Ford Motor Company has unfortunately become a prominent name in vehicle recalls during 2025, establishing a record at the National Highway Traffic Safety Administration (NHTSA) for the sheer volume of issues. By July, the Blue Oval had issued 94 recalls affecting over 6.3 million vehicles, a figure that continued to climb throughout the year. This pattern of significant recalls highlights a challenging period for Ford, stemming from various manufacturing mistakes and defects across its diverse product line.

One notable recall involves 355,656 2025 and 2026 Super Duty trucks and 2025 F-150 pickups. The issue centers on the instrument panels, specifically the digital display located between the speedometer and tachometer. These panels have the potential to remain in a standby or blank state after certain ignition cycles. This critical malfunction occurs if the instrument panel receives a CAN bus signal to wake up during a narrow window of its sleep entry sequence, preventing it from turning on. The consequence is severe, as drivers would be unable to monitor their speed, or see essential warning indicators such as the check engine light, ABS, or other critical alerts. Fortunately, the remedy is a straightforward software update. However, owners may need to bring their trucks to a dealership if their vehicles are not equipped for over-the-air (OTA) updates or if mobile dealer repair services are unavailable. Due to the inherent danger of driving without an operational instrument panel, Ford advises against driving affected vehicles to the dealership; instead, the company should arrange and cover the cost of towing and the subsequent recall service. Furthermore, any prior related repairs for this specific blanking cluster issue should have been covered under warranty, and affected customers are advised to contact Ford for reimbursement if they were charged.

Another significant safety concern led to the recall of 100,900 2024–2026 Ford Ranger pickups. This recall addresses a defect in the curtain airbags, which are designed to protect occupants during impacts and prevent ejection. The issue was initially identified during a safety audit conducted by the NHTSA on the 2025 Ford Ranger, where the vehicle marginally passed a side impact test. Further investigation by Ford and a third-party lab revealed a small slit, approximately 15/32 of an inch long, in the curtain airbag, caused by an external source. Ford's deeper analysis subsequently found that an inner reinforcement flange for the airbags could also lead to similar tears and premature pressure loss, compromising the airbag's effectiveness. The affected Rangers were built from the start of production on December 9, 2022, through July 29, 2025, the date a fix was introduced. The solution involves adding a protective shield to the curtain airbags during deployment, eliminating the need to replace the airbags themselves. As of the time of reporting, the necessary parts for this fix were not yet available, with Ford anticipating owner notifications and repairs to commence in the latter half of December. Owners are currently not advised to park their affected Rangers.

Adding to Ford's recall woes, a large-scale recall impacts over 210,000 2025 Ford Explorer, 2025 Police Interceptor Utility (based on the Explorer), and 2025 Lincoln Aviator models. This issue pertains to a potentially defective Body Control Module (BCM), which Ford refers to as BCMC. Manufactured by Aptiv Services, these modules contained an improperly soldered printed circuit board from the production facility. The primary manifestation of this defect, particularly for vehicles capable of towing up to 5,000 pounds, is the failure of trailer lights and the appearance of a trailer-error message on the dashboard. However, the BCM's widespread function means other electrical components can also be affected, including inoperative power windows or mirrors, the HVAC system blowing warm air, non-functional USB chargers, a glove box light going out, or even the horn failing to beep when the alarm function is activated. Interestingly, Ford's statistical analysis suggests that if an Explorer or Aviator has reached 9,000 miles, its BCMC is likely functioning correctly. Nevertheless, it is still recommended for owners of these vehicles to bring them in for inspection, as Ford or Lincoln technicians will inspect and replace the BCMC with a functional one if needed, free of charge. Vehicles with less than 9,000 miles will have their BCMC replaced regardless of its verified condition. Recall notices for Explorer and Aviator owners were scheduled to begin on October 13, but replacement BCMCs are not expected to be available until between March 31 and April 3, 2026. Owners of vehicles below the 9,000-mile threshold are advised to refrain from towing until the replacement part is installed, and to schedule their inspection promptly upon receiving the notice.