Incident: Recall of 3.3 Million Ford Vehicles Due to Gear Shifting Issue

Published Date: 2022-06-16

Postmortem Analysis
Timeline 1. The software failure incident related to the Ford vehicle recall happened between April 2015 and March 2022 as per the information provided in Article 129006. 2. The incident related to the Ford vehicle recall happened between 2013 and 2019 as per the details in Article 129306.
System 1. Under-hood shift bushing and shift cable bushing in various Ford vehicles [Article 129006, Article 129306]
Responsible Organization 1. The software failure incident in the Ford vehicles was caused by a damaged or missing shift cable bushing, which prevented the vehicle from shifting into the intended gear, leading to potential rolling away of the vehicle [Article 129006, Article 129306].
Impacted Organization 1. Customers who owned the affected Ford vehicles [Article 129006, Article 129306]
Software Causes 1. The software cause of the failure incident was related to a damaged or missing shift cable bushing preventing the vehicle from shifting into the intended gear, leading to potential rolling of the vehicle after selecting the 'Park' position [129006, 129306].
Non-software Causes 1. Damaged or missing shift cable bushing preventing the vehicle from shifting into the intended gear, leading to potential rolling away of the vehicle [Article 129006, Article 129306] 2. Missing or damaged bearings that could prevent the vehicles from shifting into gear properly, allowing them to move even if the shifter indicates they are in park [Article 129306]
Impacts 1. Property damage and injuries potentially related to the issue were reported, with Ford being aware of six reports of property damage and four reports of injuries [129006, 129306]. 2. The incident led to a Hollywood actor, Anton Yelchin, being killed in a similar risk scenario involving Jeeps and Fiat Chrysler models in the past [129306]. 3. The software failure incident resulted in Ford recalling a significant number of vehicles, including 2.9 million vehicles in North America [129006, 129306]. 4. Ford had to take actions such as replacing parts, adding protective caps, and updating vehicle software to address the issue [129006, 129306].
Preventions 1. Implementing thorough quality assurance testing procedures to detect issues with shift cable bushings and other components that could lead to the vehicles not shifting into the intended gear [Article 129006]. 2. Conducting regular software updates and maintenance checks to ensure the proper functioning of critical vehicle systems, such as the battery connectors in electric vehicles like the Mustang Mach-E [Article 129306].
Fixes 1. Dealers will replace the under-hood shift bushing and add a protective cap to address the issue in the recalled vehicles [Article 129006]. 2. Ford will update the vehicle software for the recalled Mustang Mach-E electric vehicles to address the overheating issue related to battery connectors [Article 129006]. 3. An over-the-air software update will be sent to correct the problem causing battery connectors to overheat in the Mustang Mach-E electric SUVs [Article 129306].
References 1. National Highway Traffic Safety Administration (NHTSA) [Article 129006, Article 129306] 2. Ford Motor Co [Article 129006, Article 129306]

