Tag Archives: manufacturing error

Crankshaft Position Sensor Failure

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Fiat Chrysler Automobiles (FCA) has recently taken action to address a potential problem that may affect certain 2014-2019 Ram 1500 trucks and 2014-2020 Jeep Grand Cherokee SUVs. The issue involves an unexpected engine stall, which could pose a safety risks to vehicle owners.

In May 2023, the FCA Technical Safety and Regulatory Compliance (TSRC) organization initiated an investigation into certain models manufactured between 2014 and 2019 for Ram 1500 trucks and between 2014 and 2020 for Jeep Grand Cherokee SUVs. The focus of the investigation was on vehicles equipped with 3.0L Diesel engines. It was discovered that these particular vehicles had a tone reluctor wheel with an insufficient bond between the magnetic coating and the tone wheel body. Upon analyzing the stall patterns and reviewing vehicle history, it was determined that the affected vehicles were those manufactured with Gen II 3.0L diesel engines, and the crankshaft tone wheel was identified as the source of the stalls.

According to the defect report, the magnetic material attached to the reluctor wheel provides a crucial signal to the crankshaft position sensor. When this signal is lost, the engine’s ability to synchronize injector pulses and cam timing is compromised. Consequently, the loss of the crankshaft position can lead to an engine stall, leaving the vehicle unable to restart.

To address this issue, FCA will be updating the powertrain control module software to ensure that vehicle propulsion is maintained even in the event of a lost crankshaft position signal. By reading the camshaft position signal, the updated software will mitigate the risk of engine stalls.

As part of the recall process, FCA has assigned the number 66A to this specific recall, while the NHTSA campaign number is 23V-411. It is important to note that this recall represents an expansion of a previous recall, namely recall 20V-475.

FCA US will be contacting vehicle owners to ensure that they are informed about the issue and the necessary steps to resolve it. The company is aware of 10 customer assistance records, 611 warranty claims, and three field reports that may be associated with this particular issue.

2023 Hyundai Palisade Loss of Brake Assist

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Hyundai Motor Company (HMC) has recently taken steps to address a potential issue with certain 2023 Hyundai Palisade vehicles, which may affect their brakes. The company has initiated a recall and will be reaching out to the owners of these specific models to address the problem.

The concern revolves around the brake booster diaphragm, which has the potential to become misaligned. This misalignment can lead to an internal vacuum leak, resulting in a loss of power brake assist. Hyundai became aware of this issue during the assembly of certain 2023 Hyundai Palisade vehicles produced between April 28, 2023, and May 5, 2023.

These particular vehicles were equipped with brake boosters that contained diaphragms prone to becoming unseated. The cause of this problem was traced back to improperly manufactured assembly housings from one of Hyundai’s suppliers. Upon further investigation, by the end of May, Hyundai Motor America (HMA) identified several affected vehicles from the production range that were not retained at the port.

In light of this information, the North America Safety Decision Authority (NASDA) of the National Automotive Safety Organization (NASO) promptly convened to discuss the situation. After careful evaluation, NASDA made the decision to initiate a safety recall in order to address all potentially affected 2023 Hyundai Palisade vehicles sold in the United States.

Owners of the affected vehicles will receive official notices from Hyundai, instructing them to return to their authorized dealers for further assistance. Upon visiting the dealership, the brake booster of each vehicle will be thoroughly inspected, and if necessary, replaced to rectify the issue. Hyundai has assigned the recall number 245 to this particular action, and the National Highway Traffic Safety Administration (NHTSA) has designated it as campaign number 23V-415.

Ensuring the safety and satisfaction of its customers is of utmost importance to Hyundai, and the company is taking action to address this brake-related concern in a comprehensive and timely manner. By promptly contacting affected vehicle owners, conducting thorough inspections, and making any necessary repairs or replacements, Hyundai aims to resolve the issue and provide peace of mind to its customers.

2023 Nissan Leaf EV Brake Line Damage

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Nissan has determined that certain 2023 model year Nissan Leaf EVs may have a damaged right hand brake tube that could result in a brake fluid leak.

