Tag Archives: manufacturing defect

Slow Battery Replacement On Some Chevrolet Bolt EVs

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We are still receiving inquiries concerning Chevy Bolts. GM continues to work on replacing the batteries in the 2017-2021 Bolts, but it seems as though progress has slowed dramatically in the replacement of the 2020 and 2021 vehicles. In the meantime, GM continues to sell 2022 and now 2023 with the new generation batteries, which of course begs the question as to why the batteries in the 2022 and 2023 Bolts are not first finding their way into the 2020 and 2021 Bolts. Unfortunately, we do not have an answer to this. We will continue to accept Chevy Bolt cases until every Bolt owner can be assured that their vehicle is safe for their family.

The Chevrolet Bolt was one of the first electric vehicles to gain mainstream popularity. It was marketed as an affordable and practical EV with a range of over 200 miles on a single charge. However, the Bolt has been plagued with battery problems that have affected its reliability and safety.

One of the main issues with the Bolt is the slow replacement of its battery. Unlike gasoline-powered cars, EV batteries are not interchangeable, and replacing them can take weeks or even months. This is because the process involves removing the entire battery pack, shipping it to a specialized facility, and replacing it with a new one. The slow replacement process has left many Bolt owners stranded without their cars for extended periods.

Despite these battery problems, GM is still manufacturing new Bolt vehicles. This has raised concerns among consumers about whether the company has fully addressed the underlying issues with Bolt’s battery. GM has released several recalls related to the battery problem, including 20V-701, 21V-560, and 21V-650. These recalls aim to fix the issue by updating Bolt’s software to prevent battery fires and reducing the charging capacity to prevent battery degradation.

However, the repeated problems with the Bolt’s battery have led many to question its reliability. If a car experiences the same problem repeatedly, it may be considered a “lemon.” A lemon is a car that has a substantial defect that cannot be fixed despite multiple repair attempts. In the case of the Bolt, repeated battery problems could mean that the car is defective and not fit for purpose.

If you own a Chevy Bolt and have experienced repeated battery problems, contact us at 1-888-395-3666 to explore your options. Lemon laws protect consumers from defective products and ensure that they receive compensation or a replacement vehicle if their car is a lemon.

In conclusion, the Chevy Bolt’s battery problems have affected its reliability and safety. The slow battery replacement process has left many owners stranded without their cars for extended periods. Despite several recalls, the repeated battery problems have raised concerns about the Bolt’s reliability and whether it is a lemon. If you own a Chevy Bolt and have experienced repeated battery problems, it is crucial to explore your options under the lemon law and protect your rights as a consumer.

Front Wheels May Lock Up in 2023 Ford Trucks and SUVs

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Ford is reaching out to the owners of certain 2023 Ford trucks and SUVs regarding a power-train issue that could lead to a loss of 4-wheel drive. The front wheels could also lock up as a result of the defect. This problem has been discovered in the 2023 model year Ford F-150 4×4, as well as the Ford Expedition 4×4 and Lincoln Navigator 4×4 vehicles.

The problem was first detected in January 2023 during the loading process, when reports of front axle pinion fractures on three F-150 4×4 vehicles were received by Ford’s critical concern review group (CCRG). An investigation into the issue found that the same pinions were installed on the Expedition and Navigator 4×4 vehicles.

Further investigation showed that the fractured pinions did not undergo the required heat treatment process at Ford’s axle manufacturing plant. This heat treatment process is crucial to reduce the hardness and brittleness of the pinion stem threads. The problem was limited to pinions in 3.73:1 gear ratio axles, and a team was dispatched to conduct eddy current hardness checks of all available stock at affected assembly plants. The CCRG investigative team also reviewed plant process records to determine the build population of suspect dates.

The pinion can break at any time in 4×4 applications, but it is expected to happen primarily while in reverse as the pinion is subject to higher loads. The driver may hear a loud noise when the pinion breaks or when the drive shaft and flange hit the frame cross member and stability bar after the pinion fractures.

Ford will replace the front axle pinion gear set, and if there is a broken front axle pinion, the entire axle assembly will be replaced. Ford’s recall number is 23S07, and the NHTSA campaign number is 23V-128.

