Ford Recalls Roughly 133,000 Lincoln Aviators Over Trim Detachment Issues

3.2% or approximately 4,256 of the 133,000 recalled vehicles involve a safety defect prompting Ford to recall roughly 133,000 Lincoln Aviator SUVs from model years 2020 to 2025.

The C-pillar appliques and rear door window division bars may detach while driving, posing potential hazards to other vehicles, pedestrians, and cyclists.

The root cause is traced to insufficient adhesive bonding during assembly, increasing the risk of these parts loosening or falling off.

Ford has been monitoring this issue for over three years and has received 1,105 warranty claims worldwide.

Fortunately, no accidents or injuries have been reported to date. Notably, this trim-related recall marks the second issued for the Aviator in June 2025, following an earlier recall involving second-row seat switch bezels.

Why Is There a Lincoln Aviator Trim Recall?

The Lincoln Aviator trim recall was issued due to a defect involving exterior trim pieces that may detach while the vehicle is in motion.

Specifically, the C-pillar trim appliques and rear door window division bars were not properly bonded during manufacturing.

The adhesive used to secure these components was inadequate, increasing the likelihood that these parts could come loose or fall off entirely.

This defect is more than just a cosmetic concern. Trim pieces that detach while driving can create road hazards, potentially striking nearby vehicles or pedestrians.

The safety risk becomes especially serious at highway speeds, where debris can cause significant damage or injury.

The affected vehicles were assembled at Ford’s Chicago Assembly Plant, with the problematic trim parts supplied by Cooper Standard Automotive in Mexico.

How the Defect Impacts Safety on the Road

When these components detach while the vehicle is in motion, they can create hazardous situations for other drivers, pedestrians, and cyclists.

At highway speeds, loose trim pieces may strike nearby vehicles, potentially damaging windshields or causing drivers to swerve and lose control.

In more populated areas, such as city streets or residential neighborhoods, detached trim could injure pedestrians or cyclists.

Beyond direct impact, detached parts become debris on the roadway. Other drivers may run over these pieces, leading to tire damage or accidents.

In addition to physical risks, there are potential legal and liability concerns. If a detached component causes an accident, the vehicle owner might be held responsible, even if they were unaware of the defect. Ford could also face legal consequences if the problem is not addressed in a timely manner.

While this issue is primarily seen as a cosmetic defect, the trim contributes to the vehicle’s structural finish and aerodynamics.

Over time, detachment could lead to increased wind noise or water intrusion, affecting the overall integrity and comfort of the vehicle.

Ford’s Official Response and Repair Plan

Although Ford had been aware of this issue for several years—with over 1,100 warranty claims reported globally between June 2020 and April 2025—initial investigations led by Ford’s Critical Concern Review Group between April 2022 and May 2023 concluded that the problem did not pose a significant safety risk.

However, in April 2025, a loose trim piece was identified on a test vehicle, prompting further analysis. Following renewed discussions and coordination with the National Highway Traffic Safety Administration (NHTSA), Ford’s Field Review Committee officially approved the recall on June 6, 2025.

As part of the remedy, Ford dealerships will repair or replace the affected trim components at no cost to the vehicle owner.

The replacement parts will be permanently secured to prevent future detachment. Ford will begin notifying owners of the recall through letters mailed on July 28, 2025, with a second notification planned once the repair solution becomes available.

This recall is identified under Ford Recall Number 25S66. For additional support, owners can contact Ford Customer Service at 1-866-436-7332 or reach out to the NHTSA Vehicle Safety Hotline at 1-888-327-4236. More information can also be found at www.nhtsa.gov.

Owner Notification and Next Steps

Lincoln Aviator owners should be aware of the recall process and what actions to take. Below is what to expect and how to proceed:

1. Initial Notification Letter: Lincoln Aviator owners will receive letters beginning on July 28, 2025, informing them that their vehicle may be affected by the recall. This letter advises owners to wait for further instructions before visiting a dealership.
2. Second Notification Letter: Once repair parts and procedures are ready, a second letter will be sent with instructions on how to schedule a free repair at an authorized Ford or Lincoln dealership.
3. Wait for Repair Availability: Do not visit a dealership until the second letter confirms that repairs can be performed and parts are available.
4. Schedule Your Repair: After receiving the second notification, contact your local Ford or Lincoln dealer to schedule a free repair appointment.
5. Report Existing Issues: If trim parts have already detached, owners should report the issue to Ford Customer Service at 1-866-436-7332 or the NHTSA at 1-888-327-4236 or www.nhtsa.gov.

What to Do If the Trim Problem Returns After Repair

If the trim issue reappears after your Lincoln Aviator has already been repaired under the recall, you should contact the same dealership that performed the original repair as soon as possible.

Explain that the trim problem has returned and request a follow-up inspection. Be sure to bring any relevant documentation, such as your service receipt or recall notice, to assist in the process.

Document the issue thoroughly by taking photos or videos of the detached or loose trim. It’s also helpful to note the date, time, and driving conditions when the problem occurred.

Keep a detailed record of all communications with the dealership and Ford, which can be useful if the issue persists.

Recall repairs are typically covered under warranty; however, coverage for additional repairs may depend on whether the problem is caused by faulty parts or installation and how much time has passed since the original repair.

If the dealership is unresponsive or the trim problem continues, you can escalate the issue by contacting Ford Customer Service at 1-866-436-7332.

Additionally, you have the option to file a complaint with the National Highway Traffic Safety Administration (NHTSA) through their website at nhtsa.gov/report-a-safety-problem.

When to Speak with a Lemon Law Attorney About Your Lincoln

The recall affecting Lincoln Aviators due to detaching exterior trim parts—like the C-pillar appliques and rear door window division bars—raises important safety concerns.

While Ford is providing free repairs to permanently fix these defects, some vehicles may still experience issues after the recall service is completed.

If your Lincoln Aviator has experienced warrant repairs related to trim problems or related to other safety concerns even after the recall repairs, you may be entitled to pursue a Lemon Law claim.

Successfully filing a claim can result in the manufacturer paying for your legal fees and costs. This makes pursuing a lemon law claim an easy consumer decision since there should be no out of pocket expense with pursuing a lemon law claim.

Since 2009, the Lemon Law Experts have assisted vehicle owners in holding manufacturers accountable when their vehicles fail to meet safety and quality standards.

If you’re dealing with ongoing issues in your Lincoln Aviator despite recall repairs, contact our team for a free consultation.

We’re here to help you understand your options and secure the resolution you deserve.