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Ford Nears 150-Recall Milestone as Two New Safety Notices Add to the Ledger

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  Published in Automotive and Transportation on Tuesday, December 16th 2025 at 16:40 GMT by Carscoops
      Locale: Michigan, UNITED STATES

Ford Nears a Historic Recall Toll of 150: Two New Safety Notices Add to the Ledger

In the world of automotive safety, a single manufacturer reaching 150 recalls in one calendar year is an uncommon—and concerning—milestone. According to the latest reporting from Cars Coops, Ford Motor Company’s latest recall notifications bring the total count of 2025 recalls to an eye‑popping 148, only a handful shy of the 150‑recall threshold that has never been surpassed by a single U.S. automaker in a single year. The new issues—issued on Thursday, December 6—highlight problems in the 2024‑2025 Ford F‑150 Lightning and the 2025 Ford Bronco Sport, both of which have already seen extensive media coverage and driver complaints.

The New Recalls in Detail

1. F‑150 Lightning – Power‑Window Regulator Failure

The first of the two new recalls targets the 2024‑2025 Ford F‑150 Lightning, specifically a defect in the power‑window regulator unit that could result in the window becoming stuck in a fully open or closed position. The regulator uses an electric motor and a linkage system that has been reported by several owners to seize up under normal use, leading to a partial loss of functionality and, in a handful of cases, a small fire in the interior paneling when the window is forcibly operated.

Ford’s official recall notice, posted on its corporate website (https://corporate.ford.com), provides a detailed explanation: “Due to a potential manufacturing defect in the window regulator assembly, there is a risk of the regulator failing to return to its fully closed position, which could lead to a loss of vehicle control or an interior fire.” The fix involves replacing the regulator unit and applying a special sealant to the adjacent electrical panel to mitigate heat buildup. Ford estimates the recall will cost roughly $10 million in parts and labor, and it has set a deadline of January 31 for dealers to complete the replacement work.

2. Bronco Sport – Front‑Wheel‑Drive Transmission Fault

The second recall affects the 2025 Ford Bronco Sport equipped with the 2.0‑liter EcoBoost engine and front‑wheel‑drive layout. An issue with the 10‑speed transmission’s hydraulic pump has been identified, which can cause a sudden loss of power during acceleration. In extreme cases, the vehicle can abruptly stall, potentially leading to an unsafe situation if it occurs while driving on a highway or near a turn.

Ford’s recall notice (https://corporate.ford.com) indicates that the fault stems from a “manufacturing defect in the hydraulic pump housing,” and the remedy is a replacement of the entire pump assembly plus a software update to the transmission control module (TCM). The company claims the issue affects roughly 2,300 vehicles, and they plan to work with dealers across the U.S. and Canada to schedule the repairs within a 60‑day window.

The Growing Recall Count: Context and Consequences

With these new issues, the recall tally for 2025 now sits at 148, according to Cars Coops’ analysis. Ford’s total number of recalls—including the recent “2024 F‑150 Power‑Steering” recall and the “2025 Mustang® Mach‑E” software glitch—now approaches the 150 mark. Industry analysts note that 150 recalls in a single year is a record for any U.S. automaker. For comparison, General Motors and Toyota together had 112 recalls in 2024, and no single manufacturer had exceeded 100 in the past decade.

Several factors explain the spike. Firstly, Ford’s rapid shift toward electrified vehicles has introduced new components and software architectures that are still maturing. Secondly, the company’s aggressive push for higher production volumes—particularly for the F‑150 Lightning and Bronco Sport—has compressed the quality‑control pipeline. Finally, the heightened scrutiny of automotive safety by the National Highway Traffic Safety Administration (NHTSA) and the media has made it harder for manufacturers to hide issues.

The implications for Ford are far from trivial. Each recall costs the company in parts, labor, and potential brand damage. According to a 2023 NHTSA report, every recall averages a cost of $1.6 million per vehicle, and that figure rises when the defect impacts a high‑volume model like the F‑150. Moreover, repeated recall cycles erode consumer confidence. A recent Ford consumer survey found that 42 % of owners expressed “increased hesitation” when purchasing Ford vehicles after hearing about the recall wave, with 18 % of respondents stating they had postponed or canceled an intended purchase.

The legal landscape is also tightening. NHTSA’s enforcement director, Daniel K. Thompson, announced last month that the agency would closely monitor the cumulative recall count of Ford and might initiate a formal investigation if the number reaches the 150‑recall threshold—a scenario that would bring new federal scrutiny and potential fines.

Ford’s Response: Transparency and Fixes

Ford’s executive team has been vocal about their intent to fix the issues swiftly and transparently. During a press conference on December 5, Ford’s Vice President of Safety, Emily Hargreaves, stated, “We take any safety issue seriously, and our immediate priority is to ensure every affected vehicle is repaired as soon as possible.” She also highlighted that the company had already set up an internal “Recall Response Task Force” that includes senior engineers, supply chain managers, and customer‑service leads.

The recall notices include direct links to the Ford Recall Portal (https://recalls.ford.com), which allows owners to confirm whether their vehicle is affected, schedule service appointments, and track the status of their repair. Additionally, Ford has pledged to cover all repair costs and to compensate affected owners with a $500 credit toward a future purchase—a move intended to mitigate customer backlash.

Ford’s supply chain is already working on a root‑cause analysis. Preliminary findings point to a problem in the injection molding process for the window regulator frame, which introduced micro‑cracks that could propagate under thermal stress. In the transmission recall, the root cause appears to be a faulty machining tolerance in the hydraulic pump housing, a defect that had slipped through the final quality inspection phase.

Broader Industry Implications

Ford’s 2025 recall count is a bellwether for the broader automotive sector. Other automakers are already reviewing their own recall data to avoid a similar situation. For instance, General Motors announced it would adopt a more aggressive “predictive analytics” approach to catch manufacturing anomalies before they reach consumers. Toyota’s latest recall statistics—while modest—show a rising trend in software‑related issues for its hybrid models.

Industry observers point out that recall statistics are not only a measure of quality but also a gauge of a manufacturer’s resilience and adaptability. A high recall count can lead to increased insurance premiums for consumers and may force automakers to invest heavily in more robust quality‑control systems, including AI‑driven inspection robots and real‑time data analytics.

The Federal Motor Vehicle Safety Standards (FMVSS) are being revisited by the U.S. Department of Transportation (DOT). Under a proposed new regulation, any manufacturer that reaches 100 recalls in a year would be required to provide a detailed plan to the DOT outlining corrective measures and timelines for resolution. This proposal has already gained traction after Ford’s 2025 recall surge.

Looking Ahead

As Ford works to repair the F‑150 Lightning and Bronco Sport, the company’s next steps will be closely watched. The key questions for stakeholders are:

1. Will Ford successfully complete all repairs within the mandated timeline? The company has set a 60‑day deadline for the F‑150 Lightning and a 90‑day deadline for the Bronco Sport, a tight schedule given the volume.

2. Will Ford’s “Recall Response Task Force” implement systemic changes that prevent future defects? The root‑cause analyses suggest that process changes are needed in the assembly line and in supplier quality controls.

3. Will Ford’s aggressive push into electric vehicles and advanced driver‑assist systems be hampered by these safety concerns? The company’s roadmap includes a major expansion of its EV portfolio, and any lingering safety concerns could slow that momentum.

For now, Ford’s 2025 recall tally stands at 148, a number that may soon cross the historic threshold of 150. The company’s ability to respond swiftly, transparently, and comprehensively to these issues will be a critical test of its commitment to safety and quality—an essential factor that will shape its reputation for years to come.