If you own a 2023 Ford Expedition, F-150, or Navigator, it is important to be aware of this recall and take appropriate action. This is a safety-related issue that should be addressed to avoid any potential safety hazards while driving.

Tesla Model Y Second-Row Seat Frame Improperly Secured

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A manufacturing error will have the owners of certain 2022-2023 Tesla Model Y all-electric SUVs, returning to their dealerships for an inspection and possibly repairs. The second-row seat frame in these vehicles may have been improperly secured.

Tesla first became aware of the problem in December 2022 when an operator in Tesla’s Freemont, CA manufacturing facility identified a second-row driver-side seat back frame bolt that was not torqued to the proper specification.

The second-row seat belt loads go through the lower seat frame, and if the bolts that secure the frame to the seat backs are not torqued to specifications, the seat belt system may not perform as designed during a collision. Occupants seated in the second-row seating positions could experience an increase in the risk of injury during an accident.

According to the defect report, on some Model Y vehicles, the second-row driver-side seat back frame (second-row driver-side and center seating positions) and the second-row passenger-side seat back frame (second-row passenger-side seating position) are secured to the lower seat frame with 4 bolts per seat back. During the supplier’s production of both seat back frames for certain Model Y vehicles, one or more of the bolts that secure the seat back frames to the lower seat frame may not have been torqued to specifications.

Tesla has identified 5 warranty claims, received between December 9, 2022, and February 14, 2023, that may be related to the problem described above. Tesla is not aware of any injuries or deaths that may be related to the condition.

Owners receiving notices will be asked to return to their Tesla Service Centers to have the second-row seat back frames inspected and the bolts will be torqued. Tesla’s number for this recall is SB-23-13-001 and the NHTSA Campaign Number is 23V-130.

If you are the unfortunate owner of a lemon like a Tesla Model Y all-electric SUV with persistent defects that the manufacturer is unable to fix, you may feel like you are out of options. However, there is hope: the California Lemon Law provides some protections for owners of defective vehicles, and a lemon law lawyer can help you navigate the process.

A lemon law lawyer can help you understand your rights under the California Lemon Law and negotiate with the manufacturer on your behalf. They can also help you prepare and submit a claim to the manufacturer and, if necessary, file a lawsuit to protect your rights. Lemon law cases can be complex, and having an experienced attorney on your side can make all the difference in the outcome of your case.

If you are having repeated problems with your Tesla Model Y and you think it could be a Lemon, or if you have any questions about your rights under the California Lemon Law, please call our office at 1-888-395-3666 or fill in the “Case Review” form at the top of this page, and get some great Lemon Law advice!

Chrysler Pacifica Unexpected Loss Of Power

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Some 2017-2023 Chrysler Pacifica plug-in hybrid electric vehicles (PHEVs) could experience a loss of drive power. The suspect period began in August 2016, when production of the Chrysler Pacifica began, and ended in January 2023, when Stellantis (Chrysler) started containing vehicles suspect to have the defect.

Chrysler became aware of this issue in August 2022, when the Stellantis Technical Safety and Regulatory Compliance (TSRC) opened an investigation into certain Chrysler Pacifica PHEVs after receiving reports of unexpected loss of motive power. The investigation revealed six customer assistance records, 242 warranty claims, and 59 field reports potentially related to this issue. Chrysler decided to issue a recall.

According to the defect report, there could be an internal transmission wiring connector that could short and unexpectedly shut down the engine. An unexpected engine shut down and a loss of motive power can increase the chance of a vehicle crash.

The remedy is a Product information management (PIM) and Instrument Panel Cluster (IPC) software update for 2017-2018 model year vehicles and a PIM software update for 2019-2023 model year vehicles. This update will provide messaging to the drivers giving them sufficient drive time to exit traffic before the vehicle completely shuts down. Owner notification letters are expected to be mailed out in March 2023. Stellantis number for this recall is 03A and the NHTSA campaign number is 23V-010.

If you are having repeated problems with your Chrysler Pacifica PHEV and think it could be a Lemon, or if you have any questions about your rights under the California Lemon Law, please call our office at 1-888-395-3666 and get some great Lemon Law advice!

