Tag Archives: safety defect

2020-2022 Ford Explorer Repeated Repair Attempts

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Ford Explorer Axle Problem
Certain 2020-2022 Ford Explorer Vehicles May Still Be at Risk

A critical issue affecting certain 2020-2022 Ford Explorer vehicles has come to light, despite previous repair attempts under recalls 23V-199 or 22V-255. The problem lies in the rear axle horizontal mounting bolt, which may fracture and cause the driveshaft to disconnect. This can lead to a loss of forward power, increased risk of crash and injury, and even unintended vehicle movement.

The root cause of the issue is attributed to a software tool malfunction that failed to upload the correct software update to the vehicle during previous repair attempts. As a result, the underlying condition specified in Safety Recalls 23S16 / 23V-675 and 22S27 / 22V-255 may still exist, putting drivers and passengers at risk.

The Technical Explanation

Affected vehicles were built with a 3-point mounted axle design, which can lead to a fracture of the rear axle horizontal mounting bolt. When powertrain torque is applied through the driveline, it causes axle rotation, exerting a bending force on the rear axle bolt. Repeated peak torque events, typically experienced during launch events, can cause fatigue failure of the bolt. This can result in a loud, grinding, binding, or clunking noise, as well as severe vibration.

The Consequences

If the rear axle bolt breaks, the driveshaft or half-shafts may become disconnected, leading to a loss of forward power and transmission torque to the rear wheels. This increases the risk of crash and injury. Furthermore, if the parking brake is not applied, the loss of primary park torque can allow the vehicle to roll in park, increasing the risk of crash and injury.

The Solution

To correct the problem, dealers will update the powertrain control module (PCM) software. Ford’s number for this recall is 25S22, and the NHTSA campaign number is 25V-166. It is essential that owners of affected vehicles take immediate action to have their vehicle repaired to prevent any potential accidents or injuries.

2024-2025 Tacoma 4-Wheel Drive Reduced Braking

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A potentially serious issue has been identified in certain 2024-2025 Toyota Tacoma 4-wheel drive trucks, prompting a safety recall by the manufacturer. The problem involves dirt buildup inside the rear wheels of affected vehicles, which can cause damage to the rear brake hoses and potentially lead to brake fluid leaks.

The issue affects Toyota Tacoma trucks equipped with 16-inch brake systems and 17-inch wheels, where the brake hoses are attached to the rear brake calipers and transfer brake fluid under hydraulic pressure. The clearance between the brake hoses and wheels in these vehicles is smaller than in other combinations, making them more susceptible to damage from mud and dirt buildup.

When operating in off-road conditions, mud and dirt can accumulate on the interior of the rear wheels and come into contact with the brake hoses. Over time, this can cause wear and tear on the hoses, leading to damage and potentially resulting in a brake fluid leak. A brake fluid leak can reduce brake performance and increase stopping distances, significantly increasing the risk of a crash.

The problem was first reported by dealers in mid-July 2024, with several instances of rear brake hose leaks observed in 2024 Toyota Tacoma vehicles with the affected wheel and brake combination. Upon further inspection, dealer technicians found that the rear brake hoses were damaged and worn through, and that mud and dirt buildup on the inside of the rear wheels was causing the hoses to rub against the debris.

Toyota’s investigation into the issue revealed that the manufacturing processes used to install the brake hose were following proper routing procedures. However, a design review of the rear brake system found that the clearance between the brake hose and wheel in affected vehicles was smaller than in other combinations. Additionally, the positioning of the rear brake hose on 16-inch brakes was different and outside of the rear caliper profile.

Based on the results of its investigation, Toyota concluded that 4-wheel drive vehicles with 16-inch rear brakes and 17-inch Toyota wheels may experience rear brake hose damage due to mud and dirt buildup on the interior of the wheels. The company has decided to conduct a safety recall to address the issue. As of January 29, 2025, Toyota has received five field technical reports and twelve warranty claims related to this condition in affected vehicles.

To correct the problem, dealers will replace both rear brake hoses in affected vehicles. Interim letters notifying owners of the safety risk are expected to be mailed on March 24, 2025, with a second letter to follow once the remedy is available. Toyota’s recall numbers for this campaign are 25TB04 and 25TA04, and the NHTSA campaign number is 25V-058.

