Category Archives: Lemon Alert

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.

Mazda Engine Stall From Fuel Pump Failure

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Mazda is recalling certain 2018-2020 vehicles because the impeller inside the low-pressure fuel pump may crack and deform, potentially causing the fuel pump to fail.

In March 2019 Mazda received the first field report of an engine stall due to an inoperative fuel pump. A study of the pump showed that cracking on the impeller surface made the impeller more likely to deform. Further investigation found that solvent used during the manufacturing process and low-density impellers may be factors causing impeller cracking. During the test, the surface of the impeller cracked as the solvent dried over time. It was confirmed that fuel pumps produced with impellers of lower density exposed to production drying solvent for longer periods of time could experience the impeller cracking at a level that could lead to excessive fuel absorption, and could cause impeller deformation.

The Vehicles Affected Include:
2019 Mazda CX-3
2018-2019 Mazda CX-5
2018-2019 Mazda CX-9
2019-2020 Mazda Mazda2
2018 Mazda Mazda3
2018 Mazda Mazda6
2018-2019 Mazda MX-5

Fuel pump failure may result in engine no start and/or vehicle stall while driving at low speed and, in rare instances, a vehicle stall could occur while driving at higher speeds, increasing the risk of a crash. Drivers may notice this defect by a check engine light, and/or rough engine operation.

Mazda will be contacting owners of affected vehicles with instructions to return to their dealers to have the fuel pump replaced. Mazda’s number for this recall is 5321K and the NHTSA campaign number is 21V-875.

RAM Trucks Fuel Pump Failure Investigation

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The NHTSA Office of Defects Investigation (ODI) have opened up an investigation into certain 2019-2020 RAM trucks after receiving 22 complaints and 2 field reports alleging incidents of stalling and loss of engine power. The vehicles affected are equipped with 6.7L Cummins turbo diesel engines. According to the investigation report, the complaints found that most stall/loss of motive power incident allegations occurred at speeds above 25 MPH and resulted in permanent disablement of the vehicle.

The Vehicles Affected Include:
2019-2020 Ram 2500
2019-2020 Ram 3500
2019-2020 Ram 4500
2019-2020 Ram 5500

In November 2019, FCA issued Warranty Bulletin D-19-02 to announce to its dealers a Fast Feedback Program wherein they were notified of a campaign to collect, monitor, and correct quality issues on certain 2018-2020 Ram trucks equipped with the 6.7L Cummins engine. As a result of this campaign, high-pressure fuel pumps have been collected and inspected by the manufacturer and pump manufacturer.

ODI is opening this investigation to further assess the scope, frequency, root cause, and potential safety-related consequences of the alleged defect leading to stall/loss of motive power on 2019-2020MY RAM heavy-duty trucks.

Tesla Model S and Model X Battery Fire Investigation

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In September 2019, the NHTSA was asked to initiate an investigation into certain Tesla Model S and Model X vehicles that received a revised battery management software update in one or more over-the-air updates from Tesla, beginning in May 2019. The petitioner based his request on vehicle fires that took place worldwide and over the air software updates Tesla made to the Battery Management System (BMS) of certain Tesla vehicles that resulted in loss of available vehicle mileage range and increased charging duration’s.

The five non-crash fires referenced in the petition include two fires that occurred in China in early 2019 involving vehicles that:

  • Had recently completed Supercharging sessions.
  • Were at a high state-of-charge (SOC) of the HV battery.
  • Were parked with the battery cooling system shutoff.
  • Had histories of high-stress usage for the HV batteries.

The three fires that occurred outside China did not involve the same patterns regarding vehicle state and charging history. The two fires that occurred in the United States include one involving a vehicle with no Supercharging history that was driving when the fire occurred and another in which the origin of the fire was external to the HV battery. The fifth fire, which also originated external to the HV battery, involved a vehicle in Germany that had been parked at a low SOC for an extended period. To date, incidents of fires involving parked vehicles with recent Supercharging and histories of high-stress use have only been observed in China, where high-stress use factors appear to be more common.

Given the absence of any incidents in the United States related to fast charging, and the absence of any such incidents globally since May 2019, the petition has been denied. The denial of this petition does not stop the Agency from taking further action if future findings find that a safety defect exists based on additional information received. NHTSA could initiate a recall if they find a defect in the design, construction, or performance of a motor vehicle that presents an unreasonable risk to safety.