Ford Fuel Pump Issues Could Lead to Engine Stalls in More Than 850,000 Vehicles: NHTSA

Over 1,800 warranty claims have been filed related to fuel pump failures in certain 2021 through 2023 Ford vehicles.

Ford has announced yet another massive recall, this time impacting approximately 850,318 vehicles equipped with defective fuel pumps, which may cause the engine to stall while driving and increase the risk of an accident.

The U.S. National Highway Traffic Safety Administration (NHTSA) announced the Ford fuel pump recall on July 8, warning that the low-pressure fuel pump may fail suddenly, resulting in engine failure.

The low-pressure fuel pump is essential for transferring fuel from the gas tank to the engine. If it fails, fuel pressure may drop and disrupt the flow from the fuel delivery module, preventing the engine from receiving enough fuel. This can cause the engine to stall unexpectedly, increasing the risk of a crash, serious injury or death.

While Ford has not received any reports involving injuries or accidents caused by the engine issues, the auto maker has documented at least 1,860 warranty claims, 28 field reports, and 57 customer service reports.

The recall affects certain model year 2021 through 2023 Ford Bronco, Explorer, Lincoln Aviator, F-250 SD, F-350 SD, F-450 SD and F-550 SD vehicles, as well as the 2021 through 2022 Lincoln Navigator, Mustang, F-150 and 2022 Ford Expedition.

Drivers are being warned that fuel pump failures are more likely to occur when fuel levels are low or during hot weather and elevated fuel temperatures. Warning signs may include poor engine performance, misfiring, rough idling, reduced power, or an illuminated check engine light.

According to the recall chronology report, Ford first noticed a rise in warranty claims related to fuel delivery parts in 2022. Investigations revealed blockages in the fuel system, which were caused by contamination. Although failure rates dropped after an early fix, NHTSA opened its own investigation in 2024, following new complaints. Ford later traced the issue to a 2021 supplier change.

Ford reviewed the issue and approved a field action late last month, which led to the current safety recall. Owners will begin receiving recall notification letters starting July 14. A second notice will be sent once repairs are ready.

Ford’s number for this recall is 25S75. 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.

Recent Ford Recalls

Ford has issued several major recalls over the past two years due to critical engine and fuel system problems.

Nearly 300,000 Ford Super Duty trucks were recalled at the beginning of this year due to fuel pump failures caused by biodiesel deposit buildup. The company also recalled certain Bronco Sport and Escape vehicles in April after discovering a defective fuel injector that can leak fuel, which may have caused four vehicle fires.

In September 2024, Ford recalled more than 90,000 vehicles due to faulty valves that could cause engine failure and lead to unexpected loss of power.

That same month, a class action lawsuit was filed against Ford, alleging that the automaker continued selling vehicles with defective belts in EcoBoost engines. These belts were likely to break shortly after the 60,000-mile warranty period, causing the engines to seize and stop.

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