2021 Ford Bronco Sport
Ford
Fordis recalling 694,271 crossoverSUVsin the United States due to afuelleakissue that could increase the risk of a fire, the U.S. National Highway Traffic Safety Administration said on Wednesday, following ayear-longinvestigation.
The NHTSA saidfuelinjector in affected vehicles may crack, causingfueltoleakinto the engine compartment and potentially ignite.
Ford shares were down 3% inafternoon trading.
The recall covers certain 2021–2024 Bronco Sport and 2020–2022 Escape models equipped with 1.5-litre engines. The NHTSA estimates that 0.3% of recalled vehicles may have the defect.
“We estimate the aggregate cost of the action, based on the remedy options we are evaluating, to be about $570 million and will be reflected in our second quarter 2025 results,”Fordsaid.
Wednesday’s action expands on previousrecallsfrom 2022 and 2024, which provided software updates but did not replace the potentially faulty injectors.
Thefuelinjectors were supplied by Italy-based Dumarey Flowmotion Technologies, according to the recall report.
Ford’s interim fix includes a software update designed to detect aleaking injector, reduce engine power, and shut offfueldelivery. The company is still developing a final mechanical remedy.
An internal committee initially recommended the software update and an additional drain tube to redirectfuelaway from ignition sources. At that time, about 42,000 vehicles were covered.
In 2024, the NHTSAopened a recall queryto evaluate the adequacy ofFord’s remedy, adding that the proposed fix did not address theroot causeof the issue.
Afterreassessment,Fordreported this month that it found crackedfuelinjectors in eight vehicles that experienced under-hood fires, despite having undergone repairs. Six of these vehicles did not have the updated engine software the company previously recommended.
The latest recall includes vehicles previously repaired under earlier campaigns, as well as newer models built with the same engine and updated software.
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