Ford Kuga reliability

On affected vehicles the high voltage battery may have some cells that could potentially develop a short circuit leading to a Stop Safely Now message and possible loss of motive power or battery thermal venting.

Fix: Update the vehicle's Battery Energy Control Module software.

Recalled models: KUGA · 7,659 vehicles

On affected vehicles the cylinder head may have loose ball plugs. This condition may result in a rapid oil leak if a ball plug comes out of the cylinder head.

Fix: Replace the cylinder head.

Recalled models: KUGA · 3 vehicles

On affected vehicles a software problem may result in issues with the rear-view camera that reduce the driver’s view or with it remaining on after a reversing event.

Fix: Update the vehicle software to the latest level.

Recalled models: KUGA · 1 vehicles

Certain Kuga S-Max and Galaxy vehicles equipped with a 2.5L HEV/PHEV Engine may not have the remedy for Safety Recall 23S27 installed correctly but were recorded as having received the repair successfully. Because the correct software update may not have been installed on these vehicles the underlying condition specified in Safety Recall 23S27 potential under hood fire may still exist.

Fix: Dealers are to update the Powertrain Control Module (PCM) software.

Recalled models: KUGA · 547 vehicles

On affected vehicles the remedy software for a previous recall which was needed to mitigate a potential fire risk may not have been installed correctly.

Fix: Update the Power Control Module software and perform an additional verification process to ensure the software has been installed correctly.

Recalled models: KUGA · 7 vehicles

On affected vehicles software from a previous recall may not have been installed correctly. Vehicles may have Hybrid Powertrain Control Module (HPCM) software that can result in a forced neutral condition while driving.

Fix: Update and verify the software.

Recalled models: KUGA · 3 vehicles

Affected vehicles may develop a crack in the Diesel Particulate Filter (DPF).

Fix: Update software to prevent a cracked DPF. Test and replace DPFs that are already cracked.

Recalled models: KUGA · 47 vehicles

On affected vehicles a recent update to the Power Control Module (PCM) software could result in the vehicle shifting into neutral and coasting to a stop. The subsequent limp home mode results in unintended acceleration or 'supercreep'.

Fix: Update the Powertrain Control Module (PCM) software

Recalled models: KUGA PHEV · 328 vehicles

A small number of vehicles on which the fuel injectors may crack and leak. In the event of an injector failing this may result in fuel accumulating on the top of the engine. The accumulation of fuel could become the catalyst for a fire due to the proximity to the exhaust system and lack of an escape route for the leaking fuel.

Fix: The dealer will fit a specially developed drain tube which will safely drain any leaking fuel away from hot surfaces like the cylinder head or exhaust. Also the vehicle software will be updated which will allow any drop in fuel pressure to be detected. This software will reduce the power of the engine if a drop in fuel pressure is detected and a warning light will be illuminated in the instrument cluster.

Recalled models: KUGA · 1,136 vehicles

Engine failure that may lead to a breach of the engine oil sump or engine block

Fix: Software update

Recalled models: KUGA · 26 vehicles

The steering gear could potentially develop excessive movement. Over time a wear condition may manifest in an audible noise increased steering efforts and the steering wheel not returning to the centre position. In rare circumstances if the issue of noise increased steering efforts and the steering wheel not returning to the centre position are not addressed the excessive movement in the steering gear may lead to the pinion shaft becoming disconnected from the steering rack.

Fix: Replace affected components.

Recalled models: KUGA · 2,302 vehicles

In the event of a fuel injector failing this will potentially cause a fuel leak.

Fix: A drain tube will need to be installed to allow safe passage of the fuel away from hot surfaces in the event of a leak occurring. Also the dealer will perform a PCM software update that will reduce the engine power if a drop in fuel pressure is detected and a warning light will be illuminated to make the user aware.

Recalled models: KUGA · 13,671 vehicles

A small number of vehicles may be fitted with tyres that do not meet the high specification expected.

