Ford issues a major recall affecting 133,000 Lincoln Aviators due to parts that could fly off while driving, potentially causing accidents on America’s highways.
Key Takeaways
- Ford is recalling 132,914 Lincoln Aviator SUVs from model years 2020-2025 due to rear door window bars and C-pillar trim that may detach while driving
- The defect stems from insufficient adhesive application during assembly, with approximately 4,250 vehicles (3.2% of those recalled) estimated to have the issue
- Despite 1,105 warranty claims related to the problem, Ford reports no accidents or injuries have occurred
- Owners will receive notification letters by July 28, and dealers will repair or replace affected parts at no cost
Manufacturing Defect Puts Drivers at Risk
Ford Motor Company has announced a significant recall of Lincoln Aviator SUVs due to a manufacturing defect that could create dangerous road hazards. The recall affects nearly 133,000 vehicles spanning model years 2020 through 2025. The specific components at issue, rear door window bars and C-pillar trim, may detach from the vehicle while in motion due to improper adhesive application during the assembly process. This potentially creates a serious road hazard for both Aviator owners and other motorists.
Ford is recalling 132,914 Aviator SUVs in the United States because parts, including rear door window bars, may detach due to insufficient adhesive retention, the U.S. National Highway Traffic Safety Administration (NHTSA) said Tuesday. https://t.co/2PAEqimE5e
— NEWSMAX (@NEWSMAX) June 24, 2025
“Ford is recalling nearly 133,000 SUVs because some parts, including rear door window bars, may disconnect due to not enough adhesive, the National Highway Transportation Safety Administration announced,” stated National Highway Transportation Safety Administration
The problem originated at the supplier facility where components were installed with inadequate application pressure, resulting in insufficient adhesive retention. This manufacturing error means the pieces could potentially separate from the vehicle, creating dangerous projectiles on highways and roads. While Ford estimates that only about 3.2% of the recalled vehicles, approximately 4,250 SUVs, actually have the defect, the company is taking the precautionary step of recalling all potentially affected vehicles.
No Injuries Reported Despite Widespread Issue
Despite the serious nature of the defect, Ford reports that no accidents or injuries have been attributed to the issue as of the recall announcement. However, the company has documented 1,105 warranty claims related to the problem as of May 29, indicating that many consumers have already experienced some form of the defect. The faulty part was reportedly removed from production on May 30, suggesting that Ford acted relatively quickly once the pattern of failures became apparent.
“The components may detach due to inadequate application pressure of the components during assembly at the supplier facility that results in insufficient adhesive retention,” stated the report
Owners should monitor their vehicles for any signs that the C-pillar applique or division bar is separating from the vehicle. These components are primarily decorative but could create significant hazards if they detach at highway speeds. The company will be sending notification letters to all affected vehicle owners by July 28, with a second notification to follow once the remedy is available at dealerships. This proactive approach should help minimize the risk to consumers while the repair process is implemented.
Free Repairs and Part of a Larger Recall Trend
Ford has committed to repairing or replacing the affected parts at no cost to vehicle owners. Customers can bring their Lincoln Aviators to any Ford or Lincoln dealer to have the necessary work performed once parts are available. This recall is identified by the number 25S66, and owners with questions can contact Ford’s customer service at 1-866-436-7332 for additional information. The National Highway Traffic Safety Administration also offers resources through their Vehicle Safety Hotline at 1-888-327-4236.
“Owners should bring their vehicle to a Ford or Lincoln dealer, where the faulty parts can be repaired or replaced free of charge, the automaker said,” stated the automaker
This recall follows a pattern of quality control issues plaguing major automakers in recent months. Earlier this year, Ford recalled nearly 400,000 trucks, SUVs, and other vehicles for various issues, including over 197,000 Mustang Mach-E SUVs due to a risk of passengers becoming trapped in the back seat. Similarly, Honda recently announced a recall of approximately 259,000 vehicles due to a potential brake pedal issue. These ongoing manufacturing and safety concerns raise questions about quality control processes in the automotive industry and the regulatory oversight ensuring consumer safety.