2023 Ford Bronco Sport ABS Module Leak

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Ford will be asking the owners of certain 2023 Bronco Sports vehicles, to return to their dealerships to repair a problem that could lead to unexpected brake problems. Ford used supplier records to determine the population of affected vehicles in which the problematic Anti-lock Braking Systems (ABS) is installed. (Component Part Number: LX6C-2B373-LG)

In December 2022, Ford was contacted by the manufacturer of their ABS, about a quality issue affecting the Hydraulic Control Unit (HCU) of an Electronic Brake Booster (EBB). According to the defect report, a foreign object was introduced into the tool that assembles the Normally Closed (NC) valves used in the ABS Module. This object could create a “flat spot” damage to the ball which creates the seal. This damage could allow an unintended leak path through the valve. If the valve leaks, the driver may experience inconsistent brake pedal travel without warning. Additionally, the driver-selectable Auto Vehicle Hold feature may not operate as intended. The vehicle could creep unexpectedly after an auto-hold event is initiated.

Owners who receive notices will be asked to return to their dealerships to have the ABS module replaced. Ford’s number for this recall is 23S01 and the NHTSA campaign number is 23V-021.

This is the third recall affecting the 2023 Ford Bronco Sport. In November 2022, Ford recalled half a million 2020-2023 Escape and 2021-2023 Bronco Sport vehicles equipped with 1.5L engines. A fuel injector may crack and leak fuel inside the engine compartment and cause an under hood fire. (NHTSA Campaign Number: 22V-859)

In September, Ford recalled 2022-2023 Bronco Sport and 2022 F-150 vehicles because the parking lights may flicker during any of the three following scenarios. (NHTSA Campaign Number: 22V-859)

  • Scenario 1: When the customer manually selects the “position lamp on” mode.
  • Scenario 2: When the customer manually selects “Headlamp On” Mode.
  • Scenario 3: When the customer is driving in automatic headlamp mode, and the environment gets dark enough to trigger “Night Mode”, which turns on the headlamp and parking lamp function.

GM Repurchases Certain 2022-2023 Chevrolet Malibu For Structural Problems

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General Motors (GM) will be contacting the owners of certain 2022-2023 Chevrolet Malibu’s because of a problem affecting a structural portion of the vehicle frame.

GM first became aware of the problem in August 2022 when a production operator installing parts on a vehicle discovered a section of the motor rail was missing. Further investigation found that the front rail outer panel was cut too short and, as a result, was not completely welded to the front right-hand side of the front impact bar.

The problem was reported to GM’s Speak Up For Safety (SUFS) program which worked with the plant and supplier to identify and contain affected vehicles. Of the 1,875 vehicles that GM contained and inspected, they found none that had an incomplete weld. GM opened an investigation into the subject condition to analyze the potential effects of this condition during a crash. There are no known field incidents related to this condition., but GM has decided to conduct a safety recall.

According to the defect report, the sheet metal blank for the front frame rail outer panel for the 2022-2023 Chevy Malibu was improperly loaded into the die. As a result, the front frame rail was cut 10 millimeters short of its intended design. The shortened frame rail prevented proper welding of the front impact bar to the front frame rail. This defect may be present on the right hand and/or left-hand side of the vehicle.

Owners will be asked to return to their GM dealer to have the right-hand and left-hand sides of the vehicle’s motor rail inspected for incomplete welds. If the condition is found, the vehicle will be repurchased by GM. The NHTSA campaign number for this recall is 22V-923.

Is GM Repurchasing Your Lemon Vehicle?

Under the Lemon Law, if you qualify, you should be able to recover your down payment, (including registration fees, licensing fees, taxes, transportation costs, etc.), plus your total monthly lease or loan payments. The manufacturer will also pay off the balance of your loan or lease. The manufacturer will also pay all or most of your attorney’s fees.

If you have any questions about your rights and the California Lemon Law, please call our office at 1-888-395-3666 and get some great Lemon Law advice!

Kia Forte Loss Of Steering Control & Kia Niro EV Loss Of Drive Power

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A small number of 2023 Kia Forte vehicles could experience a loss of steering control due to a manufacturing problem at the supplier.

