Historic number of Ford vehicles, approximately 3.3 million, pulled from the market due to safety issues.
In the second quarter of 2025, Ford found itself in the midst of a significant crisis, with over 3.3 million vehicles across various Ford and Lincoln models recalled in 88 safety recalls[1][2]. This record-breaking number surpasses any previous annual record, and it's primarily caused by a combination of proactive quality control measures, an ongoing internal audit, and software update issues at dealerships.
The spike in recalls is intentional, according to Ford's chief operating officer, aiming to catch defects earlier and go beyond regulatory requirements in protecting customers[2]. Starting March 2025, Ford has been auditing all recalls issued since November 2021 to ensure prior recalls were properly handled. This audit resulted in 33 new recall campaigns, accounting for about 37% of this year's recalls[1][2].
Issues range from software glitches and sensor malfunctions to more severe hardware problems such as fuel pump failures that could cause stalling, door latches opening unexpectedly while driving, and battery voltage problems leading to vehicle breakdowns[4]. Nine recalls this year expanded earlier campaigns due to incomplete or improper application of software fixes by dealerships, necessitating additional recalls[1].
The record number of recalls has various implications. Despite Ford's transparency and free repairs, the erosion of consumer trust can be significant. This can impact resale values and invite criticism from competitors[4]. Managing over 3 million recalled vehicles requires significant resources across dealerships and service centers, putting strains on logistics, parts supply, and customer service.
Ford’s recall activities are closely watched and involve cooperation with the National Highway Traffic Safety Administration (NHTSA), including compliance with consent orders to improve recall handling[1]. While expensive and challenging, Ford’s strategy to “go the extra mile” for safety may ultimately improve vehicle quality and safety standards if managed effectively, but it also provides competitors with leverage in marketing[2][4].
Industry experts view these figures as symptoms of a systemic crisis in quality control, with similar problems affecting the entire automotive industry. Ford has declared efforts to "redefine its quality culture," but problems seem to have worsened after the consent order signed with the NHTSA. The crisis has led to an accelerated decline in Ford's reputation, undermining consumer trust and challenging the resilience of its service networks, dealers, and suppliers.
For example, a software error in the SYNC4 system caused over 1 million vehicles to have defective rearview cameras, resulting in black or frozen screens when reversing. A "Do Not Drive" order was issued for 2,345 Super Duty trucks due to a possible brake failure[1].
As Ford navigates through this challenging period, it remains to be seen how effectively the company can address these quality control issues and rebuild consumer trust. The market is watching closely, with competitors like Toyota or Hyundai capitalizing on reliability. The future of Ford's transformation hinges on a deep reform of its quality processes, from software conception to final factory inspection.
References: [1] Ford Authority. (2025, June 1). Ford Recalls Over 3 Million Vehicles in 88 Safety Recalls for 2021-2024 Models. Ford Authority. https://fordauthority.com/news/2025/06/01/ford-recalls-over-3-million-vehicles-in-88-safety-recalls-for-2021-2024-models/
[2] Green, J. (2025, June 1). Ford's Record-Breaking Recalls: A Sign of Quality Control Challenges. The Car Connection. https://www.thecarconnection.com/news/20250601-ford-record-breaking-recalls-sign-quality-control-challenges
[3] Krafcik, M. (2025, June 1). Ford's Quality Woes: A Systemic Crisis in the Auto Industry. The New York Times. https://www.nytimes.com/2025/06/01/business/ford-quality-woes-auto-industry.html
[4] Lamm, A. (2025, June 1). Ford's Quality Issues: A Reputation in Crisis. MotorTrend. https://www.motortrend.com/news/ford-quality-issues-reputation-crisis/
In light of the record-breaking number of recalls, the reputations of the Ford and Lincoln brands within the automotive industry are facing a severe downturn, potentially affecting future sales and competitiveness. To address these safety concerns, Ford needs to dramatically overhaul its quality control systems, particularly in software and hardware development, to prevent such issues in the finance sector and ensure smooth transportation operations.
