Ford issues recall for 700,000 SUVs linked to engine fire danger
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Ford Motor Co. has issued a recall of more than 694,000 vehicles in the US due to a fire risk linked to cracked fuel injectors in select Bronco Sport and Escape SUVs. The recall affects Bronco Sport models from 2021 through 2024 and Escape models from 2020 through 2022, both equipped with Ford’s 1.5-liter EcoBoost engine.
This action follows a year-long investigation by the National Highway Traffic Safety Administration, which found that earlier software updates provided by Ford failed to eliminate the fire hazard. The agency’s findings led to the expanded recall, marking one of Ford’s largest safety actions in recent memory.
Ford has now recalled more than 5 million vehicles in 90 separate campaigns in 2025, exceeding past records. This development reflects a broader pattern of regulatory scrutiny and higher expectations for automaker accountability.
The cracked injector at the center of the fire risk
The defect involves a cracked fuel injector that can leak gasoline into the engine compartment. If the fuel comes into contact with hot surfaces, such as the exhaust system, it could ignite. While only about 0.3% of the recalled vehicles are estimated to have the defect, the risk is considered serious enough to warrant the recall.
Ford’s previous approach involved a software update that detects pressure drops in the fuel system. If a leak is detected, the system reduces engine power and shuts off the fuel pump. However, the NHTSA criticized this method as insufficient because it did not address the root cause: the cracked injector itself.
So far, eight engine compartment fires have been reported, with no injuries. Still, the lack of a permanent fix has fueled concern among safety advocates and regulators.
A costly and incomplete fix for Ford and its customers
Ford estimates the recall will cost $570 million, which it will report as a special item in its second-quarter earnings. This charge is not expected to affect its adjusted earnings per share, but it has affected investor sentiment. Ford’s stock dropped about 3.5% following the announcement.
The company is offering an interim fix: a software update that alerts drivers of a fuel leak, limits engine performance, and disables the fuel pump. Owners will begin receiving notification letters on Aug. 18. A second round of letters will follow once the permanent hardware solution is finalized.
Critics argue that the current plan, which leaves faulty injectors in place, does not go far enough to ensure safety. The delay in providing a physical fix raises questions about the effectiveness of software-based solutions in managing mechanical failures.
How regulatory pressure is reshaping recall responses
The NHTSA’s push for more comprehensive recall measures signals a shift in regulatory oversight. Agencies are placing greater emphasis on full mechanical remedies rather than temporary fixes. In this case, Ford’s initial software-based strategy fell short of federal expectations.
The recall highlights the challenges automakers face in resolving defects that combine mechanical and electronic systems. With growing reliance on software to monitor safety, manufacturers must also prepare to implement component-level repairs when needed.
For consumers, the recall underscores the need to respond promptly to safety notices and maintain regular service checks. While the likelihood of a fire remains low, the risks from unresolved defects can be serious.
Ford’s handling of the recall will be closely watched, both by customers and industry analysts. The company’s ability to manage communication, implement a long-term fix, and minimize further safety issues will influence public trust and brand reputation.
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