Tag Archives: Manufacturer defect

2025 Chrysler Pacifica PHEVs – Insufficient Bolt Torque on Front Brake Caliper Bracket

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A potential safety issue has been identified in some 2025 Chrysler Pacifica Plug-In Hybrid Electric Vehicles (PHEVs) that may have been produced with insufficient bolt torque on the front brake caliper bracket. The problem, which affects vehicles produced on December 19, 2024, can lead to a range of serious consequences, including reduced steering control, brake fluid leakage, and diminished front braking performance.

According to FCA US LLC (FCA US), the issue was first identified on February 20, 2025, when the Technical Safety and Regulatory Compliance (TSRC) organization opened an investigation into the matter. The company worked with its engineering team and supplier to understand the potential consequences of the problem and determine if any vehicles with suspect front brake caliper brackets had left the factory.

As of March 13, 2025, FCA US is aware of one warranty claim related to this issue, which was received on January 8, 2025. However, there have been no field reports of accidents or injuries resulting from the problem.

The suspect vehicles were produced with front brake caliper bracket bolts that were not properly torqued, which can cause the bracket to separate from the steering knuckle. This can lead to a range of serious safety issues, including reduced steering control and diminished braking performance. In certain crashes, this can increase the risk of injury to occupants of the vehicle.

To address the issue, FCA US will be conducting a recall of affected vehicles. Dealers will inspect and replace the front brake caliper brackets and bolts as necessary, free of charge. Owner notification letters are expected to be mailed on April 24, 2025. The recall is identified as FCA’s number 27C and the NHTSA campaign number is 25V-191.

Vehicle owners who receive a notification letter should contact their local Chrysler dealer to schedule an appointment for the inspection and repair. It is essential to have the issue addressed promptly to ensure the safety of the vehicle’s occupants and other road users. The recall highlights the importance of regular maintenance and inspections to identify potential safety issues before they become major problems. FCA US’s prompt action in addressing the issue demonstrates its commitment to ensuring the safety and quality of its vehicles.

If you own a 2025 Chrysler Pacifica PHEV, it is essential to be aware of this potential issue and take immediate action if you receive a notification letter. By doing so, you can help ensure your safety and the safety of others on the road.

NHTSA Investigates Engine Failure in GM Trucks And SUVs

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A shocking number of complaints has prompted the National Highway Traffic Safety Administration (NHTSA) to launch a safety probe into engine failure reports affecting approximately 870,000 Chevrolet, GMC, and Cadillac models manufactured by General Motors (GM). The Office of Defects Investigation (ODI) has received a staggering 39 complaints, accompanied by numerous Early Warning Reporting (EWR) Field Reports, all pointing to engine failure in vehicles equipped with the L87 V8 engine.

Which Vehicles Are Affected?

The following models are under scrutiny:

  • 2019-2024 Chevrolet Silverado 1500
  • 2019-2024 GMC Sierra 1500
  • 2021-2024 Chevrolet Tahoe
  • 2021-2024 Chevrolet Suburban
  • 2021-2024 GMC Yukon
  • 2021-2024 Cadillac Escalade

The Alarming Reality of Engine Failure

Complainants have reported a disturbing trend: a bearing failure can trigger either engine seizure or a catastrophic breach of the engine block by the connecting rod. In many cases, there are no warning signs before the failure occurs, resulting in a sudden and unexpected loss of power. This increases the risk of a crash, which can lead to devastating consequences, including injuries and property damage.

NHTSA Takes Action

In response to these disturbing reports, the ODI has initiated a Preliminary Evaluation (PE) to determine the scope and severity of the potential problem. The investigation aims to assess the safety-related issues associated with engine failure and identify any necessary corrective actions to prevent future incidents.

What California Drivers Need to Know

If you’re behind the wheel of one of these affected vehicles, it’s crucial to be aware of this potential issue. Engine failure can be a significant safety concern, especially when driving at high speeds. Don’t wait until it’s too late – stay informed and take proactive steps to protect yourself and your loved ones.

