S Max

Defect

Certain Kuga S-Max and Galaxy vehicles equipped with a 2.5L HEV/PHEV Engine may not have the remedy for Safety Recall 23S27 installed correctly but were recorded as having received the repair successfully. Because the correct software update may not have been installed on these vehicles the underlying condition specified in Safety Recall 23S27 potential under hood fire may still exist.

Remedy

Dealers are to update the Powertrain Control Module (PCM) software.

Defect

Certain Kuga S-Max and Galaxy vehicles equipped with a 2.5L HEV/PHEV Engine may not have the remedy for Safety Recall 23S27 installed correctly but were recorded as having received the repair successfully. Because the correct software update may not have been installed on these vehicles the underlying condition specified in Safety Recall 23S27 potential under hood fire may still exist.

Remedy

Dealers are to update the Powertrain Control Module (PCM) software.

Defect

Affected vehicles may develop a crack in the Diesel Particulate Filter (DPF).

Remedy

Update software to prevent a cracked DPF. Test and replace DPFs that are already cracked.

Defect

Affected vehicles may develop a crack in the Diesel Particulate Filter (DPF).

Remedy

Update software to prevent a cracked DPF. Test and replace DPFs that are already cracked.

Defect

Affected vehicles may develop a crack in the Diesel Particulate Filter (DPF).

Remedy

Update software to prevent a cracked DPF. Test and replace DPFs that are already cracked.

Defect

Affected vehicles may develop a crack in the Diesel Particulate Filter (DPF).

Remedy

Update software to prevent a cracked DPF. Test and replace DPFs that are already cracked.

Defect

Affected vehicles may develop a crack in the Diesel Particulate Filter (DPF).

Remedy

Update software to prevent a cracked DPF. Test and replace DPFs that are already cracked.

Defect

Affected vehicles may develop a crack in the Diesel Particulate Filter (DPF).

Remedy

Update software to prevent a cracked DPF. Test and replace DPFs that are already cracked.

Defect

Affected vehicles may develop a crack in the Diesel Particulate Filter (DPF).

Remedy

Update software to prevent a cracked DPF. Test and replace DPFs that are already cracked.

Defect

Affected vehicles may develop a crack in the Diesel Particulate Filter (DPF).

Remedy

Update software to prevent a cracked DPF. Test and replace DPFs that are already cracked.

Defect

Affected vehicles may develop a crack in the Diesel Particulate Filter (DPF).

Remedy

Update software to prevent a cracked DPF. Test and replace DPFs that are already cracked.

Defect

Affected vehicles may develop a crack in the Diesel Particulate Filter (DPF).

Remedy

Update software to prevent a cracked DPF. Test and replace DPFs that are already cracked.

Defect

Affected vehicles may develop a crack in the Diesel Particulate Filter (DPF).

Remedy

Update software to prevent a cracked DPF. Test and replace DPFs that are already cracked.

Defect

Affected vehicles may develop a crack in the Diesel Particulate Filter (DPF).

Remedy

Update software to prevent a cracked DPF. Test and replace DPFs that are already cracked.

Defect

It may be possible that the eCall feature will stop functioning due to a malfunction.

Remedy

The Telecommunication Module will need to be replaced

Defect

Vehicles fitted with Adaptive Headlamps will not display a warning message should a failure of the module that controls the Adaptive Headlamps occur.

Remedy

Update the Instrument Panel Cluster (IPC) software.

Defect

The Rear Suspension Toe Link bolt is exposed to corrosion growth which over time leads to reduced material and load capacity and finally to a breakage of the bolt.

Remedy

Replace the bolt utilising an alternative bolt supplier and update all affected vehicles.

Defect

Drivers airbag may not deploy correctly

Remedy

Replace Driver air bag assembly

Defect

Possible thermal incident within the battery monitor sensor wiring

Remedy

Install a fused jumper loom into the battery monitor sensor wiring

Defect

localized overheating of the engine cylinder head may cause the cylinder head to crack.This may cause a pressurized oil leak which in extreme circumstances could result in a fire in the engine compartment.

Remedy

A coolant level sensor needs to be fitted to provide an audible and visual warning to the customer and in extreme circumstances reduce the engine power.

Defect

A number of vehicles fitted with a 1.0 1.5 or 1.6 Ecoboost engine and 6-speed manual transmission could suffer clutch pressure plate fracture. This results in clutch smell reduced vehicle speed and performance. In the unlikely event of clutch pressure plate fracture a noise (thud / bang) could be heard from the vicinity of the transmission in extreme cases resulting in clutch / transmission fragments being released and striking under hood components creating a risk of smoke and fire from the under hood area.

Remedy

To prevent the repeated heating /cooling events a new calibration has been developed for vehicles fitted with Engine Stop Start feature. The software with the additional feature sets the Instrument panel �Wrench light� and de-rates the engine performance if prolonged clutch slip is detected. The software feature includes a drive cycle strategy for latching the wrench light and engine performance de-rate if the customer should experience repeated clutch slip events. For vehicles that do not have Engine Stop Start feature an alternative clutch kit has been released.

