NHTSA Complaint #11563226 — 2020 FORD ESCAPE HYBRID

bracket tack welds failed in drivers side front door at attachment of the door check to the door frame. Resulting loose end causes multi-part safety hazard. First, it jams door, randomly presenting it from closing and latching properly, which defeats the auto-lock safety features designed to maintain body integrity in the event of an accident (hazard 1). It also binds now and then, preventing door from being opened for the driver of the car (hazard 2). Third, while flopping around inside the door, the part interferes with the opening of drivers side window (hazard 3). Hazard 2 and 3 in combination create a condition where safe egress from the vehicle in the event of an emergency is not assured for the driver. Dealer confirmed issue and issued quote to replace the door. Manufacturer thinks its not their problem unless its under warranty. Issue is well described in various locations on the web, so its not a one-off manufacturing issue, rather a systemic design/implementation problem.