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Ford Recalls Plug-In Hybrid Explorer and Lincoln Aviator Due to LG Battery Cell Defect

Lincoln Aviator 9 photos
Photo: Lincoln / edited
Lincoln Aviator Grand Touring for the USLincoln Aviator Grand Touring for the USLincoln Aviator Grand Touring for the USLincoln Aviator Grand Touring for the USLincoln Aviator Grand Touring for the USFord Explorer Plug-In Hybrid for EuropeFord Explorer Plug-In Hybrid for EuropeFord Explorer Plug-In Hybrid for Europe
Based on the CD6 platform that was incorrectly rumored to underpin the seventh-generation Mustang as well, the Ford Explorer and Lincoln Aviator have been hit by a recall. Only plug-in hybrids equipped with the 3.0-liter EcoBoost V6 are called back, which is a little peculiar because the Explorer Plug-In Hybrid isn't sold in the United States of America.
Manufactured at the Chicago Assembly Plant in the state of Illinois, the Explorer Plug-In Hybrid is Ford's only Explorer available in Europe. In Germany, which is the continent's largest market for new cars, the mid-size crossover slots above the Kuga Plug-In Hybrid, a.k.a. Escape Plug-In Hybrid in the USA.

Stateside, the Dearborn-based automaker does offer the Explorer Hybrid in combination with a 3.3-liter V6 of the naturally-aspirated variety. As per a report published by the National Highway Traffic Safety Administration, 13 examples of the Explorer Plug-In Hybrid are included in recall number 23V-626.

Given the small number, it's likely that we're dealing with vehicles operated by Ford Motor Company or a government agency. As noted earlier, there is no Explorer Plug-In Hybrid listed on the automaker's configurator for the US.

Regarding the Lincoln Aviator, the plug-in hybrid is curiously marketed as the Grand Touring. This fellow does have the aforementioned 3.0-liter EcoBoost V6, a twin-turbo affair that's also employed in the Explorer ST and Bronco Raptor.

A grand total of 2,941 units are recalled, featuring June 2019 through May 2022 production dates for the 2020 through 2022 model years. Ford became aware of the potential of a short circuit in the high-voltage battery cells on June 28. How? By means of a report describing a Transit Custom Plug-In Hybrid experiencing battery thermal venting in France.

The teardown analysis revealed a short in a single cell due to a folded anode tab. According to battery supplier LG Energy Solution, the folded tab was introduced during the battery cell manufacturing cell. Come August 11, the automaker learned of three additional reports of battery cells with folded anode tabs. These reports involved two 2020 model year Lincoln Aviator Grand Touring vehicles for the US market and one sold in the Canadian market.

Of the two vehicles for the United States, one experienced battery thermal venting. The other didn't, yet still triggered a malfunction indicator lamp. The Canadian vehicle also showed a warning light without experiencing any thermal venting.

Documents filed with the federal watchdog reveal that dealers have been instructed to perform a battery energy control module diagnostic test. In the event of an anomaly involving battery cell capacity, the entire battery pack will be replaced at no charge to the customer. The replacement batteries are equipped with cells assembled with greater attention to detail. Be that as it may, Ford didn't explain what kind of manufacturing process improvements were introduced by the Seoul-based supplier.

Owners will be informed by first-class mail of this recall in the period between October 2 and October 6. The three-row Aviator Grand Touring is currently available to configure at $70,190 (excluding the destination freight charge). As for the Explorer Plug-In Hybrid, make that €86,490 or a staggering $92,290 at current exchange rates. The EPA and WLTP electric driving range estimates for these PHEVs are 21 miles (34 kilometers) and 42 km (26 mi).
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Editor's note: Ford Explorer Plug-In Hybrid for Europe pictured in the gallery.

 Download: Ford Explorer PHEV and Lincoln Aviator PHEV battery recall (PDF)

About the author: Mircea Panait
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After a 1:43 scale model of a Ferrari 250 GTO sparked Mircea's interest for cars when he was a kid, an early internship at Top Gear sealed his career path. He's most interested in muscle cars and American trucks, but he takes a passing interest in quirky kei cars as well.
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