Ford Recall Disaster

[rmc523]

3 hours ago, Sherminator98 said:

 

Crap....I've been noticing that my Bronco has been running ever so slightly rough in the hot weather we've been having...this would explain that. And I fall into that range. 

 

I've had this thing recently where it'll seemingly lose some power for a split second or two as I'm pulling away at low speeds after starting it (I typically let the engine warm up until the rpms drop)....don't know if it's related to this or not.

[Sherminator98]

45 minutes ago, rmc523 said:

 

I've had this thing recently where it'll seemingly lose some power for a split second or two as I'm pulling away at low speeds after starting it (I typically let the engine warm up until the rpms drop)....don't know if it's related to this or not.

 

Well the notice is showing up in my Fordpass App now also and Carfax send me an email about it. Now to just wait and see when they get the repair for it. 

[02MustangGT]

47 minutes ago, rmc523 said:

 

I've had this thing recently where it'll seemingly lose some power for a split second or two as I'm pulling away at low speeds after starting it (I typically let the engine warm up until the rpms drop)....don't know if it's related to this or not.

Same, I doubt it’s related to the fuel pump though.  

[rmc523]

16 hours ago, Sherminator98 said:

 

Well the notice is showing up in my Fordpass App now also and Carfax send me an email about it. Now to just wait and see when they get the repair for it. 

 

I opened my app and saw it too....I'd assume I'll receive the mail version soon.  That makes 3 now without a solution/parts yet lol.

 

 

16 hours ago, 02MustangGT said:

Same, I doubt it’s related to the fuel pump though.  

 

It was the only thing I'd noticed out of the ordinary recently.

[rmc523]

Ford Quality: Management Using This Technique To Fix Issues

 

“In the manufacturing lanes, we’re doing Gemba Walks and going to the plants and spending a lot of time at individual stations, making sure that we’re leveraging the best of our plants across the whole Ford ecosystem in each individual plant,” Andrew Frick, president of Ford Blue and Model e, said at the Deutsche Bank Global Auto Industry Conference. “We’ve seen really good progress there. And we’ve spent a lot of time with our supply chain team and our supplier partners. So much of our progress will be done through the supplier partners.”

For those that aren’t aware of what this method is, “Gemba” is a Japanese term meaning “the real place,” or “the place where value is created.” Gemba walks occur when leaders from companies travel to locations where physical work is performed – in this case, places where parts and vehicles are built – to observe that work, better understand it, and identify potential areas of improvement while interacting with employees, rather than simply relying on second-hand information from others.

[rmc523]

As was previously mentioned....

 

Ford Just Issued Another Massive Recall. And It Doesn't Even Have a Fix Yet

[tbone]

The number of recalls at this point is beyond ridiculous. Our 22 Explorer is included in the fuel pump recall. 

[morgan20]

5 hours ago, rmc523 said:

Ford Quality: Management Using This Technique To Fix Issues

 

“In the manufacturing lanes, we’re doing Gemba Walks and going to the plants and spending a lot of time at individual stations, making sure that we’re leveraging the best of our plants across the whole Ford ecosystem in each individual plant,” Andrew Frick, president of Ford Blue and Model e, said at the Deutsche Bank Global Auto Industry Conference. 

 

 

ROFL! Ford's big shots have been talkin' about Gemba Walks, Genchi Genbutsu, DMAIC, and other lean principles for decades. When I worked at the former Indianapolis Steering Systems plant, Ford even paid for my external Lean Six Sigma training and Green Belt certification.

 

Yet, despite all the talk, there was ALWAYS inadequate follow-through by the big shots. Some things never change... 🙄 

[Sherminator98]

5 hours ago, tbone said:

The number of recalls at this point is beyond ridiculous. Our 22 Explorer is included in the fuel pump recall. 

 

That is part of the problem with using more standardized powertrains...larger amount of vehicles using it mean more recalls.  

[tbone]

6 hours ago, Sherminator98 said:

 

That is part of the problem with using more standardized powertrains...larger amount of vehicles using it mean more recalls.  

I don’t mind standardization, but just make the damn parts better. That nickel Ford saved per pump is now likely costing them hundreds of millions of dollars. 

[Sherminator98]

6 hours ago, tbone said:

I don’t mind standardization, but just make the damn parts better. That nickel Ford saved per pump is now likely costing them hundreds of millions of dollars. 

 

We don't know that is case or not. Shit happens sometimes. 

[akirby]

6 hours ago, tbone said:

I don’t mind standardization, but just make the damn parts better. That nickel Ford saved per pump is now likely costing them hundreds of millions of dollars. 

That’s the double edged sword.  Building 300k-400k engines per year is efficient but that also dramatically multiplies any cost savings making it easier to justify cutting corners.

[tbone]

6 hours ago, Sherminator98 said:

 

We don't know that is case or not. Shit happens sometimes. 

True, but based on Ford’s past actions and terrible supplier relations scores, it isn’t an unreasonable assumption.  

[SoonerLS]

FWIW, here’s the NHTSA report on the recall. It looks like a supplier used a sub-contractor who wasn’t up to the task.

RCLRPT-25V455-7716.pdf

[coupe3w]

Don't worry the next new quality guy will fix this. Where have I heard this before? 

[akirby]

I’ve said it before but you don’t fix quality with a separate team.  You fix it by changing your processes and by making quality a priority for compensation and promotion over cost and schedules.  And you fire people who don’t comply.

 

Suppliers should not be allowed to outsource without approval.  But that also means you can’t squeeze suppliers for that last nickel.

