Ford expands SUV fire-risk recall advising parked vehicles outside
Ford expands SUV fire-risk recall advising parked vehicles outside
Ford Motor Company has extended its recall efforts to include an additional 4,632 units of its 2020 Ford Expedition and Lincoln Navigator SUVs in the United States due to a potential fire risk. The automaker is urging owners of the affected vehicles to park them outdoors and away from buildings until necessary repairs are completed.
The problem stems from defects in the battery junction box's internal circuit board, which may cause under-hood fires even when the vehicles are parked and powered off. According to documents filed with the National Highway Traffic Safety Administration (NHTSA), the issue arises from insufficient solder mask coverage and minimal conformal coating on certain boards. These shortcomings allow moisture and debris to infiltrate the electrical components, potentially leading to overheating and fire.
Manufacturing Issues During the Pandemic
The affected vehicles were manufactured between November 17 and December 1, 2020. Ford has linked the issue to a period when its supplier relocated production facilities during the early stages of the COVID-19 pandemic. This shift may have contributed to flaws in the coating process, leaving the circuit boards vulnerable to damage.
This latest action builds on a prior recall issued in early 2022, which addressed similar concerns in the 2021 model year versions of the same vehicles. Ford has reported two engine-compartment fires related to this expanded group but noted that no injuries or accidents have been associated with the cases. Some owners had previously observed smoke or a burning smell near the front passenger side of the engine bay.
Record Recall Numbers in 2025
So far in 2025, Ford has issued approximately 115 recalls - a record-setting number that has already surpassed previous annual totals. With three months still remaining in the year, the automaker continues to address safety concerns across its product lineup.
Repair and Notification Plans
Ford dealerships will inspect the recalled vehicles and make necessary repairs to mitigate the risk of overheating. Depending on the type of cooling fan installed, different solutions will be applied. Vehicles equipped with an 800-watt cooling fan will have the ground wire removed from the battery junction box, while those with a 700-watt fan will receive an auxiliary fuse box and jumper wire as preventive measures.
Owners will be officially notified of the recall via mail or through the FordPass app. Additionally, consumers can verify whether their vehicle is affected by checking their Vehicle Identification Number (VIN) on the NHTSA recall database.
This recall highlights Ford’s ongoing commitment to addressing safety issues, even as it grapples with a growing number of recalls this year. For now, affected vehicle owners are urged to follow the company’s advice to park their SUVs outdoors until the necessary repairs are completed.