GM Wheel Lock-Up From Transmission Control Valve Defect

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General Motors (GM) has announced a safety defect affecting the transmission control valve in certain Chevrolet, GMC, and Cadillac vehicles equipped with diesel engines. The issue involves excess wear on the transmission control valve, which could lead to a gradual loss of pressure. This defect has the potential to cause harsh shifting, and in rare cases, a momentary lock-up of the rear wheels.

The Affected Vehicle Models Are:

2021 Cadillac Escalade
2021 Cadillac Escalade ESV
2020-2022 Chevrolet Silverado 1500
2020-2022 Chevrolet Silverado 2500
2020-2022 Chevrolet Silverado 3500
2021 Chevrolet Suburban
2021 Chevrolet Tahoe
2020-2022 GMC Sierra 1500
2020-2022 GMC Sierra 2500
2020-2022 GMC Sierra 3500
2021 GMC Yukon
2021 GMC Yukon XL

GM first became aware of this issue in June 2024 through the company’s Speak Up for Safety (SUFS) program, after a customer claimed that the rear wheels of a 2021 GMC Sierra 2500 HD pickup allegedly locked up while towing a trailer. The incident caused property damage to both the vehicle and the trailer. This report prompted GM to open a new investigation.

Previously, GM had already investigated the condition, finding that excessive wear in the transmission control valve could cause harsh downshifting and, in some cases, a momentary lock-up of the rear wheels. Earlier tests and analyses suggested that the lock-up was unlikely to lead to loss of vehicle control, and no accidents or injuries were reported at the time.

In July, the National Highway Traffic Safety Administration (NHTSA) notified GM that its Vehicle Owner Questionnaire (VOQ) monitoring process had flagged additional reports that could be related to this issue. GM’s investigators conducted an extensive analysis of these reports and reviewed comprehensive field data, identifying 1,888 field reports alleging a potential lock-up condition. Further examination revealed eleven specific incidents where the vehicles veered off the road, causing minor property damage. There were also three minor injuries reported, although none were linked to a collision.

Based on these findings, GM’s Safety Field Action Decision Authority (SFADA) decided in October to initiate a safety recall.

To address the defect, GM dealers will install updated transmission control module software. This software will monitor valve performance and detect signs of excess wear approximately 10,000 miles before a wheel lock-up condition could occur. If excess wear is detected, the software will limit the transmission to fifth gear, effectively preventing a wheel lock-up scenario, which typically happens during a downshift from eighth gear. Additionally, the vehicle’s instrument panel will display a service engine light and a reduced propulsion warning message to alert the driver. GM’s number for this recall is N242454440 and the NHTSA campaign number is 24V-797.

GM Roof Rail Air Bag Inflator Defect

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General Motors (GM) have identified a safety issue affecting certain Chevrolet and GMC vehicles. This issue involves a defect in the roof-rail airbag (RRAB) inflator, which could pose a serious risk to the safety of drivers and passengers. The defect may cause the inflator to malfunction, potentially resulting in the separation of the inflator’s end cap or a split in its sidewall. If this happens, the airbag system may not deploy as intended, increasing the risk of injury in the event of a crash or other incident.

Affected Vehicle Models

The following models are impacted by this recall due to the potential defect in the RRAB inflators:
2018 Chevrolet Silverado 1500
2018-2019 Chevrolet Silverado 2500
2018-2019 Chevrolet Silverado 3500
2018 GMC Sierra 1500
2018-2019 GMC Sierra 2500
2018-2019 GMC Sierra 3500

How the Issue Was Discovered

GM became aware of this problem in August 2024, after receiving reports of four incidents where RRAB inflators ruptured in vehicles from another manufacturer. These reports raised concerns about a possible defect in the inflator system, prompting GM to initiate its own investigation. During this investigation, GM found evidence of a similar incident involving a 2018 Chevrolet Silverado 2500, which was equipped with the same type of inflators.

In this particular case, the vehicle was parked and unoccupied when the RRAB inflator on the right side ruptured. Photos confirmed the inflator malfunctioned while the truck was idle, reinforcing concerns about the integrity of the RRAB system. GM is continuing its investigation to determine the exact cause of the failure.

Steps Taken by GM

On October 3, 2024, GM’s Safety Field Action Decision Authority (SFADA) determined that a safety recall was necessary. This recall affects vehicles that were built using RRAB inflators from the same production lot as the Chevrolet Silverado 2500 involved in the initial incident. As of now, GM has not received any further reports of similar incidents involving its vehicles.

