2021 Ford Ecosport electrical problems

Engine loses all power and shuts down entirely with no warning while vehicle is in motion at highway speeds (50+ mph). Vehicle rolls to a stop; power steering locks, all lights and electronics cut off instantly, and braking becomes severely compromised. Owners report this has occurred multiple times—up to six times in some cases—often without prior warning lights. Some incidents happened shortly after engine replacement under recall #23S64.

When: During highway driving and freeway transitions, some within 20 miles of recall repair completion; recurring across multiple incidents per owner

Symptoms owners cite: Complete loss of engine power while driving; Engine will not restart immediately; All lights and electronics shut off instantly; Power steering locks up; Brakes become non-functional or severely compromised; Vehicle cannot be steered or controlled; Vehicle rolls until it stops

Codes mentioned: Check engine light illumination (post-repair)

Repairs/costs cited: One owner reported dealership blamed faulty battery ($300 replacement) and knock sensor issue ($200 repair) after engine shutdown. Dealership unable to determine root cause or guarantee it won't happen again. Recall #23S64 (Engine Oil Pump Belt and Tensioner Replacement / engine replacement) did not resolve issue and may have caused it in some cases.

Recalls/TSBs owners mention: Recall #23S64 for engine oil pump belt and tensioner replacement existed for 2 months before some owners acquired vehicles. Ford denied recall repair approval in at least one case, claiming the failure was not recall-related despite it being a known problem. Ford customer service representative abandoned communication with one owner after months of contact.

Vehicle illuminates Engine Coolant Over-Temperature and Service Engine Soon warnings. Owners report that replacement of the coolant temperature sensor and associated wiring does not resolve the issue; the same warning reoccurs within a short time. One owner experienced this over six times. When the warning occurs, the vehicle enters limp mode with reduced power and acceleration, sometimes at highway speeds. One vehicle developed an overheating issue after recall repairs that dealership deemed unsafe to operate.

When: Recurring episodes after sensor replacement; overheating issue emerged post-recall repair

Symptoms owners cite: Engine Coolant Over-Temperature warning light; Service Engine Soon warning light; Vehicle enters limp mode with reduced power; Loss of acceleration, sometimes at highway or merge speeds; Overheating condition (post-recall)

Codes mentioned: Engine Coolant Over-Temperature warning, Service Engine Soon

Repairs/costs cited: Ford service centers repeatedly replaced the engine coolant temperature sensor and wiring, but issue recurs. One owner cited part costs over $580 for Transmission Roller Restrictor Mount and overheating repair parts (awaiting arrival at dealership).

Recalls/TSBs owners mention: No manufacturer response documented. Parts for overheating repair were on backorder with estimated one-week lead time.

Vehicle suddenly lost power while driving, illuminated multiple warning lights, and caught fire under the hood. Owner sustained minor injuries while exiting the vehicle. Fire department extinguished the fire; vehicle was deemed a total loss.

When: At approximately 41,000 miles

Symptoms owners cite: Multiple warning lights illuminated; Loss of automotive power; Black smoke leaking from under hood; Vehicle caught fire; Driver-side door lock/latch failed during emergency

Repairs/costs cited: Vehicle was towed and deemed a total loss. Local dealer not contacted; vehicle not diagnosed or repaired.

Recalls/TSBs owners mention: Manufacturer was made aware of the failure. No further response documented.

Vehicle illuminates traction control and other warning lights due to faulty sensors. One instance resolved with a software update; another involved sensors incorrectly indicating the vehicle is in park, causing wheel lock and loss of drive assist and steering controls. Battery was replaced as temporary repair in one case.

When: At approximately 30,000 miles and recurring

Symptoms owners cite: Traction control warning light; Multiple unknown warning lights; Wheel lock-up; Loss of drive assist controls; Loss of steering controls; Limp mode activation

Repairs/costs cited: One owner paid out of pocket for software update repair. Battery replacement performed as temporary fix.

Recalls/TSBs owners mention: Software update was identified as repair solution in at least one case; manufacturer was made aware of the failure.

After engine replacement under Recall #23S64, vehicle developed multiple new defects within 20 miles: sudden engine shutdown while in motion, knock sensor failure, unusual piston sounds from the new engine, and hood damage while in dealership care. Issues were nonexistent before the recall repair.

When: Within 20 miles of recall repair completion

Symptoms owners cite: Abrupt engine shutdown while in motion; Engine will not restart; Check engine light illumination; Knock sensor fault; Unusual piston sounds from engine; Hood damage

Codes mentioned: Knock sensor diagnostic code

Repairs/costs cited: Dealership charged approximately $200 for knock sensor diagnosis and repair, claiming it was unrelated to engine replacement and 'bad timing.' One-time use bolts had to be replaced, extending repair timeline by 3-4 days. Vehicle remained unrepaired for nearly two months.

Recalls/TSBs owners mention: No warranty repair or recall coverage offered. Dealership stated defects were consequences of Ford's mishandling of engine replacement but did not assume responsibility.