I recently took ownership of a 2021 BMW i3S built in June of 2021, just as COVID lockdowns and madness started to taper off. The effects of the lockdown on manufacturing were profound: Limitations were placed on who could work and when, supply chains were severely constrained, and turnover in the workforce was tremendous. How, then, will these COVID-built cars fare long-term?
It was four years ago when COVID really began kicking the U.S.’s butt, and pretty much everything shut down. People were told not to come into work, though some had no choice — among those some were factory workers, who had to put cars together. The problem was: Sometimes the parts needed to complete a car weren’t available. Factories in different nations had to abide by whatever their countries’ rules were, so if you needed an engine from Mexico, for example, and Mexico had to shut that plant down for safety reasons, you were pretty well screwed.
Dealing with the various COVID restrictions around the world put huge limitations on manufacturing to the point where some car companies were building cars without certain features because they just didn’t have the parts. The chip shortage at around the same time caused huge issues, with automakers building incomplete cars, only to keep them in holding yards until parts were available to complete them.
In the case of the BMW i3, the company was unable to offer the Harman Kardon stereo system during COVID because the parts just weren’t available. Luckily, my car has that option somehow, but it also has some build quality issues that my 2014 just doesn’t:
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Can these build quality issues be attributed to COVID? It’s a question that lots of folks are asking (see below), though I don’t really have an answer; my car’s quality issues could also just be seven year-old tooling getting long in the tooth or regular Technical Cost Reduction leading to worse fitment. In any case, it seems almost certain that at least some COVID built cars will end up having issues that non-COVID cars don’t; automakers were clamoring to build as many vehicles as they could as demand spiked after a long lull.
With folks “finding themselves” and switching careers to lead inexperienced replacements to have to handle difficult manufacturing jobs, parts hard to obtain, and demand vastly outweighing supply, you’d think that some corners would have to be cut. But the data on that front isn’t yet clear. We’ve seen huge recalls/warranty costs at Ford lately, but does that have to do with COVID? I don’t know.
I reached out to Consumer Reports, whose Sr. Communications Specialist James McQueen told me there’s no clear data pointing to “COVID Cars” being a thing. “The short answer is no,” he emailed me. “Our data doesn’t reflect any noticeable change in car reliability/problem rates in 2020 or 2021. From what we can tell, it has remained fairly consistent.”
Hmm.
Meanwhile, back in the summer of 2022, JD Power released the results of its Initial Quality Study, and it concluded something different:
In the wake of the COVID-19 pandemic, initial vehicle quality notably declined, according to the J.D. Power 2022 U.S. Initial Quality StudySM (IQS), released today. The disruptions caused by the pandemic—supply chain issues, record-high vehicle prices and personnel dislocations—contributed to vehicle problems reaching a record high in the 36-year history of this benchmark study. Compared with 2021 results, the industry experienced an 11% increase in problems per 100 vehicles (PP100), which is 18 PP100 worse than last year, resulting in an industry average of 180 PP100. A lower score reflects higher vehicle quality.
Hot damn! A record high in the 36-year history of the study! More from JD Power:
In the wake of the COVID-19 pandemic, initial vehicle quality notably declined, according to the J.D. Power 2022 U.S. Initial Quality StudySM (IQS), released today. The disruptions caused by the pandemic—supply chain issues, record-high vehicle prices and personnel dislocations—contributed to vehicle problems reaching a record high in the 36-year history of this benchmark study. Compared with 2021 results, the industry experienced an 11% increase in problems per 100 vehicles (PP100), which is 18 PP100 worse than last year, resulting in an industry average of 180 PP100. A lower score reflects higher vehicle quality.
Many of the issues (six of the top 10) were related to infotainment, which isn’t surprising, as results of JD Power studies are often dragged down by infotainment. What about powertrain reliability, though? The important stuff that actually affects how a car drives? How much did those change during the pandemic?
Some of this stuff we’re just not going to know until we “wait and see,” but logical thinking leads me to think: COVID cars are a compromise. They had to be in order to get off the assembly line. For those compromises to in no way affect longevity would be putting a lot of faith into an automaker’s (and all of its suppliers) quality control regimen during a pandemic that brought uncertainty to all. I’m not sure that passes my laugh-test.
I haven’t had any issues with my car that weren’t self wrought. It was built in late 2020, but I think I lucked out because it was the last year of the car.
