Ford is recalling 66,383 hybrid vehicles because the repair from an earlier recall didn't fully fix the problem.
The issue involves the pedestrian warning system, which may randomly fail to emit sounds at low speeds.
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Affected Models and the Defect
The recall covers 2025-2027 Ford Explorer Hybrid and 2024-2027 Lincoln Nautilus Hybrid models equipped with the Phoenix audio system.
Ford says 18,242 Explorers and 48,141 Nautilus SUVs are involved.
Federal regulations require electrified vehicles to produce warning sounds below 18.6 mph (30 km/h) because they are often too quiet for pedestrians to hear.
A software error in the audio processing system can cause the sound to fail.
Previous Recall Didn't Work
Ford's earlier Safety Recall 25SA2 addressed a software defect in the Digital Signal Processor and Audio Control Module.
After dealers applied the fix in late 2025, owners reported the pedestrian warning system stopped working again. Many saw a dashboard message reading, "Pedestrian Sounder Fault.
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Service Now."
Ford's investigation found a potential software issue in the 24-channel DSP system used on some Nautilus hybrids.
However, engineers later identified another problem that may affect all audio configurations in both models.
Root Cause Still Unknown
Ford believes the issue may involve a loss of communication between the Audio Control Module and the Accessory Protocol Interface Module.
The exact root cause remains under investigation.
As of May 1, Ford had received 72 warranty claims related to post-recall pedestrian alert failures, including 65 for the Nautilus and seven for the Explorer.
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The automaker says it is not aware of any crashes or injuries tied to the defect. Additional remedies beyond a software update are being developed.
