Weidman v. Ford Motor Company

District Court, E.D. Michigan·Decided April 8, 2022·No. 2:18-cv-12719·Unknown

Opinion

UNITED STATES DISTRICT COURT EASTERN DISTRICT OF MICHIGAN SOUTHERN DIVISION PAUL WEIDMAN, et al.,

Plaintiffs, Case No.: 18-cv-12719 Hon. Gershwin A. Drain

v.

FORD MOTOR COMPANY,

Defendant. ______________________________/

REDACTED1 OPINION AND ORDER GRANTING IN PART AND DENYING IN PART DEFENDANT’S MOTION FOR SUMMARY JUDGMENT [#157, #158] AND GRANTING IN PART AND DENYING IN PART PLAINTIFFS’ MOTION FOR CLASS CERTIFICATION [#150, #154]

I. INTRODUCTION Plaintiffs are purchasers and lessees of 2013-2018 F-150 trucks (“Class Vehicles”) from Alabama, California, Colorado, Connecticut, Florida, Georgia, Michigan, New York, South Carolina, Texas and West Virginia who filed the instant putative class action alleging Defendant Ford Motor Company sold them trucks with a defective brake system (“Brake System Defect”). All of the Plaintiffs

1 The Court entered a Sealed Opinion and Order on March 29, 2022 and required the parties to submit a proposed opinion and order with redactions consistent with this Court’s orders. Accordingly, on April 7, 2022, Ford submitted its proposed redactions indicating the Plaintiffs have no objection to the proposed redactions. As such, the Court files the instant Redacted Opinion and Order. allege they experienced brake system failure due to the Brake System Defect. Plaintiffs bring claims against Ford for common law fraud and violation of

consumer protection statutes. Now before the Court is the Defendant’s Motion for Summary Judgment. Also, before the Court is the Plaintiffs’ Motion to Certify Class. These motions are

fully briefed, and a hearing was held on March 25, 2022. For the reasons that follow, the Court grants in part and denies in part the Defendant’s Motion for Summary Judgment and grants in part and denies in part the Plaintiffs’ Motion to Certify Class.

II. FACTUAL BACKGROUND During the 2013 through 2018 model years, the Class Vehicles were sold with eight different engine packages. All of the Class Vehicles’ engines have a

Hitachi manufactured, step-bore master cylinder. The master cylinders are covered by Ford’s 3-year/36,000-mile warranty, thus any parts that fail within that period are to be replaced at no charge to the consumer. A brake master cylinder is a component of a vehicle’s braking system that

converts the mechanical force drivers apply to the brake pedal into hydraulic pressure on the vehicle’s brake fluids, which in turn pushes that output to the calipers at wheel ends and allows the pedal force to activate the brake system.

There are five seals within the master cylinder which maintain brake fluid pressure. A pressurized, closed system like the Hitachi-made, step-bore master cylinder used in the Class Vehicles is dependent on seal integrity and seal performance.

Plaintiffs’ maintain the Brake System Defect causes the seals in the master cylinders to fail resulting in loss of hydraulic brake fluid pressure. This causes longer brake pedal travel and requires longer distances to stop the vehicle.

The Brake System Defect manifests in the Class Vehicles in at least two ways. The first–leak into booster–occurs when the master cylinder’s rearmost containment seal deforms due to slide friction, thereby rolling or lifting out of its intended position, allowing pressurized brake fluid to leak from the master cylinder

into the brake booster. The second manifestation of the Brake System Defect– bypass failure–occurs when brake fluid pushes the master cylinder’s middle pressure seal out of its intended position, damaging the seal so that it can no longer

regulate hydraulic pressure, allowing brake fluid to escape or bypass through and around the seal. Plaintiffs maintain Defendant knew about the Brake System Defect prior to the Plaintiffs’ purchase of their vehicles. Plaintiffs argue the first red flag came in

2011 when Ford engineers learned Subaru issued a recall for some of its models that used Hitachi-made master cylinders like those used in Ford’s F-150 line. However, Ford executives were informed by Hitachi that “there is no risk to Ford. This Subaru primary seal has a unique cross section and material which are different from any Ford design.” ECF No. 154, PageID.8137 (filed under seal).

Plaintiffs also point to pre-sale testing that led Ford to issue a stop shipment order for some Class Vehicles in March of 2013 because they were experiencing “soft pedal feel” and “fluid bypass,” which are associated with the bypass failure in

the Hitachi master cylinders. Ford disputes the stop shipment order related to the Brake System Defect. Once the Class Vehicles entered the market, Ford monitored warranty claims data, replacement parts data, and customer complaints. Plaintiffs argue that as

early as January of 2013–the first model year of the Class Vehicles–replacement parts sales data for master cylinders doubled from 2012 to 2013. In March of 2013, Ford brake engineer Kam Aynessazian emailed Hitachi noting “2 more

warranty repairs for mcyl bypass. Pls let me know when you get them (or perhaps I will).” ECF No. 154, PageID.8182 (filed under seal). Plaintiffs also rely on the fact Ford and Hitachi convened to study master cylinder in-warranty failure issues in September of 2014. By 2015, Plaintiffs argue replacement master cylinders

were selling at such a fast rate that they reached backorder status. Around this time, Ford issued a TSB to its dealerships for all 2013-2014 F-150s for the leak into booster failure mode. Ford denies knowledge of the Brake System Defect until late 2015 or early 2016 when it first began to detect an abnormal level of warranty claims for master

cylinders leaking brake fluid into the brake booster. Ford asserts that once it evaluated this data, it became clear that the elevated warranty claims were limited to F-150s built in late 2013 and early 2014 equipped with the 3.5L GTDI engine,

one of the eight engines available in the Class Vehicles. Ford asserts that out of the approximately 3.3 million F-150s from model years 2013 through 2018 sold in the United States, only 32.5% were equipped with the affected 3.5L GTDI engine. Additionally, out of the remaining 67.5% of F-150s with other engine types, the

master cylinder warranty claim rate is merely 0.3%. In May of 2016, Ford announced a recall of all F-150s equipped with the 3.5L GTDI engine built between August 1, 2013 and August 31, 2014. The 2016

Recall entitled owners of affected vehicles to a replacement of the master cylinder with a purported redesigned master cylinder. Specifically, Ford claims Hitachi undertook numerous manufacturing changes including adding a silicone lubricant to the rearmost seal in the master cylinder to prevent the seal from rolling or

lifting. This redesigned master cylinder was available on August 1, 2016. Ford maintains it did not include F-150s produced after August 31, 2014 in the 2016 Recall because other F-150s did not have an elevated rate of master cylinder

repairs at the time. Ford further claims that at the time of the 2016 Recall, it believed the 2016 Hitachi redesign of the master cylinder would address the concerns that led to the

recall. Ford asserts that its belief proved accurate because “the silicone lubricant addition, along with the other manufacturing improvements made by Hitachi, essentially eliminated the external leak to the brake booster.” ECF No. 157,

PageID.9486. Ford highlights that its analysis of warranty data for all master cylinder issues fell to less than 0.5% after the August 2016 redesigned master cylinder was introduced. Plaintiffs argue the 2016 changes made by Hitachi did not cure the leak into

booster issue. Rather, the change merely served to delay the manifestation of the defect so that failures happened outside of the warranty period.

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