Ford Recalls 694,000 SUVs Over Fuel Injector Leak Risking Engine Fires

Ford Motor Co. is recalling nearly 700,000 SUVs across the United States due to a defective fuel injector that could leak fuel into the engine compartment, significantly raising the risk of under-hood fires. The U.S. National Highway Traffic Safety Administration (NHTSA) confirmed the recall on Wednesday, citing the fire hazard as a critical safety concern.

The recall affects 694,271 vehicles, specifically 2021–2024 Ford Bronco Sport and 2020–2022 Ford Escape models. According to the NHTSA, a cracked fuel injector may leak fuel, which, when exposed to an ignition source, could spark a fire.

Ford disclosed that it expects to incur about $570 million in costs related to evaluating and implementing a solution. This will be classified as a special item in its Q2 earnings and will not impact its adjusted earnings or free cash flow, the automaker said in a regulatory filing.

“We are committed to the safety of our customers and are taking all necessary steps to resolve the issue swiftly,” Ford stated. Owners of the affected vehicles will receive recall notices and will be directed to authorized dealerships for free inspections and repairs.

Dealers will install a drain tube to reroute any leaked fuel away from high-temperature surfaces. Additionally, Ford will update the engine control software to monitor fuel rail pressure, triggering a dashboard warning if a leak is detected.

This marks a continuation of safety concerns first flagged in 2022 when Ford recalled about 500,000 vehicles for similar issues. In 2024, U.S. auto regulators launched a recall query questioning whether Ford’s previous fixes addressed the root cause of the fuel injector defect.

Despite no injuries reported to date, Ford is urging customers to act promptly once notified. The recall intensifies regulatory pressure on the auto giant, as safety issues continue to impact its reputation and bottom line.