Software Taxonomy of Faults

Category Option Rationale
Recurring one_organization, multiple_organization (a) The software failure incident having happened again at one_organization: - Ford Motor Co has experienced a similar software failure incident before. This recent recall is Ford's fifth recall over the issue since 2018, indicating a recurring problem with the shift cable bushing causing vehicles to roll away or have difficulty shifting gears [129006]. (b) The software failure incident having happened again at multiple_organization: - The article mentions a similar risk affecting Jeeps and several other models made by Fiat Chrysler several years ago, where vehicles equipped with an electronic shifter could leave drivers thinking they had shifted into park when the vehicles were still in neutral or drive. This indicates that the issue of vehicles moving unexpectedly due to gear shift problems has occurred in multiple organizations [129306].
Phase (Design/Operation) design (a) The software failure incident related to the design phase is evident in the articles. Ford Motor Co recalled over 3.3 million vehicles due to a damaged or missing shift cable bushing that prevented the vehicle from shifting into the intended gear, leading to potential rolling after selecting the 'Park' position. This issue was identified in various models from 2013-2019, indicating a design flaw in the shift cable part [Article 129006, Article 129306]. (b) The software failure incident related to the operation phase is not explicitly mentioned in the articles.
Boundary (Internal/External) within_system (a) within_system: The software failure incident related to the Ford vehicles' recall is primarily within the system. The articles mention that the recall is due to a damaged or missing shift cable bushing that may prevent the vehicle from shifting into the intended gear, leading to the vehicle potentially rolling away even after the driver selects the 'Park' position. Ford is addressing this issue by replacing the under-hood shift bushing and adding a protective cap, as well as updating vehicle software to address the problem [129006, 129306]. (b) outside_system: The software failure incident related to the Ford vehicles' recall is not primarily due to factors originating from outside the system. The root cause of the issue, which involves the shift cable bushing and the potential for the vehicle to roll away, is internal to the vehicle system itself. The recall is focused on addressing this internal system issue to prevent further incidents [129006, 129306].
Nature (Human/Non-human) non-human_actions (a) The software failure incident occurring due to non-human actions: - The software failure incident in the Ford vehicles was related to a damaged or missing shift cable bushing that could prevent the vehicle from shifting into the intended gear, leading to the vehicle potentially rolling away after the driver selects the 'Park' position [129006, 129306]. - The defect in the vehicles could enable them to move even if the gear shift seems to be in the park position, indicating a non-human action causing the issue [129306]. (b) The software failure incident occurring due to human actions: - There is no specific mention in the articles about the software failure incident being caused by human actions.
Dimension (Hardware/Software) hardware, software (a) The software failure incident occurring due to hardware: - The recall by Ford Motor Co involved more than 3.3 million vehicles in North America due to a damaged or missing part that may prevent the vehicle from shifting into the intended gear, indicating a hardware issue [Article 129006]. - The vehicles could have missing or damaged bearings that could prevent them from shifting into gear properly and allow them to move even if the shifter indicates they are in park, further pointing to a hardware-related problem [Article 129306]. (b) The software failure incident occurring due to software: - Ford also recalled 49,000 Mustang Mach-E electric vehicles because a part could overheat and result in a loss of propulsion power. The automaker will update vehicle software to address the issue, indicating a software-related problem [Article 129006]. - The defect in the Mustang Mach-E electric SUVs was discovered by analyzing diagnostic data that the vehicles transmit to Ford, highlighting a software-related issue [Article 129306].
Objective (Malicious/Non-malicious) non-malicious (a) The articles do not mention any malicious software failure incidents related to the Ford vehicle recalls or the Mustang Mach-E electric vehicles recall [129006, 129306]. (b) The non-malicious software failure incident related to the Ford vehicle recalls involves a defect in the shift cable bushing, which may prevent the vehicle from shifting into the intended gear or cause the vehicle to roll after the driver selects the 'Park' position. This defect is attributed to missing or damaged parts in the vehicles, leading to unintended movement [129006, 129306]. Additionally, the Mustang Mach-E electric vehicles recall is due to a problem that could cause battery connectors to overheat if the vehicles are being charged rapidly or driven at high speeds. Ford addressed this issue by sending an over-the-air software update to correct the problem [129306].
Intent (Poor/Accidental Decisions) unknown The articles do not mention any software failure incident related to poor decisions or accidental decisions.
Capability (Incompetence/Accidental) accidental (a) The software failure incident related to the Ford vehicle recall is not directly attributed to development incompetence or lack of professional competence by humans or the development organization. The issue in the vehicles was due to a damaged or missing shift cable bushing, which could prevent the vehicle from shifting into the intended gear, leading to potential rolling after selecting the 'Park' position. This issue was identified as a mechanical problem rather than a software failure caused by development incompetence [129006, 129306]. (b) The software failure incident related to the Ford vehicle recall was accidental in nature. The issue with the vehicles moving even when the gear shift seems to be in the park position was due to missing or damaged bearings, which could prevent proper shifting into gear and allow movement despite indicating 'Park' on the shifter. This accidental defect was identified as a mechanical issue rather than a software failure introduced accidentally [129306].
Duration temporary The software failure incident related to the Ford vehicle recall is temporary. The issue was identified as a potential defect in the vehicles' shift cable bushing, which could prevent the vehicle from shifting into the intended gear or cause the vehicle to roll after selecting the 'Park' position. Ford addressed this issue by planning to replace the under-hood shift bushing and add a protective cap, with the new parts being manufactured from a different grade material [129006, 129306].
Behaviour omission, other (a) crash: The articles do not mention any software crashes where the system loses state and does not perform any of its intended functions [129006, 129306]. (b) omission: The software failure incident related to the Ford vehicles involved a potential defect that could enable them to move even if the gear shift seems to be in the park position. The vehicles could have missing or damaged bearings that could prevent them from shifting into gear properly and allow them to move even if the shifter indicates they are in park [129306]. (c) timing: The articles do not mention any software failures related to timing issues where the system performs its intended functions correctly, but too late or too early [129006, 129306]. (d) value: The software failure incident did not involve the system performing its intended functions incorrectly [129006, 129306]. (e) byzantine: The articles do not mention any software failures related to Byzantine behavior where the system behaves erroneously with inconsistent responses and interactions [129006, 129306]. (f) other: The other behavior in this software failure incident is related to a potential defect in the software that could allow the vehicles to move even if the gear shift indicates they are in park due to missing or damaged bearings [129306].

IoT System Layer

Layer Option Rationale
Perception None None
Communication None None
Application None None

Other Details

Category Option Rationale
Consequence harm, property, theoretical_consequence (a) death: The articles do not mention any deaths resulting from the software failure incident. [129306] (b) harm: The articles mention that Ford was aware of four reports of injuries potentially related to the software failure incident. [129006, 129306] (c) basic: There is no mention of people's access to food or shelter being impacted by the software failure incident. (d) property: Ford stated that they were aware of six reports alleging property damage potentially related to the software failure incident. [129006] (e) delay: There is no mention of people having to postpone an activity due to the software failure incident. (f) non-human: The articles do not mention any non-human entities being impacted by the software failure incident. (g) no_consequence: The articles do not state that there were no real observed consequences of the software failure incident. (h) theoretical_consequence: The articles discuss potential consequences of the software failure incident, such as the risk of vehicles moving even if the gear shift seems to be in the park position. [129306] (i) other: The articles do not mention any other specific consequences of the software failure incident.
Domain transportation, manufacturing, utilities (a) The failed system was intended to support the transportation industry as it affected vehicles manufactured by Ford Motor Co. The recall of over 3.3 million vehicles due to a damaged or missing part preventing the vehicle from shifting into the intended gear directly impacts the transportation sector [Article 129006, Article 129306]. (g) Additionally, the software failure incident also indirectly relates to the utilities industry as Ford Motor Co had to recall vehicles due to issues with the shift cable bushing, which could lead to the vehicle rolling away after the driver selects the 'Park' position. This poses a safety risk and affects the power and safety services provided by the vehicles [Article 129006, Article 129306]. (m) The software failure incident does not directly relate to any other industry mentioned in the options provided.

Sources

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