Ford Fuel Injector Leaks Lead to Recall Over Engine Fire Risks: NHTSA

Manufacturer is recalling nearly 700,000 vehicles following eight reports of car fires potentially caused by a fuel leak.

Ford has issued a recall for 694,271 Bronco Sport and Escape SUVs due to defective fuel injectors that can leak gasoline onto hot engine surfaces, increasing the risk of a fire.

The U.S. National Highway Safety Administration (NHTSA) announced the Ford Bronco Sport and Escape recall on July 14, after receiving multiple reports of fuel injectors cracking and leaking gasoline into the cylinder head.

Officials are warning that leaking fuel can escape through a drain hole in the engine and pool near ignition sources, further increasing the risk of a fire. This accumulation of gasoline near hot components makes the defect especially dangerous, even when the vehicle is parked or turned off.

While no accidents or injuries have been reported, Ford’s investigation has identified at least eight instances of customers reporting fires emanating from under the hood. 

The current recall affects:

• Certain 2020 through 2022 Ford Escape vehicles
• Certain 2021 through 2024 Ford Bronco Sport vehicles

According to the recall chronology report (PDF), Ford previously issued field actions in November 2022 and March 2024 to update engine control software and fuel tubing for related issues. A separate recall in March 2025 involved nearly 34,000 vehicles with similar fuel injector defects linked to four vehicle fires.

Further investigation revealed that corrosion may also contribute to injector cracking. On July 15, Ford’s review committee approved the new safety recall (PDF). However, a long-term fix is still in development.

Safety officials advise owners to watch for fuel odors inside or outside the vehicle, as well as dashboard warnings. In the event of a fire, signs may include smoke or flames from the engine compartment or underbody.

Customer notification letters will begin mailing on August 18. Dealers will update engine control software to detect fuel injector leaks as an interim fix. A second letter will be sent when a final remedy is available.

Ford’s number for this recall is 25S76. Customers may contact Ford customer service at 1-866-436-7332 or contact Ford Motor Company’s contact for this recall, Dusty Gardner, who may be reached by email at dusty.gardner@dot.gov.

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-275-9171), or go to www.nhtsa.gov.

Ford Fuel System Recalls

Ford has faced a series of fuel system-related issues throughout the past year, prompting multiple large-scale recalls.

Earlier this month, more than 850,000 additional Ford vehicles were recalled after the company received at least 1,860 warranty claims related to fuel pump issues that could lead to engines stalling.

In addition, nearly 300,000 Ford Super Duty trucks were recalled at the beginning of this year due to fuel pump failures caused by biodiesel deposit buildups.

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