What Owners Need to Know

To address this issue, GM dealers will replace the left and right roof-rail airbag modules in the affected vehicles. This recall is part of GM’s proactive efforts to ensure vehicle safety and prevent potential accidents resulting from defective inflators.

For reference, GM has assigned this recall the number N242474500, and the National Highway Traffic Safety Administration (NHTSA) has labeled it as campaign number 24V-560.

2021 Nissan Rogue Safety Investigations: Tie Rod Failures and Engine Issues

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The 2021 Nissan Rogue, one of Nissan’s popular compact SUVs, is currently under investigation by the Office of Defects Investigation (ODI) due to reports of safety defects. Two major concerns have emerged—one involving inner tie rod failures that could lead to a loss of steering control, and the other concerning engine failures that could result in a complete loss of motive power. These issues raise significant safety risks for drivers and passengers, and Nissan is facing increasing scrutiny as the investigations unfold.

Inner Tie Rod Failures: Loss of Steering Control

Nissan Rogue Tie Rod FailureOne of the top issues reported is inner tie rod failures, which can lead to a sudden and complete loss of steering control. The ODI received reports from owners and early warning data indicating that these failures can occur on either the driver’s or passenger’s side of the vehicle. In several instances, the vehicles had to be towed for repairs.

One notable case involved a 2021 Nissan Rogue owner who experienced a sudden and severe steering malfunction while pulling out of a parking lot. According to the owner, the steering wheel suddenly pulled to the right, causing the front passenger tire to become misaligned. The vehicle became undrivable, multiple warning lights illuminated, and it had to be towed to a dealership. Although the dealership diagnosed a bent tie rod and performed a repair, the steering wheel did not return to its normal position. The owner reported no impact that could have caused the damage, yet the manufacturer declined to cover the repair under warranty. This incident occurred with just over 16,600 miles on the vehicle, raising concerns about the durability and safety of the Rogue’s steering system.

This ongoing investigation into tie rod failures has raised serious concerns about the overall safety of the vehicle, as a sudden loss of steering control could lead to catastrophic accidents.

Engine Failures: Loss of Motive Power

In addition to the tie rod issue, the 2021 Nissan Rogue is also under investigation for engine failures that could lead to a complete loss of motive power. The ODI has identified multiple reports of engine knock, strange noises, and metal chunks or shavings found in the oil pan of vehicles equipped with Nissan’s KR15DDT and KR20DDET engines. The KR15DDT, a 1.5-liter 3-cylinder engine, is found in the Rogue, while the KR20DDET, a 2.0-liter 4-cylinder engine, powers other models such as the Altima, QX50, and QX55.

The variable compression ratio engines, designed to deliver both high power and fuel efficiency, have shown an elevated failure rate. These engine issues have been linked to bearing and L-link damage, which could lead to total engine failure, leaving drivers stranded or worse, in a dangerous situation while driving. Nissan has made manufacturing changes in an attempt to address these issues, but the investigation is still open as the company works to find a more permanent solution.

Alongside these investigations, the 2021 Nissan Rogue has been the subject of several recalls, addressing a variety of safety concerns:

  1. Missing Internal Bushing in Brake Calipers – This defect could lead to brake fluid loss, reducing braking performance and increasing the risk of a crash.
  2. Rear View Camera Malfunctions – The rearview camera display may become inoperative, reducing rear visibility and raising the risk of an accident.
  3. Seat Belt Retraction Issues – Some seat belts may not retract properly, making them difficult to use, which could increase the risk of injury in a crash.
  4. Fuel Pump Overheating – An overheated fuel pump can cause the engine to stall unexpectedly, posing a serious safety risk.
  5. Second Row Seatback Welding Issues – Improperly welded seatbacks may fail to secure a child seat, increasing the risk of injury in the event of a sudden stop or crash.
  6. Wheel Separation Risk – Incorrectly fitted wheel nuts could cause the wheel assembly to separate from the vehicle, which could result in a loss of vehicle control.
  7. Fuel Hose Detachment – A poorly secured fuel hose can disconnect, causing a fuel leak or engine stall, both of which increase the risk of fire or crash.

With ongoing investigations into tie rod and engine failures, as well as several recalls addressing safety concerns, the 2021 Nissan Rogue has been thrust into the spotlight for potential safety risks. Drivers should stay informed about any updates from Nissan and take immediate action if their vehicle is affected by any recalls or investigations. Safety should always be a top priority, and these investigations aim to ensure that any defects are properly addressed to protect drivers on the road.

