Tag Archives: manufacturing error

Certain 2023-2024 GM Vehicles Fail to Meet FMVSS for Brake Systems

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Certain 2023-2024 Cadillac, Chevrolet and GMC vehicles fail to meet the Federal Motor Vehicle Safety Standard (FMVSS) for light vehicle baking systems. The problem is, the driver may not receive an indicator of a loss of brake fluid before the level is below FMVSS 135’s requirement.

The FMVSS 135 requires that vehicles have a system in place to warn the driver when the brake fluid level drops to a certain point. This allows time for the problem to be addressed before it affects braking performance. However, in the affected vehicles, the brake fluid warning light may not illuminate in time to alert the driver before the fluid drops below the required level. This delay in the warning light could lead to reduced brake performance, increasing the risk of a crash.

The following vehicle models are affected by this problem:

2023-2024 Cadillac Escalade
2023-2024 Cadillac Escalade ESV
2023 Chevrolet Silverado 1500
2023-2024 Chevrolet Suburban 1500
2023-2024 Chevrolet Tahoe
2023 GMC Sierra 1500
2023-2024 GMC Yukon
2023-2024 GMC Yukon XL

GM became aware of this issue through its Speak Up for Safety (SUFS) program. A GM engineer noticed during a brake fluid leak test that the required warning light (referred to as the BRAKE telltale) did not illuminate as expected. This led GM to launch a full investigation. The issue was traced to a mismatch in the software and calibrations of the Electronic Brake Control Module (eBCM). This software mismatch was preventing the vehicle from detecting a brake fluid leak in time to alert the driver. Fortunately, GM has not received any reports of crashes or injuries related to this issue, but the potential for delayed notification of a brake fluid leak poses a safety concern.

In the event of a brake fluid leak, the vehicle’s brake pedal could become less responsive before the warning light appears. This degraded brake performance, combined with the delayed warning, could increase the likelihood of a crash. However, GM has confirmed that even in these circumstances, the vehicles still meet federal stopping distance requirements, meaning they should still be able to stop within the legally required distance.

Owners of affected vehicles will be notified by mail starting October 28, 2024. GM will provide a software update for the eBCM that will correct the issue. This update can be done remotely through an over-the-air (OTA) update or by visiting a dealership. If you own one of these vehicles, you do not need to take immediate action unless you notice any issues with your brakes. The recall is precautionary, and the software update will ensure that your vehicle meets all federal safety standards moving forward.

GM’s recall number for this issue is N242447990, and the National Highway Traffic Safety Administration (NHTSA) campaign number is 24V-674.

Jeep Gladiator And Wrangler Instrument Panel Failure

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Jeep Instrument Panel FailureFiat Chrysler Automobiles (FCA) US have decided that there is a safety related problem affecting certain 2020-2024 Jeep Gladiator and 2018-2024 Jeep Wrangler vehicles. The recall was prompted by an issue that could cause the instrument panel cluster (IPC) to fail, leading to a blank display. This defect may occur due to an internal short circuit, which could compromise the instrument panel’s functionality and cause the vehicle to fall out of compliance with Federal Motor Vehicle Safety Standard (FMVSS) No. 101, which governs controls and displays in vehicles.

The problem was first identified by FCA’s Technical Safety and Regulatory Compliance (TSRC) organization, which had received reports of blank IPCs in affected models. Following this, the TSRC conducted a detailed analysis, including reviewing patterns of IPC failures and performing warranty part return inspections. After collaborating with suppliers and conducting rigorous testing, it was determined that the IPCs in certain vehicles might experience an internal short circuit, causing the display to go blank unexpectedly.

A non-functional instrument panel cluster is a serious concern, as it can result in drivers losing access to critical vehicle information such as speed, fuel levels, and warning indicators. This increases the risk of accidents and reduces the driver’s ability to make informed decisions while operating the vehicle.

On August 30, 2024, FCA US decided, through its Vehicle Regulations Committee, to issue a safety recall for the affected vehicles. The recall applies to Jeep Wrangler models manufactured between 2018 and 2024, as well as Jeep Gladiator models produced from 2020 to 2024. To address the issue, FCA will replace the faulty instrument panel cluster in affected vehicles.

The recall is identified as FCA campaign number 30B, and the corresponding National Highway Traffic Safety Administration (NHTSA) campaign number is 24V-652.

