- Ford Recalls Over 694,000 SUVs In US Over Fuel Leak Fire Risk
- Bronco Sport and Escape models from 2020–2024 affected
- Issue linked to eight confirmed under-hood fires in US
By Grateful Ogunjebe
Ford has announced the recall of over 694,000 of its popular crossover SUVs in the United States due to a serious fuel leak issue that could result in engine fires.
Eko Hot Blog reports that the recall affects 2021–2024 Bronco Sport and 2020–2022 Escape models equipped with 1.5-litre engines.
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The US National Highway Traffic Safety Administration (NHTSA) disclosed that the fuel injectors may crack and leak fuel into the engine compartment, increasing the risk of fire.
The issue is not entirely new. Ford had initiated similar recalls in 2022 and 2024. However, the expanded recall now includes even the units that were previously repaired, as well as new models that share the same engine components.
In a public statement, Ford confirmed that the cracked injectors have led to at least eight reported under-hood fires in affected vehicles. Of these, six vehicles did not have the latest engine software updates installed at the time of the incident.
The company estimates that the cost of addressing this expanded recall will hit $570 million. This amount will be reflected in its second-quarter 2025 financial results, signalling a significant blow to the automaker’s bottom line.
The NHTSA estimates that about 0.3% of the recalled SUVs may actually be affected by the cracked injectors. Despite the small percentage, the risk has been deemed serious enough to warrant immediate intervention.
The injectors at the heart of the issue were supplied by Dumarey Flowmotion Technologies, a firm based in Italy. Ford says it is working with the supplier to further investigate the root cause.
To temporarily mitigate the risk, Ford has issued a software update that detects potential fuel leaks, reduces engine power, and cuts off fuel supply if a leak is detected. This is meant to limit the chances of fire while a more permanent fix is developed.
The automaker had earlier suggested installing a drain tube to channel any leaking fuel away from hot surfaces. However, the recent fires have led to an expansion of that recommendation to more vehicles.
Customers who own the affected vehicles are being advised to watch out for warning signs like fuel odour, dashboard alerts, smoke, or visible flames near the engine.
This marks yet another blow to Ford’s safety reputation, especially as the recall affects newer model vehicles that were expected to be problem-free.
The NHTSA had previously warned that Ford’s earlier fix, mostly relying on software updates, may not have adequately addressed the hardware defect.
Ford says it is accelerating efforts to create a more robust mechanical solution to replace the compromised fuel injector systems.
Vehicle owners in the United States will be contacted directly, and free repairs will be provided at Ford-authorised service centres.
This is one of the largest US vehicle recalls so far in 2025, further highlighting growing concerns over quality control in the global auto industry.
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