A few Maverick pickup trucks produced by FoMoCo for the 2024 model year have been subject to a recall due to an increased risk of fire.
This issue stems from a temporary stoppage in the mold shuttle of the fuel tank supplier, Plastic Omnium Clean Energy Systems, leading to misalignment between the mold and extruded sheets. Consequently, an open pitch joint was created, causing a shift in wall thickness between the molds.
Manufactured at Ford’s Hermosillo facility in Mexico, the Maverick shares production space with the Bronco Sport. Before these models, the facility produced the Fusion and Lincoln MKZ sedans.
Ford became aware of the issue on February 6, prompting an immediate halt in the shipment of vehicles with suspect fuel tanks following the discovery of a fuel tank leak in a new Maverick.
Though no field reports of leakage or fire have been reported, Ford estimates that around 217 trucks produced between January 19 and January 26, 2024, may be affected.
Owners will be notified between March 18 and March 22, and dealers have been instructed to replace the fuel tanks with properly manufactured assemblies. Owners can verify if their vehicles are included in the recall by checking their VIN on the NHTSA’s recall portal.
Despite this setback, the Maverick remains the most affordable new truck in the United States, with impressive sales figures in 2023. However, changes in the 2024 model year, including the shift from the standard 2.5-liter hybrid to an optional feature, mark a notable shift in the lineup.