Seeking Help from a California Lemon Law Expert

If you’re experiencing engine problems or other issues with your Chevy, GMC, or Cadillac vehicle, don’t hesitate to reach out to our experienced California Lemon Law attorneys. Our team is dedicated to helping you navigate the complex process and determine if you’re eligible for compensation or relief under the law. If you have concerns about your vehicle or would like to report an incident, consult with a California Lemon Law attorney for expert guidance and support.

Jeep Grand Cherokee Front Seat Side Airbag May Not Deploy

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If you own a 2022-2024 Jeep Grand Cherokee or a 2021-2024 Jeep Grand Cherokee L , it’s crucial to be aware of a recent safety recall. A small number of these vehicles may have an improperly secured connector for the front seat side airbags (SAB), which could prevent the airbags from deploying in case of a crash. This issue compromises compliance with Federal Motor Vehicle Safety Standards (FMVSS) for side impact protection.

Discovery and Investigation

On April 25, 2023, FCA US LLC’s Technical Safety and Regulatory Compliance (TSRC) organization was notified of a potential safety issue involving improperly secured seat wiring connectors in certain 2022-2024 Jeep Grand Cherokee and 2021-2024 Jeep Grand Cherokee L vehicles .

From May 2023 to October 2023, the TSRC organization conducted a thorough review of warranty data, vehicle production records, field reports, and customer assistance records. This comprehensive analysis aimed to understand the potential impact on customers.

Regular meetings were held from October 2023 to September 2024 between FCA US TSRC, Engineering, and Supplier Quality teams. These discussions focused on identifying all possible failure modes of the issue and determining which vehicles were at risk.

On October 9, 2024, the TSRC organization officially recognized that a front seat SAB squib connector problem existed in certain vehicles due to improperly secured connectors. This defect could result in non-compliance with FMVSS No. 214, which governs side impact protection.

Recall Announcement

On November 21, 2024, FCA US decided through the Vehicle Regulations Committee to conduct a voluntary safety recall of the affected vehicles. This proactive step ensures that owners are aware of and can address this critical safety concern.

Identifying Affected Vehicles

If your vehicle is affected by this issue, you may notice an illuminated airbag warning light on the dashboard. This light indicates a potential problem with the front seat side airbags.

Owner notification letters are expected to be mailed on December 19, 2024. These letters will provide detailed instructions on how to proceed with the recall process.

Owners will be instructed to take their vehicles to a Jeep dealership. There, technicians will secure the improperly connected front seat side airbag connectors free of charge.

Recall Details

  • FCA US Recall Number : B3B
  • NHTSA Campaign Number : 24V-897

Ensuring your vehicle complies with federal safety standards is essential for protecting yourself and others on the road. By staying informed about recalls like this one, you can take necessary actions to maintain your vehicle’s safety features.

Audi Announces High-Voltage Battery Issue In Certain PHEV Models

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Audi has announced a safety defect affecting certain high-voltage battery modules in its 2022-2023 Q5 Plug-in Hybrid Electric Vehicle (PHEV) and A7 PHEV models. The recall is necessary due to the risk of thermal events, which may cause smoke or even fires.

According to Audi, the root cause of the issue is still under investigation, but current analysis suggests that manufacturing deviations at a supplier of battery modules may be to blame. The company has been working closely with its supplier, Samsung SDI, and conducting comprehensive analyses of affected batteries to determine the conditions and circumstances that trigger thermal events.

The recall affects approximately 50 high-voltage batteries from non-U.S. markets, as well as an additional batch of batteries collected from field incidents in the United States. Audi has also received reports of other vehicles outside of these specific models, which are also under investigation.

To mitigate the risk, Audi plans to install advanced onboard diagnostic software, which will detect potential issues with battery module performance and alert the driver before problems may occur. The software is expected to be available in the second quarter of 2025.

In addition to the software update, Audi will offer two interim remedies for vehicles affected by this recall:

  1. Vehicles with online data: Affected modules or high-voltage batteries must be replaced.
  2. Vehicles without online data: Customers will be instructed not to charge their vehicle from external sources or via the combustion engine until the new software becomes available.

To date, Audi reports no injuries, crashes, or fires related to this issue in the United States market. Interim letters notifying owners of the safety risk will be mailed on January 24, 2025, with a second notice to follow once the final remedy is available.

