Ford has issued a recall for 694,271 crossover SUVs in the United States due to a fuel leak issue that could increase the risk of a fire.
Gatekeepers News reports that the recall affects certain 2021-2024 Bronco Sport and 2020-2022 Escape models equipped with 1.5-litre engines.
According to the U.S. National Highway Traffic Safety Administration (NHTSA), fuel injectors in affected vehicles may crack, causing fuel to leak into the engine compartment and potentially ignite. Drivers may notice a strong fuel smell, dashboard warnings, smoke, or visible flames.
The NHTSA estimates that 0.3% of recalled vehicles may have the defect. Ford has estimated the aggregate cost of the action to be around $570 million, which will be reflected in their second-quarter 2025 results.
“We estimate the aggregate cost of the action, based on the remedy options we are evaluating, to be about $570 million and will be reflected in our second quarter 2025 results,” Ford said.
Wednesday’s action expands on previous recalls from 2022 and 2024, which provided software updates but did not replace the potentially faulty injectors.
The fuel injectors were supplied by Italy-based Dumarey Flowmotion Technologies, according to the recall report.
Ford’s interim fix includes a software update designed to detect a leaking injector, reduce engine power, and shut off fuel delivery. The company is still developing a final mechanical remedy.
An internal committee initially recommended the software update and an additional drain tube to redirect fuel away from ignition sources. At that time, about 42,000 vehicles were covered.
In 2024, the NHTSA said it evaluated the adequacy of Ford’s remedy, adding that the proposed fix did not address the root cause of the issue.
After reassessment, Ford reported this month that it found cracked fuel injectors in eight vehicles that experienced under-hood fires, despite having undergone repairs. Six of these vehicles did not have the updated engine software that the company previously recommended.