Airbag Issue in 2021 and 2024 Nissan Titan Vehicles

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A recent safety concern has emerged for a small number of 2021 and 2024 Nissan Titan vehicles due to a potential issue with their Air Bag Control Unit (ACU). This problem, if left unaddressed, could increase the risk of injury to occupants in the event of a crash.

In May 2024, Nissan was alerted by their airbag supplier about a production error that involved a missing spacer between the ACU fastener and the base plate. This spacer plays a critical role in ensuring that the ACU is properly secured. Without it, there is a risk that the fastener could interfere with the vehicle’s floor pan, leading to the fastener becoming loose. If this occurs, the airbag may deploy late or not at all, which could significantly increase the risk of injury during a crash.

Upon learning about the problem, Nissan and the supplier conducted a thorough audit. They discovered that 531 affected parts had been shipped to Nissan’s Canton, MS Plant. Fortunately, 528 of these parts were identified and quarantined before they could be installed in vehicles. However, three parts had already been installed in 2024 Nissan Titan vehicles that had been shipped.

In June 2024, the supplier identified additional affected parts included in a service part kit, of which 41 were shipped to Nissan. Nissan was able to quarantine and scrap 37 of these parts, but four had already been installed in 2021 Nissan Titan vehicles during repairs.

On July 19, 2024, after further assessment, Nissan confirmed that the absence of the spacer could indeed cause interference with the floor pan, potentially leading to loose fasteners and compromised airbag deployment.

As a result of these findings, Nissan decided on July 29, 2024, to initiate a Voluntary Safety Recall for the seven affected vehicles—three from the 2024 model year and four from the 2021 model year. While there have been no reports of accidents or injuries related to this issue, Nissan is taking precautionary measures to ensure the safety of its customers.

Nissan will address the issue by replacing the ACU in the affected vehicles. Owners of these vehicles will receive notification letters starting September 19, 2024. The recall number assigned by Nissan is PD120, and the corresponding National Highway Traffic Safety Administration (NHTSA) campaign number is 24V-580.

Although the number of vehicles affected is small, this recall is a critical step to ensure the safety of Nissan Titan drivers and passengers. If you own a 2021 or 2024 Nissan Titan, keep an eye out for the notification letter and get the the necessary repairs.

2021 Jeep Wrangler and Gladiator PCM Software Update

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A select number of Jeep Wrangler and Jeep Gladiator vehicles that were previously repaired under NHTSA recall number 23V-116 are now slated for a crucial Powertrain Control Module (PCM) software update.

In February 2023, FCA US LLC’s Vehicle Regulations Committee launched a safety recall (19A) targeting specific 2018-2023 Jeep Wrangler and 2020-2023 Jeep Gladiator models with manual transmissions. This recall was triggered by reports of potential overheating of the clutch pressure plate due to friction. Such overheating could cause the pressure plate to fracture rapidly, leading to cracks or holes in the transmission case. This damage could result in the expulsion of heated debris from the transmission case, posing safety risks to vehicle occupants and other road users.

By June 2024, FCA’s Technical Safety and Regulatory Compliance (TSRC) organization received reports of vehicles stalling after undergoing the 19A recall remedy. An investigation focused on specific 2021 Jeep Wrangler and 2021 Jeep Gladiator vehicles with manual transmissions that had received the initial remedy under FCA US Recall ID 19A / NHTSA Recall 23V-116. The investigation found that these vehicles might encounter an issue with the Revolutions per Minute (RPM) reduction feature in the PCM software.

The issue was traced to a suspect software release that began on June 19, 2024. This software release introduced a malfunction affecting the RPM reduction feature. The release period ended on June 26, 2024, when the software was withdrawn from availability. Affected vehicles were identified using PCM scan data, ensuring precise identification of those needing further attention. It was confirmed that similar vehicles not included in the recall either lacked manual transmissions or were not updated with the problematic software version.

The remedy involves updating the PCM software in the affected vehicles to ensure the RPM reduction feature operates correctly. This update aims to eliminate the risk of stalling and enhance overall vehicle performance.

Owners of the affected Jeep Wrangler and Jeep Gladiator models will receive notification letters by August 15, 2024. These letters will provide detailed instructions on how to proceed with the necessary software update.

For reference, FCA US LLC has assigned the number 92B to this recall, and the NHTSA campaign number is 24V-572. It is crucial for vehicle owners who had previously completed repairs under recall 23V-116 to ensure this new remedy is completed to maintain vehicle safety and reliability.

