The Biggest SUV Recalls In US History
The SUV segment is one of the largest and most popular vehicle segments in the US automotive market. The segment has steadily increased over the years. In 2016, SUVs only accounted for roughly 36% of the total new vehicle sales in the US, which is no small feat at all. According to GoodCarbadCar, the SUV segment accounted for almost 50% of the total new vehicle sales in 2021.
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Alongside an increase in sales, the SUV segment has also been bolstered since the 2010s, with many manufacturers jumping into a segment that has acted as a veritable money printer. However, with the widespread introduction of new names and monikers to the segment, many have fallen victim to severe recalls. These are the largest SUV-related recalls to ever happen in the US.
The figures provided, and this article is in no way a definitive depiction of the overall reliability of the vehicles listed. Additionally, recalls which have included other models besides SUVs have not been included as many have not included individual figures for the various models included in the recall orders. This article simply covers the largest SUV recalls in US history.
10
BMW SUV Recall
255,551 units
BMW’s recall issued in August this year covered more than 720,000 vehicles from the automaker’s fleet. The recall order included several models, including the Z4, 5 Series, and 2 Series. BMW’s SUV range was also included in the recall, with models like the X1, X3, and X4 accounting for almost a third of the affected vehicles. According to the recall order, the affected vehicles may have a defective water pump seal that over time could increase the risk of a “thermal event” and even, in rare cases, a fire.
9
GM Recall
354,507 units
This is one of the most recent recalls on this list and is a relatively small recall considering GM’s other recalls over the last decade. GM issued a recall for over 450,000 of its vehicles recently, which included several major nameplates within the automaker’s fleet. While the recall included the likes of the GMC Sierra 1500 and Chevrolet Silverado, it was the umbrella corporation’s SUVs like the Cadillac Escalade, Yukon, and Suburban that accounted for 354,000 of the total number of potentially affected vehicles. The recall issued concerned models produced between 2023 and 2024, which may potentially have a brake fluid leak caused by the mismatch between electronic brake control software and the system’s calibration which would result in the brake pedal performance degrading.
8
Kia Telluride
462,869 units
The Kia Telluride is an appealing offering from Kia, affording ample interior space and a commendable list of options even in its most basic form. Earlier this year, Kia issued a recall for the Kia Telluride, specifically models produced between 2019 and 2024, because of a fault with the seat components. According to Kia’s report, in the event of a crash or any significant impact, the power seat back cover could dislodge and cause the misalignment of the seat motor control switch. Over time, the motor could overheat, thereby increasing the risk of a spontaneous fire while driving or parked. Kia has stated that until repairs are made, Telluride owners should avoid parking next to buildings or other cars.
7
Ford Escape And Ford Bronco Sport
521,746 units
In 2022, Ford issued a recall for two of its SUV products, namely; the Ford Escape and Ford Bronco Sport. Both models were recalled due to one common trait, the 1.5L engine offered for each model. The potentially affected models that were flagged as being included in this recall were models produced in 2018 for the Ford Escape and 2022 for the Bronco Sport. The Escape model accounted for most of the affected vehicles. The fuel injector used in the 1.5L engine could crack, potentially causing the fuel to move to the ignition sources, and potentially causing a fire under the hood. To address the issue, Ford installed a new engine control system capable of detecting a drop in pressure in the fuel rail and a drain tube to allow fuel to drain from the cylinder head drain hole away from potential combustion sources and onto the ground.
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6
Nissan Rogue and Rogue Sport
712,458
Nissan’s recall of the Rogue and Rogue Sport models was significant as it affected many vehicles, but the defect was only present in the “S” Grade trim of each derivative. For the Rogue model, the defect was present in models produced from 2014 to 2020, while the Rogue Sport models produced from 2017 to 2022 were at risk. These “S” Grade models suffered from a defect in the jackknife key that would not be able to hold the key blade in the open position. This could weaken the internal pivot of the jackknife key, which could cause the SUV to turn off while driving without warning.
5
GM Recall
994,736 units
In 2023, GM issued a recall of its Buick Enclave, Chevrolet Traverse, and GMC Acadia models produced from 2014 to 2017. GM said these three SUV models were produced with a faulty front-driver airbag inflator that could rupture during deployment. This was an issue because, aside from being a defective safety measure, the airbag inflator defect could cause metal fragments to pass through the airbag into the cabin, risking the possibility of these fragments causing serious injury to the occupants, and in the worst case, death.
4
Toyota RAV4 and RAV4 EV
1,123,752 units
In 2016, Toyota issued a recall order for more than 1.1 million examples of the Toyota RAV4 and the RAV4 EV derivative. These models were equipped with 3-point lap-shoulder belt assemblies in the outboard seating in the second row. What caused the recall was a defect relating to the seat webbing which would be cut by the seat frame in the event of a front collision. The reason for this was because of the shape of the metal seat cushion, which could cause the seat belt to not properly restrain its occupants.
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3
Ford Explorer
1,194,173 units
Ford once issued a recall for its Explorer SUV, specifically models that were produced from 2011 to 2017. These models suffered from defects relating to the rear suspension. According to Ford’s report, these Explorer models were liable to suffer a fracture of the rear tor link which could cause a sudden degradation of the vehicle handling and a significant increase in the risk of a crash. Ford stated that it would offer to replace the rear suspension toe links.
2
Toyota RAV4
1,853,568 units
This was one of Toyota’s largest recalls in recent years, especially considering that it was only one model within Toyota’s expansive fleet that had this issue. In 2023, Toyota issued a recall for over 1.8 million Toyota RAV4s which were produced from 2013 to 2018. The issue was the specific battery hold-down assembly and battery tray which were not secured correctly and could cause, under specific conditions, a short circuit. The heat generated from the battery short circuit could potentially cause the components around the battery to be damaged and increase the risk of a fire.
1
Ford Explorer
1,889,110 units
Compared to the rest of the models and issues included in this list, the largest recall on this list related to an exterior piece on the Ford Explorer. Over 1.8 million Ford Explorer models were at risk of a faulty A-pillar trim piece that could detach while driving, which could potentially become a hazard to others on the road. This was caused by improper trim clips that weren’t properly assembled during production.
Sources: NHTSA, CarAndDriver, GoodCarBadCar
