Dive Brief:
- Ford Motor Co. has recalled up to 240,510 model year 2020-2021 Explorer SUV and Lincoln Aviator models for improperly secured front seat belt buckle anchor bolts and second row seat retractor bolts, which may not properly restrain an occupant in a crash, according to the National Highway Traffic Safety Administration.
- Ford discovered the problem on Nov. 5, 2024, after Transport Canada contacted the company following a customer complaint alleging the presence of a loose or uninstalled second-row center seat belt anchor bolt on a 2020 model year Explorer.
- Owners are being notified to schedule a service appointment at a dealer for an inspection of the affected components, which Ford will replace at no cost. Notification letters are expected to be mailed March 31.
Dive Insight:
Ford conducted a review of the vehicle’s assembly and warranty history to trace the cause of the loose bolts. However, the investigators found no instances in which the vehicle’s seat belt anchor bolts may have been removed and reinstalled, according to the NHTSA report. Ford’s investigation expanded to include Indiana-based Tier-1 supplier Lear, the manufacturer of the seats.
Ford’s Critical Concern Review Group subsequently opened a broader investigation into the issue on Dec. 10, 2024, including visiting the manufacturing facility the supplier.
Throughout December and January, Ford’s investigators reviewed manufacturing records and interviewed employees to better understand the plant’s operations.
Ford concluded that undocumented rework of the seats was performed which was “outside of standard operating procedures,” according to the NHTSA report. Ford investigators also discovered that the supplier’s production data showed no documented rework history of the seat assemblies. Lear did not respond to requests for comment from Automotive Dive about the recall.
The automaker’s investigators believe that this undocumented rework may have resulted in seat belt anchor bolts not being properly secured, according to the report. Customers may also experience squeaks or rattles in vehicles with improperly secured anchor bolts.
Through its investigation, Ford also identified four additional warranty claims as of Feb. 4 related to loose or missing seat belt anchor bolts on vehicles. The seats were manufactured by Lear between June 2019 and June 2020. In all of these incidents, Lear’s production data showed no rework history of the seat assemblies, according to the NHTSA.
Based on these findings, Ford’s Field Review Committee approved a field service action on Feb. 7 to recall the vehicles to inspect for loose seat belt buckle bolts in all seating positions. Ford and Lincoln dealers will replace any seat belt components on the recalled vehicles if needed.
To date, Ford is not aware of any injuries related to the issue.
Ford has issued 10 recalls since Jan. 1, which potentially extends to over 759,000 vehicles, according to the NHTSA.
In January, Ford recalled over 149,000 2021-2024 Bronco SUV models for rear shocks that could corrode and fail, causing them to detach from the external reservoir. Also last month, Ford issued a recall that potentially extends to 272,817 vehicles for 12-volt battery failures, including some 2021-2023 Bronco models and 2023 Maverick pickups.