Vehicles Affected:

  • 2022-2023 Audi Q5 PHEV
  • 2022 Audi A7 PHEV

Recall Numbers:

  • Volkswagen’s number: 93AA
  • NHTSA campaign number: 24V-898

Interim Remedies:

  1. Vehicles with online data: Replacement of affected modules or high-voltage batteries.
  2. Vehicles without online data: Instructed not to charge vehicle from external sources or via combustion engine until new software becomes available.

Engine Cup Oil Leak In 2024-2025 Ford & Lincoln Vehicles

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Low Oil Pressure WarningFord Motor Company have identified a critical issue in certain 2024-2025 F-150, 2024 Expedition, and 2024 Lincoln Navigator vehicles equipped with the 3.5L GTDI engine. A misaligned engine cup plug has been found to potentially result in a rapid oil leak, posing serious safety risks.

The Problem: Misaligned Engine Cup Plug

The defect stems from a misalignment of the hydraulic press used to insert engine cup plugs into the cylinder head bore during assembly. This misalignment, approximately 1.5 mm off center, distorts the cup plug, reducing its retention within the bore. This defect may result in:

  • Rapid Oil Leak: A misaligned plug can cause sudden, large-volume oil loss.
  • Increased Fire Risk: Oil leaks in the presence of hot engine or exhaust components may lead to a fire.
  • Loss of Motive Power: A sudden loss of oil can result in reduced engine performance or a complete loss of motive power, increasing the risk of a crash.

Warning Signs for Customers

Drivers of affected vehicles may notice several warning signs, including:

  • Low Oil Pressure Warning: A warning light on the instrument cluster.
  • Burning Smell or Smoke: White smoke or a burning odor from the engine compartment.
  • Oil Leak or Engine Noise: Visible oil leakage or unusual noises from the engine.

Discovery and Investigation

The issue first came to Ford’s attention in October 2024 during a vehicle evaluation at the Kansas City Assembly Plant. A 2024 F-150 equipped with the 3.5L GTDI engine experienced a significant oil leak caused by the expulsion of a 13mm engine cup plug on the exhaust side.

Ford’s Critical Concern Review Group (CCRG) conducted an investigation and tear down analysis. They found no damage to the cylinder head bore but discovered that the cup plug was off center. The misalignment was traced back to maintenance work on the cylinder head assembly line at the Cleveland Engine Plant between September 9, 2024, and September 16, 2024. Other stations were confirmed to have proper alignment.

Field Action and Customer Notification

As of October 30, 2024, Ford has not received any warranty claims or field reports from customers regarding this issue. However, the company is taking measures to ensure customer safety:

  • Field Action Approval: Ford’s Field Review Committee approved the recall on November 1, 2024.
  • Dealer Inspections and Repairs: Dealers will inspect the cup plug alignment and replace any misaligned plugs.
  • Customer Notifications: Owner notification letters are scheduled to be mailed by December 2, 2024.

Recall Details

  • Ford Recall Number: 24S70
  • NHTSA Campaign Number: 24V-851

Next Steps for Vehicle Owners

Ford advises owners of the affected 2024-2025 F-150, 2024 Expedition, and 2024 Lincoln Navigator vehicles to monitor for any signs of the defect and to schedule an inspection with their dealer once notified. This precautionary recall aims to address the issue and ensure vehicle safety and reliability.

2024 Mazda CX-90 PHEV Issues: Could Your Vehicle Be a Lemon?

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The 2024 Mazda CX-90 Plug-in Hybrid Electric Vehicle (PHEV) is facing serious concerns from owners, with a reported 130 complaints, 10 recalls, and 303 manufacturer communications. As this model hits the market, many drivers are voicing their frustration over problems that range from safety-critical issues to major mechanical failures. The list of concerns brings into question whether some of these vehicles could qualify for a buyback under California’s Lemon Law. Here’s an in-depth look at the problems plaguing the 2024 CX-90 PHEV.

Top Complaints About the 2024 Mazda CX-90 PHEV

Consumer reports and complaints have highlighted four major areas of concern: forward collision avoidance, engine performance, electrical systems, and steering. These issues are not just minor inconveniences; they could pose significant safety hazards for drivers and passengers.