Toyota Venza, 2021, first model year in the USA, MIJ. flippin’ fantastic!
Build quality is fantastic.
The only major issues I’ve heard is a handful of glove boxes not closing requiring replacement, center console storage bin having issues because it slides forward and backward, lastly the special dual pane gas “StarGaze” panoramic sunroof shattering when ceramic/rock road debris impact the roof at a stress point causing the ENTIRE thing to shatter.
Other than that, 31k miles, very happy.
Maybe I got lucky, but I bought a 2021 JLU Wrangler at the end of September 2020. It’s been flawless in almost four years of ownership now. No recalls, and has never seen the dealer since I bought it.
I have probably jinxed myself now…
Pandemic parts are going to haunt multiple industries for years to come. It also seems that a general trend of sub-par build quality and QA still permeates many suppliers and industries. There are things that I would usually proactively replace on my older DDs that I simply won’t now because the new part may last a shorter amount of time than the original 20+ year old part. This problem affects new car buyers and us bangernomics champions alike.
I have a 2022 WL Trailhawk. Could be covid or could be that it was the first production year, but the interior has some fit and finish issues and there are some annoying noises that I’ve had to deal with.
Also, the only reason we have the Trailhawk trim is that it was the cheapest one we could get with the full tow package due to the parts shortage. Every other trim level was being sold as “Tow package prep”. Which had everything but the wiring harness and actual hitch.
It’s been fine overall. I don’t care for the air suspension much. It’s not terrible, but bouncier than I like. Also I have no need for it. If I’m going wheeling it’s in the XJ in my profile pic
Most of the problems were probably masked…
Got a Maverick that was produced in 2022, so tail end of those pandemic shortages, etc. Infotainment system was very glitchy, had bad water leaks that the dealership gaslighted us about, generally felt buggy. We traded it in after about 11 months because we were just sick of all the crappy stuff. Ford ended up sending us $20 because it apparently lacked some chips it was supposed to have for features that I didn’t actually care about. Anyway, I kinda want to believe that the buggyness was because of shortages because it was such the perfect vehicle for us… kinda want to buy another one.
Definitely been wondering this. Been shopping for a new/newer used car for my wife and I, and I’ve wondered would if we are to buy used should we try to find one from 2018 or 2019? I worry less about workers etc doing poor work and more that based on shortfalls were manufacturers cutting costs by using lower quality materials, and were their parts suppliers doing similar by looking for ways to cut costs, especially once you get into the 2021 and 2022 models and the shortages had started to last.
I can tell you from experience they already are. As are the majority of things on the market during that time.
My best friend works for a supplier making parts for Mercury marine, Stellantis, Textron, etc. He said during the pandemic there was basically no quality control. Metal they would have prior rejected they were passing because the only other choice would be to close shop.
We now are feeling that on the consumer service / warranty side of things and it’s very frustrating
I have seen this as well. Like so many others, we did a home renovation during the pandemic and the appliances we bought are very obviously made not their manufacturer’s best efforts. The dishwasher started leaking through the seam sealer they used on the “fully welded tub” model I bought, and it’s “5 year defect-free warranty” has fine print stating that it doesn’t apply to models made during periods of the pandemic. The fridge, purchased at the same time, trips the breaker at random every month or so (it did it again this morning) in addition to the interior door shelf-skin constantly wanting to separate from the door despite only holding lighter things like butter sticks. I won’t even get into the microwave and washer/dryer that were purchased during the pandemic…
Sucks to hear people going through this! It’s basically every industry. We’re even seeing the welds on commercial mower decks failing, maybe due to the metal quality
I didn’t have to wait to find out. My 2023 Pacifica phev bought earlier this year broke within 2 months and has been sidelined since waiting for backordered parts. At least I have next April to look forward to when I claim the tax credit, I wonder if it’ll be running by then.
The real problem with Covid era cars is how difficult it can be to figure out what features your model/trim was supposed to come with but didn’t for a year, two years, or even just a few months.
Toyota’s entire new multimedia system was clearly designed by people working from home that forgot how a car works, if that counts.
sadly I think this is every multimedia system…
At one point Ford had hundreds, if not thousands of brand new F-150 trucks stored in the lots at Kentucky Raceway outside Louisville waiting on chips. My mind still boggles at the lost upfront investment of millions just sitting, waiting on one part to be sold.
