In November 2023, the Office of Defects Investigation launched a preliminary evaluation following complaints from owners of the 2019 Ford Expeditions regarding the inadvertent deployment of front seatbelt pre-tensioners. Among the 10 identified complaints at the time, one resulted in an injury.
Three months later, the federal watchdog’s investigation prompted Ford Motor Company to issue a safety recall for both the Explorer and its Lincoln counterpart. Approximately 77,574 vehicles, including truck-based SUVs manufactured between 2018 and 2020 at the Kentucky Truck Plant, require inspection.
The suspect vehicles, based on the F-150 pickup truck’s frame, were assembled between October 1, 2018, and June 30, 2019. Ford initiated the investigation into the inadvertent deployment of front seatbelt pre-tensioners in September 2021, following four reports from Middle Eastern markets between July and September of that year.
The front seatbelt retractor pretensioners, supplied by ZF, were found to exhibit corrosion on the squib pins where the bridge wire is welded. Despite the potential for incorrect firing, CAE analysis indicated compliance with regulatory standards.
Ford attributed the corrosion to two primary factors: high moisture content sealed in the squibs and a potential manufacturing issue from the supplier. In December 2023, the manufacturer reviewed a drain seal change implemented at the start of production in 2019.
The absence of a drain seal on the right front floor may elevate humidity levels during extended MAX A/C usage, exacerbating corrosion.
Inadvertent deployment of front seatbelt pre-tensioners can result in locked seatbelts, rendering them unusable by front occupants. As of reporting, Ford is aware of 140 instances of inadvertent deployment, involving 119 vehicles, with six reports indicating injuries. Additionally, five NHTSA vehicle owner questionnaires allege injuries.
Dealers have been instructed to inspect seatbelt retractors for suspect production date codes. Any defective pre-tensioner assemblies will be replaced with units manufactured outside the suspect window. Dealers will also check for the presence of an HVAC drain tube elbow and install one at no cost if absent.
Known owners will receive Ford-branded envelopes between March 4 and March 8, containing recall notifications. Owners of 2018 to 2020 Ford Expeditions and Lincoln Navigators can verify their vehicle’s recall status by entering the 17-character VIN on Ford’s, Lincoln’s, or the NHTSA’s website.
