Ford Battery Recall - #25S02

[Chadwick]

I just received notice of a recall on my ‘22 Bronco Sport:

Jan 17,2025
Manufacturer Recall Number25S02
NHTSA Recall Number25V019
Recall StatusRecall Incomplete, remedy not yet available
SummaryON YOUR VEHICLE, THE 12-VOLT BATTERY MAY EXPERIENCE INTERNAL WELD AND OR CAST-ON-STRAP FAILURES, WHICH COULD LEAD TO A SUDDEN BATTERY DEGRADATION WHILE DRIVING.

Safety RiskIF THE BATTERY SUDDENLY DEGRADES DURING A DRIVE, YOUR VEHICLE MAY BE UNABLE TO RESTART AFTER AN AUTO STOPSTART EVENT OR EXPERIENCE A STALL WHILE COMING TO A STOP AT LOW SPEED. EITHER OF THESE CONDITIONS MAY BE ACCOMPANIED BY A LOSS OF ELECTRICAL ACCESSORIES, INCLUDING HAZARD LIGHTS. A LOSS OF MOTIVE POWER CAN INCREASE THE RISK OF A CRASH. WHEN THE REMEDY IS AVAILABLE, FORD MOTOR COMPANY WILL SEND A LETTER TO INFORM YOU TO CONTACT YOUR DEALER TO SCHEDULE A REPAIR. FORD HAS NOT ISSUED INSTRUCTIONS TO STOP DRIVING YOUR VEHICLE UNDER THIS SAFETY RECALL. WHEN THE REMEDY IS AVAILABLE, YOU SHOULD CONTACT YOUR DEALER FOR AN APPOINTMENT TO HAVE YOUR VEHICLE REMEDIED AS SOON AS PRACTICABLE.

RemedyPARTS ARE NOT AVAILABLE. FORD MOTOR COMPANY IS WORKING TO PROVIDE PARTS FOR THIS REPAIR. WHEN THE REMEDY BECOMES AVAILABLE, FORD MOTOR COMPANY WILL NOTIFY YOU VIA MAIL TO SCHEDULE A SERVICE APPOINTMENT WITH YOUR DEALER FOR REPAIRS TO BE COMPLETED FREE OF CHARGE. THE REMEDY IS ANTICIPATED TO BE AVAILABLE Q2 2025.

Manufacturer's NotesTO CHECK FOR NON-SAFETY-RELATED PROGRAMS APPLICABLE TO YOUR VEHICLE, SEE HTTP://WWW.FORD.COM/ OR CALL YOUR FORD DEALER.

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[Ponyrider]

2021 here. I got the same recall. Parts available in the second quarter? Sigh...

 

[Mark S.]

So it appears all the speculation is correct; some Bronco Sports shipped from the factory with defective batteries.

 

[cprcubed]

Our 2022 BB has this recall as well. We've never had any battery issues to date, although with the recent cold weather down here, it's been charging at 15V+ more often. Cheers!

 

[Jack62748]

My 22 OBX 50k miles got the same recall notice, I just had the battery tested and it is at 86%. I was thinking to go ahead and replace it with a AGM type but maybe I'll wait to see if Ford replaces it for free.

 

[Dude]

In case anyone is wondering..

In a 12V battery, what is a cast-on-strap failure?

Thanks go to ChatGPT:
A cast-on-strap (COS) failure in a 12V battery refers to a defect or failure in the intercell connectors, also known as the straps, which link the individual cells inside the battery. These straps are usually made of lead or lead alloys and are formed by casting molten lead to bond the plates of a cell and create an electrical connection between adjacent cells.

Causes of COS Failure:
1. Manufacturing Defects: Poor casting quality during the manufacturing process can lead to weak or incomplete bonding of the straps to the plates.
2. Thermal Fatigue: Repeated charging and discharging cycles cause heating and cooling, leading to thermal expansion and contraction. Over time, this can weaken the straps or cause cracks.
3. Corrosion: The lead straps can corrode due to the acidic environment inside the battery, reducing their conductivity or causing them to fail entirely.
4. Overloading or High Current: Excessive current draw or overcharging can generate heat that weakens or melts the straps, causing them to break.
5. Vibration or Physical Shock: In automotive or other high-vibration environments, mechanical stress can cause the straps to crack or separate.
6. Poor Alignment: Improper alignment of plates during assembly can lead to uneven stress distribution, increasing the likelihood of failure.

Symptoms of COS Failure:
• Sudden loss of battery power.
• Intermittent electrical issues.
• A battery that cannot hold a charge or shows a dead cell when tested.

Prevention and Mitigation:
• High-quality manufacturing processes to ensure proper casting of straps.
• Regular maintenance to detect early signs of corrosion or damage.
• Using vibration-resistant designs for batteries in automotive or industrial applications.

COS failures are critical because they disrupt the electrical connection between cells, rendering the battery inoperable.

 

[Dude]

Hmmm, my OE EFB (Battery) was replaced under warranty by a Ford dealership July 2024 with a motorcraft AGM Battery … and I also just received Recall 25S02

Update 1/23/2025: Recall 24S02 Attachment in Post #18 explains why the recall was applicable to my 2022 Badlands (OE EFB). Because I have the Motorcraft AGM Battery as of July 2024 the Recall is not applicable to my vehicle.

