterize connecting rod

bearing failures for all cylinders. The team used these findings to develop a connecting rod bearing

failure detection algorithm which will limit engine speed/load after detecting a bearing that is in the

process of failing, and provide notification to the driver. Once the software was developed, the

engineering teams tested its effectiveness through dynamometer and vehicle testing. The results of the

testing indicate that this algorithm will detect a connecting rod bearing failure and protect the engine

from a block breach.

On December 15, 2023, Ford’s Field Review Committee approved the remedy for the 23S27 field action."

https://static.nhtsa.gov/odi/rcl/2023/RMISC-23V380-5342.pdf

This is the single most informative post on this topic that I have read. Where did you get this info. Thank you!

 

[Deleted member 5597]

I got that letter on 2/13/24 for my 'hybrid 22 Maverick and my 'hybrid 22 Escape. I have two open recalls on both now.

 

[Ponypower50]

Notice how Ford is not jumping into our conversation with new information about this recall!

 

[Hammerstein]

What in the world are you talking about? I also had a Cmax and it was a great car. The Maverick is a great truck! I have no stuttering, no hesitation, and no shifting at all with the eCVT. As far as the engine recall, you let me know when your 2.5l throws a rod and I will worry then… or not.

 

[Ponypower50]

I love my Hybrid Maverick.

 

[BuddyS]

Is it just me or were there just a few of these actual failures/fires a year or so back and then no new incidents since? So maybe -- maybe -- the few flawed engines have had their failures and the rest of us out there in the real world might be just fine? Perhaps wishful thinking, but again, I'm not hearing of any actual failures these days.

 

[Scupking]

Maybe Ford can give us a big discount on trade in for a 2025!!

 

[MavJet]

Maybe Ford can give us a big discount on trade in for a 2025!!

Probably would for a ECOBOOST

 

[LSchicago]

Notice how Ford is not jumping into our conversation with new information about this recall!

Ford doesn't comment on these type of posts.

 

[Darnon]

They did post the notice when there was a TSB for the ICE/Hybrid shudder issue that came out.

 

[thevol]

Man this sounds eerily similar to the KIA issue with the theta 4 cyl engine. They added logic to the ecm to detect a failing engine using the knock sensors. I guess it was so common they would alert the driver to return to dealer for service immediately to avoid failure and a fire. It gave you 25 miles or so in limp mode then shut engine down. They replaced the engine no questions asked for 100-150k but it spooked me and I sold the car, didnt want something I couldnt trust. Think they had issues with false alarms too for awhile. Good luck everyone.

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