I shudder to think of the drying seals, fading paint, oxidizing parts and more on all those trucks that sat. When you buy one, is it a 2024 model or a 2022 model that has been sitting for 2 years waiting for a chip. Does the warranty fully extend out and cover it from purchase date or date of manufacture?
My 2022 Bronco was sold as that model year even though it arrived at the dealership as a new vehicle in mid-2023. Warranty started from date of purchase, not manufacture.
A friend of mine bought a GMC truck a couple years ago. Has the fancy tailgate that does yoga or whatever. Or at least it is supposed to. Most of it does not work due to a chip shortage at the time.
The cars are not the only victim of COVID build quality issues. Caravans and motorhomes are also built worse during the COVID. Because of the travel restrictions, staycations / domestic tourism boomed in the Europe like never before. Demand overwhelmed the factories and they rushed the production to keep up. With many manufacturers the build quality is much weaker than few years before. Also lots of standard equipment from previous years were left out.
You pasted the same JD power quote twice.
It’s really really important
Sorry, it’s my occupational quirk.I usually get paid for quality control so they should appreciate my free feedback 😉
I lemoned a 2021 Wrangler 4xe.
Though, after talking it over with a tech friend, it’s possible all 4xe are lemons. Their owners just haven’t realized it yet.
What was the issue(s) with it? Besides it being a jeep /s hah
Hybrid battery coolant heater went bad. Tech friend says it’s a very common fault with them, and the design hasn’t been changed yet. They just replace them as they go. Also had one computer module and part of the wiring harness replaced.
Yeah that would make me completely steer clear of any hybrid tech from Chrysler for the near future. Crap not even hybrids but if their are ECU’s and harnesses crapping the bed that quickly I would steer clear of their whole lineup.
Don’t the hybrid Chrysler vans have a tonne of issues too?
Yup. All the 4XE products are struggling, as is the Wagoneer (interestingly enough)
Yeah, that one is a head scratcher. No consistency either. I’ve been told they get those Wagoneer, Gran Wagoneer at the shop for all kinds of different faults.
Yep. Same design. Common point of failure is the hybrid coolant heater.
We test drove one. My buddy traded his in when Jeep couldn’t fix it on 4+ visits. He had CEL lights on within hours of leaving the service bay each time. I couldn’t justify paying so much for something that was clearly half-baked.
My 2022 Ford Bronco sure is a lemon. Literally waiting for the Lemon Law buy back offer now.
Yeah I am glad I didn’t jump the gun on the new Bronco was really debating about trading in the FJ for a 2 door bronco but I haven’t heard many good things about them and fjord build quality has been suspect for a while now on anything that doesn’t seem to be a truck.
I think that’s more of a Ford thing than a covid thing.
From my experience in an unrelated engineering/manufacturing field, we had parts shortages left and right. We were constantly working to qualify alternative parts, or find new suppliers, anything we could do to keep the lines running. We did our best to make sure we got quality parts, but we had some things slip through. We also had quality from our old well established suppliers fall through, it was just a mess. I’d imagine any COVID time car will have some sorts of issues
I am the Warranty Manager at a very large lighting/controls company. I feel this pain every damn day. The things we did to get product out during the pandemic is going to haunt us for years to come.
Lutron or Vantage?
Counterfeits too. Good to see you’re Autopian MarkW from Jersey
You’re just gonna keep on coming up with a reason to post a picture of your i3 aren’t ya?
Its been a few years. What problems do you expect to see later that wouldn’t have already shown up?
Car prices were also higher than usual. It could be consumers being extra picky to justify their high spend, and knowing that there were issues with computer chips, raising any and all potential quality issues. Even for things they may have never cared about before.
Follow-up question: is there a discernible difference in quality between COVID cars and the ones historically built by the Big 3 on Monday mornings and Friday afternoons? 🙂
The covid era ones didn’t have old roach clips behind the door cards.
Or sandwiches in the floor.
Just the opposite! All them new fangled computer chips are
what makes your modern horseless carriage so unreliable.
Your covid-mobiles are missing them chips, so you’re good!
“sorry but due to the chip shortage, we had to replace your touchscreen with physical knobs, your electronic parking brake with a braided steel cable, and your CVT with a manual transmission” would have got me out of the house to buy a COVID car
In one particular instance, this is what happened with GM trucks. They stopped putting the AFM system in the trucks for a while during Covid, which I’m pretty sure significantly increased the longevity of those engines.