Ford recalls nearly 700,000 SUVs in US over fire risk linked to fuel leak

Ford Motor Company is recalling approximately 694,271 SUVs in U.S. due to a potentially dangerous fuel leak that could cause engine fires, according to a statement from the U.S. National Highway Traffic Safety Administration (NHTSA).

The recall affects select 2021–2024 Bronco Sport and 2020–2022 Escape models equipped with 1.5-litre engines, Caliber.Az reports per foreign media.

The NHTSA found that the vehicles’ fuel injectors—supplied by Italy-based Dumarey Flowmotion Technologies—may develop cracks, allowing petrol to seep into the engine compartment, potentially leading to ignition. Drivers may detect a strong fuel odour, dashboard alerts, smoke, or even visible flames.

Although the defect is estimated to affect just 0.3% of the recalled vehicles, Ford said the cost of the latest recall could reach $570 million. This amount will be reflected in the company’s second-quarter 2025 financial results.

The action builds on earlier recalls in 2022 and 2024, which primarily involved software updates but did not replace the suspect injectors.

Ford’s interim solution now includes a new software patch that detects leaks, reduces engine power, and cuts off fuel delivery. A final mechanical fix is still under development.

An internal Ford committee had initially recommended the software solution alongside a drain tube to divert leaking fuel.

At that stage, only 42,000 vehicles were affected. However, a 2024 investigation by the NHTSA questioned whether the remedy addressed the underlying problem.

Ford recently reported that eight vehicles equipped with the updated software still suffered under-hood fires, suggesting the issue was more persistent than originally believed. Six of those vehicles reportedly lacked the updated software.

By Aghakazim Guliyev