​Ford to discontinue Escape and Corsair as plant converts to EV output

Ford ending Escape and Corsair in 2026

Ford says Escape and Corsair production will end in 2025 as Louisville begins retooling, with inventory expected to last into 2026. This would retool the Louisville, Kentucky, plant for a $30,000 EV pickup and at least two SUVs on the same platform.

According to Edmunds on August 12, 2025, the change was part of a $5 billion investment to install the Universal EV Production System. The first EV pickup from the plant was scheduled for 2027, replacing both entry-level gas-powered SUVs.

Stock availability until 2026

Enough stock of Escape and Corsair was expected to last well into 2026. Once these were sold, both models would be permanently removed from showrooms. After their removal, Ford’s least expensive SUVs would be the Bronco Sport and Bronco.

Industry sales tallies show Escape was Ford’s #2 SUV in 2024 (146,859 units), behind Explorer, and the Corsair was Lincoln’s entry-level, conventionally powered SUV in the U.S. lineup.

Price differences after removal

According to Edmunds, the Bronco Sport costs about $1,500 more than the cheapest Escape and includes standard all-wheel drive. The Corsair was approximately $13,000 cheaper than the Nautilus.

The Ford Maverick was the only affordable model Ford had introduced recently, but its price had increased to near midsize truck levels. This followed Ford’s earlier discontinuation of the Fiesta, Focus, Fusion, and EcoSport in the U.S. market.

Past removals from Ford’s lineup

Ford had removed several lower-priced vehicles from its lineup in prior years. These included the Fiesta, Focus, Fusion, and the EcoSport, which had been smaller than the Escape.

The Escape and Corsair had remained as lower-priced SUVs for each brand until the decision to discontinue them. Their removal was in line with Ford’s shift toward electrified models, beginning with the new EV pickup planned for the Louisville Assembly Plant in 2027.

January 3, 2025 recall announcement

On January 3, 2025, Ford recalled about 20,000 plug-in hybrid SUVs due to a battery defect. This recall affected 16,480 Ford Escape Plug-In Hybrids from 2020–2024 and 4,004 Lincoln Corsair Grand Touring plug-in hybrids from 2021–2024.

According to the National Highway Traffic Safety Administration, the defect involved damage to the separator layer between the cathode and anode. This could cause short-circuiting, loss of propulsion, and potentially a fire. Steering, braking, and lights were not affected.

Battery defect incidents and causes

According to the NHTSA, Ford reported four incidents of “battery thermal venting” linked to the defect. The first three occurred in European-market vehicles; no related accidents or injuries were reported.

An investigation concluded that changes in the cell manufacturing process allowed minor defects in the cathode. This caused added stress on the separator layer, leading to potential damage and an increased risk of short-circuiting in the high-voltage battery cells.

Repair plan for recalled vehicles

Ford instructed dealers to install a software update for the battery energy control module first. If needed, battery packs would be replaced free of charge to the owner. Ford expected to mail owner notification letters by January 20, 2025.

The recalled Escape PHEV had front-wheel drive and a 37-mile electric range. The Corsair Grand Touring had all-wheel drive and a 27-mile electric range, with the range difference caused by drivetrain type.

Canadian class-action lawsuit

In January 2025, Charney Lawyers filed a class-action lawsuit over the Canadian-present Escape PHEV and Corsair Grand Touring models. According to Charney Lawyers, defective batteries could cause fires even when parked and turned off.

They stated Ford could not repair or replace the batteries, leaving owners without plug-in charging. They also claimed battery defects reduced electric driving ability and increased engine wear, and that Ford sold the vehicles despite knowing of the defects.

United States lawsuit in April 2025

In April 2025, a U.S. lawsuit was filed over the same battery issue in Escape PHEV and Corsair Grand Touring models. According to the lawsuit, Samsung-sourced lithium-ion batteries could cause fires while parked and turned off.

The complaint alleges Ford knew of the risk prior to sale, claims the company has not admitted, and which remain unproven in court. No plaintiffs reported actual fires, but the lawsuit claimed Ford had the means to anticipate, test for, and prevent the defect.

Longstanding discontinuation rumors

Rumors of discontinuing the Ford Escape had existed for years before 2025. In January 2025, Ford Authority reported the model was still set to end after the 2025 calendar year.

In an interview, Ford CEO Jim Farley hinted that the Louisville Assembly Plant could be retooled for EV production. He referred to a California-based team developing a low-cost EV platform for multiple vehicle types.

Farley’s comments to Yahoo Finance

Farley told Yahoo Finance that 50 percent of the parts for the new platform had been quoted. He said the Louisville plant would be retooled soon.

Public statements indicate a midsize EV pickup arrives in 2027, with additional body styles to follow. The roadmap showed Escape and Corsair production replaced by an EV at Louisville.

Possible future of the Corsair nameplate

The November 2023 roadmap indicated the Corsair could be discontinued or built elsewhere and imported to the U.S. market. Farley stated that he intended for Ford to exit what he called the “boring car” business.

This direction matched the plan to end Escape and Corsair production at Louisville and replace them with electric vehicle production based on the new low-cost platform.

Customer reactions in early 2025

In January and February 2025, some customers said ending the Escape was a mistake because it had been Ford’s third-best-selling vehicle after the F-150.

Other customers criticized weak demand for EVs like the Mustang Mach-E and F-150 Lightning, questioning the need for another EV plant when production capacity was underused.

Concerns about EV cost and demand

According to one commenter in January 2025, the upcoming EV could cost at least $10,000 more than the Escape. Another said Americans did not want EVs in large numbers.

Some questioned why Ford would discontinue the Escape when, according to them, its sales had been increasing yearly. They argued that compact SUVs remained one of the most popular vehicle segments in the U.S. market.

Comparisons with other automakers

Some customers compared Ford to Toyota, saying Ford needed a full range of cars and trucks to compete effectively. One said Ford customers could not afford Porsche-level prices.

Another customer suggested Ford introduce a Lincoln sedan. One recounted an accident in which their Escape’s structure protected them from serious injury, using it as a reason to keep the model in production.

Nissan’s Frontier plug-in hybrid could pave the way for a capable off-road SUV. Read more in Frontier PHEV may spark off-road SUV.

Views on Escape’s styling

One commenter described the Lincoln Continental as “wonderful looking” and the Escape as “boring.” They said other companies could design sharper-looking small SUVs.

These opinions reflected differences in customer perspectives as Ford moved forward with discontinuing the Escape and Corsair, retooling the Louisville Assembly Plant, and preparing for electric vehicle production in the coming years.

A versatile new model blurs the lines between truck and SUV with its unique design. Full story in Twist truck or SUV? This slate ride does both.

What’s your take on Ford’s big SUV exit?

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This slideshow was made with AI assistance and human editing.