Ford S-MAX recalls

Affected vehicles may experience a loss of emergency call system (eCall) functionality which impacts both automatic and manual eCall events.

Fix: Update the Telematics Control Unit software to the latest level.

67 vehicles · built 20 Nov 2020 to 27 Mar 2023

Certain Kuga S-Max and Galaxy vehicles equipped with a 2.5L HEV/PHEV Engine may not have the remedy for Safety Recall 23S27 installed correctly but were recorded as having received the repair successfully. Because the correct software update may not have been installed on these vehicles the underlying condition specified in Safety Recall 23S27 potential under hood fire may still exist.

Fix: Dealers are to update the Powertrain Control Module (PCM) software.

• S-MAX: 14 vehicles · built 24 Nov 2021 to 2 Nov 2022
• S-MAX: 7 vehicles · built 2 Dec 2021 to 26 Jan 2022

Affected vehicles may develop a crack in the Diesel Particulate Filter (DPF).

Fix: Update software to prevent a cracked DPF. Test and replace DPFs that are already cracked.

• S-MAX: 561 vehicles · built 15 Jun 2018 to 16 Jan 2019
• S-MAX: 757 vehicles · built 5 Nov 2018 to 15 Mar 2019
• S-MAX: 218 vehicles · built 20 Mar 2019 to 4 Jun 2019
• S-MAX: 608 vehicles · built 3 Jun 2019 to 18 Sep 2019
• S-MAX: 559 vehicles · built 5 Sep 2019 to 14 Jan 2020
• S-MAX: 805 vehicles · built 15 Jan 2020 to 6 Oct 2020
• S-MAX: 651 vehicles · built 17 Sep 2020 to 26 Jan 2021
• S-MAX: 48 vehicles · built 21 Jul 2020 to 16 Mar 2021
• S-MAX: 171 vehicles · built 20 Jan 2021 to 26 May 2021
• S-MAX: 16 vehicles · built 28 May 2021 to 28 Jul 2021
• S-MAX: 16 vehicles · built 30 Nov 2021 to 5 Apr 2022
• S-MAX: 232 vehicles · built 26 May 2022 to 21 Sep 2022

On affected vehicles there is the possibility of the front brake hoses leaking.

Fix: Replace both front brake hoses and modify the hose routing and ride height sensor if necessary.

• S-MAX: 7,482 vehicles · built 19 May 2015 to 3 Oct 2018
• S-MAX: 28 vehicles · built 4 Dec 2014 to 10 Aug 2018

Engine failure that may lead to a breach of the engine oil sump or engine block

Fix: Software update

• S-MAX/GALAXY: 424 vehicles · built 6 May 2022 to 19 Dec 2022
• KUGA: 26 vehicles · built 31 Jul 2019 to 16 Mar 2021
• S-MAX/GALAXY: vehicle count not given · built 17 Mar 2021 to 19 Dec 2022
• S-MAX/GALAXY: 4 vehicles · built 17 Mar 2021 to 26 Mar 2021
• S-MAX/GALAXY: 13 vehicles · built 2 Jun 2021 to 6 Sep 2021
• S-MAX/GALAXY: 385 vehicles · built 22 Oct 2021 to 6 Apr 2021
• S-MAX/GALAXY: 665 vehicles · built 6 May 2022 to 23 Dec 2022
• KUGA: 3,456 vehicles · built 8 Jan 2020 to 22 Jul 2020
• KUGA: 1,989 vehicles · built 5 Jun 2020 to 22 Dec 2020
• KUGA: 890 vehicles · built 1 Dec 2020 to 18 Oct 2022
• KUGA: 1,161 vehicles · built 8 Mar 2021 to 17 Jun 2021
• KUGA: 1,879 vehicles · built 1 Jun 2021 to 21 Oct 2021
• KUGA: 787 vehicles · built 10 Sep 2021 to 29 Oct 2021
• KUGA: 2,944 vehicles · built 20 Sep 2021 to 16 Feb 2022
• KUGA: 582 vehicles · built 27 Jan 2022 to 31 Mar 2022
• KUGA: 2,591 vehicles · built 28 Feb 2022 to 31 May 2022
• KUGA: 6,606 vehicles · built 10 May 2022 to 26 Oct 2022
• KUGA: 1,851 vehicles · built 4 Oct 2022 to 16 Dec 2022
• S-MAX/GALAXY: 8 vehicles · built 17 Mar 2021 to 31 Mar 2021
• S-MAX/GALAXY: 23 vehicles · built 1 Jul 2021 to 2 Sep 2021
• S-MAX/GALAXY: 97 vehicles · built 22 Oct 2021 to 5 Apr 2022
• KUGA: vehicle count not given · built 8 Jan 2020 to 16 Dec 2022

