694,271 Fords Hit With New Recall
2025 has been a horrendous year for Ford’s already shaky reliability reputation. The company has already exceeded the number of recalls it had throughout all of last year in the first six months of 2025, breaking an infamous GM recall record on the way. But the misery is far from over for Ford service technicians, after a new recall for some 694,271 vehicles was announced by the National Highway Traffic Safety Administration. Reuters reports that a cracked fuel injector could leak fuel into the engine compartment, and in the worst-case scenario, this could lead to a fire.
Two Popular SUVs Impacted By New Recall
Ford
View the 2 images of this gallery on the
original article
It should be noted that this recall is separate from the one announced last week, which concerned faulty fuel pumps in various trucks and SUVs, as well as the Mustang; the potentially cracked injectors that led to this week’s recall were installed in 2021-2024 Bronco Sport and 2020-2022 Escape vehicles. While no injuries related to the defect have been reported so far, this recall is far from the beginning of buyers’ woes with the issue.
According to the NHTSA report, an internal committee at Ford had first reviewed the issue on 1.5-liter engines in March last year, suggesting that an update to the engine control software and the installation of a drain tube would resolve the issue. The drain was intended to route leaking fuel away from danger areas, while the software update was to activate a warning light when a drop in fuel rail pressure was detected. At the time, only around 42,000 vehicles were covered by the recall, and replacing the potentially defective injectors was not recommended by the committee. But a month later, the NHTSA opened a recall query and determined that the remedy did not solve the issue. Reassessment of the issue has now led to the latest recall.
No Solution Yet
Related: Ford Issues Major Recall Covering 20 Popular Models
Fortunately, only around 0.3% of the Bronco Sport and Escape SUVs are estimated to have the defect with injectors (supplied by Italy-based Dumarey Flowmotion Technologies), but unfortunately, Ford still doesn’t yet have a permanent solution. The issue has caused under-hood fires in previously recalled vehicles, so the software update that reduced engine power and shut off fuel delivery was not effective. Owners of the affected vehicles will want to take note of warning lights and any strong fuel smells inside or outside the vehicle before smoke or flames manifest.
Ford