Few things are as frustrating for auto owners as having to return their vehicles for the same issue not once, but twice. That’s precisely the situation facing approximately 300 Ford Mustang owners whose cars were part of a larger recall last summer. Roughly 30,000 Mustangs from the 2022 and 2023 model years were initially called back due to a concerning issue with the electric power-assisted steering system. While dealerships across the country worked diligently to address the problem, it now appears that a small subset of those repairs were botched, necessitating yet another trip to the shop. For these unlucky owners, the déjà vu experience is more than just an inconvenience—it’s a reminder of how even well-intentioned fixes can sometimes fall short.
The original recall, identified by the National Highway Traffic Safety Administration (NHTSA) as number 24V-493 and internally referenced by Ford as 24S44, was announced on June 28, 2024. The issue stemmed from a calibration error in the secondary digital torque sensor within the steering gear assembly. Specifically, the sensor had been configured with inverted polarity, a seemingly minor oversight that carried significant implications. If the primary steering torque sensor failed or encountered a fault, the secondary sensor’s inverted polarity could cause the steering wheel to oscillate unexpectedly—alternating between clockwise and counterclockwise movements—when the driver attempted to steer. This unintended behavior resulted in vibrations felt through the steering wheel, creating a disconcerting and potentially hazardous driving experience.
A Supplier’s Proactive Role
Credit where it’s due: the issue might have gone unnoticed for longer if not for Nexteer Automotive, the supplier responsible for manufacturing the affected steering components. In May 2024, Nexteer alerted Ford to an assembly issue with the steering gears. By June, Ford had logged two warranty claims related to the matter and swiftly decided to issue a recall. Fortunately, no crashes or injuries have been reported in connection with the defect, though it’s easy to imagine how such erratic steering behavior could escalate into something far more serious under certain conditions.
Ford moved quickly to mitigate the issue, offering free repairs at dealerships nationwide. The fix involved recalibrating the secondary digital torque sensor to correct the polarity inversion. For most owners, this resolved the problem entirely, allowing them to drive away with confidence restored. However, for about 332 Mustangs, the repair wasn’t executed correctly, leaving the underlying issue unresolved. This revelation has prompted Ford to initiate what amounts to a “recall of a recall,” assigning it the new internal reference number 25S11. Owners affected by this follow-up action should expect notification letters from Ford around March 31, 2025.
Why It Matters
While the NHTSA and Ford have emphasized that this isn’t a “do not drive” scenario, any unexpected behavior in a vehicle’s steering system is cause for concern. Even minor oscillations can compromise driver control, particularly in high-stress situations like merging onto highways or navigating tight corners. Moreover, the psychological impact shouldn’t be underestimated; knowing your car may exhibit unpredictable steering quirks can erode trust and make every drive feel less secure.
From a logistical standpoint, recalling a recall is inherently problematic. It places additional strain on dealerships, inconveniences customers who thought they’d already dealt with the issue, and tarnishes the automaker’s reputation. Yet, it also underscores the complexity of modern vehicles, which rely heavily on intricate electronic systems. A single miscalibration in one component can cascade into broader issues, highlighting the importance of precision during both manufacturing and repair processes.
Steps Toward Resolution
To its credit, Ford appears committed to minimizing disruption for affected owners. When contacted for comment, a company representative assured drivers that alternative service options would be available. “Customers can use pick-up and delivery and mobile service for this recall,” the spokesperson explained. These measures aim to reduce the hassle of visiting a dealership in person, offering some relief to those inconvenienced by the repeat repair.
For owners awaiting their notification letters, patience will be key. Given the relatively small number of vehicles involved—just 332 out of the original 30,000—it’s likely that Ford will prioritize efficiency in addressing the issue. Still, the episode serves as a sobering reminder of the challenges inherent in mass production and large-scale recalls. Even with rigorous quality control protocols in place, human error and unforeseen complications can occasionally slip through the cracks.
Lessons Learned
This latest development raises important questions about accountability and transparency in the automotive industry. While Ford acted promptly to address the initial defect, the fact that some repairs were improperly completed highlights the need for stricter oversight during recall execution. Automakers must ensure not only that parts are replaced or recalibrated correctly but also that technicians performing the work are adequately trained and equipped to handle complex tasks.
Moreover, the situation reinforces the value of proactive communication between suppliers and manufacturers. Nexteer Automotive deserves recognition for flagging the issue early, preventing what could have become a much larger crisis. Such collaboration is essential for maintaining safety standards and protecting consumers from avoidable risks.
As the affected Mustang owners prepare to bring their cars back for a second round of repairs, the broader implications of this incident warrant reflection. Modern vehicles are marvels of engineering, blending mechanical prowess with cutting-edge electronics. But with increased complexity comes heightened vulnerability to errors, whether in design, assembly, or maintenance. For automakers like Ford, the challenge lies in striking a balance between innovation and reliability, ensuring that technological advancements enhance rather than detract from the driving experience.
For now, Mustang enthusiasts can take solace in knowing that Ford is actively working to rectify the situation. While the prospect of revisiting a recall is undoubtedly frustrating, the automaker’s willingness to address the issue head-on demonstrates a commitment to customer satisfaction and safety. As the saying goes, hindsight is 20/20—but in this case, it’s also a valuable tool for improving future practices.
Until then, Mustang pilots are urged to stay vigilant behind the wheel and heed any communications from Ford regarding their vehicles. After all, peace of mind is as crucial to the joy of driving as horsepower and handling. And for the 332 owners caught in this rare double recall, here’s hoping the second time’s the charm.
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