It may be possible that the eCall feature will stop functioning due to a malfunction.

Fix: The Telecommunication Module will need to be replaced

9,388 vehicles · built 11 May 2022 to 29 Jul 2022

Vehicles fitted with Adaptive Headlamps will not display a warning message should a failure of the module that controls the Adaptive Headlamps occur.

Fix: Update the Instrument Panel Cluster (IPC) software.

2,260 vehicles · built 9 Nov 2018 to 25 Apr 2022

The Rear Suspension Toe Link bolt is exposed to corrosion growth which over time leads to reduced material and load capacity and finally to a breakage of the bolt.

Fix: Replace the bolt utilising an alternative bolt supplier and update all affected vehicles.

39,441 vehicles · built 20 Jan 2015 to 18 Feb 2020

Drivers airbag may not deploy correctly

Fix: Replace Driver air bag assembly

219,738 vehicles · built 5 Jan 2006 to 28 Feb 2017

Possible thermal incident within the battery monitor sensor wiring

Fix: Install a fused jumper loom into the battery monitor sensor wiring

56,154 vehicles · built 13 Feb 2014 to 11 Feb 2019

localized overheating of the engine cylinder head may cause the cylinder head to crack.This may cause a pressurized oil leak which in extreme circumstances could result in a fire in the engine compartment.

Fix: A coolant level sensor needs to be fitted to provide an audible and visual warning to the customer and in extreme circumstances reduce the engine power.

4,026 vehicles · built 2 Jun 2010 to 20 Dec 2014

A number of vehicles fitted with a 1.0 1.5 or 1.6 Ecoboost engine and 6-speed manual transmission could suffer clutch pressure plate fracture. This results in clutch smell reduced vehicle speed and performance. In the unlikely event of clutch pressure plate fracture a noise (thud / bang) could be heard from the vicinity of the transmission in extreme cases resulting in clutch / transmission fragments being released and striking under hood components creating a risk of smoke and fire from the under hood area.

Fix: To prevent the repeated heating /cooling events a new calibration has been developed for vehicles fitted with Engine Stop Start feature. The software with the additional feature sets the Instrument panel �Wrench light� and de-rates the engine performance if prolonged clutch slip is detected. The software feature includes a drive cycle strategy for latching the wrench light and engine performance de-rate if the customer should experience repeated clutch slip events. For vehicles that do not have Engine Stop Start feature an alternative clutch kit has been released.

66,497 vehicles · built 7 Jul 2016 to 18 Apr 2018

A/C Compressor pulley may become detached.

Fix: On affected vehicles fit a new A/C compressor clutch pulley.

3,021 vehicles · built 1 Sep 2014 to 20 Apr 2018

Affected vehicles fitted with a 1.0 1.5 or 1.6 Ecoboost engine and 6-speed manual transmission could suffer clutch pressure plate fracture. This results in clutch smell reduced vehicle speed and performance. In the unlikely event of clutch pressure plate fracture a noise (thud / bang) could be heard from the vicinity of the transmission in extreme cases resulting in clutch / transmission fragments being released and striking under hood components creating a risk of smoke and fire from the under hood area.

