Ford Faces $2.5B Verdict: Understanding Truck Roof Collapse Liability

A staggering $2.5 billion verdict against Ford Motor Co. has thrust truck roof collapse liability into the spotlight, raising critical questions about vehicle safety standards and corporate accountability. This landmark case, stemming from a tragic rollover accident, underscores the potentially devastating consequences of defective roof designs and the legal battles that can ensue. Approximately 7,000 people are killed or severely injured each year in rollover accidents where the roof collapses. This blog post will delve into the details of the Ford case, explore the legal concepts surrounding roof collapse liability, and offer insights into how victims of such accidents can seek justice.

The $2.5 Billion Verdict: A Closer Look

In February 2025, a Georgia jury ordered Ford to pay $2.5 billion in punitive damages following a wrongful death lawsuit. The case involved a 2015 Ford F-250 Super Duty pickup truck in which the roof caved in during a rollover accident in 2022, killing Debra and Herman Mills. The couple’s sons sued Ford, alleging that the automaker was aware of the defective roof design in its Super Duty trucks for years but failed to take action to correct it. The jury found Ford 85% responsible for the crash, assigning 15% of the fault to Debra Mills. In addition to the punitive damages, the sons were awarded over $30.5 million in compensatory damages, including funeral expenses and attorney fees.

The plaintiffs presented evidence that Ford knew about the risks posed by its Super Duty truck roofs since at least 1999. They argued that an internal Ford engineering team had developed a stronger roof design in 2006, but the company chose not to implement it. Instead, Ford allegedly lobbied the U.S. National Highway Traffic Safety Administration (NHTSA) to avoid stricter roof strength standards on heavy-duty trucks. Ford only began reinforcing the roofs of its Super Duty trucks in 2017.

Ford maintains that the roofs on its Super Duty trucks met federal safety standards at the time of production and that the verdict is “impermissibly extreme and not supported by the evidence.” The automaker plans to appeal the decision. This case isn’t an isolated incident for Ford. In 2022, Ford was ordered to pay $1.7 billion in punitive damages in a similar case involving a fatal roof collapse. However, the Georgia Court of Appeals overturned that verdict and granted a new trial.

Understanding Roof Collapse Liability

Roof collapse liability falls under the umbrella of product liability law. Automakers have a legal duty to design and manufacture vehicles that are reasonably safe for consumers. This includes ensuring that the roof structure can withstand foreseeable forces in the event of a rollover accident. When a vehicle’s roof is defectively designed or manufactured, and that defect causes injury or death in a rollover accident, the automaker can be held liable.

Key Legal Concepts:

Defective Design: A design defect exists when the vehicle’s design makes it inherently dangerous, even when manufactured according to specifications. In roof collapse cases, a design defect might involve a roof structure that is too weak to withstand the forces typically encountered in a rollover accident.
Manufacturing Defect: A manufacturing defect occurs when a vehicle deviates from its intended design during the manufacturing process, making it unsafe. In roof collapse cases, a manufacturing defect might involve the use of substandard materials or improper assembly techniques that weaken the roof structure.
Failure to Warn: Automakers also have a duty to warn consumers about known safety risks associated with their vehicles. In roof collapse cases, a failure to warn might involve not informing consumers about the potential for roof collapse in a rollover accident, especially if the automaker is aware of a design flaw.
Negligence: This involves proving that the manufacturer did not exercise reasonable care in the design or manufacture of the vehicle.
Strict Liability: In some states, a manufacturer can be held liable for a defective product regardless of negligence. The focus is on whether the product was defective and caused injury.

Who Can Be Held Liable?

In a roof collapse liability case, several parties may be held liable, including:

The vehicle manufacturer
The manufacturer of component parts (e.g., the steel used in the roof)
Distributors and retailers of the vehicle

The Role of Federal Safety Standards

Federal Motor Vehicle Safety Standard (FMVSS) 216, “Roof Crush Resistance,” sets minimum strength requirements for vehicle roofs. The standard aims to reduce deaths and injuries resulting from the roof of a vehicle being crushed into the occupant compartment during rollover crashes.

The initial FMVSS No. 216 was instated in 1973. It established strength requirements for the roof. The test to determine if the vehicle met the standard involved slowly applying a minimal load to the roof’s front corner.

Important Considerations:

Minimum Standards: It’s crucial to understand that FMVSS 216 sets minimum standards. Automakers can and should exceed these standards to provide greater occupant protection.
Evolution of Standards: Roof strength standards have evolved over time. In 2009, the NHTSA finalized a rule that doubled the roof strength requirements for light vehicles (those weighing 6,000 pounds or less). The new regulation specifies that both the driver and passenger sides of the roof must be capable of withstanding a force equal to three times the weight of the vehicle.
Trucks and SUVs: The standards for heavier vehicles, such as trucks and SUVs, have historically been less stringent than those for passenger cars. This has been a point of contention in roof collapse lawsuits, with plaintiffs arguing that automakers should be held to a higher standard for these vehicles, which are more prone to rollovers.

What to Do If You’ve Been Involved in a Roof Collapse Accident

If you or a loved one has been injured in a rollover accident involving roof collapse, it’s essential to take the following steps:

Seek Medical Attention: Your health and safety are paramount. Get immediate medical attention for any injuries sustained in the accident.
Document Everything: Preserve all evidence related to the accident, including photos of the vehicle, the accident scene, and your injuries. Gather copies of police reports, medical records, and insurance information.
Consult with an Experienced Attorney: Roof collapse cases are complex and require specialized knowledge of product liability law and automotive engineering. An experienced attorney can investigate the accident, gather evidence, and build a strong case on your behalf.
Preserve the Vehicle: It is critical to preserve the vehicle in its post-accident condition. Your attorney will need to have experts examine the vehicle to determine the cause of the roof collapse and assess the extent of the defect.
Be Aware of Time Limits: Each state has statutes of limitations that limit the time you have to file a lawsuit. It’s essential to consult with an attorney as soon as possible to ensure that your claim is filed within the applicable time frame.

Injuries Resulting from Roof Collapses

A collapsing roof can lead to a wide range of severe injuries, including:

Traumatic brain injuries (TBI)
Spinal cord injuries, potentially leading to paralysis
Head and neck injuries
Fractures
Internal organ damage
Lacerations and cuts
Psychological trauma, such as PTSD

Seeking Justice and Compensation

If you’ve been injured in a roof collapse accident, you may be entitled to compensation for:

Medical expenses (past and future)
Lost wages (past and future)
Pain and suffering
Disability
Property damage
Punitive damages (in cases of egregious misconduct by the automaker)

The Future of Roof Strength Standards

The Ford case and other similar lawsuits are likely to continue to put pressure on automakers and regulators to improve roof strength standards and enhance vehicle safety. As technology advances, there are opportunities to design stronger, more protective roofs that can better withstand the forces of a rollover accident. Consumers should also stay informed about vehicle safety ratings and choose vehicles with strong roof structures.

Do You Have a Case?

The $2.5 billion verdict against Ford serves as a stark reminder of the importance of vehicle safety and the potential consequences of defective designs. If you or a loved one has been affected by a roof collapse accident, it’s crucial to understand your legal rights and seek the guidance of an experienced attorney. Contact us today for a free consultation to discuss your case and explore your options for seeking justice and compensation.