Ford Isn't Sure How To Fix This Latest Recall Just Yet
Ford is recalling more than 850,000 vehicles across its Ford and Lincoln brands due to a fuel pump issue that could cause engines to stall.
Key Points
- Ford is recalling more than 850,000 vehicles across several nameplates due to a low-pressure fuel pump defect that could lead to stalling.
- The issue stems from internal contamination and manufacturing changes that increase vapor lock sensitivity, especially in warmer climates.
- A remedy is still being developed, but owner notifications are set to begin shortly, with models like the F-150, Bronco, and Mustang affected.
The recall spans multiple nameplates built between 2021 and 2023 and includes many of the company’s top-selling models. The F-150 alone accounts for more than half of the 850,318 vehicles included in the campaign. Specific model counts include 455,261 units of the F-150, 109,881 Broncos, 76,089 Explorers, 113,396 Super Duty trucks, and 24,790 Mustangs.
The recall also includes 32,470 Expeditions, 23,073 Lincoln Aviators, and 14,358 Lincoln Navigators. All of these vehicles used a specific version of the fuel pump design that Ford now believes to be vulnerable under certain conditions.
At the center of the issue is a low-pressure fuel pump whose jet assembly can become contaminated. This contamination may block fuel flow and pressure, potentially increasing the risk of vapor lock—a condition that restricts fuel delivery to the engine. Drivers may notice symptoms such as rough idling, misfiring, or sluggish acceleration before a complete failure occurs.
While Ford has confirmed the problem can lead to engine stalling, it has not reported any accidents or injuries linked to the defect so far.
According to documents submitted to NHTSA, Ford initially flagged the issue back in September 2022, when its Critical Concern Review Group (CCRG) noticed a spike in warranty claims related to fuel delivery. At the time, the issue appeared to be linked to a manufacturing variant used by one of its suppliers. Although the supplier introduced process changes intended to reduce contamination between December 2021 and September 2022, new reports continued to emerge, particularly in warmer climates and summer months.
A follow-up review in April 2025 led to a deeper analysis after consumer complaints resurfaced, specifically involving power loss in 2021 Broncos. In May, Ford traced the problem to a production change made by the supplier in July 2021, which narrowed the tolerances in the jet pump’s construction. As of early June 2025, Ford has received 1,860 warranty claims, 57 customer service contacts, and 28 field reports tied to the fuel pump defect.
A solution has not yet been finalized, though Ford is working on a repair and says affected owners will begin receiving notification letters shortly. Once a fix is ready, the company will instruct owners to bring their vehicles to a dealership for service.
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An experienced automotive storyteller and accomplished photographer known for engaging and insightful content. Michael also brings a wealth of technical knowledge—he was part of the Ford GT program at Multimatic, oversaw a fleet of Audi TCR race cars, ziptied Lamborghini Super Trofeo cars back together, been over the wall during the Rolex 24, and worked in the intense world of IndyCar.
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Just get a different fuel pump from a great German company. Bosch is one of the German brands I like.