Defect

A/C Compressor pulley may become detached.

Remedy

On affected vehicles fit a new A/C compressor clutch pulley.

Defect

Affected vehicles fitted with a 1.0 1.5 or 1.6 Ecoboost engine and 6-speed manual transmission could suffer clutch pressure plate fracture. This results in clutch smell reduced vehicle speed and performance. In the unlikely event of clutch pressure plate fracture a noise (thud / bang) could be heard from the vicinity of the transmission in extreme cases resulting in clutch / transmission fragments being released and striking under hood components creating a risk of smoke and fire from the under hood area.

Remedy

To prevent the repeated heating /cooling events a new calibration has been developed for vehicles fitted with Engine Stop Start feature. The software with the additional feature sets the Instrument panel �Wrench light� and de-rates the engine performance if prolonged clutch slip is detected. The software feature includes a drive cycle strategy for latching the wrench light and engine performance de-rate if the customer should experience repeated clutch slip events. For vehicles that do not have Engine Stop Start feature an alternative clutch kit has been released.

Defect

Affected vehicles fitted with a 1.0 1.5 or 1.6 Ecoboost engine and 6-speed manual transmission could suffer clutch pressure plate fracture. This results in clutch smell reduced vehicle speed and performance. In the unlikely event of clutch pressure plate fracture a noise (thud / bang) could be heard from the vicinity of the transmission in extreme cases resulting in clutch / transmission fragments being released and striking under hood components creating a risk of smoke and fire from the under hood area.

Remedy

To prevent the repeated heating /cooling events a new calibration has been developed for vehicles fitted with Engine Stop Start feature. The software with the additional feature sets the Instrument panel �Wrench light� and de-rates the engine performance if prolonged clutch slip is detected. The software feature includes a drive cycle strategy for latching the wrench light and engine performance de-rate if the customer should experience repeated clutch slip events. For vehicles that do not have Engine Stop Start feature an alternative clutch kit has been released.

Defect

The engine control module calibration may not adequately detect an overheat condition in certain 2.0L Duratorq Diesel engines. In extreme cases an overheated engine can result in a breach of the oil sump leading to loss of the engine oil.

Remedy

Recall the vehicles that are likely to be affected and download revised software for the control module calibration that improves overheat detection and provides an instrument cluster warning indicator to the driver and engine de-rate strategy.

Defect

Vehicles fitted with Adaptive LED Headlamps could experience a condition where the loss of a control signal in combination with a software error may cause the headlamps to switch off. There is a risk of collision if defect happens at night.

Remedy

Recall the vehicles that are likely to be affected and updated software will be loaded to the affected modules.

Defect

It is possible that a leak can occur between the injector spill rail connection and the plastic fuel return pipe. This can cause leakage of fuel which can either pool on the engine cylinder head and then become deposited onto the road surface where it could cause a skid risk to other motorist or if the fuel comes into contact with extremely hot engine components an exhaust manifold for instance it is possible that an under bonnet fire could ensue.

Remedy

Recall all affected vehicles inspect the fuel spill rail/return pipe and if required replace the spill rail with a new modified rail.

Defect

It has been identified that a small number of vehicles built with a panoramic glass roof may not have been bonded correctly. This could ultimately result in detachment of the panoramic glass roof.

Remedy

Recall all affected vehicles and check the adhesion of the roof. If found to be defective the roof will be removed and re-bonded.

Defect

During engine warm up it is possible that the non return valve within the vacuum pump may stick. It is possible that if sufficient brake applications are made before the valve releases the vacuum stored within the brake booster will be used up and a hard brake pedal and longer stopping distances may result.

Remedy

Recall the vehicles that are likely to be affected to fit a revised design of non return valve to the brake vacuum pump.

Defect

It has been identified that the panoramic glass roof panel may not have been correctly bonded to the vehicle. Should this be the case the roof panel could detach.

Remedy

Recalled vehicles will have the panoramic glass roof panel renewed.

Defect

Hard brake pedal may occur in low ambient temperatures which is caused by a non return valve in the vacuum pump sticking.

Remedy

Recall the vehicles that are likely to be affected to fit a revised non return valve to the brake vacuum pump.

Defect

It has been identified that on subject vehicles the heated windscreen earthing point may not have been tightened to the specified torque. An incorrect torque may lead to electrical arcing and in extreme cases this arcing may cause scorching or burning of the surrounding trim components.

Remedy

Recalled vehicles will have the subject earthing point inspected for correct installation and torque.

Defect

It has been identified that the fuel pipe connector between the engine fuel line and fuel tank may not be totalled secured. This may result in a disconnection of the fuel line with the possibility of engine cut out and loss of fuel onto the road surface. Whilst the vehicle is in the dealership the opportunity will be taken to carry out a slight modification to the alternator to prevent the possibility of a short circuit occurring with other components.

Remedy

Recalled vehicles will have the integrity of the fuel line connector checked. Additionally the alternator cable will be modified by removing a portion of sleeving that may be in contact with the end eyelet.