  1. Forward Collision Avoidance: Numerous drivers have reported malfunctioning collision-avoidance systems, with false positives causing the brakes to activate unexpectedly. The risk of being rear-ended due to this sudden and unnecessary braking is a valid concern, especially on busy roads or highways.
  2. Engine Issues: Many drivers have experienced engine problems, with some vehicles failing to restart after the i-stop feature engages, and others reporting a complete shutdown while in motion. This kind of unreliability in the engine system poses a clear danger, especially at high speeds.
  3. Electrical Problems: Complaints about electrical malfunctions are widespread. The Dash Electrical Supply Unit (ESU) has been known to fail, affecting vital functions like the defroster, seat belt warnings, and battery cooling systems. Given the reliance of PHEVs on complex electrical systems, these issues are alarming and inconvenient.
  4. Steering Concerns: A sudden loss of power steering assist is a particularly dangerous defect, making it difficult for drivers to control the vehicle. This kind of failure can occur without warning, putting both the driver and surrounding traffic at risk.

Recalls Highlight Safety and Reliability Concerns

The 2024 Mazda CX-90 PHEV has been subject to a staggering 10 recalls, indicating widespread problems that extend beyond individual cases. Here are some of the most notable recalls:

  • Engine Restart Failures: The i-stop feature, which automatically shuts off the engine to save fuel when idling, may prevent the engine from restarting, leading to potential stranding.
  • High-Voltage Battery Cooling System Issues: Faulty software in the ESU may lead to critical functions, including battery cooling and safety alerts, failing during startup.
  • PCM and ECM Software Malfunctions: Problems with the powertrain and engine control modules can illuminate warning lights and result in a sudden loss of drive power.
  • Inverter Software Errors: In plug-in hybrid models, improper software may lead to a total power loss when driving in electric mode.
  • Sudden Braking: The automatic braking system has a tendency to activate unexpectedly, posing a serious collision risk.
  • Power Steering Failures: An assembly issue with the worm gear can cause power steering assist to be lost without warning, making the vehicle difficult to steer.
  • Camera Malfunctions: Rear view and side cameras may not display properly due to software errors, which is a clear safety compliance issue.
  • Unexpected Engine and Motor Shutdown: Critical errors in the hybrid system software can cause both the engine and electric motor to shut down unexpectedly.
  • Pedestrian Warning Sounds: Missing software in the AVAS amplifier can result in incorrect pedestrian alert sounds, failing to meet federal safety standards for hybrid and electric vehicles.

California Lemon Law: What You Need to Know

California has some of the strongest Lemon Law protections for consumers. If your vehicle has repeated, unresolved problems that impair its use, safety, or value, you may be entitled to a buyback or replacement. Under the California Lemon Law, a car manufacturer must either replace your vehicle or refund your money if they cannot fix a substantial defect within a reasonable number of attempts.

So, what counts as a substantial defect? Issues that compromise your safety or significantly impact the car’s performance typically qualify. For instance, if your 2024 Mazda CX-90 PHEV loses power while driving, suddenly engages the brakes, or suffers from major electrical failures, these could be considered substantial defects.

If you’ve taken your vehicle in for multiple repairs for the same issue without a permanent fix, you might have grounds for a Lemon Law claim. It’s important to keep detailed records of all service visits, recall repairs, and communication with Mazda to strengthen your case.

Next Steps for Owners

If you’re dealing with repeated, unresolved issues with your 2024 Mazda CX-90 PHEV, consulting with a Lemon Law attorney can help clarify your options. California’s Lemon Law is designed to protect you from being stuck with a faulty vehicle. Given the ongoing recalls and widespread complaints, many owners may find themselves in a position to take advantage of these consumer protections.

2021-2024 Hyundai Santa Fe Problems

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The Hyundai Santa Fe is a popular choice for families and adventurers alike, known for its spacious design, modern features, and reasonable price point. However, recent models (2021-2024) have experienced a series of issues that have frustrated owners and raised safety concerns. These common problems affect Santa Fe vehicles with GDI engines.

