Ford’s recall woes just keep piling up—and this latest one comes with a fiery warning.
Nearly 700,000 Ford SUVs are being recalled due to cracked fuel injectors that can leak gasoline and potentially cause engine fires. The affected models include 2021–2024 Bronco Sport and 2020–2022 Escape vehicles equipped with 1.5-liter engines. According to the National Highway Traffic Safety Administration (NHTSA), previous software fixes didn’t fully resolve the issue, prompting this broader, more urgent recall.
This fire hazard recall follows a yearlong NHTSA investigation and will cost Ford an estimated $570 million, impacting its Q2 earnings. The company had already issued similar recalls in 2022 and 2024 but failed to replace the faulty injectors. Fires have continued to occur even in vehicles equipped with the updated software, prompting Ford to take action.
And it’s not the only safety issue grabbing headlines. Just weeks ago, Ford recalled over 850,000 vehicles—including Broncos, Explorers, and Lincoln Aviators—for fuel pump defects that could cause engines to stall, especially in warm weather or low fuel conditions.
Despite the flood of bad press, Ford executives say the recall surge reflects a deeper commitment to quality. “We’re going the extra mile to protect customers,” said COO Kumar Galhotra. CEO Jim Farley has backed a new policy of holding redesigned models for extended testing—a move that has already prevented dozens of potential recalls in new F-150s and Mavericks.
Still, Ford remains the most-recalled automaker in the U.S. since 2020. And with vehicles on the road that missed this new quality control approach, more recalls may be on the horizon.
As technology in cars becomes increasingly complex, so does the risk of failure, and Ford, more than any other automaker, is feeling the pressure.
