Thursday, July 17, 2025 - American car giants, Ford is recalling 694,271 crossover SUVs in the United States due to a fuel leak issue that poses a potential fire risk, according to a report by the U.S. National Highway Traffic Safety Administration (NHTSA).
The recall affects certain 2021–2024 Bronco Sport and
2020–2022 Escape models equipped with 1.5-litre engines. The NHTSA stated that
fuel injectors in these vehicles may crack and leak fuel into the engine
compartment, which could lead to fires. Symptoms include a strong fuel odor,
dashboard warning lights, smoke, or even visible flames.
The vehicles being recalled include units that were
previously repaired under earlier campaigns in 2022 and 2024, as well as newer
models that share the same engine and software.
Ford acknowledged the issue in a statement, estimating the
cost of the expanded recall at approximately $570 million, which will be
reflected in its second quarter 2025 financial results.
The NHTSA estimates that 0.3% of the recalled vehicles may
actually have the defect. The agency had raised concerns last year that Ford's
prior fix, primarily a software update, did not adequately resolve the root
cause of the problem.
The recall comes after Ford reassessed the effectiveness of
its previous remedies and found that eight vehicles had experienced under-hood
fires due to cracked fuel injectors, despite having undergone repairs. Six of
those vehicles had not received the updated engine software.
The injectors were manufactured by Italy-based Dumarey
Flowmotion Technologies.
As a temporary solution, Ford has introduced a software
update to detect fuel injector leaks, reduce engine power, and cut off fuel
supply. The company is continuing to develop a more permanent mechanical
remedy.
Earlier recommendations also included installing a drain
tube to redirect leaking fuel away from ignition sources, but Ford has now
moved to expand those efforts in light of the continued fire risk.
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