Ford's Most Popular Crossovers Recalled For Fuel Leaks And Fire Risks
Ford just recalled nearly 700,000 crossovers and SUVs in the U.S. after a fuel injector defect raised the risk of engine fires.
Key Points
- The recall affects 2021–2024 Bronco Sport and 2020–2022 Escape models due to cracked fuel injectors that pose a fire risk.
- Previous software-based solutions failed to prevent under-hood fires; a permanent mechanical remedy is still in development.
- The recall expands previous campaigns and will cost Ford an estimated $570 million, impacting its Q2 2025 financials.
The announcement comes after a year-long federal investigation and includes both new and previously repaired vehicles.
The recall affects 694,271 Bronco Sports from model years 2021 through and Ford Escapes from 2020 to 2022, all equipped with the 1.5-liter three-cylinder engine. According to the National Highway Traffic Safety Administration (NHTSA), the faulty fuel injectors may crack, allowing gasoline to leak into the engine bay—an obvious fire hazard.
While the defect is believed to affect only 0.3% of the recalled vehicles, drivers are being warned to watch for symptoms like a strong fuel odor, dashboard warnings, smoke, or even visible flames.
This isn’t Ford’s first attempt to address the issue. The company previously issued software-based remedies in 2022 and again in early 2024, including a system that detects leaks and reduces engine power or fuel delivery. However, those fixes failed to address the root of the problem—the actual mechanical failure of the injector itself.
Ford initially implemented these software updates alongside a fuel drain tube to divert leaking gasoline away from hot surfaces. The solution was applied to around 42,000 vehicles, but NHTSA remained unconvinced.
In 2024, the federal agency launched an investigation to determine whether Ford's software solution was sufficient—it wasn't. Eight under-hood fires were later reported in vehicles with repaired injectors, six of which didn’t have the updated software and drain tube installed.
Ford is still working on a permanent mechanical fix, but for now, affected vehicles will receive another software update and a reminder to monitor for symptoms. The problematic injectors were supplied by Dumarey Flowmotion Technologies, an Italian automotive components manufacturer.
The recall covers vehicles already serviced under previous campaigns, along with new production models built with the same engine configuration. Ford estimates the cost of this expanded action at $570 million, which will appear in its Q2 2025 financials.
If you own a Bronco Sport or Escape with the 1.5-liter engine, you’ll be contacted by Ford with instructions on scheduling a dealer visit for the interim fix.
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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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You know,,, it's getting to the point where I think FORD deserves to go bankrupt.