Cracked Fuel Injectors Behind Widespread Safety Concern
Ford has announced the recall of nearly 700,000 vehicles in the United States due to a critical safety issue involving cracked fuel injectors that could result in engine fires. The affected models include the 2021 to 2024 Ford Bronco Sport and the 2020 to 2022 Ford Escape. The recall, registered as NHTSA No. 25V467000, supersedes earlier efforts to address the problem, following new evidence that previous fixes may not have fully resolved the risk.
The automaker explained that cracked fuel injectors can leak gasoline into the engine compartment. If the fuel or vapor reaches a hot surface, it could ignite and cause an under-hood fire. Although Ford says it is not aware of any injuries linked to the issue, the potential danger prompted a full-scale review and fresh response plan. A temporary software update to detect fuel leaks and reduce fire risk is already being deployed while a permanent fix is still in development.
Scope and Background of the Recall
The recall affects 687,000 vehicles across the U.S., and a total of 694,271 when including American territories such as Puerto Rico and American Samoa. Specifically, the vehicles involved are:
- 2021-2024 Ford Bronco Sport (built between February 2020 and February 2024)
- 2020-2022 Ford Escape (built between November 2018 and December 2022)
Ford had previously issued recalls in late 2022 and early 2024 addressing similar risks with software updates and hardware adjustments. However, the National Highway Traffic Safety Administration (NHTSA) raised concerns in April 2024 about whether those fixes addressed the root of the issue. Following months of internal investigation, Ford confirmed cracked injectors were still causing fires, prompting a more extensive recall.
New Findings and Expanded Response
In July 2024, Ford’s Critical Concern Review Group began examining a vehicle that had experienced a fire even after receiving the software update. Subsequent testing revealed that the root cause was a cracked injector, leading to fire. Over nine months, Ford analyzed multiple vehicles and identified eight with similar damage, six of which had not received the updated software.
Ford’s most recent action includes notifying dealers as of mid-July and planning to send owner letters starting August 18. The current software patch detects potential injector damage and reduces engine heat sources. Vehicles already updated may not require further intervention, but owners are urged to check using their VIN on Ford’s recall site.
Next Steps for Vehicle Owners
Owners of affected vehicles should await the official recall letter or proactively check their vehicle status online. Once notified, they will be able to visit any Ford or Lincoln dealership for a free update. A full solution is under development and will be provided at no cost once finalized. Ford emphasized that safety remains its top priority and it will continue to monitor and communicate updates as needed.
