Cracking In Frame of Driver Side Door

[justinocch]

Only the driver side door right?

Mine is currently only the driver side door. The dealership told me that have dozens of this exact problem in the Escapes around 2020/2021. Body shop guy told me he CURRENTLY has 8 of them in his shop waiting for new door to arrive. He told me to call Ford and make a complaint. I'll be doing that later today.

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[ycking]

Whelp! I have new news on this issue. Ford just issued a recall/program for the spot welds on the door. They will perform a one time fix if you are having g that issue. Will post a scan of the letter when I get home tonight.

Glad they are stepping up to fix the issue

Can you post a scan of the letter? This may help others and myself with same issue.

 

[hammercon]

I'd been wondering about my noisy door for six months now. I started to think it was coming from a joint in the check arm itself, which led me to this thread. Sad to say that I can see cracks on the two spot welds on either side of the check. Not as bad as OP's, but pretty obviously the source of the noise.

I'd love to see this letter, too. I plan to reach out to the dealer soon. Buh. Glad to have been pointed in the right direction. Thanks, all.

 

[justinocch]

I had a very rough conversation with Ford customer service on Friday. My car is just out of warranty. They told me this over and over: "the warranty has expired." Then I told them that was extremely lame that their new premium EV is not something they stand behind as much as the 2020 Ford Escape (!). So they transferred me to a special EV customer support line. (BTW, I asked them for the phone number and they said it's only available via transferring the call internally.)

BUT, this customer service rep gave me the run around. They put me on a 15 minute hold to call my dealer. After they came back from hold, they told me "We work with the dealers to fix these problems." And I thought, GREAT! Then she hit me with "The dealer was able to confirm that you are out of warranty." Hahaha. Yeah, I already knew that, and she and I had already discussed that.

She only offered that I could complain to NHTSA if I wanted. Honestly made me want to get rid of the car. I know it's just a door, but a $3500 job that they are already honoring on the Escape. This despite the fact that the Mach E is way more expensive and is their first EV. I thought Ford would do better than that. There's always time for them to change their mind. But based on this issue, I am learning that they maybe aren't standing behind their product.

 

[CottonHill]

My 21 select that I had just started doing that prior to me trading it in a week ago. I thought it was a piece of rock salt or something that got stuck in there. I had 32k miles on it.

 

[ycking]

I made an appointment with dealer with little farther out from my location since my local dealership said they don’t handle body work anymore. It be nice if there is some paperwork or direction from @Ford Motor Company and I don’t end up wasting my time. They said they will have my car for few days to take pictures and work with ford. As of right now there is nothing for them to authorize for repairs. Not sure if I will be given rental for that time or have to pay out of pocket for.

 

[azerik]

I'm in this boat as well.

 

[justinocch]

I'm in this boat as well.

Sucks that it is so many of us and Ford is doing nothing.

 

[RedStormREHS]

Super! My '21 GT Job 1 driver's door starting clicking a few months and I ignored it until the clicking turned into loud clunking. My 12 year old boy said add some grease to the hinges and door stopper thing. Added a bunch of Superlube. Still clunked... Called my aerospace engineer daughter (1st yr in school) and she said check torques on fasteners, ha. Then, found this thread and discovered the failure! Yep, I have the dreaded 2 failed spot welds (cracks) on door-check assembly area . Maybe metal is too thin there? Is there a SSC yet for Mach-E's? I assume the entire door assembly needs to be replaced... I have the EV Premuim Care Ford ESP but it may fall under body defect and excluded? @Mach-Lee
@Ford Motor Company

 

[MightyMike]

I just checked my car. I can feel the divot in the metal. I don't think the weld has completely pulled away, but it is definitely working its way there. Is there a solution that doesn't perhaps cost 3500 dollars? Or is ford eventually going to do the same thing for the mach-e that they did for the escape? Or should I be looking to dump the car?

 

[RedStormREHS]

I just checked my car. I can feel the divot in the metal. I don't think the weld has completely pulled away, but it is definitely working its way there. Is there a solution that doesn't perhaps cost 3500 dollars? Or is ford eventually going to do the same thing for the mach-e that they did for the escape? Or should I be looking to dump the car?

I'm hoping this will be covered under my Ford ESP EV Extra Care since it's quite clearly a manufacturing defect! Ford will likely issue a CSP campaign or Recall at some point soon like the Escape. I've never had faulty door welds on a car! Taking into dealer soon - Ken Grody - for new tires and all the module updates.

 

[_ua]

Hi there. Mach E 2022. I have another one 2023 with the same 🫰

 

[awp0]

Same problem on my 2022 (out of warranty). Mine is on the passenger side door, but it's the same location, same spot welds under the seal. The door creaks loudly opening and closing. I can see the little cracks, feel the movement with my fingers when I open/close the door, and the sound even goes away if I spray a dab of silicone on the cracks (though I'm sure it'll return).

Has anyone had luck getting this repaired out of warranty?

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