Nissan first became aware of the potential problem in January 2023 when a Nissan technician noticed a 2023 Nissan Leaf EV being assembled with a damaged right hand brake tube assembly. Nissan collected the affected parts and began an investigation. The investigation included a parts audit of 975 brake assemblies which revealed twenty-five (25) damaged right hand brake tubes at the actuator connection bend. Nissan also conducted a yard audit of 395 vehicles and found five (5) with a scratched or damaged right hand brake tube. These parts were quarantined and the vehicles were put on a quality hold.

According to the defect report, an investigation with the supplier determined that the incorrect tooling was used to align the brake tube into the pipe bending jig. Because the brake tube was misaligned, the tooling clamped the pipe in the incorrect position and caused scratching, and in some cases deformation of the tube, at the actuator bend.

Nissan performed corrosion and stress tests on two (2) of the worst case condition parts to evaluate the effect of the damaged brake tube on brake performance over time. Nissan concluded that the brake performance could be degraded and could lead to extended stopping distances possibly without prior warning. Nissan decided to conduct a Voluntary Safety Recall to recall all potentially affected LEAF vehicles to inspect the right-hand brake tube and replace any damaged brake tube assemblies.

Owners receiving notices will be asked to return to their dealers to have the right-hand brake tube inspected for damage. If damage is found, the affected brake tube will be replaced. Nissan’s number for this recall is PC976 and the NHTSA campaign number is 23V-362.

Stall From Unsecured Fuse Inside High Voltage Battery

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Addressing the Issue of Unsecured Fuses and Steps to Take if Your Vehicle is Affected

Jeep Wrangler Plug-In Hybrid Electric vehicles (PHEV) have gained popularity for their eco-friendly features and impressive performance. However, recent reports have surfaced regarding a potential safety concern that could affect certain 2022-2023 models. The FCA Technical Safety and Regulatory Compliance (TSRC) organization has identified an issue with an unsecured fuse inside the high voltage battery, which may result in an unexpected loss of drive power.

Discovery of the Issue:
In February 2023, the FCA TSRC organization received its first report of a fuse melting in the HV battery of a 2022 Jeep Wrangler PHEV, drawing immediate attention to the matter. A subsequent incident involving another 2022 Jeep Wrangler PHEV with the same problem prompted the initiation of a comprehensive investigation.

Root Cause and Potential Impact:
The investigation revealed that an incorrect fastener used during vehicle production could increase resistance and generate excess heat at the 200 amp fuse interface. The prolonged exposure to high temperatures could cause the fuse to fail, leading to a loss of motive power. Drivers experiencing this issue might notice a Malfunction Indicator Lamp (MIL) illuminated, changes in drivability, and/or noise originating from the HV battery pack assembly.

Suspect Period and Population:
The suspect period for this issue spans from January 10, 2022, when the incorrect fasteners were introduced, to September 20, 2022, when the use of incorrect fasteners ceased. The identification of the suspect population was determined through careful examination of vehicle and supplier manufacturing records.

Recall and Resolution:
To address this safety concern, Jeep has issued a recall, known as recall number 53A by Chrysler and NHTSA campaign number 23V-303. Owners of affected vehicles will receive notifications instructing them to visit their authorized dealerships. At the dealership, the battery fuse will be inspected, and if necessary, replaced to ensure proper functionality. Additionally, the battery assembly will undergo inspection for signs of charring or discoloration on the bus bars, and if required, will be replaced as part of the resolution process. It is crucial to respond promptly to recall notifications and schedule an appointment with your dealership.

Taking Action if You Suspect Your Vehicle is Affected:
If you believe your Jeep Wrangler PHEV falls within the suspect population or are experiencing any symptoms associated with this issue, it is essential to take the appropriate steps. Firstly, check if you have received a recall notification from Jeep. The notice will provide instructions on how to proceed and schedule an appointment with an authorized dealership. If you have not received a notification but suspect your vehicle may be affected, you can directly contact your local dealership to inquire about the recall and share your concerns.

