Beyond a major manufacturing flaw that directly impacts safety and performance, recall campaigns often start with smaller failures and nuisance defects. When such issues become systemic, regulators step in, and automakers along with dealers must repair or replace tens of thousands of vehicles.
Kia Optima and the poorly glued roof
The United States market saw recalls of the 2012 and 2013 Kia Optima sedans due to a loose roof. A minimal amount of adhesive on that panel allowed the roof to detach over time, potentially injuring the driver. The apology came after a single accident where a decorative panel bracket detached during a side curtain airbag deployment. That event spurred a recall of 250,000 sedans for repairs in the US market.
Ford Bronco and a loose windshield
The retro-styled Ford Bronco has emerged as a strong competitor against the Jeep Wrangler and Land Rover Defender. Yet its rollout faced early quality issues. In early July, a batch of large SUVs was recalled due to a loose windshield. More than 39,000 vehicles could experience glass detachment, a concern raised after a customer complaint. A similar issue was found on 24,000 Ford Ranger pickups. Ford did not specify the exact cause of the defect.
Volkswagen Golf and an overly sensitive sunroof button
Over 2,000 tuned Volkswagen Golf GTI and Golf R hatchbacks required repairs in the US because the sunroof control button proved too sensitive. Investigations revealed the part did not meet standards for such devices. Regulators indicated that an overly responsive sensor could be pressed accidentally, risking injury. Volkswagen will replace the buttons with units that offer a more controlled press. In the eighth-generation Golf, analog buttons were minimized as part of a broader move toward touch interfaces.
Toyota bZX4 and wheel detachment risk
Unlike the Volkswagen issue, the problems with Toyota’s electric crossover wheels presented a real safety threat. In 2022, owners were urged to stop driving their bZX4 crossovers immediately after reports of wheels coming loose on the go. Investigations showed that hub bolts could loosen after a short drive, potentially causing wheel detachment.
Approximately 2.7 thousand new electric crossovers from 2022 were affected. Subaru recalled about 2.6 thousand Solterra units for the same reason. Both crossovers share a platform and design roots, created through a cooperative effort between Japanese firms.
Skoda and a license plate labeling issue
In spring 2022, over 1,800 Skoda Kodiaq crossovers were recalled in Russia due to incorrect labeling on the B-pillar. Specifically, the packaging and markings that indicate the vehicle type approval number (OTTS) were misstated. While this labeling error does not affect road safety, it triggered a full recall campaign due to certification concerns.
Tesla and pedestrian warning concerns
Tesla faced recalls affecting several of its models due to issues with the pedestrian warning system. The cars emit a warning sound to alert pedestrians because electric propulsion is quiet. A software defect could cause the external speaker to turn off when the Boombox feature is active, potentially preventing the system from sounding properly. With pedestrian safety standards in mind, the carmaker adjusted the system so street sound alerts are maintained when the vehicle is in motion.
Nissan Pathfinder and hood latch contamination
More than 350,000 Nissan Pathfinder crossovers across multiple markets, including the United States, Canada, and South Korea, were recalled to address hood support latch contamination. Although the primary latch function remained intact, a stuck latch posed a risk if the hood failed to close properly while driving or if the release lever was accidentally pulled. The affected models span production years from 2012 to 2016, and owners were advised to clean the latch if it began to lose performance or to replace the lock as needed.
Sources: regulatory filings and manufacturer notices. [Citation: NHTSA; manufacturer communications; market recalls documentation]