The problem was first discovered in late October 2022 when a front left steering knuckle was found broken in a 2023 Kia Forte at one of their manufacturing plants. Kia worked with the supplier to investigate the cause of the knuckle crack and revealed a manufacturing procedure that was not followed by a worker at the knuckle supplier. Although a field analysis of data finds no customer complaints or warranty claims for loss of steering due to knuckle crack or fracture, Kia decided to recall certain 2023 Kia Forte vehicles.

According to the defect report, a manufacturing issue at the supplier of the front left steering knuckle installed in the subject vehicles may have been cast improperly. An improperly cast knuckle can fracture and may result in the loss of steering control.

All owners of the affected vehicles will be notified by first-class mail with instructions to bring their vehicles to a Kia dealer to have the left front steering knuckle inspected. If the knuckle is identified as being part of the affected production lot, the knuckle will be replaced with a new one. Kia’s number for this recall is SC259 and the NHTSA campaign number is 22V-907.

Kia will also be contacting the owners of certain 2020 Niro EVs because of a problem with the Electric Power Control Unit (EPCU). In November 2022 Kia became aware of Niro EVs in the European market involving complaints loss of motive power. An investigation identified seven warranty claims in the US, involving loss of motive power for the same reasons.

According to the defect report, the Electric Power Control Unit (EPCU) assembly in the affected vehicles may have been produced by the supplier with improper sealing. The EPCU could leak coolant internally and contact the EPCU circuit board. If coolant contacts the EPCU circuit board, the vehicle could unexpectedly stall. Drivers may notice a “Check Electric Vehicle System” warning light.

Dealers will inspect and replace the EPCU as necessary. Kia’s number for this recall is SC258 and the NHTSA campaign number is 22V-897.

Hyundai Issues Seventh Seat Belt Pretensioner Recall

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Hyundai Motor America (Hyundai) has issued a recall (22V-816) affecting certain 2023 Genesis G80 Electric, 2021-2022 Santa Fe Hybrid, and 2022-2023 Santa Fe Plug-In Hybrid vehicles. These vehicles have front driver-side and/or passenger-side seat belt pretensioners that could explode under certain deployment conditions.

This is the seventh recall issued by Hyundai for seat belt pretensioner problems. Hyundai has determined that the subject vehicles were manufactured with driver/passenger pyrotechnic-type seat belt pretensioners that may deploy abnormally in certain crashes due to over pressurization of the pretensioner pipe. The potential of a pretensioner exploding is dependent on vehicle characteristics, pretensioner load limiter specifications, airbag control unit logic, crash duration and severity.

Hyundai first became aware of the problem in September 2021, when they were contacted by the NHTSA’s ODI about an incident involving a 2021 model year Hyundai Elantra. The driver-side seat belt pretensioner allegedly deployed abnormally, causing metal fragments to enter the rear cabin and injuring an occupant’s leg. The NHTSA was notified of the incident by a law firm representing the operator of the incident vehicle.

According to the defect report, the front driver-side and/or passenger-side seat belt pretensioners in the subject vehicles were installed from a suspect production lot containing pyrotechnic-type pretensioners that may deploy abnormally during a crash. At the time, the cause of the abnormal deployment was unknown. Hyundai decided to recall vehicles equipped with pretensioners produced within the same production lot.

Recall 21V-796 vehicles affected include:

2021 Hyundai Elantra
2021 Hyundai Elantra HEV
2021 Hyundai Venue
2022 Genesis GV70
2021 Genesis GV80

Recall 22V-069 vehicles affected include:

2020-2021 Hyundai Accent

Recall 22V-123 vehicles affected include:

2022 Hyundai Elantra
2022 Hyundai Elantra HEV

Recall 22V-218 vehicles affected include:

2020 Hyundai Accent
2021-2022 Hyundai Elantra

Recall 22V-354 vehicles affected include:

2020-2022 Hyundai Accent
2021-2022 Hyundai Elantra
2021-2022 Hyundai Elantra HEV

Recall 22V-458 vehicles affected include:

2020-2022 Hyundai Venue

Owners receiving notices will be asked to return to their Hyundai dealer to have the seat belt pretensioners secured with a cap. Hyundai’s number for this recall is 238/011G.