Conclusion:
The discovery of an unsecured fuse issue affecting certain 2022-2023 Jeep Wrangler Plug-In Hybrid Electric vehicles is a matter of utmost importance. If you suspect that your vehicle is part of the affected population or are experiencing any relevant symptoms, it is crucial to act swiftly by following the instructions provided in the recall notification or reaching out to your local dealership.

2020-2023 Jeep Wrangler Fuel Leak

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Some 2020-2023 model-year Jeep Wrangler vehicles may have been built with an unnecessary and unused frame stud that could puncture the fuel tank, potentially starting a fire. The suspect period began in October 2019, when frames with the extra frame stud were introduced into vehicle production, and ended on May 14, 2022, when frames with the frame stud were no longer used. The frames involved are Mopar Frame Assembly’s and the NHTSA Campaign Number is 23E-023.

The FCA Technical Safety and Regulatory Compliance (TSRC) opened an investigation into the problem as a result of an assembly plant report of some frames containing an extra frame stud. FCA reviewed supplier data, met with engineering to understand the frame design and change history, and review frame and vehicle measurement data. Although there have been no warranty claims or field reports related to the problem, the FCA TSRC have decided to conduct a recall on all affected vehicles.

According to the defect report, some Mopar frame assemblies may have been manufactured with an extra frame stud that, when installed in a vehicle, could contact the fuel tank. Over time, the problem could result in a fuel leak and an increased chance of a fire.

Owners receiving notices will be asked to return to their Chrysler dealer to have their vehicle inspected. If there is a potential problem, the frame stud will be removed and the area will be painted. FCA US, LLC’s number for this recall is 28A and the NHTSA campaign number is 23V-191.

If you are having repeated problems with your Jeep Wrangler and you think it could be a Lemon, or if you have any questions about your rights under the California Lemon Law, please call our office at 1-888-395-3666 or fill in the “Case Review” form at the top of this page, and get some great Lemon Law advice!

Nissan Ariya EV – Loose Steering Wheel

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Nissan has initiated a voluntary safety recall for certain 2023 Nissan Ariya EVs that underwent a recent port modification activity to replace the steering wheel due to a quality issue. The modification required the replacement of the vehicle’s steering wheel, which could have led to an inadvertent application of incorrect torque settings to the steering wheel bolt by the technician. In certain cases, the steering wheel bolt may not have been installed, causing the steering wheel to experience some play or potentially separate from the steering column if pulled toward the driver. This can increase the risk of a crash. Owners are advised to contact their dealer immediately for transport and repair if they notice excessive play or looseness in the steering wheel.

Nissan first became aware of the issue in January 2023, following a report from one of their dealers about a loose steering wheel found on a 2023 Ariya vehicle. An investigation found the steering wheel center bolt was completely missing. After receiving a second report of a loose steering wheel and missing steering wheel bolt on another 2023 Ariya vehicle in February, Nissan opened an investigation and identified that both vehicles had been serviced by the same technician during the port modification activity.

In response, Nissan launched a dealer quality action to inspect the steering wheels on 418 Ariya vehicles in dealer inventory that was previously repaired as part of the port modification activity. One additional Ariya vehicle with a loose steering wheel was identified during the audit, and an investigation found that the incorrect torque had been applied to the affected steering wheel bolt during the port modification activity. Out of an abundance of caution, Nissan decided to conduct a voluntary safety recall to remedy all vehicles included in the port modification activity.

To address the issue, dealers will replace the steering wheel bolt, and Nissan’s recall number for this issue is PC956, while the NHTSA campaign number is 23V-131.

Jeep Safety Alert: Clutch Failures Could Result In A Vehicle Fire

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Jeep is a well-known brand in the automotive industry for producing powerful off-road vehicles. However, in December 2022, Jeep’s Technical Safety and Regulatory Compliance (TSRC) investigators began to receive reports of vehicle fires in certain Jeep Gladiator and Wrangler vehicles. It was found that the fires were related to pressure plate failures, which led to overheating and eventual fires.

An investigation was opened, and it was discovered that the trend of vehicle fires related to failed clutch assemblies was found in vehicles built after Recall 21V-028. In this recall, Chrysler repaired certain 2018-2021 Jeep Wrangler and 2020-2021 Jeep Gladiator vehicles equipped with manual transmissions because the clutch pressure plate could overheat and fracture.