Nissan Leaf Fire Risk From Quick Charging Battery

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Nissan Leaf Smoking BatteryCertain 2019-2020 Nissan Leaf vehicles, specifically those equipped with quick charge ports for Level 3 charging using the CHAdeMO connector, are facing a potential issue where the battery could overheat during quick charging. This issue is serious, as it significantly raises the risk of a vehicle fire, which could lead to injury or property damage. The affected LEAF models were produced at Nissan’s Smyrna, Tennessee plant between August 29, 2018, and November 3, 2020. Nissan has identified this issue through their production records, confirming that it is limited to these specific Model Year 2019-2020 LEAF vehicles. Importantly, no other Nissan or INFINITI vehicles are known to be impacted by this defect, offering some reassurance to owners of other Nissan models.

Nissan is actively investigating the cause of this issue. Preliminary findings suggest that the problem stems from excessive lithium deposits forming inside the lithium-ion battery cells of these vehicles. These deposits increase the electrical resistance within the battery, which can cause fluctuations in the battery’s state of charge. This elevated resistance becomes particularly problematic during Level 3 quick charging, as it may result in the battery heating up more rapidly than intended. If the charging session continues under these conditions, the risk of a battery fire is significantly heightened, posing a serious safety concern.

Drivers may notice several warning signs during Level 3 charging that indicate something is wrong. These include the presence of smoke, unusual noises, interrupted charging sessions, or strange thermal odors emanating from the vehicle’s battery compartment. If any of these signs are observed, Nissan strongly advises stopping the charging process immediately and avoiding Level 3 charging altogether until the problem can be resolved.

Nissan is developing a solution for this issue in the form of a software update for the affected vehicles. Once available, this software update will be installed by dealers and is designed to correct the problem by managing the battery’s charging process more effectively. Nissan is taking steps to notify affected vehicle owners. Interim letters, alerting them to the safety risk, are expected to be mailed in October 2024. A second notice will follow once the software remedy is ready for deployment.

Until the fix is in place, Nissan advises owners to avoid using Level 3 quick charging stations and instead rely on slower charging methods, which do not present the same risk. For those affected, Nissan’s recall number is R24B2, and the corresponding NHTSA campaign number is 24V-700.

Cadillac Lyriq Defective Brake Performance

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A potential safety issue has been identified in certain 2023-2024 Cadillac Lyriq all-wheel-drive vehicles. This defect could affect the vehicle’s braking performance, posing a risk to drivers and passengers.

The investigation into this issue began in May 2024, when General Motors (GM) received reports of two minor accidents allegedly caused by a sudden loss of braking. Both incidents were suspected to be linked to a software problem within the vehicles’ Anti-lock Braking System (ABS). In addition to these accidents, GM was also alerted to a separate field complaint that, while not resulting in an accident, seemed potentially related to the same problem.

To get to the bottom of the issue, GM’s investigation team gathered and analyzed field data from various sources. Despite the initial reports, they found no additional cases that could be connected to this defect. However, through careful analysis, they determined that the problem could indeed occur, but only in extremely rare situations. Specifically, the issue arises when a false ABS event occurs on a dry road at speeds under 25 mph. During this event, if a particular series of wheel movements takes place, the ABS system might continue to release brake pressure in the vehicle’s service brake system, even when it shouldn’t.

Fortunately, GM has confirmed that no injuries or fatalities have been associated with this condition. However, given the potential risk, GM’s Safety Field Action Decision Authority (SFADA) decided in August 2024 to issue a safety recall for the affected vehicles.

The defect report explains that under certain rare braking conditions on dry surfaces at speeds below 25 mph, the ABS may become overly sensitive. If the ABS falsely activates and a specific sequence of wheel movements occurs, the system might continue to release brake pressure, which can significantly reduce the effectiveness of the service brakes. This could lead to a reduction in stopping performance or even cause the brakes to become inoperative, thereby increasing the risk of a crash.

To address this issue, GM has made an update to the electronic brake control module software. This update can be installed either through an over-the-air (OTA) update or by visiting a GM dealership. If you own one of the affected vehicles, GM urges you to take action as soon as possible. The recall number for this issue is N242453471, and the National Highway Traffic Safety Administration (NHTSA) campaign number is 24V-598.

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.