Dive Brief:
- Ford Motor Co. has recalled nearly 109,000 Escape SUVs for loose rear liftgate hinge covers, which can detach while driving, creating a road hazard that can increase the risk of a crash, according to the National Highway Traffic Safety Administration.
- The recalled models include certain 2020-2022 and 2025 model year Escapes equipped with an optional panoramic glass roof. Around 6% of the recalled models are estimated to have the defect.
- Dealers will inspect and reinstall or replace any loose or missing liftgate hinge covers as needed for free. Interim owner notification letters are expected to be mailed starting Jan. 15, 2026. A second letter will be sent once a final remedy is made available.
Dive Insight:
Ford was alerted to the potential safety issue after its Critical Concern Review Group first investigated the concern in July 2021. At the time, its investigators concluded that the loose liftgate hinge covers did not pose an “unreasonable risk” to motor vehicle safety if the parts fell onto the roadway due to their small size and light weight. But the automaker noted in its recall notification to dealers that customers may experience wind or rattling noise while driving.
Ford chose not to issue a safety recall at the time because only a small number of vehicles were affected and the issue would not affect normal vehicle operation. The plastic hinge covers, which were manufactured by Ford, are located on the top roof near the rear liftgate on the Escape models.
However, in May of this year, Ford’s Field Review Committee approved a separate recall for 492,000, model year 2016-2017 Explorer SUVs for detached B-pillar trim. It led to Ford’s body exterior team to conduct a read-across to identify potential trim detachment risks on other Ford and Lincoln vehicles from model year 2010 and upward.
This investigation identified additional warranty claims for liftgate hinge cover detachment on Escape vehicles, leading Ford to reassess the risk factors of road hazard safety recalls. As a result, the automakers Critical Concern Review Group opened a new investigation on July 22.
Ford’s investigators conducted an extensive review of warranty data to determine the number of Escape models with potentially loose liftgate hinge covers. It included a review of detachment rates, vehicle production dates, part design and installation process changes over the course of Escape production.
Although no relevant part design changes were identified by Ford, its teams identified “multiple supplier quality items” and “manufacturing process changes” at the automaker’s Louisville Assembly Plant where the recalled Escapes were built, according to the report.
On Nov. 21, the automaker chose to issue a recall based on its understanding of the potential causes of hinge cover detachments on the affected Escape models.
As of that date, Ford said it is aware of 1,835 warranty claims for the issue received between Nov. 16, 2019, and August 25, 2025, but is not aware of any accidents or injuries.
Ford has now issued over 140 recalls in 2025, according to NHTSA data, the highest number in a single year by any automaker.
The company issued a recall last month for nearly 230,000 Bronco and Bronco Sport SUVs for a software error that may cause the instrument panel cluster (IPC) to be blank upon startup. It followed an October recall of over 1.4 million vehicles for rearview camera display issues, including distorted images and blank screens.
But Ford has been working on improving quality, including at its Kentucky Truck Plant which produces F-Series trucks and the full-size Expedition.
Beginning with the 2026 Expedition, Ford added 1,200 inspections, 203 new inspectors, 72 new technology tests and six times the number of AI-powered inspection tools compared to last year’s model launch.
The automaker also implemented a new Mobile Artificial Intelligence Vision System across 27 of its global plants to spot defects. The system uses AI, machine learning and computer vision technology to help workers identify vehicle quality issues in real-time.
