Category Archives: Lemon Alert

2020-2021 Kia Rio Spongy Brake Pedal And Increased Stopping Distance

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A small number of 2020-2021 Kia Rio vehicles may have been built with brake master cylinders that are not designed to manufacturer specifications. Kia will be contacting the owners of the affected vehicles starting January 11, 2022. The letter will have information describing the problem and how owners can get repairs done.

Kia first became aware of the defect in October 2021 when the supplier of the brake master cylinder notified them of a brake-related complaint in a Hyundai vehicle. Because this vehicle uses the same brake master cylinder as certain Kia Rio vehicles an investigation into the problem was opened for both Kia Rio and Hyundai Accent vehicles.

Based on a review of supplier quality control records and Kia’s vehicle production records, vehicles produced before 7/2/2021 could be equipped with improperly machined brake master cylinder bodies.

According to the defect report, the master cylinder body may have been machined with a sharp edge that could contact and damage the oil seal in the master cylinder. A damaged oil seal can impair vehicle braking functions, such that the driver may experience a hard or spongy brake feel, longer brake pedal travel, and extended stopping distances.

All owners of the affected vehicles will be notified by first class mail with instructions to bring their vehicles to a Kia dealer. Dealers will replace the brake master cylinder with a new one. Kia’s number for this recall SC223 and the NHTSA campaign number is 21V-936.

This problem also affects certain 2021 Hyundai Accent vehicles. The brake master cylinder may have been manufactured with sharp edges that can damage the inner oil seal and result in reduced braking performance. Hyundai’s recall number is 213 and the NHTSA campaign number is 21V-937.

Don’t live with a Lemon. If you are having problems with your vehicle and have questions about your rights and the California Lemon Law, please call our office at 888-395-3666.

2021 Nissan Rogue Fuel Pump Failure

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Nissan North America, Inc. (Nissan) will be asking the owners of certain 2021 Nissan Rogue SUVs to return to their dealerships to fix a problem affecting the fuel system in their vehicles. An assembly defect in the fuel pump could lead to an unexpected vehicle stall.

The problem began in March 2021, when Nissan first received a field report about a 2021 Rogue SUV crossover that allegedly experienced a fuel pump failure. According to the driver of the vehicle, the Malfunction Indicator Lamp (MIL) illuminated just before the engine stalled. The driver was not able to restart the vehicle and needed to have it towed. Nissan initiated an investigation into the problem and collected parts from the field to perform duplication testing to identify the scope of the issue. The supplier also conducted a field investigation and process check in an attempt to track down the problem.

Nissan discussed the ongoing investigation with the NHTSA and reviewed their field claims checks for the U.S. Market and identified 87 warranty claims alleging the same problem… engine stalls while driving. Based on manufacturer production records the problem affects certain model year 2021 Nissan Rogue vehicles manufactured between March 2021 and October 2021. No other Nissan or Infiniti vehicles have been affected.

According to the defect report, the problem is the result of an operator assembly error at the supplier. Some fuel pumps may experience excessive friction between the fuel pump brush and commutator. This will cause heat and melting damage that would result in the fuel pump failing. If the fuel pump fails, it will cause the engine to stall and not restart.

Owners receiving notices will be asked to return to their dealers to have the fuel pump assembly replaced. Nissan’s number for this recall is R21B8 and the NHTSA campaign number is 21V-957.

2021 Ford Bronco and 2021 Ford Ranger Collision Avoidance Reacts Slowly

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Owners of certain 2021 Ford Bronco SUVs and 2021 Ford Ranger trucks will be returning to their Ford dealership to fix a problem affecting the forward collision avoidance system. According to the defect report, a misaligned radar module may prevent the vehicle from maintaining a safe distance from other vehicles when adaptive cruise control is active. In addition, the automatic emergency braking (AEB) system may react slowly, or not react at all, during a pre-collision assist braking event.

Back in July 2021, a problem affecting the alignment of the cruise control radar modules was brought to the attention of Ford’s Critical Concern Review Group (CCRG). An investigation was carried out to understand the potential effect of an incorrect calibration and how it could vary on the vehicle configuration and ride height. They found that radars aligned with the incorrect programming could be up to 2.6 degrees lower than design intent. Numerous reviews were conducted to understand the effect on vehicle Adaptive Cruise Control (ACC) and Pre-Collision Assist (PCA) features as part of the Advanced Automatic Emergency Braking system.

The ACC and PCA features use information from the vehicle’s forward-looking radar and camera sensors to detect and track objects in the host vehicle path. A misaligned cruise control module radar can cause the vehicle to have a closer-than-expected following distance when using the adaptive cruise control feature, or the automatic emergency braking system may react late resulting in a sudden loss of speed during an automatic Pre-Collision Assist braking event. As a result, the Pre-Collision Assist system’s effectiveness to detect a potential frontal collision may be compromised and could increase the risk of a crash.