Pacifica Plug-In Hybrid Battery Fire Warning

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Chrysler Pacifica Battery FireChrysler (FCA US, LLC) has found a problem with some 2019-2021 Pacifica Plug-In Hybrid Electric (PHEV) vehicles, as well as some 2017-2018 Pacifica PHEVs that got a software update under a previous recall (NHTSA recall number 22V-077). The issue is with the battery pack, which could cause a fire even when the car is parked and the ignition is off.

Chrysler first learned about this issue in February 2022 through the Vehicle Regulations Committee, which led them to start a voluntary safety recall on certain Pacifica PHEVs, known as recall Z11.

Since then, Chrysler and LG Energy Solution (LGES) have been working to figure out the root cause of the problem. They’ve analyzed field reports, bought back vehicles, looked at vehicle data, conducted thermal tests, and torn down battery packs to get to the bottom of it.

In November 2022, the Technical Safety and Regulatory Compliance (TSRC) team at Chrysler was informed about a battery fire in a Pacifica PHEV that had already been fixed under recall Z11.

From June 2023 to December 2023, TSRC learned about five more fires involving the HV battery in some Pacifica PHEVs that had the Z11 remedy. They tried to buy back these vehicles to analyze if the recall fix was working.

In April 2024, Chrysler received a Pacifica PHEV with a post-Z11 remedy fire in the battery pack. After analyzing the vehicle and battery pack, they sent the battery back to the supplier for further inspection. They found a torn anode tab in one of the cells, but couldn’t identify a second factor causing the fires. This confirmed that the Z11 remedy wasn’t effective.

A folded or torn anode tab can lead to lithium by-product build-up over time. This defect, combined with another unknown factor, can cause an internal short in the battery pack, potentially resulting in a vehicle fire.

Chrysler advises owners not to charge their vehicles and to park them outside and away from structures until repairs are made. Dealers will update the high voltage battery pack control module (BPCM) software, and if necessary, replace the battery pack assembly. The recall numbers are 72B and 73B, and the NHTSA campaign numbers are 24V-356 and 24V-358. Vehicles previously repaired under recall 22V-077 will need to have the new fix applied.

Steering Wheel Could Unexpectedly Turn

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The secondary steering torque sensor may not be properly calibrated on certain 2018-2023 Ford Mustang, 2018-2020 Ford F-150, 2018-2021 Ford Expedition, and 2018-2021 Lincoln Navigator vehicles. These vehicles are equipped with electronic power assist steering (EPAS) gears, which were installed as replacement service parts and are now found to have potential calibration issues.

This issue came to light when Ford’s Critical Concern Review Group (CCRG) was alerted by the supplier about an assembly problem affecting certain steering gears. To thoroughly understand the extent of this problem, Ford’s CCRG conducted a detailed review that included examining supplier maintenance records, warranty reports, and vehicle testing data. The findings prompted Ford’s Field Review Committee to decide on issuing a recall to address the defect.

The defect report indicates that the electronic Power Assist Steering (EPAS) gears, which were sold as service parts, may have an incorrectly calibrated secondary digital torque sensor in the steering gear. Specifically, the polarity of this sensor may be inverted. If the primary steering torque sensor fails or develops a fault, and the secondary digital torque sensor’s polarity is inverted, the steering wheel could start oscillating without warning. This means the steering wheel might alternate between clockwise and counterclockwise movements when the driver attempts to steer, leading to unintended steering assist from the electronic power steering gear.

This oscillation poses a significant safety risk as it can make steering unpredictable and difficult to control, potentially leading to accidents. Recognizing the severity of this issue, Ford has taken measures to address it.

Ford dealers will update the Power Steering Control Module (PSCM) software in the affected vehicles to correct the calibration issue. This update is intended to ensure the proper functioning of the secondary torque sensor, thereby preventing the unintended steering oscillation.

Owner notification letters were mailed on August 5, 2024, to inform vehicle owners about the recall and the necessary steps to have their vehicles repaired. Ford has assigned this recall the number 24S45, and it is also registered under the National Highway Traffic Safety Administration (NHTSA) campaign number 24E-055.

