Dive Brief:
- Ford Motor Co. recalled nearly 133,000 Lincoln Aviator SUVs due to loose exterior C-pillar and window division bar trim that could detach from the vehicle while driving, posing a safety hazard, according to the National Highway Traffic Safety Administration.
- The recalled vehicles include 2020-2025 Aviator models produced between Oct. 19, 2018, and May 30, 2025, the date when the recalled part(s) were taken out of production. The loose trim is due to insufficient adhesive bonding during assembly, per the report.
- Dealers will repair or replace C-pillar appliques and window division bars for free and the replacement components “will be permanently affixed to the vehicle,” according to the report. Owner notification letters are expected to be mailed July 28. A second letter will be sent to customers once a remedy is made available.
Dive Insight:
Ford was first aware of reports of detached trim on Aviator models over three years ago. From April 2022 though May 2023, Ford’s Critical Concern Review Group investigated the concern, but concluded at the time that it wasn’t an unreasonable risk to motor vehicle safety, so no action was taken.
According to the recall report, the loose trim was not deemed a significant safety risk from falling to the ground or on a roadway due to its “low masses and narrow profiles with no sharp protrusions.”
On April 15, however, Ford’s Product Development Quality team identified a loose C-Pillar applique on an internal test vehicle, which prompted another investigation into the issue. The concern was brought to Ford’s Critical Concern Review Group on April 22.
Throughout the month of May, Ford’s engineering team worked to identify the cause of the trim C-pillar applique detachments and division bar looseness, which are referred to as “glass run channels” in the report. Ford investigators also reviewed field and warranty data, as well as the potential for higher occurrences of detachment on higher mileage Aviator SUVs.
In addition, supplier process improvement actions were reviewed by Ford’s Supplier Technical Assistance team to determine the scope of the problem. The trim parts were were manufactured in Mexico by Tier 1 supplier Cooper Standard Automotive and the recalled Aviators were built at Ford’s Chicago Assembly Plant.
The investigation also included discussions with NHTSA on the road hazard risks of trim detachments while driving, which led to Ford’s Field Review Committee to approve the recall on June 6.
As of May 29, the automaker is aware of 1,105 warranty claims of trim pieces falling off Lincoln Aviator models globally, but is not aware of any accidents or injuries. The warranty claims were received between June 17, 2020, and April 14, 2025.
It’s the second recall this month for the Aviator. Ford also recalled over 300,000 Explorer and Aviator SUVs this month for incorrectly installed second-row seat switch bezels, which can lead to the switch becoming stuck in the down position. Customers may also not be able to latch/unlatch or fold the second-row seat.
Also this month, Ford recalled over 492,000, 2016-2017 Explorer models for exterior B-pillar door trim on the driver and front passenger side that may become loose or detach while driving.
Ford has now issued a total of 13 recalls in June for a variety of vehicle problems. Since Jan. 1, the automaker has issued over 80 recalls extending to over 4.2 million vehicles, according to the NHTSA. It’s the highest number of recalls for a major automaker in 2025 and more than the combined total of General Motors, Stellantis, Toyota, Honda, Hyundai, Volkswagen and Tesla.
