A nationwide review of vehicle safety data from 2020 to 2025 reveals a growing crisis on U.S. roads: nearly one in five American vehicles carries an active safety recall. According to the new “Defect Hall of Fame” study from DeMayo Law, more than 130 million cars have been recalled in just five years — many for defects that appear repeatedly across automakers and model years.
The findings paint a clear picture of a safety system struggling to keep pace with both aging fleets and increasingly complex automotive technology. Mechanical failures remain widespread, while software-based defects have surged, creating problems that are both harder to detect and faster to spread.
The Automakers Behind the Most Recalls
The study ranks the brands responsible for the highest number of recalls since 2020, highlighting how legacy mechanical issues and emerging digital defects now co-exist on U.S. roads.
Ford leads the nation with 17 million recalled vehicles, driven largely by brake and fire risks.
General Motors follows with 14.2 million recalls, tied to engine and ignition failures.
Chrysler (Jeep, Dodge, Ram) ranks third with 11.1 million, dominated by airbag and emissions-related issues.
But the most notable shift is the rise of software-heavy recalls. Tesla, with 6.1 million recalls, resolves most defects in as little as three to five days through over-the-air (OTA) updates — a stark contrast to traditional automakers, whose mechanical repairs often take eight to ten months to fully complete.
Hyundai and Kia also stand out, issuing 9 million engine-fire-related recalls and facing a $200 million class-action settlement, one of the largest defect settlements in automotive history.
The 10 Defects Driving America’s Recall Crisis
The study identifies the most common defect categories behind U.S. recalls since 2020. Together, they account for tens of millions of affected vehicles:
- Airbag defects
- Battery fires
- Brake failures
- Software glitches
- Ignition switch failures
- Seatbelt malfunctions
- Engine stalls
- Fuel system leaks
- Structural failures
- Airbag programming errors
Despite over 20 years of regulatory scrutiny, airbags and restraint systems still represent one-quarter of all recalls, while battery and charging failures have risen 43%, fueled by rapid EV adoption.
Millions of “Zombie Recalls” Still on the Road
One of the study’s most troubling findings is the persistence of “zombie recalls” — defects that remain unrepaired long after a recall is issued. An estimated 10 to 15 million vehicles in circulation today fall into this category.
Older cars and used vehicles show the lowest compliance rates, often because recall notices do not reach second or third owners. In high-turnover states such as Texas, Florida, and California, the combination of large vehicle fleets, older model years, and low repair follow-through keeps millions of defective vehicles on the road.
State-Level Recall Burdens
Large, car-dependent states face the biggest exposure. According to the study:
- California: 5.5 million recalled annually
- Texas: 4.2 million
- Florida: 3.5 million
- North Carolina: 1.7 million
These figures reflect both population density and the age of the state’s vehicle fleets. In particular, Sun Belt states experience recall compliance rates below 70%, creating a disproportionate safety risk.
Why the Crisis Is Growing
The data suggests the problem is not simply the number of recalls, but the speed and consistency of the response.
Mechanical repairs often require months to complete due to supply-chain delays, dealer scheduling backlogs, and slow part distribution. Software-heavy vehicles introduce new flaws — such as phantom braking or display freezes — that traditional oversight frameworks were not designed to regulate.
Meanwhile, repeat defects fuel class-action lawsuits. GM’s V8 engine breakdowns, Ford’s transmission issues, Hyundai and Kia’s theft vulnerability, and Tesla’s autopilot complaints all demonstrate how long-running engineering issues escalate when fixes are delayed.
A Public Safety Threat Hidden in Plain Sight
With 283 million vehicles registered in the U.S., even a small percentage of defective cars creates a significant risk. The study’s analysis shows that high-defect states also experience higher rates of crash injuries, insurance claims, and consumer losses.
According to DeMayo Law, unresolved recalls are not just an engineering failure — they represent a structural gap in consumer protection.
“Each year, tens of millions of defective vehicles remain unrepaired, even after official recalls,” the firm stated. “The same automakers topping the recall charts are also the ones most frequently sued. It shows that unresolved defects aren’t simply a technical issue; they’re a legal and ethical one.”
Methodology
The analysis draws on 2020–2025 data from:
- National Highway Traffic Safety Administration (NHTSA)
- CARFAX open-recall datasets
- State DMV registration records
- Federal court filings for defect-related litigation
- DeMayo Law’s internal “Defect Hall of Fame” dataset
The study includes more than 130 million recall records, with defect categories, repair timelines, and brand comparisons verified using official manufacturer filings.
Click here for further information: https://demayolaw.com/research/the-defect-hall-of-fame/
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