American automaker Ford Motor Company is recalling 694,271 crossover SUVs in the United States due to a fuel injector defect that poses a potential fire hazard, according to the 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. The NHTSA warned that cracked fuel injectors could leak fuel into the engine compartment, potentially leading to fires. Symptoms include a strong fuel smell, dashboard alerts, smoke, or visible flames.
Ford acknowledged the issue and estimated the cost of the expanded recall at $570 million, which will be reflected in its Q2 2025 financial results. The company said the recall includes vehicles previously repaired under earlier campaigns in 2022 and 2024, as well as newer models with similar engine configurations.
The injectors were manufactured by Dumarey Flowmotion Technologies, based in Italy.
As a temporary fix, Ford has rolled out a software update to detect leaks, reduce engine power, and cut off fuel supply. A more permanent mechanical solution is in development. Earlier remedies included installing a drain tube to redirect leaking fuel away from ignition sources.
The NHTSA estimates that 0.3% of the recalled vehicles may actually have the defect. Eight under-hood fires have been reported, six of which involved vehicles that had not received the updated software.