Fix: Conduct a visual inspection of the summer tyres to identify known and specific build codes. If after inspecting the vehicle a tyre(s) is identified as one of the known specific build numbers that falls in the suspect build range the Dealer will replace the affected tyre free of charge.

Recalled models: KUGA · 142 vehicles

Some Kuga vehicles with a panoramic roof may have a fixed glass panel with poor adhesion to the roof frame assembly. As a result there is a possibility that the fixed glass panel could detach during driving causing a hazard to vehicle occupants and other road users.

Fix: Check the panoramic roof frame If an affected date is present the fixed glass roof panel will need to be removed to inspect the integrity of the adhesive. If the adhesive is found to be compromised a new roof frame assembly will need to be installed.

Recalled models: KUGA · 2,359 vehicles

The lower front seatbelt bolt may not be correctly tightened to specification.

Fix: Inspect and re-torque the front lower seatbelt bolts to specification

Recalled models: KUGA · 35 vehicles

It may be possible that the eCall feature will stop functioning due to a malfunction.

Fix: The Telecommunication Module will need to be replaced

Recalled models: KUGA · 9,388 vehicles

Under certain operating conditions an oil and/or fuel vapour leak in the presence of an ignition source may result in an engine compartment or vehicle fire localized melting or smoke.

Fix: Modification of the engine undertray and active grill assemblies.

Recalled models: KUGA · 16,155 vehicles

A number of Kuga PHEV (Plug-in Hybrid Electric Vehicle) have a High Voltage (HV) battery that may have an internal fault with one of the battery arrays causing overheating

Fix: A new HV battery must be installed

Recalled models: KUGA PHEV · 760 vehicles

Certain vehicles could have an engine oil separator that may have been damaged prior to engine assembly.

Fix: Inspect the engine oil separator and if found to be damaged and/or leaking a replacement engine oil separator must be installed

Recalled models: KUGA · 9,818 vehicles

A battery may have an incorrectly positioned/welded busbar in one of the battery arrays

Fix: Install a new High Voltage battery.

Recalled models: KUGA PHEV · 14 vehicles

Vehicles may have an issue with the current software that controls the functionality of the eCall system.

Fix: Carry out a software update.

Recalled models: KUGA · 100 vehicles

Particle contamination can cause internal short circuiting of high-voltage battery cells.

Fix: The HV battery pack will be replaced on affected vehicles.

Recalled models: KUGA PHEV · 2,326 vehicles

The Fuel Operated Heater could start inadvertently

Fix: New SYNC system software must be applied.

Recalled models: KUGA · 1 vehicles

The HV battery pack can overheat and result in the venting of hot gas which can ignite vehicle components or in extreme cases the entire vehicle.

Fix: To prevent a vehicle fire the vehicles should not be charged using the external charging cable and the vehicles should only be driven using the default Auto EV mode only.

Recalled models: KUGA · 5,046 vehicles

The High Voltage Battery Control Charger Module (BCCM) connector may be damaged

Fix: An inspection of the BCCM is required to confirm an undamaged connector. If a failed inspection occurs the vehicle must be reworked with a replacement BCCM and charge cable.

Recalled models: KUGA · 30,202 vehicles

A number of vehicles fitted with a 1.0 1.5 or 1.6 Ecoboost engine and 6-speed manual transmission could suffer clutch pressure plate fracture. This results in clutch smell reduced vehicle speed and performance. In the unlikely event of clutch pressure plate fracture a noise (thud / bang) could be heard from the vicinity of the transmission in extreme cases resulting in clutch / transmission fragments being released and striking under hood components creating a risk of smoke and fire from the under hood area.

Fix: To prevent the repeated heating /cooling events a new calibration has been developed for vehicles fitted with Engine Stop Start feature. The software with the additional feature sets the Instrument panel �Wrench light� and de-rates the engine performance if prolonged clutch slip is detected. The software feature includes a drive cycle strategy for latching the wrench light and engine performance de-rate if the customer should experience repeated clutch slip events. For vehicles that do not have Engine Stop Start feature an alternative clutch kit has been released.

