Ford is showing signs of improvement in vehicle quality after years of recall campaigns, with the automaker ranking as the top mass-market brand in J.D. Power’s 2026 Initial Quality Study. The shift follows changes designed to identify and fix problems before vehicles leave the factory.
Ford Changes Its Approach to Vehicle Quality
Since the start of the decade, Ford has frequently been associated with quality issues and led major automakers in National Highway Traffic Safety Administration recall campaigns for several years. That gave Chrysler, now part of Stellantis, an opportunity to move away from the top spot on the unwanted list after previously leading it.
Ford eventually made internal changes focused on identifying problems earlier rather than discovering them later. The results were reflected in J.D. Power’s 2026 Initial Quality Study, where Ford ranked first among mass-market brands.
The improvement represents a significant change from three years ago, when Ford ranked 23rd. Automotive News reported that the company shifted from a “find-and-fix” approach to identifying defects before vehicles leave the factory in 2023, following a problematic redesign of the Super Duty pickup line that cost Ford $1 billion.
Ford Adds More Than 350 Technical Specialists
Ford’s quality strategy has been supported by hiring or promoting more than 350 technical specialists over the past three years. Informally known as “graybeards” because of their expertise, these specialists concentrate on individual vehicle components and processes.
Some focus on preventing engine contamination, while others work on wiring systems. Another recent hire, Samuel Matt, specializes in rear closures, including liftgates, tailgates and cargo doors.
During Explorer testing, Matt and his team discovered that a supplier error had caused a component in the liftgate closure system to malfunction. They diagnosed and resolved the problem the same day, before the vehicle launched.
Problems that escape detection can potentially result in recalls later. While repairs are generally free for owners, they can still consume their time and damage Ford’s reputation for quality, even when the underlying issue is caused by a supplier.
Charles Poon, Ford’s vice president of vehicle hardware engineering, said the process has already produced hundreds of changes to vehicle designs before parts are manufactured.
“There [have] been hundreds of corrections, improvements, I would say, in our designs even before the first part is even produced, going through this process. We’re starting to see the payoffs of that occur right now,” Poon said.
Ford Expands Testing and Daily Problem Solving
Ford’s quality efforts extend beyond identifying defects earlier. The company has introduced daily problem-solving sessions designed to track issues through resolution.
The automaker has also subjected vehicles to longer durability testing equivalent to 15 years or 225,000 miles.
Ford Still Leads Major Automakers in 2026 Recalls
Despite the improvements in its quality ranking, Ford continues to lead major automakers in NHTSA recall campaigns so far this year. As of this writing, the company has 67 recalls, including a recent campaign involving five models equipped with EcoBoost engines.
Stellantis ranks second with 32 recalls, followed by General Motors with 22, Toyota with 21 and Hyundai with 18.
Ford executives say they are pleased with the progress as the company continues its efforts to identify and resolve quality problems earlier in the vehicle development process.