Common Issues Affecting the 2021-2024 Hyundai Santa Fe

  1. Fuel Injector Problems Leading to Stalling
    A major concern for many Santa Fe owners is the vehicle’s fuel injector system. Faulty fuel injectors can cause the engine to stall unexpectedly, especially in models with GDI (Gasoline Direct Injection) engines. These issues have led to numerous complaints of the vehicle stalling while driving, creating hazardous situations on busy roads.
  2. Loss of Power
    Some owners report a sudden loss of power while driving, particularly when accelerating or maintaining speed on the highway. This loss of power can be alarming and dangerous, especially in situations where acceleration is necessary, such as merging or overtaking. Many drivers have reported that their Santa Fe either stalls entirely or hesitates significantly before regaining power, often triggering check engine or warning lights.
  3. Persistent Check Engine Light
    For Santa Fe models across 2021-2024, the check engine light has become a frequent visitor. Many owners report that the light comes on without clear resolution, even after multiple trips to the dealership. While the check engine light could signify any number of issues, the combination of repeated lights and related powertrain issues has led to frustration and concerns about reliability.

Complaints and Recalls for Each Model Year

2021 Hyundai Santa Fe

Owners of the 2021 model have raised concerns about fuel system problems, including fuel leaks at the pipe connection and improperly tightened fuel pipes. Powertrain complaints are also prevalent, with owners describing issues such as failure to accelerate and hesitation while driving. Recalls include:

  • Tow Hitch Harness Fire Hazard: Due to water accumulation, an electrical short could lead to a fire.
  • Loss of Drive Power: A transmission oil pump malfunction can cause total power loss.
  • Inadequate Windshield Bonding: Improper bonding during manufacturing may cause the windshield to detach in a crash.

2022 Hyundai Santa Fe

The 2022 Santa Fe has seen similar powertrain issues, with some owners reporting a sudden inability to accelerate and warning lights like “Check Hybrid System.” The “phantom braking” issue has also emerged, where the emergency braking system activates without reason, nearly causing accidents. Recalls for the 2022 model include:

  • Tow Hitch Harness Fire Hazard
  • Loss of Drive Power
  • Turbocharger Oil Supply Pipe Leak: A cracked oil supply pipe could lead to leaks in the engine compartment.

2023 Hyundai Santa Fe PHEV

In the 2023 plug-in hybrid models, forward collision avoidance issues have led to abrupt braking in traffic. Complaints also include poor acceleration response, with significant delay or lag from the time the accelerator is pressed to when the vehicle actually moves. Key recalls include:

  • Tow Hitch Harness Fire Hazard
  • Seat Belt Pretensioners May Explode: This recall affects the front seat belt pretensioners, which may explode upon deployment in a crash.

2024 Hyundai Santa Fe

For the latest 2024 model, powertrain and electrical issues are significant. Some drivers report the vehicle losing motive power and experiencing flickering dashboard screens. Complaints include blacked-out instrument panels, “Transmission System Check” warnings, and persistent audio issues that continue even when the vehicle is off. Recalls for this model include:

  • Unintentional Airbag Deployment or Deactivation: Damaged wiring harnesses can lead to unintended airbag activation or deactivation.
  • Vehicle Roll Away from Software Error: A transmission software error may result in a roll-away when the vehicle is parked.
  • Obstructed Rear-View Camera Image: A trailer parking assist message may obstruct the rear-view camera, violating rear visibility standards.

Should You Be Concerned?

These issues have led to frustration for many Hyundai Santa Fe owners. If you’re experiencing any of the above problems, it’s essential to address them promptly for your safety. Keep an eye out for any recalls or technical service bulletins (TSBs) from Hyundai, and report any persistent issues to your dealer.

What’s Next?

The 2021-2024 Hyundai Santa Fe offers many attractive features but has also faced considerable challenges, particularly with its powertrain and fuel injector systems. If you’re dealing with ongoing issues, it’s crucial to know your rights, especially if repairs have been ineffective. Lemon laws may protect you if your vehicle has recurring problems that affect its performance or safety. Consider consulting with a lemon law professional to discuss options if repairs haven’t resolved the issue.

Owning a car should be about convenience and freedom – not worry over performance and safety. If you’re having trouble with your Santa Fe, stay informed, stay safe, and know your options.