Fix: To prevent the repeated heating /cooling events a new calibration has been developed for vehicles fitted with Engine Stop Start feature. The software with the additional feature sets the Instrument panel �Wrench light� and de-rates the engine performance if prolonged clutch slip is detected. The software feature includes a drive cycle strategy for latching the wrench light and engine performance de-rate if the customer should experience repeated clutch slip events. For vehicles that do not have Engine Stop Start feature an alternative clutch kit has been released.

• S-MAX: 122,199 vehicles · built 1 Aug 2009 to 31 Dec 2014
• S-MAX: 122,199 vehicles · built 1 Aug 2013 to 30 Jun 2016

The engine control module calibration may not adequately detect an overheat condition in certain 2.0L Duratorq Diesel engines. In extreme cases an overheated engine can result in a breach of the oil sump leading to loss of the engine oil.

Fix: Recall the vehicles that are likely to be affected and download revised software for the control module calibration that improves overheat detection and provides an instrument cluster warning indicator to the driver and engine de-rate strategy.

48,595 vehicles · built 25 May 2015 to 19 Oct 2015

Vehicles fitted with Adaptive LED Headlamps could experience a condition where the loss of a control signal in combination with a software error may cause the headlamps to switch off. There is a risk of collision if defect happens at night.

Fix: Recall the vehicles that are likely to be affected and updated software will be loaded to the affected modules.

9,705 vehicles · built 6 Oct 2014 to 8 Feb 2016

It is possible that a leak can occur between the injector spill rail connection and the plastic fuel return pipe. This can cause leakage of fuel which can either pool on the engine cylinder head and then become deposited onto the road surface where it could cause a skid risk to other motorist or if the fuel comes into contact with extremely hot engine components an exhaust manifold for instance it is possible that an under bonnet fire could ensue.

Fix: Recall all affected vehicles inspect the fuel spill rail/return pipe and if required replace the spill rail with a new modified rail.

1,985 vehicles · built 12 Jan 2012 to 11 Feb 2013

It has been identified that a small number of vehicles built with a panoramic glass roof may not have been bonded correctly. This could ultimately result in detachment of the panoramic glass roof.

Fix: Recall all affected vehicles and check the adhesion of the roof. If found to be defective the roof will be removed and re-bonded.

7 vehicles

During engine warm up it is possible that the non return valve within the vacuum pump may stick. It is possible that if sufficient brake applications are made before the valve releases the vacuum stored within the brake booster will be used up and a hard brake pedal and longer stopping distances may result.

Fix: Recall the vehicles that are likely to be affected to fit a revised design of non return valve to the brake vacuum pump.

13,029 vehicles · built 1 Nov 2008 to 12 Mar 2009

It has been identified that the panoramic glass roof panel may not have been correctly bonded to the vehicle. Should this be the case the roof panel could detach.

Fix: Recalled vehicles will have the panoramic glass roof panel renewed.

9 vehicles · built 27 Sep 2006 to 5 Oct 2006

Hard brake pedal may occur in low ambient temperatures which is caused by a non return valve in the vacuum pump sticking.

Fix: Recall the vehicles that are likely to be affected to fit a revised non return valve to the brake vacuum pump.

17,972 vehicles · built 2 Nov 2005 to 30 Dec 2006

It has been identified that on subject vehicles the heated windscreen earthing point may not have been tightened to the specified torque. An incorrect torque may lead to electrical arcing and in extreme cases this arcing may cause scorching or burning of the surrounding trim components.

Fix: Recalled vehicles will have the subject earthing point inspected for correct installation and torque.

5,153 vehicles · built 1 Dec 2005 to 28 Jun 2006

It has been identified that the fuel pipe connector between the engine fuel line and fuel tank may not be totalled secured. This may result in a disconnection of the fuel line with the possibility of engine cut out and loss of fuel onto the road surface. Whilst the vehicle is in the dealership the opportunity will be taken to carry out a slight modification to the alternator to prevent the possibility of a short circuit occurring with other components.

Fix: Recalled vehicles will have the integrity of the fuel line connector checked. Additionally the alternator cable will be modified by removing a portion of sleeving that may be in contact with the end eyelet.

209 vehicles · built 1 Feb 2006 to 11 Jun 2006