In January, FCA received inspection details of a 2023 MY Jeep Wrangler vehicle built after the Recall 21V-028, which experienced a complete clutch failure. FCA US identified 26 customer assistance records, 36 warranty claims, and six field reports potentially related to this issue for all markets with dates of receipt ranging from July 5, 2021 to January 12, 2023.

In February 2023, FCA US determined, through the Vehicle Regulations Committee, to conduct a safety recall of the affected vehicles. The recall expands and replaces the previous recall 21V-028. Vehicles previously repaired under recall 21V-028 will need to have the new remedy completed.

The remedy is currently under development, and owner notification letters are expected to be mailed in April. In some circumstances, the operator may smell a clutch burning odor and/or clutch slippage before the failure, and may receive cluster warning message. It is important for owners to pay attention to any warning signs and immediately bring their vehicles in for repair.

This is not the first time Jeep has had to issue a recall. In recent years, Jeep has had to recall various models due to issues such as faulty airbags, faulty brake systems, and faulty fuel pumps. While recalls can be inconvenient for owners, they are necessary to ensure the safety of drivers and passengers on the road.

Jeep has always prided itself on producing high-quality, durable vehicles that are built to withstand rugged terrain. However, as with any machine, there is always the potential for failure. It is important for Jeep owners to stay informed about any recalls or issues with their vehicles and to promptly bring them in for repair.

In conclusion, Jeep’s recent recall of certain Gladiator and Wrangler vehicles is a reminder of the importance of vehicle safety and the need for regular maintenance and inspection. The remedy for this recall is currently under development, and owners should pay attention to any warning signs and bring their vehicles in for repair as soon as possible.

Tesla Model Y Second-Row Seat Frame Improperly Secured

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A manufacturing error will have the owners of certain 2022-2023 Tesla Model Y all-electric SUVs, returning to their dealerships for an inspection and possibly repairs. The second-row seat frame in these vehicles may have been improperly secured.

Tesla first became aware of the problem in December 2022 when an operator in Tesla’s Freemont, CA manufacturing facility identified a second-row driver-side seat back frame bolt that was not torqued to the proper specification.

The second-row seat belt loads go through the lower seat frame, and if the bolts that secure the frame to the seat backs are not torqued to specifications, the seat belt system may not perform as designed during a collision. Occupants seated in the second-row seating positions could experience an increase in the risk of injury during an accident.

According to the defect report, on some Model Y vehicles, the second-row driver-side seat back frame (second-row driver-side and center seating positions) and the second-row passenger-side seat back frame (second-row passenger-side seating position) are secured to the lower seat frame with 4 bolts per seat back. During the supplier’s production of both seat back frames for certain Model Y vehicles, one or more of the bolts that secure the seat back frames to the lower seat frame may not have been torqued to specifications.

Tesla has identified 5 warranty claims, received between December 9, 2022, and February 14, 2023, that may be related to the problem described above. Tesla is not aware of any injuries or deaths that may be related to the condition.

Owners receiving notices will be asked to return to their Tesla Service Centers to have the second-row seat back frames inspected and the bolts will be torqued. Tesla’s number for this recall is SB-23-13-001 and the NHTSA Campaign Number is 23V-130.

If you are the unfortunate owner of a lemon like a Tesla Model Y all-electric SUV with persistent defects that the manufacturer is unable to fix, you may feel like you are out of options. However, there is hope: the California Lemon Law provides some protections for owners of defective vehicles, and a lemon law lawyer can help you navigate the process.

A lemon law lawyer can help you understand your rights under the California Lemon Law and negotiate with the manufacturer on your behalf. They can also help you prepare and submit a claim to the manufacturer and, if necessary, file a lawsuit to protect your rights. Lemon law cases can be complex, and having an experienced attorney on your side can make all the difference in the outcome of your case.

If you are having repeated problems with your Tesla Model Y and you think it could be a Lemon, or if you have any questions about your rights under the California Lemon Law, please call our office at 1-888-395-3666 or fill in the “Case Review” form at the top of this page, and get some great Lemon Law advice!