Ford is issuing a new recall affecting thousands of its full-size 2021 E-Series vans in the United States after discovering that parts of the engine cover can overheat, creating a potential burn hazard for drivers and front-seat passengers. The recall carries an unusual twist: it stems from a previous fix that was never properly applied to many of the affected vehicles, leaving the underlying problem unresolved.
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According to Ford, the insulation on the engine cover can allow the corners of the panel, located near the driver’s and passenger’s feet, to become excessively hot. The automaker warned that “direct and continuous contact with certain areas of the engine cover surface in the passenger compartment may cause burns to the skin of the driver or front seat passenger.” The original solution involved a software update that recalibrated the powertrain management system, reducing heat buildup during extended idle periods. However, in practice, many vans were incorrectly labeled as having received the update when, in reality, the fix was never installed.
The initial recall for this issue was issued in December 2020, at which time Ford also instructed dealers to hold deliveries of new E-Series vans until the correction could be verified. The latest re-recall affects a total of 7,046 vehicles, all 2021 models manufactured between May 23, 2019, and November 12, 2020. Ford discovered the discrepancy in November 2025, realizing that some vans marked as “repaired” had not actually undergone the intended software update.
An internal audit revealed that only 69.71 percent of the affected vans had been properly updated, leaving nearly a third of vehicles still vulnerable to the overheating problem. While the situation is concerning, Ford reported that it has not received any reports of injuries or accidents linked to this defect, offering some reassurance to owners.
The automaker plans to notify owners of the affected vans between January 5 and January 9, 2026. Dealerships will then perform the necessary powertrain recalibration, which adjusts the system to better manage heat during prolonged idling, effectively resolving the issue once and for all. The re-recall underscores how administrative oversights during earlier recall efforts can leave safety concerns unaddressed, even years after the initial problem was identified. With these updates, Ford aims to finally close the chapter on a problem that should have been fully resolved long ago, ensuring both driver and passenger safety.