- Ford is recalling 255,404 Focus models it believed were already fixed.
- Audit found that some software fixes may not have been installed correctly.
- Engine stall risk from the original defect could still exist in these cars.
Ford seems like a brand unable to stop the bleeding when it comes to recalls. That said, the vast majority of the recalls issued are for newly discovered defects. This one is different. Ford is recalling more than a quarter-million Focus models because it can’t confirm that an earlier safety recall from October 2018 was actually completed correctly.
The new recall, 26S40, covers 255,404 Ford Focus vehicles from the 2012-2018 model years that were previously repaired under recall 18S32 (NHTSA campaign 18V735). According to Ford, some vehicles were recorded as having received the required Powertrain Control Module software update even though the correct software may never have been installed. That means the original defect could still be lurking beneath the surface.
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The problem centers on the canister purge valve (CPV). If the valve sticks open, it can create excessive vacuum inside the fuel system. Over time, that vacuum can deform the Focus’s plastic fuel tank. The resulting symptoms can include an illuminated check-engine light, inaccurate fuel gauge readings, incorrect distance-to-empty calculations, drivability problems, and, in the worst cases, an engine stall. That’s right. All these issues can pop up due to a software issue.
How did Ford manage to find this new issue affecting over a quarter-million cars? A software audit. Late in 2024, it discovered a discrepancy between software records and actual vehicle software states. According to documents filed with the NHTSA, it traced the issue to inconsistencies during the transition between its older IDS service tool and the newer FDRS platform. In some cases, recall repairs may have been closed out without the intended software ever being successfully installed.
Ford spent more than a year digging through records and auditing vehicles repaired under various software recalls. By April 2026, its Critical Concern Review Group concluded that some recall remedies may not have been applied despite being marked complete. The company then launched a VIN-by-VIN verification effort and eventually approved a new field action on June 2, 2026.
Owners will need to return to a Ford or Lincoln dealer, where technicians will update the PCM software and verify that the correct software package is installed before closing the recall. The repair will be performed free of charge.