 

[Colonel Angus]

What year(s) Bronco Sport does this recall cover?

 

[thomasm23]

21 Outer Banks 138,000
OEM battery was AGM
Replaced in 2022 with Motorcraft AGM
No battery issues currently.

I received the recall.

 

[BLUEOVALRACER]

It was cold -11 here in Northeast,Ohio last Night.When i woke up and went out for the Paper i but the Battery Charger Maintainer on it for over 3 Hours and when i started it,it cranked Very Slow almost thought it wasn't going to start and it came up on center screen System Off To Save Battery.And like i said this was after the charger was on it for over 3 hours.And another thing that makes no sense to me on these Bronco Sports is why do the fans for the Headlights come on when you open the hood? I really think my Battery could be going bad and i'm going to go to Auto Zone Thursday and have them test it. I wonder if my fuel gauge not showing full when i fill it could be battery related? FWIW i tested the charging system on Sunday with it running and it was over 15 Volts.FWIW my BS is a 2023 with less than 6.000 miles on it and IMO the Recall is Crap if they don't have a Remedy at this Time.

 

[BLUEOVALRACER]

My 22 OBX 50k miles got the same recall notice, I just had the battery tested and it is at 86%. I was thinking to go ahead and replace it with a AGM type but maybe I'll wait to see if Ford replaces it for free.

The problem with Ford replacing it IMO is what if it's with the Same Battery with the problem?

 

[Dude]

The problem with Ford replacing it IMO is what if it's with the Same Battery with the problem?

I would hope the issue was traced to the manufacturer(s) of the defective batteries, a design fix was done and production needs to ramp up to produce good quality batteries. I see the same recall on the Maverick forum who are getting the 25S02 recall. We will have to wait and see how many affected vehicles are defined in the full write up for the recall.

 

[CrashBend]

I just received notice of a recall on my ‘22 Bronco Sport:

Jan 17,2025
Manufacturer Recall Number25S02
NHTSA Recall Number25V019
Recall StatusRecall Incomplete, remedy not yet available
SummaryON YOUR VEHICLE, THE 12-VOLT BATTERY MAY EXPERIENCE INTERNAL WELD AND OR CAST-ON-STRAP FAILURES, WHICH COULD LEAD TO A SUDDEN BATTERY DEGRADATION WHILE DRIVING.

Safety RiskIF THE BATTERY SUDDENLY DEGRADES DURING A DRIVE, YOUR VEHICLE MAY BE UNABLE TO RESTART AFTER AN AUTO STOPSTART EVENT OR EXPERIENCE A STALL WHILE COMING TO A STOP AT LOW SPEED. EITHER OF THESE CONDITIONS MAY BE ACCOMPANIED BY A LOSS OF ELECTRICAL ACCESSORIES, INCLUDING HAZARD LIGHTS. A LOSS OF MOTIVE POWER CAN INCREASE THE RISK OF A CRASH. WHEN THE REMEDY IS AVAILABLE, FORD MOTOR COMPANY WILL SEND A LETTER TO INFORM YOU TO CONTACT YOUR DEALER TO SCHEDULE A REPAIR. FORD HAS NOT ISSUED INSTRUCTIONS TO STOP DRIVING YOUR VEHICLE UNDER THIS SAFETY RECALL. WHEN THE REMEDY IS AVAILABLE, YOU SHOULD CONTACT YOUR DEALER FOR AN APPOINTMENT TO HAVE YOUR VEHICLE REMEDIED AS SOON AS PRACTICABLE.

RemedyPARTS ARE NOT AVAILABLE. FORD MOTOR COMPANY IS WORKING TO PROVIDE PARTS FOR THIS REPAIR. WHEN THE REMEDY BECOMES AVAILABLE, FORD MOTOR COMPANY WILL NOTIFY YOU VIA MAIL TO SCHEDULE A SERVICE APPOINTMENT WITH YOUR DEALER FOR REPAIRS TO BE COMPLETED FREE OF CHARGE. THE REMEDY IS ANTICIPATED TO BE AVAILABLE Q2 2025.

Manufacturer's NotesTO CHECK FOR NON-SAFETY-RELATED PROGRAMS APPLICABLE TO YOUR VEHICLE, SEE HTTP://WWW.FORD.COM/ OR CALL YOUR FORD DEALER.

2021 Outer Banks. I replaced battery a little over a year ago. I hope I got a good one.

 

[wireman]

Hmmm, my OE EFB (Battery) was replaced under warranty by a Ford dealership July 2024 with a motorcraft AGM Battery … and I also just received Recall 25S02

Same here.

 

[coopny]

Nothing from Ford for my vehicle I did see an email from another forum that there were new recalls on the 2023 BS.

I'm waiting for Feb 3rd to see if I get an owner notification letter. Battery is two years old. If I'm not part of this recall I may just bite the bullet and buy an AGM, or I may wait to see if my battery goes kaput in the 3yr/36k bumper-to-bumper.

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