Rear View Camera Issue Prompts FCA Recall of Over One Million Vehicles

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blank-dashboard-displayChrysler (FCA US, LLC) is taking steps to address an issue affecting the rear view cameras in over a million of its vehicles. On October 23, 2023, the FCA Technical Safety and Regulatory Compliance (TSRC) organization was alerted to a potential problem where rear view cameras were not displaying images in certain Dodge, Chrysler, Jeep, and Ram models. This issue potentially violates the Federal Motor Vehicle Safety Standards (FMVSS) for rear visibility.

An investigation revealed that a software glitch in the radio system of these vehicles could cause the rear view camera to fail to display the required image when the vehicle is put into reverse. This noncompliance with FMVSS No. 111, which mandates that rear visibility systems must default to showing the rear view image and adhere to specific field of view and image size requirements at the start of each backing event, regardless of any prior modifications made by the driver.

The issue, affecting 1,033,433 units, was identified during a thorough investigation. By June 2024, FCA US’s Vehicle Regulations Committee determined that a voluntary safety recall was necessary to rectify the problem.

The vehicles affected include:

2021-2023 Chrysler Pacifica
2021-2022 Dodge Durango
2022-2023 Jeep Compass
2021-2023 Jeep Grand Cherokee
2022-2023 Jeep Grand Wagoneer
2022-2023 Jeep Wagoneer
2022 RAM 1500
2022 RAM 2500
2022 RAM 3500
2022-2023 RAM Promaster

NOTE: Owners of these vehicles will notice that the rear view image does not appear when the vehicle is placed into reverse.

To resolve this issue, dealers will update the radio software in the affected vehicles. Owner notification letters are scheduled to be mailed out by August 2, 2024. FCA has designated this recall with the number 66B, and it corresponds to the National Highway Traffic Safety Administration (NHTSA) campaign number 24V-436.

Improperly Secured Clutch Pressure Line

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Ford Issues Recall for Certain 2024 Mustang Models Due to Under Hood Fire Risk

Ford Motor Company (Ford) have identified a problem that could potentially lead to under hood fires in certain 2024 Mustang vehicles. Owners of the affected vehicles will receive notification letters with detailed instructions on how to get the necessary repairs. These letters are expected to be mailed by June 17th, 2024.

Discovery of the Problem

Ford became aware of the issue in April 2024 after receiving two reports of under hood fire allegations in 2024 Mustang models equipped with manual transmissions. Upon receiving these reports, Ford’s Critical Concern Review Group (CCRG) promptly conducted inspections of both vehicles to determine the root cause of the fires. Following their investigation, the company decided to issue a recall to address the identified defect.

Details of the Defect

The defect report indicates that the vehicle’s clutch pressure line may not be properly secured to the vehicle’s firewall stud. An improperly retained clutch pressure line can come into contact with hot exhaust components and potentially melt, leading to brake fluid leakage. Although this leakage does not affect the brake system’s fluid volume or functionality, it can significantly impact the clutch system. Specifically, the defect can result in an inability to change gears, and in certain situations, the engine may stall when the throttle is released. Moreover, if the leaked brake fluid accumulates near a hot surface, there is a risk of smoke and an under hood fire, posing a serious safety hazard.

Recall Details and Repair Process

To address this issue, Ford dealers will inspect the clutch pressure line and perform necessary repairs to ensure it is properly retained. The recall has been assigned Ford’s internal number 24S36, and the National Highway Traffic Safety Administration (NHTSA) campaign number is 24V-394.

What Should Owners Do?

If you own a 2024 Mustang, especially one with a manual transmission, it is crucial to stay informed about this recall. Keep an eye out for the notification letter from Ford, which will provide specific instructions on how to proceed with the necessary repairs. In the meantime, if you experience any issues with your vehicle’s clutch or observe any unusual smoke from under the hood , contact your local Ford dealer for repairs, immediately.

Could Your Vehicle Be A Lemon?

The Lemon Law is a consumer protection statute designed to provide relief to car buyers who purchase vehicles that fail to meet quality and performance standards. It ensures that consumers can seek recourse if their new car has serious defects that the manufacturer cannot fix within a reasonable number of attempts. An essential aspect of leveraging the Lemon Law is maintaining accurate and detailed paperwork whenever your vehicle undergoes repairs. This documentation includes repair orders, work performed, dates, and technician notes. Accurate records are crucial because they serve as evidence of the recurring issues and the attempts made to resolve them, which can substantiate a Lemon Law claim. Without proper documentation, proving that your vehicle qualifies as a “lemon” can be challenging, potentially hindering your ability to receive a replacement, refund, or compensation.