Ford is facing fresh legal trouble over the Transit Trail, a van specifically marketed toward off-road campers and “van life” buyers. According to a new lawsuit, the company’s recall fix may have solved one problem while creating another.
The issue centers around the Transit Trail’s factory 30.5-inch Goodyear Wrangler all-terrain tires. Owners say those tires could rub against the wheel arch liners under certain steering and braking conditions, especially when the van was heavily loaded.
Ford acknowledged the problem in a 2024 recall covering roughly 1,900 examples of the 2023 and 2024 Transit Trail. The automaker’s fix involved replacing the original tires with smaller ones and fitting revised wheel arch liners.
Now, at least one owner claims that the solution effectively stripped the van of the off-road capability he paid for in the first place.
The Recall Problem Started With Tire Rubbing
The Transit Trail was introduced in 2022 as a more adventurous version of the standard Transit van. It came equipped with a lifted suspension, all-wheel drive, selectable drive modes, and aggressive all-terrain tires aimed at overlanding buyers.
According to Ford’s recall documents filed with the National Highway Traffic Safety Administration, the larger front tires could contact the wheel arch liner and body flange during hard braking or tight turns. Ford engineers reportedly found contact occurring at around 60 percent of full steering lock when the van was loaded near its front axle weight limit.
Some owners reported rapid tire wear, flat tires, and even belt separation due to the rubbing issue. Ford said it had received multiple field reports and warranty claims before issuing the recall.
Owners Say The Fix Defeats The Point Of The Van
The latest lawsuit was filed by Connecticut owner Joseph Falman III, who says he paid around $80,000 for his 2023 Transit Trail, expecting a capable off-road van. Instead, he claims the recall repair reduced the vehicle’s performance in snow, mud, and other rough terrain.
According to the complaint, Ford’s replacement tires are smaller and less suited to off-road use. The lawsuit argues that reducing tire size also hurts ground clearance and approach angles, both of which are important for trail driving.
Falman claims the recall remedy “removes the ability” to use the Transit Trail for the purpose it was advertised. He also alleges Ford should have discovered the clearance problem during testing before the van ever reached customers.
This Isn’t Ford’s First Transit Trail Lawsuit
The new filing is not the only legal action tied to the Transit Trail recall. A separate class action lawsuit filed in 2025 raised similar concerns about the reduced off-road capability after Ford’s repair was completed.
That earlier case is still moving through the court system. Together, the lawsuits create an unusual situation where owners are not simply complaining about a defect, but about the official fix itself.
Cases like this are relatively rare in the auto industry. Most recall repairs aim to restore a vehicle to its intended capability, not potentially reduce it.
Ford May Face A Difficult Argument
Ford could argue that safety had to take priority over maximum off-road performance. Tire rubbing severe enough to damage the tires obviously creates a legitimate safety concern, especially on a heavy van.
Still, the Transit Trail was sold as a specialized adventure vehicle, not a basic work van. Buyers specifically paid extra for features like increased ride height, all-terrain tires, and enhanced capability.
That may become the core issue in court. If owners can convince a judge that the revised setup materially changes what the Transit Trail was marketed to be, Ford may have to offer something more substantial than smaller replacement tires.