Nearly 150,000 Ford vehicles recalled after defect raises risk of sudden power loss while driving

A broken eyelet can cut power to the drivetrain and disable systems such as headlights, the cooling fan, air‑conditioning and the windshield‑washer pump, raising the risk of a crash. Owners will be mailed notice in early September and dealers will perform the fix free of charge.

The root cause lies in the interaction between the heat‑shrink adhesive that secures the wiring harness and the metal eyelet terminals. Repeated engine vibration then induces fatigue, eventually cracking the eyelet. When the eyelet fails, the ground path to the engine is lost, which can trigger a “check engine light” and, in the worst case, a sudden loss of motive power. The design flaw also permits the failure to cascade into ancillary circuits, explaining why headlights or the air‑conditioning might drop out at the same time.

Ford first learned of the problem in June when two eyelets broke on a 2027 test vehicle, prompting an immediate stop‑ship on the 2026 model year. Over the next two months the automaker’s Critical Concern Group reviewed eight warranty claims – half filed within three months of ownership – and confirmed the issue was present in current production. Replacement terminals, featuring a redesigned stepped‑neck geometry that eliminates the interference, are projected to be ready by March 2027.

For drivers, the practical impact is immediate: no accidents or injuries have been linked to the defect so far, but the potential hazard is real. Dealers will swap the four ground terminals with the new pigtails at no cost. The recall has drawn modest attention from investors – Ford’s stock held steady as the news filtered through – and underscores the brand’s effort to address safety issues before they manifest in crashes. Owners who notice the engine‑check warning or a sudden dimming of lights should schedule service promptly, even if they have not yet received a letter.

The broader question is whether this eyelet design appears elsewhere in Ford’s lineup. Regulators and consumer advocates will be watching the rollout closely, and any sign that the defect spreads could reshape the risk calculus for Ford’s current‑generation vehicles.