2021 Escape Hybrid - Engine Damage Could Result In Stall And Fire
Ford Motor Company (Ford) will be contacting the owners of certain 2021 Escape Hybrid vehicles because the engine crankshaft may have been manufactured incorrectly and could result in engine damage.
A small number of 2021 Ford Escape Hybrid vehicles may have an engine crankshaft that was manufactured out of specification. An investigation was opened into the problem in February 2022 after Ford's engine plant contacted Ford's Critical Concern Review Group about a potential problem involving 2.5L Escape engine failures. The investigation revealed that between February 22 and February 23, 2021, twenty-five crankshafts with potentially out-of-specification surface finishes on the crankshaft connecting rod were shipped to the engine assembly plant. Plant records indicate the crankshafts could have been installed in two hundred suspect engines.
A search of Ford’s warranty database identified 15 warranty claims, including 8 claims in the U.S., for engine replacement including one report of an engine stall while driving because of a connecting rod bearing failure on a 2021 model year Escape HEV vehicle with a 2.5L engine.
According to the defect report, vehicles included in this action were built with an engine crankshaft that may not meet the surface specification due to a missing polishing operation. Improper surface finish can cause excessive friction and heat, resulting in premature bearing wear and engine noise. If the vehicle is driven in this condition, it will lead to bearing failure that may result in an engine stall, or broken connecting rod and potential engine breach, significant engine oil loss, and fire increasing the risk of crash and injury.
Dealers will inspect the crankshaft and replace the engine, as necessary. Interim letters notifying owners of the safety risk are expected to be mailed on March 2, 2022. Second letters will be sent once the remedy is available. Ford's number for this recall is 22S10 and the NHTSA campaign number is 22V-109.