Ford Issues Second Recall for 20,000 PHEVs: Fire Risk Persists, No Fix in Sight

Ford is back in trouble with its plug-in hybrids. The company has announced a second large-scale recall involving the Ford Escape PHEV and Lincoln Corsair PHEV — more than 20,000 vehicles in the United States may catch fire due to a defect in their high-voltage batteries. What’s most alarming is that, just like a year ago, the automaker still has no permanent fix.

The risk stems from an internal short circuit inside Samsung SDI battery cells produced in Hungary. Even the updated battery-control software installed after the first recall isn’t capable of detecting every faulty module. Europe has already reported seven fires involving the Kuga PHEV, even in vehicles that received the original “repair.”

In the new recall campaign, Ford admits it still hasn’t pinpointed the root cause. Engineers suspect damage to the thin separator between the cathode and anode — a flaw likely tied to instability on the production line. While the investigation continues, owners are being told to limit how they use their vehicles.

Drivers are advised to charge the battery only partially, avoid topping it off, and operate the vehicle strictly in Auto EV mode. The crossover’s brakes, drivetrain and lights continue to function normally, but if the battery’s protection system trips, the vehicle immediately loses propulsion.

Ford says a long-term solution will be developed, but for now, there’s no timeline.