An Unsettling Discovery
In the world of automotive safety, few things jolt owners quite like a recall—especially when it involves something as critical as airbags. For Ford, 2025 has already been rough. Having racked up more recalls than almost any other automaker this year, the Blue Oval is now facing another serious issue: one involving side-curtain airbags in its freshly redesigned Ford Ranger.
It all began quietly. During a routine safety audit by the National Highway Traffic Safety Administration (NHTSA), a 2025 Ranger was subjected to a side-impact test. The truck passed, but just barely. Closer scrutiny revealed a troubling detail: the curtain airbag, during deployment, had a small tear—just 15/32 of an inch long—caused by contact with an exterior flange on the B-pillar. Although the tear was small, it was sufficient to cause premature deflation, which means the airbag might not perform as needed in a severe crash scenario.
Sensing the implications, Ford dug deeper. What they found was that the internal reinforcement flange (inside the B-pillar region) could similarly shear the curtain during airbag deployment. In other words, there’s a structural component that, in certain crashes, could damage the curtain, reducing its ability to protect occupants.
So, Ford made the call—this is serious enough to warrant a recall. And not just a handful of vehicles: this affects 100,900 Rangers built from December 9, 2022 through July 29, 2025.
What’s Being Done
Here’s how Ford is responding to the issue:
- A shield will be added between the curtain airbag and the reinforcement flange so that during deployment the airbag cannot be torn by that metal edge. No need to replace the airbag itself; the fix is preventive.
- The recall applies only to Rangers built before July 29, 2025. Rangers built on or after that date are unaffected, because by then the shield had already been implemented in production.
The Stakes
Why does this matter? Because if that curtain airbag fails—even slightly—it compromises one of the vehicle’s key safety lines in side collisions or rollovers. The purpose of side-curtain airbags is not just cushioning but also helping prevent occupant ejection and minimizing head injury risk. A tear caused by interior metal causes air to escape prematurely, meaning the airbag can’t maintain protective pressure. For occupants, this could mean the difference between mild injury and something far worse.
Timeline & What Drivers Should Do
| Date / Item | Details |
|---|---|
| Dec 9, 2022 – Jul 29, 2025 | Manufacturing window for affected 2024-2026 Ford Rangers (approx. 100,900 pickups). |
| Defect Identified | Side curtain airbag may tear if it contacts the B-pillar inner reinforcement flange. A 15/32″ slit was observed in testing, leading to noncompliance with FMVSS 226. |
| Recall Action | Ford will install protective shields between the airbag and B-pillar flange. The airbags themselves are not replaced. |
| Vehicles Not Affected | Rangers built on or after July 29, 2025, as production included the protective shield from that point onward. |
| September 8, 2025 | Ford mailed interim letters to affected owners notifying them of the recall. |
| December 2025 | Protective shield parts expected to be available. Final owner letters mailed and dealers ready to perform repairs free of charge. |
| Owner Action | Check VIN to confirm recall status via Ford or NHTSA. Wait for notification, then schedule the free repair at a Ford or Lincoln dealer. |
Broader Context
This recall is a reminder that even with modern design and safety tech, small interactions between components (like an airbag and a flange) can create big consequences. For Ford, this adds yet another chapter to a rough year in terms of recalls, bringing attention to the complexity of vehicle safety compliance—not only with crash test outcomes, but with every bit of hardware that the airbag might touch during deployment.
NHTSA Recall Wording & Case Number
NHTSA Campaign Number: 25V541 Manufacturer Recall Number: 25C41 Defect / Noncompliance: Affected vehicles were built with side curtain air bags that may not meet the displacement requirements of FMVSS 226 S4.2.1. The inflating side curtain air bag cushion can interact with the B-pillar inner reinforcement flange. Description of Remedy: Dealers will install a protective shield between the side curtain air bag and the inner sheet metal for both right and left side curtains. Free of charge. Recall Schedule: Interim owner notification letters mailed Sept. 8–12, 2025. Final remedy notification & repair expected Dec. 19-27, 2025. Other Details: Production Dates of Affected Vehicles: December 9, 2022 – July 29, 2025 Approximate Number of Affected Units: 100,900 FMVSS Violated: FMVSS 226, “Ejection Mitigation”
If you own a 2024, 2025, or 2026 Ranger, double-check your build date or VIN—and don’t wait for parts to arrive before you plan your remedy. Once the fix is in, it’s in your best interest to get it done. Airbags save lives—but only if they work as they should.
Jim Oaks is the founder of TheRangerStation.com, the longest-running Ford Ranger resource online since 1999. With over 25 years of hands-on experience building and modifying Ford Rangers — including magazine-featured builds like Project Transformer — Jim has become one of the most trusted authorities in the Ford Ranger off-road and enthusiast space. In 2019, he was loaned a Ranger FX4 by Ford Motor Company to test and document across the TransAmerica Trail. Jim continues to inspire and guide Ranger owners around the world.
