NHTSA Complaint #11568602 — 2020 FORD ESCAPE

All 3 welds that hold the drivers front door check arm failed over the course of a day. When travelling with the car I observed some strange creaking/cracking sounds when opening or closing the door, and within a day I found that the door was difficult to close and latch. I looked at the hinges, and notices 3 holes where the welds were, and the check arm moving inside the door. The safety issue is its difficult/impossible to close and latch the door, and difficult to make sure the door is actually latched and stays latched. The door has opened while driving, and I'm not sure if this is due to not being able to close it all the way or of the loose check arm is breaking other parts inside the door. The power window no longer works because the loose check arm appears to be blocking it or has destroyed those components. The dealer inspected the issue, and claimed that they have seen many cars with the same defective door welds. They claimed the door would have to be replaced and repainted though this work hasn't been completed yet. According to the dealer though this is a safety issue and 100% a manufacturing defect that Ford is well aware of they are forcing customers to pay for the repairs. This has not been inspected by police or insurance since it is a manufacturing defect and not related to an accident. This has only been an issue for a day, but if an accident, injury or death results from the door flying open while driving I will contact the police, insurance, and get legal representation. No warning lamps or symptoms prior to failure. I opened and closed the door less than 5 times after the first odd noise to when all the door welds failed.