NHTSA Complaint #11559082 — 2020 FORD ESCAPE

ISSUE: Left front door (driver's door) door check spot welds broke free from the door frame making it impossible to close the door without damage. Issue presented itself as a loud popping sound approximately 36 hours prior to weld failure. Until weld failure, I was unsure what the issue was, and was unable to visit a dealership due to time constraints. Door was operated with caution after the issue was discovered, and I figured that something had just popped out of place and would look at it over the weekend and/or schedule a service visit with the local dealer. I was not expecting factory welds to break. The component has not yet been inspected by the dealership or other parties. SAFETY CONCERN: Lack of a functional door check may allow the door to forcefully swing closed while the driver is entering/exiting the vehicle, causing injury. The door may also swing outward uncontrolled in which multiple injury or damage outcomes are possible. The breaking of the welds also caused the check arm to be stuck in the extended position, preventing the door from being able to close. To allow closure of the door without additional damage, bolts and nuts securing the check arm to the door frame and bracket were removed, allowing insertion of the door check assembly into the door body.