Major car manufacturer, Ford, has issued a chilling four-word warning to its customers while they work to resolve a significant manufacturing issue with one of their best-selling cars
Ford has issued an urgent warning to owners of its popular Kuga plug-in hybrid electric vehicle (PHEV). It is urging people ‘do not charge car’ due to a potential fire risk. The company has identified a significant fault in the vehicle’s battery pack that could lead to a short circuit, posing a considerable safety hazard.
Owners have been instructed to refrain from charging their vehicles until Ford executes a suitable solution. In the meantime, drivers have been advised to operate their vehicles in ‘Auto EV’ mode, which allows the car to function primarily on petrol power. This setting ensures the car runs as a conventional hybrid, minimising reliance on the high-voltage battery system. Ford has also urged drivers to remain vigilant for dashboard warnings, particularly a “Stop Safely Now” message. If this message appears across the dashboard, along with a warning light on the driver’s display, it may indicate a short circuit. While braking and steering systems would remain operational, the drivetrain could lose power.
The company sent letters to over 26,000 affected owners of the Kuga PHEV, which has been on sale since April 2020, BirminghamLive reports. In the letters, the company stated, ‘Ford engineers are developing new software to remedy this potential condition,’ which it says could trigger battery thermal venting, ‘potentially resulting in a vehicle fire, increasing the risk of injury.’ The letter continued: “In the meantime, please DO NOT PLUG YOUR VEHICLES IN TO CHARGE THE HIGH-VOLTAGE BATTERY and use the drive mode “Auto EV” only. This will prevent the potential issue from occurring while charging or driving.”.
Ford is working tirelessly to address the issue through a software update designed to reduce the risk of a short circuit within the battery pack. The update will be provided free of charge, and the company has set up a dedicated customer service line for affected drivers seeking further information or assistance.
This latest manufacturing error comes as part of a growing trend of safety concerns within the automotive industry. Volkswagen has recently recalled 177,493 crossover SUVs, including specific Atlas and Atlas Cross Sport models from the 2024 to 2025 production years, due to potential fire risks posed by improperly installed engine covers in the United States.
These covers could come loose and make contact with hot engine surfaces, increasing the likelihood of a fire. Dealers have been instructed to remove the engine covers at no cost to vehicle owners. Similarly, Hyundai has recalled approximately 9,000 vehicles due to concerns that brake fluid could leak into affected cars, potentially causing engine fires. Until the issue is resolved, owners have been advised to park their vehicles in open spaces away from flammable materials. Vehicle recalls have become increasingly common in recent years due to the growing complexity of modern cars. In 1994, only 27 passenger car recalls were issued. By the end of 2024, that number had risen to nearly 250, affecting up to 2.7 million vehicles, with BMW topping the chart for the most cars recalled in the UK in 2024.
With the rise of electric and hybrid technology, vehicle risks have increased as manufacturers work to integrate advanced battery systems safely. Drivers are legally obligated to ensure their vehicles are safe and free from outstanding recall notices. Owners should regularly check for recall updates related to their cars. In the UK, this can be done using the government’s official website, where drivers can enter their vehicle registration details to see if any recalls apply. Ford Kuga PHEV owners are strongly encouraged to take the warning seriously and follow the manufacturer’s guidance until the issue is fully resolved.