Dealers will correct the problem by adjusting the angle of the cruise control radar module. Ford’s number for this recall is 21S52 and the NHTSA campaign number is 21V-982.

2018-2022 Audi Q5 And SQ5 Sportback Loss Of Engine Power

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In August 2020, Volkswagen / Audi received an inquiry about a gateway control module failure in an Audi Q5 vehicle in China. An inspection of the situation found that the gateway control module had gone into fail safe mode because of liquid entering the module from a rear bench seat spill.

The gateway control module has been programmed to go into a fail-safe mode when an implausible signal is detected in the control unit. If an implausible signal is detected, the gateway switches off its function in order to avoid unwanted vehicle reactions. The vehicle remains steerable and the brake system will work, but the engine will go into emergency mode and remains in operation with reduced power.

Audi performed a safety assessment to evaluate the potential conditions and consequences that could result from a power shutdown of the gateway control module due to liquid ingress. Audi also conducted a risk assessment which indicated that the risk of a liquid spill leading to a failure of the gateway control module is very low and rare over the lifetime of the vehicle. At the time there were only isolated cases in the North American region and all of them happened after an outside influence, mostly after a beverage spill. Audi continued to monitor the problem.

In March 2021, Audi experienced an increase in customer reports related to gateway control module failures on Q5 vehicles after a liquid spill. Audi conducted additional testing and continued to investigate a potential solution to be implemented in production and in the field. Due to single field cases alleging the failure without a liquid spill, an additional investigation was initiated to rule out other root causes for liquid ingress. In August 2021 Audi identified a potential manufacturing issue in the factory in Mexico. “Due to a programming error of a glue bead robot, an underbody seam may not have been sealed sufficiently and therefore allow water ingress from underneath in very rare cases when driving through heavy rain or deep puddles.” The adjustment to the robot was implemented immediately and analysis continued regarding the impact of this additional potential cause for liquid ingress.

The Audi Safety Committee began to issue a service campaign in order to install a protective cover for the gateway control module and to seal the underbody in the area of the insufficient glue bead, but after a meeting with Transport Canada and the Defective Product Administrative Center in China, the Audi Product Safety Committee re-evaluated their decision and decided to conduct a voluntary recall to fix affected vehicles.

The Vehicles Affected Include:
2018-2022 Audi Q5 Sportback
2018-2022 Audi SQ5 Sportback

2021-2022 Ford Bronco Sport And Escape Reduced Brake Performance

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Ford Motor Company (Ford) is recalling certain 2021-2022 Bronco Sport and 2021-2022 Escape vehicles because they fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 135, “Light Vehicle Brake Systems.”

In October 2021, Ford was contacted by the NHTSA’s Office of Vehicle Safety Compliance regarding the results of a compliance audit on the 2021 Bronco Sport vehicle equipped with a brake vacuum booster. According to the defect report, the stopping distance test results for “Brake Power Assist Unit Inoperative” exceeded the federal regulation stopping distance of 168 m. Ford compared data from the NHTSA test vehicle to data from the Ford certification test vehicle and could not identify the difference in performance between the two test vehicles.

In November, Ford conducted further testing which included the “Brake Power Assist Unit Inoperative” portion, on a 2021 Bronco Sport equipped with a brake vacuum booster without a vacuum sensor, to replicate NHTSA’s test vehicle. The test vehicle was fitted with a new current batch of brake linings from the assembly plant and the stopping distance test results exceeded the federal requirements.

Analysis of the brake system identified that the friction coefficient of the rear brake caliper linings was below manufacturer specifications. Vehicles equipped with rear brake linings that have a friction coefficient that is outside of the specified tolerances would experience longer stopping distances if the vacuum sensor is not there to compensate for variations in brake pad friction performance.

The 2021-2022 Ford Escape shares the same brake system as the Bronco Sport and the same certification test applies to both vehicles. Some Bronco Sport and Escape vehicles are equipped with a brake vacuum booster and some are equipped with an Electronic Brake Booster (EBB). Vehicles with an EBB are not affected by this issue because they have higher system pressures if the booster malfunctions.

The remedy is currently under development. Ford’s number for this recall is 21C31 and the NHTSA campaign number is 21V-922.

2021-2022 Toyota Sequoia and 2021 Toyota Tundra Power Steering Leak

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Toyota will be contacting the owners of certain 2021-2022 Sequoia and 2021 Tundra trucks because of a problem affecting the power steering gear assembly. Owner notification letters are expected to be sent out on January 22, 2022.

In late September 2021, Toyota observed an increase in field reports and warranty claims affecting the power steering in certain 2021-2022 Sequoia and 2021 Tundra trucks. A high percentage of these vehicles experienced power steering fluid leaks, all from the area of the power steering gear assembly. Manufacturing records showed that these reports mainly involved vehicles produced during the months of August and September 2021. Toyota began recovering additional parts involved in these reports and sent them to the supplier for inspection.

