Technology is advancing at a rapid rate, and automobile systems, while remarkably advanced, are complex and prone to failure. While we enjoy the new features, we now face new problems they can present. These are problems that could, in some instances, be substantial defects that severely impact a vehicle’s use, value, or safety. Some auto manufacturers’ vehicles demonstrate more tech-related failures than others. One of these is Ford.
We’ll review Ford’s recall issues in the last few years and also its particular problems involving EV battery recalls. Within that focus, we’ll look at software patches and how they are used to repair vehicles. Not all software patches work, and sometimes manufacturers have to reapply them. This has happened with Ford.
First, let’s define what a substantial defect is under lemon law, then we’ll put Ford’s EV battery issues within that context. In this way we’ll show how certain types of EV battery problems can be lemon law-worthy claims.
Defining a Substantial Defect Under Lemon Laws
Not every defect makes a car a lemon. That key point we stated above is what all state lemon laws are based on: the vehicle must exhibit a substantial defect that severely impacts its use, value, or safety. The defect must be unfixable across the allotted number of repair attempts a state provides to the manufacturer (usually 3–4 repair attempts). Each state has its own additional lemon law criteria, which can involve mileage, reporting timeframes, if the law covers used vehicles, and more. A lemon law attorney will take all this into account and determine if a consumer’s vehicle can qualify as a lemon. If so, the attorney can offer to the client to pursue the case.
Some states require that the manufacturer get one last repair attempt before a lemon law claim proceeds. The timeframe the manufacturer receives to make this final repair attempt is often 7-15 days (depending on state law). If the manufacturer is unsuccessful with the repair or refuses or ignores the request, the lawyer can go forward with the claim.
What Types of Recall Problems Are Consumers Facing with Ford?
Ford has consistently led all manufacturers with recalls in recent years. In 2025 it recalled a record of nearly 13 million vehicles throughout its 153 total recalls.
So, it might seem unusual to note that Ford was, actually, the most awarded brand in the 2025 J.D. Power U.S. Initial Quality Study. On July 16, 2025, Ford’s COO stated that the manufacturer is making strides in improving quality. Meanwhile, the company is dealing with recalls as it continues to push for more consistent quality.
While software recalls are an industry-wide trend (which makes sense because today’s vehicles are essentially rolling computers), Ford deals with a high incidence of “second-try” or repeat recalls. In particular, failed software patches are a concern for Ford, in some cases involving second recalls to get the patches reinstalled.
Key point: Since software is now seen under the law as central to a vehicle’s operation, failed software patches can count as a ‘repair attempt.
How Ford Recalls May Lead to Lemon Law Claims
Some of the recalls that stand out with Ford involve EV battery issues. Ford’s software patch repair attempts sometimes were incorrect versions or were misapplied, causing car owners to have to return to the dealer for another patch. In some cases, the patches did not work at all, sometimes not catching all issues causing a problem.
Here we’ll review several of these problems via composite narratives based on actual Ford recalls, such as this one and this one.
The Mustang Mach-E with Sudden Power Loss
A woman purchased a new Mustang Mach-E, but within three months, she kept having sudden power losses while driving on the highway. She took the car in to the dealership three times. The technicians performed two “Over-the-Air” (OTA) software updates and replaced minor sensors. None of these fixes worked.
Frustrated by the safety risk, the woman contacted a lemon law attorney. The attorney gathered her repair orders as evidence that the “software fixes” had failed to address a likely hardware defect in the high-voltage battery junction box.
For more information on arbitration and other frequently asked lemon law questions, click here.
The attorney filed a formal demand letter to Ford, and within two months, it agreed to a full buyback. Note: Your timeframe for a claim resolution may vary, as manufacturers usually do not have a fixed schedule for resolving claims.
F-150 Lightning Charging Problem
A man used his new F-150 Lightning for daily work, but within eight months, his truck wouldn’t accept a full charge. When charging it, it would often get to 40%, or it would overheat during DC fast charging. With the truck’s 37 total days in the shop across four service visits, the truck owner couldn’t figure out what to do.
The dealer’s technicians tried a few software patches to repair the issue, with no success. When Ford refused his initial request for a replacement, the man hired a lemon law firm.
The attorney argued that the vehicle fit the state lemon law definition of a substantial impairment of use and value. The lawyer got an automotive expert to determine that Ford failed to diagnose and repair a cell misalignment in the high-voltage battery.
Image Source: Pexels
By documenting that the truck was “out of service” for more than the legal limit (typically 30 days), the attorney pressured Ford’s early resolution department. Ford eventually settled by providing a replacement vehicle and covering the man’s legal fees.
Rapid Range Loss Predicament
A woman noticed her Ford Escape Plug-In Hybrid (PHEV) was experiencing a dramatic drop in electric-only driving range. Her vehicle was only a year old. Every time she visited the dealer (she went three times), she was told the battery was fine. It “passed diagnostics” and at one time was given a software patch. The patch didn’t work, and she got way less range than she should have.
When the woman consulted a lemon law attorney, they checked TSBs (internal service bulletins) and National Highway Traffic Safety Administration (NHTSA) records. These showed that the battery’s internal short-circuiting was a known manufacturing defect.
After the attorney filed a formal claim, Ford agreed to the consumer’s buyback request.
Lemon laws are confusing. Read our guide to the lemon law complaint process.
Note: Your lemon law attorney will explain the formula for your offset fee (this usually applies to both buybacks and replacement vehicle compensation). It’s a deduction from your total compensation. It is an offset fee for miles driven while the vehicle operated properly.
Also, in addition to the down payment, monthly payments, registration, and other fees, consumers can also often recover associated costs such as rental cars, towing, and more.
Why You Need a Lemon Law Attorney for Your Ford EV Battery Case
Since Ford deals with a high number of recalls every year, and since it has been involved in some failed software patch repairs, Ford owners can benefit from consulting a lemon law lawyer.
The attorney will review the vehicle owner’s repair records and other documentation, plus bring in expert testimony and other evidence to show the failure of the manufacturer to repair the vehicle. The manufacturer may try to evade, ignore, or minimize the claim or even try to point the finger at the consumer, saying that they neglected or abused the vehicle. The attorney’s goal is clear: it is to prove the substantial defect.
The attorney’s negotiation skill is key to winning the claim, as most lemon law cases settle out of court. Whether the client’s lemon law claim is about software or mechanical parts, the lawyer fights for their client’s rights and holds the manufacturer responsible to provide compensation for the defective vehicle.
Trust Allen Stewart, P.C. for Comprehensive Lemon Law Representation
Allen Stewart, P.C. has won many lemon law cases across the country involving Ford vehicles, including Ford vehicles that were subjects of recalls. If you are having issues with your Ford (or any other make of car), contact us now (866-440-2460) for a free consultation. We’ll review your evidence and discuss the problems your vehicle is exhibiting. Should your claim be valid, we will offer to represent you against the manufacturer?
You may wonder if you need a lawyer. Perhaps you’re worried about cost. You do not have to pay our attorneys to represent you. The manufacturer is obligated to pay your attorney fees when you win your case.
Allen Stewart, P.C. is a well-known lemon law firm that aggressively holds manufacturers accountable. We will fight to win you the compensation you deserve. Call us at 866-440-2460 or schedule your free consultation online.