Ford has announced two safety recalls in North America, affecting about 2.4m vehicles, some of which have been previously recalled for one of the required repairs.

The automaker said some 2011-15 Ford and Lincoln vehicles may not have had all door latches replaced or correctly replaced by dealerships under earlier safety recalls (15S16 or 16S30).

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These were to replace door latches with latch pawl spring tabs that were susceptible to cracking and failure in areas with high thermal loads (a combination of outdoor air temperature and solar radiation).

A door latch with a fractured pawl spring tab typically results in a 'door will not close' condition and, if the door latches after repeated attempts to shut it, there is potential for the door to unlatch while driving, increasing the risk of injury, Ford said, adding it was not aware of any accidents or injuries related to the problem.

This recall affects around 2.15m vehicles in the US and its federal territories.

Affected models are:

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  • 2011-14 Ford Fiesta vehicles built at Cuautitlan Assembly Plant, Jan. 26, 2010, to Oct. 31, 2013
  • 2012-15 Ford Focus vehicles built at Michigan Assembly Plant, Oct. 4, 2010, to Jan. 31, 2015
  • 2013-14 Ford Fusion vehicles built at Hermosillo Assembly Plant, May 11, 2012, to Oct. 31, 2013
  • 2013-14 Lincoln MKZ vehicles built at Hermosillo Assembly Plant, July 19, 2012, to Oct. 31, 2013
  • 2013-15 Ford Escape vehicles built at Louisville Assembly Plant, Dec. 23, 2011, to Jan. 31, 2015
  • 2013-15 Ford C-MAX vehicles built at Michigan Assembly Plant, Feb. 2, 2012, to Jan. 31, 2015
  • 2014 Ford Fusion vehicles built at Flat Rock Assembly Plant, June 18, 2013, to Oct. 31, 2013
  • 2014-16 Ford Transit Connect vehicles built at Valencia Body and Assembly Plant, from Aug. 9, 2013, to Feb. 1, 2016
  • 2015 Ford Mustang vehicles built at Flat Rock Assembly Plant, Feb. 14, 2014, to April 30, 2015
  • 2015 Lincoln MKC vehicles built at Louisville Assembly Plant, Nov. 18, 2013, to Jan. 31, 2015

Owners will be given the option to inspect the door latch date codes and child safety locks and submit latch date codes online to confirm if repairs done under safety recalls 15S16 or 16S30 were completed correctly. The online system will provide instant validation that the door latches are OK or the latches cannot be confirmed and require dealer service.

If a customer does not want to do the inspection, has difficulty completing the inspection, or receives an indication that the latches cannot be validated, dealers will inspect the latch date codes and replace latches as needed. The Ford reference number for this recall is 20S30.

On top of that, some 2014-17 Ford F-150 trucks equipped with the 3.5-litre V6 EcoBoost petrol engine may have a master cylinder leaking brake fluid from the front wheel circuit into the vacuum booster.

Depending on the amount of fluid loss, the driver will receive an audible chime, message centre alert, red brake warning indicator in the instrument cluster, and/or may begin to experience a change in brake pedal travel and feel, including increased pedal effort. If a loss of brake fluid is substantial enough to reduce brake function to the front wheels, full braking function will remain in the rear wheel circuit. However, reduced brake function in the front wheels can extend stopping distance, increasing the risk of a crash.

Ford said it was aware of seven low speed/low impact accident allegations with two injuries associated with this issue.

That recall affects 292,311 vehicles in the US and federal territories, 43,536 in Canada and 8,053 in Mexico.

Affected vehicles:

  • Some 2015-17 Ford F-150 vehicles built at Dearborn Truck Plant, Oct. 1, 2014, to Aug. 1, 2016
  • Some 2014-17 Ford F-150 vehicles built at Kansas City Assembly Plant, Sept. 1, 2014, to Aug. 1, 2016

Dealers will replace the brake master cylinder and, if it is leaking, the brake booster will also be replaced. The Ford reference number for this recall is 20S31.