These inspections found that the circlip holding the oil seal and end stopper in position at the end of the power steering rack housing was disengaged from the groove machined in the rack housing and that the oil seal and the end stopper were moved from the correct position. Further investigation of the returned parts revealed that the groove where the circlip is installed was improperly machined leading to an incorrect groove shape.

Based on these findings, the supplier investigated their production process and identified that one of the four pieces of equipment used to machine the groove in the rack housing was not creating a groove of the correct shape. The tool was inspected, it was found that certain teeth on the cutting tool, which creates the groove in the rack housing, were damaged. Based on these results Toyota has decided to conduct a safety recall campaign.

Owners of the affected vehicles will be notified to return to their Toyota dealer to have the power steering gear assembly inspected and replaced if necessary. Toyota’s numbers for this recall are 21TB10 and 21TA10, and the NHTSA campaign number is 21V-920.

Chrysler, Alfa Romeo And RAM Fuel System Failure

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Chrysler (FCA US, LLC) will be contacting owners of certain Chrysler, Alfa Romeo, and RAM vehicles for a problem affecting the fuel system. In total, approximately 236 000 vehicles are being recalled.

2020-2021 Alfa Romeo Stelvio and Alfa Romeo Giulia vehicles fuel line sensor housing may crack and leak fuel. NHTSA Campaign Number: 21V-878

The problem was traced to September 11, 2020, when defective fuel sensors were introduced into vehicle production, and ended on May 25, 2021, when the fuel sensors from the suspect batches were no longer used. The suspect population was determined using part traceability and vehicle production records.

According to the defect report, a leak in the fuel line sensor may cause fuel starvation of the engine and in rare circumstances, if the leaked fuel comes in contact with an ignition source, a fire could occur. A vehicle fire can result in an increased risk of occupant injury and/or injury to persons outside the vehicle, as well as property damage. Fuel starvation could also result in an unexpected loss of motive power.

2019 Fiat 124 Spider fuel pump failure may cause an engine stall. NHTSA Campaign Number: 21V-879

The suspect period began on April 6, 2018, when the defective fuel delivery module (FDMs) were introduced into vehicle production, and ended on October 18, 2018, when FDMs with improved molding of the impellers were implemented in vehicle production.

Some 2019 Fiat 124 Spider vehicles may have been manufactured with a fuel delivery module (FDM) with impellers that could deform. An FDM with a deformed impeller may interfere with other fuel pump components which can inhibit the operation of the fuel pump potentially causing fuel starvation. : Fuel starvation may result in an unexpected loss of motive power.

2019-2020 RAM 2500, 3500, 4500, and 5500 diesel trucks fuel pump failure may cause an engine stall. NHTSA Campaign Number: 21V-880

The suspect period began on October 11, 2018, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on November 13, 2020, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were no longer used in vehicle production.

According to the defect report, the high-pressure fuel pump could fail and introduce debris into the fuel system. Fuel starvation and an unexpected loss of motive power could result without prior warning. Vehicle occupants may notice an illuminated Malfunction Indicator Lamp, a fuel leak or smell, abnormal engine noises, or a change in drive quality.

Jeep Cherokee And Wagoneer Air Bags Disabled With No Warning

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During a configuration review at the supplier for an unrelated manufacturing issue, FCA US LLC Product Engineering became aware of an error with an airbag squib driver circuit that identified three internal faults not mapped to a diagnostic trouble code (DTC). An investigation was opened and it was discovered that some 2021 Jeep Grand Cherokee, 2022 Jeep Wagoneer, and 2022 Jeep Grand Wagoneer vehicles may not set a DTC, and the airbag warning indicator may not illuminate.

The problem started in February 2021, when occupant restraint controllers (ORCs) with an incorrect software version were introduced into vehicle production, through to November 1, 2021, when the suspect ORCs were no longer used in vehicle production. Vehicle and supplier production records were used to determine the vehicles included in the recall population.

According to the defect report, “If specific ORC internal faults are active then a DTC will not be set and the airbag warning indicator may not illuminate. The internal faults will disable deployment of both the driver and passenger airbag squib 3 (related to airbag venting post-deployment) and knee airbags. The airbag warning indicator may not illuminate to notify the driver of possible compromised airbag system functionality. Reduced occupant protection in the event of a crash may result in an increased risk of injury to motor vehicle occupants.”

Owners receiving notices will be asked to return to their FCA dealers to have the occupant restraint controller reprogrammed with the correct software version that maps subject internal faults to a DTC. FCA US, LLC’s number for this recall is Y79 and the NHTSA campaign number is 21V-873.

If you purchased or leased a defective vehicle in California, it has turned out to be a lemon, and you need help to get rid of it, just fill out the above contact form or call us now at 1-888-395-3666 for a free case evaluation.