Recalled models: KUGA · 66,497 vehicles

Affected vehicles fitted with a 1.0 1.5 or 1.6 Ecoboost engine and 6-speed manual transmission could suffer clutch pressure plate fracture. This results in clutch smell reduced vehicle speed and performance. In the unlikely event of clutch pressure plate fracture a noise (thud / bang) could be heard from the vicinity of the transmission in extreme cases resulting in clutch / transmission fragments being released and striking under hood components creating a risk of smoke and fire from the under hood area.

Fix: To prevent the repeated heating /cooling events a new calibration has been developed for vehicles fitted with Engine Stop Start feature. The software with the additional feature sets the Instrument panel �Wrench light� and de-rates the engine performance if prolonged clutch slip is detected. The software feature includes a drive cycle strategy for latching the wrench light and engine performance de-rate if the customer should experience repeated clutch slip events. For vehicles that do not have Engine Stop Start feature an alternative clutch kit has been released.

Recalled models: KUGA · 122,199 vehicles

The engine control module calibration may not adequately detect an overheat condition in certain 2.0L Duratorq Diesel engines. In extreme cases an overheated engine can result in a breach of the oil sump leading to loss of the engine oil.

Fix: Recall the vehicles that are likely to be affected and download revised software for the control module calibration that improves overheat detection and provides an instrument cluster warning indicator to the driver and engine de-rate strategy.

Recalled models: KUGA · 48,595 vehicles

Localized overheating of the engine cylinder head may cause the cylinder head to crack.This may cause a pressurized oil leak which in extreme circumstances could result in a fire in the engine compartment.

Fix: On affected vehicles Inspect engine and cooling system. Replace affected components and fit a Coolant Level Sensor along with associated software to provide and audible and visual warning to the driver.

Recalled models: KUGA · 15,228 vehicles

The airbag initiator may be defective and may prevent the side airbag(s) and/or knee airbag deploying in the event of an accident. In a collision the airbags not deploying could put the occupants at further risk.

Fix: Recall the 1943 vehicles that are likely to be affected to check and where necessary replace the side and knee protection airbags complete with initiators.

Recalled models: KUGA · 1,943 vehicles

In the event of a colision which deploys the front seat belt retractor pre-tensioner there is a possibility that the insulation material on the inner face of lower 'B' pillar trim could be subjected to a concentrated heat source that could ignite the insulation material resulting in fire.

Fix: Remove a section of the insulation material on both �B� pillar trims.

Recalled models: KUGA · 29,904 vehicles

The heated washer jets fitted to some Kuga vehicles may have jet heating elements that are not correctly sealed. There is a possibility that poor sealing could lead to corrosion due to water ingress and subsequent overheating of the jets. An overheating jet element will damage the nozzle housing and may cause local heat/fire damage to the cowl grille accompanied by smoke and burning smell.

Fix: Recall the vehicles that are likely to be affected and fit new washer jets.

Recalled models: KUGA · 4,382 vehicles

The heated washer jets may have jet heating elements which are not correctly sealed. There is a possibility that poor sealing could lead to corrosion due to water ingress and subsequent overheating of the jets. An overheating jet element will damage the nozzle housing and may cause local heat/fire damage to the cowl grille accompanied by smoke and burning smell.

Fix: Recall the vehicles that are likely to be affected and fit new washer jets.

Recalled models: KUGA · 20,358 vehicles

During engine warm up it is possible that the non return valve within the vacuum pump may stick. It is possible that if sufficient brake applications are made before the valve releases the vacuum stored within the brake booster will be used up and a hard brake pedal and longer stopping distances may result.

Fix: Recall the vehicles that are likely to be affected to fit a revised design of non return valve to the brake vacuum pump.

Recalled models: KUGA · 13,029 vehicles