Investigation into Fire Hazards of Enel X Way USA’s JuiceBox Level 2 Residential EV Chargers

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Enel X Way USA’s JuiceBox Level 2 residential EV chargersThe National Highway Traffic Safety Administration (NHTSA) has launched an investigation into potential fire hazards associated with Enel X Way USA’s JuiceBox Level 2 residential EV chargers. Prompted by several complaints received by the Office of Defects Investigation (ODI), this evaluation aims to determine the extent and safety implications of electrical arcing and thermal incidents reported by users of these chargers. This probe focuses on the potential for fire risks arising from electrical malfunctions and the company’s recent operational shutdown announcement.

Summary of Complaints Filed with ODI

ODI has received six Vehicle Owner Questionnaires (VOQs) concerning alleged incidents involving the JuiceBox Level 2 charger. These complaints raise serious concerns regarding potential fire hazards that may arise while charging electric vehicles at home. The following highlights from the complaints showcase the range of issues reported:

  1. Total Home Loss Due to Explosion: One complaint involves a significant incident where a vehicle owner claims that charging their EV with a JuiceBox led to an explosion in their garage. This catastrophic event resulted in a fire that destroyed the home entirely.
  2. Car Fire in Driveway: Another complaint describes an incident where a vehicle caught fire in the driveway while connected to a JuiceBox charger. The details of this incident underscore concerns about charger reliability and the potential for dangerous outcomes.
  3. Electrical Malfunctions and Circuit Breaker Issues: Four additional complaints describe issues with electrical malfunctions that caused circuit breakers to trip and charging cycles to be disrupted. These electrical disruptions may indicate underlying issues with the chargers’ compatibility or durability under varying conditions.

Enel X Way’s Operational Shutdown and Potential Impact on User Safety

In an unexpected development, Enel X Way North America announced its intention to cease operations in the United States and Canada by October 11, 2024. A notification was sent to JuiceBox owners on October 2, 2024, which was also posted on the company’s website. This cessation of operations could potentially impact several aspects of the product’s performance and user experience:

  • Software and App Support: As Enel X Way discontinues its North American presence, questions remain about the continuity of the charging app and supporting software. Given that many smart chargers rely on connected software for updates and safety monitoring, the lack of support could leave users with outdated or unsupported technology.
  • Customer Support and Warranty Services: The cessation of operations may also impact the company’s ability to provide customer support, particularly regarding ongoing technical issues, troubleshooting, or warranty claims for JuiceBox chargers.

ODI Preliminary Evaluation and Safety Scope

In response to these serious complaints, ODI has opened a Preliminary Evaluation to examine the safety and reliability of JuiceBox Level 2 chargers. The purpose of this evaluation is to assess the scope, frequency, and potential hazards associated with these products. The investigation seeks to determine:

  • Risk of Fire and Explosion: By evaluating complaints of thermal events, such as the explosion in the garage and the driveway car fire, ODI aims to understand the risk factors and whether the JuiceBox charger’s design or operational faults are contributing factors.
  • Electrical Stability and Safety Consequences: ODI’s analysis will also delve into the frequency of electrical malfunctions and whether these events pose a risk of property damage, personal injury, or loss of life.
  • Impact of Software and Operational Changes: With the discontinuation of Enel X Way North America’s operations, ODI is concerned about the potential safety implications arising from the lack of app and software support. The investigation will evaluate if and how this operational change might exacerbate existing safety concerns or introduce new risks.

Affected Vehicles and Part Numbers

The ODI investigation includes a review of incidents involving various EV models that utilized the JuiceBox Level 2 charger. The vehicles associated with these complaints include:

  • Chevrolet Bolt EV (2018)
  • Chrysler Pacifica Hybrid (2018)
  • Hyundai Ioniq 5 (2022)
  • Hyundai Ioniq 6 (2023)

Additionally, the specific product part under scrutiny is the Enel X JuiceBox Level 2 Charger.

Steps for Consumers and Further Information

For EV owners who currently use the JuiceBox Level 2 charger, awareness of this investigation is crucial. Users are encouraged to follow any guidance issued by the NHTSA and consider consulting with licensed electricians to ensure proper installation and safe operation of their EV chargers.