 

CE1 has the potential to fix some of it by having less complicated parts and doing more in house.  Plus they’re already losing money with Blue providing the profits so less pressure to cut costs initially - but that obviously changes over time.
 

 

[coupe3w]

44 minutes ago, akirby said:

I’ve said it before but you don’t fix quality with a separate team.  You fix it by changing your processes and by making quality a priority for compensation and promotion over cost and schedules.  And you fire people who don’t comply.

 

Suppliers should not be allowed to outsource without approval.  But that also means you can’t squeeze suppliers for that last nickel.

 

CE1 has the potential to fix some of it by having less complicated parts and doing more in house.  Plus they’re already losing money with Blue providing the profits so less pressure to cut costs initially - but that obviously changes over time.
 

 

Agree, but they have had plenty of time to fix this and they keep making the same mistakes over and over again. They need some one or team as you say, to really look at what is wrong and fix the root problem(s)

[Bob Rosadini]

If my memory serves me right, didn't Mulally  have weekly meetings with key staff and status of prior meeting issues were reviewed?  "What gets measured gets done" to use a worn out slogan.

Anyone have an opinion of the recall  history during his regime?

 

Also my opinion, the difference when  a guy with operations/engineering roots runs the show vs. a guy who got the job because  he was a marketing "genius".

Human nature IMO, a guy tends to concentrate on his area of expertise..no doubt Mulally and Farley came up via very different paths.

[Bob Rosadini]

48 minutes ago, akirby said:

I’ve said it before but you don’t fix quality with a separate team.  You fix it by changing your processes and by making quality a priority for compensation and promotion over cost and schedules.  And you fire people who don’t comply.

 

Suppliers should not be allowed to outsource without approval.  But that also means you can’t squeeze suppliers for that last nickel.

 

CE1 has the potential to fix some of it by having less complicated parts and doing more in house.  Plus they’re already losing money with Blue providing the profits so less pressure to cut costs initially - but that obviously changes over time.
 

 

Wow..if suppliers were allowed to sub out, that is a huge problem.  I would hope Ford did due diligence when it came to picking a vendor..."what you see should be what you get".  But good procedures costs money..for a supplier to cut corners unknown to Ford, unbelievable IMO.

[tbone]

Another lovely headline, and not from some auto rag…

 

Ford Breaks Annual Record for Safety Recalls Within First Six Months of Year

 

https://www.wsj.com/business/autos/ford-safety-recall-record-df03416d

[AM222]

If there's a standard feature Ford should drop from their vehicle lineup, it's the "guaranteed recall feature".

[coupe3w]

1 hour ago, AM222 said:

If there's a standard feature Ford should drop from their vehicle lineup, it's the "guaranteed recall feature".

They can't do that. It's what people expect from the Blue Oval. It's in their name Fixed Or Repaired Daily

[lfeg]

On 7/12/2025 at 11:28 AM, coupe3w said:

Agree, but they have had plenty of time to fix this and they keep making the same mistakes over and over again. They need some one or team as you say, to really look at what is wrong and fix the root problem(s)

From my experience the problem starts at the top, and the only way to correct it is with top down change (usually requiring a change in corporate culture). Having been on the supplier side, I do not see anything changing soon. Funny story, when Ford was doing a massive press shop modernization, all new hydraulic operated equipment was being installed in one area. There was a panic call just before startup that the hydraulic systems were malfunctioning - turns out the piping was very poorly done. Digging into how this happened, it seems that the contract for the hydraulic piping in that area was awarded to an electrical contractor due to their bid being lowest. And they had no experience in hydraulic piping, but knew how to run rigid conduit, and did a very substandard job. It looks as if this is endemic still.

[Sherminator98]

Another one

 

Ford recalls over 694,000 SUVs in US after year-long fuel leak probe

 

Quote

The recall covers certain 2021–2024 Bronco Sport and 2020–2022 Escape models equipped with 1.5-litre engines. The NHTSA estimates that 0.3% of recalled vehicles may have the defect.

 

"We estimate the aggregate cost of the action, based on the remedy options we are evaluating, to be about $570 million and will be reflected in our second quarter 2025 results," Ford said.

 

Wednesday’s action expands on previous recalls from 2022 and 2024, which provided software updates but did not replace the potentially faulty injectors.

 

The fuel injectors were supplied by Italy-based Dumarey Flowmotion Technologies, according to the recall report.

 

I just checked my Wife's BS and it doesn't seem like is affected by it but it was also a later production 2024

 

 

[coupe3w]

On 7/10/2025 at 8:56 AM, rmc523 said:

Ford Quality: Management Using This Technique To Fix Issues

 

“In the manufacturing lanes, we’re doing Gemba Walks and going to the plants and spending a lot of time at individual stations, making sure that we’re leveraging the best of our plants across the whole Ford ecosystem in each individual plant,” Andrew Frick, president of Ford Blue and Model e, said at the Deutsche Bank Global Auto Industry Conference. “We’ve seen really good progress there. And we’ve spent a lot of time with our supply chain team and our supplier partners. So much of our progress will be done through the supplier partners.”

For those that aren’t aware of what this method is, “Gemba” is a Japanese term meaning “the real place,” or “the place where value is created.” Gemba walks occur when leaders from companies travel to locations where physical work is performed – in this case, places where parts and vehicles are built – to observe that work, better understand it, and identify potential areas of improvement while interacting with employees, rather than simply relying on second-hand information from others.

So they are walking the walk and talking the talk. That gets you nothing!