Ford Motor Company (NYSE: Ford) is recalling 2021-2024 Bronco Sport and 2020-2022 Escape vehicles equipped with 1.5-liter engines. A fuel injector may crack and leak fuel inside the engine compartment and cause a fire. This is an ongoing safety problem related to NHTSA Recall numbers 22V859, 24V187, 25V165. It’s the latest in a growing series of Ford recalls that were not properly repaired the first time because of software programming errors, requiring a recall of the recall, so to speak. The injectors were supplied by Dumarey Flowmotion Technologies S.R.L. of Italy. (read AutoInformed.com on: Ford Recalls Previous Bronco and Escape Fire Recalls)
The fix is currently under development. As an interim repair, dealers will update the engine control software, free of charge. Owner notification letters notifying owners of the safety risk are not expected to be mailed until 18 August 2025. Second letters will be sent once the remedy is available, according to documents released by the National Highway Safety Administration today.
Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 25S76.
This recall expands and replaces previous NHTSA recall numbers 22V859, 24V187, and 25V165. Vehicles previously remedied under 22V859, 24V187, and 25V165 will need to have the new final remedy performed once it is available. Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 888-327-4236 or go to nhtsa.gov.
Chronology
On 1 March 2024 Ford’s Field Review Committee (FRC) approved Field Service Action (FSA) 22S73/22V859 on November 10, 2022, and FSA 24S16/24V187 on March 1, 2024, to address the risk of underhood fire due to fuel leaks from cracked injectors in Escape and Bronco Sport with 1.5L Dragon GTDI engines. The remedy for both recalls updates the engine control software to allow for detection of a cracked fuel injector and invokes a strategy to disable the high-pressure fuel pump, derate engine power output and reduce temperatures of possible ignition sources in the engine compartment. The remedy also includes installation of a tube for additional robustness to allow fuel to drain from the cylinder head drain hole, away from surfaces which may initiate combustion. Ford’s FRC also approved FSA 25S21/25V165 on March 7, 2025, to address a subset of vehicles that did not properly receive the software portion of the recall remedy when having FSA 22S73/22V859 or 24S16/24V187 performed.
On April 11, 2024, the National Highway Traffic Safety Administration (NHTSA) opened a Recall Query (RQ24-008) to assess the “adequacy and safety consequences” of the 24S16/24V187 remedy. NHTSA’s communication noted they believe that “the remedy program does not address the root cause of the issue and does not proactively call for the replacement of defective fuel injectors prior to their failure.”
Ford provided its response to RQ24-008 on May 21, 2024, and June 21, 2024. On September 26, 2024, NHTSA requested additional information through a supplemental information request associated with RQ24-008 and Ford provided a response to this request one month later.
On July 23, 2024, Ford’s Critical Concern Review Group (CCRG) opened an investigation into a vehicle that had experienced an underhood fire subsequent to receiving the 22S73/22V859 remedy. Ford repurchased this vehicle and conducted component testing, which identified a cracked injector. “Fire damage to the vehicle prevented a conclusive determination that the cracked injector was the cause of the fire,” Ford said.
From August 2024 through May 2025, Ford continued efforts to verify the effectiveness of the 22S73/22V859 and 24S16 /24V187 remedies through inspection of vehicles that had experienced underhood fires post-remedy. Ford inspected additional vehicles and identified one vehicle with an injector that showed evidence of slight weeping. Ford believes this low leak rate would be insufficient to result in a fire. Ford confirmed that this vehicle had not received the software portion of the recall remedy and was part of the FSA 25S21/25V165 population. “Ford also recovered injectors that had been replaced in warranty to better understand injector cracking occurrence rate and injector leak rates.”
Between April and May 2025, Ford learned more about corrosion’s role as a contributing factor to injector cracking through further analyses of returned injectors. Ford analyzed potential corrosion contributing factors, injector leak testing results, remedy software operation, and drive cycle conditions. To evaluate the adequacy of the remedy, Ford also reviewed data on how the size of an injector crack could impact the amount of fuel that could leak to the roadway for vehicles equipped with and without the software and drain tube recall remedy.
On May 29, 2025, Ford had a meeting with NHTSA in which NHTSA provided a full technical briefing about their concerns with the 22S73/22V859 and 24S16/24V187 remedy. Ford had a follow-up meeting with NHTSA on June 10, 2025, where Ford presented their latest findings on issue root cause, the current and projected occurrence rate of injector cracking, potential for fuel leakage on roadways, and evidence demonstrating the effectiveness of the remedy at preventing underhood fires. As part of this review, Ford and NHTSA discussed whether the remedy fully addressed the combination of risks related to fires and fuel spillage on roadways resulting from cracked injectors.
On July 7, 2025, Ford’s Field Review Committee reviewed the concern and approved a field action to administer a safety recall with a to-be-determined remedy for vehicles previously recalled under 22S73/22V859 and 24S16/24V187, as well as an additional population of vehicles produced with the 1.5L engine and the updated engine control software.
Ford has identified injector cracking on 8 vehicles experiencing underhood fire, 6 of which did not have updated engine control software. Ford claims is aware of no allegations of injuries associated with these 8 fires.
About Ken Zino
Ken Zino, editor and publisher of AutoInformed, is a versatile auto industry participant with global experience spanning decades in print and broadcast journalism, as well as social media. He has automobile testing, marketing, public relations and communications experience. He is past president of The International Motor Press Assn, the Detroit Press Club, founding member and first President of the Automotive Press Assn. He is a member of APA, IMPA and the Midwest Automotive Press Assn.
He also brings an historical perspective while citing their contemporary relevance of the work of legendary auto writers such as Ken Purdy, Jim Dunne or Jerry Flint, or writers such as Red Smith, Mark Twain, Thomas Jefferson – all to bring perspective to a chaotic automotive universe.
Above all, decades after he first drove a car, Zino still revels in the sound of the exhaust as the throttle is blipped during a downshift and the driver’s rush that occurs when the entry, apex and exit points of a turn are smoothly and swiftly crossed. It’s the beginning of a perfect lap.
AutoInformed has an editorial philosophy that loves transportation machines of all kinds while promoting critical thinking about the future use of cars and trucks.
Zino builds AutoInformed from his background in automotive journalism starting at Hearst Publishing in New York City on Motor and MotorTech Magazines and car testing where he reviewed hundreds of vehicles in his decade-long stint as the Detroit Bureau Chief of Road & Track magazine. Zino has also worked in Europe, and Asia – now the largest automotive market in the world with China at its center.
Ford Fuel Injector Leak Recall Now at ~694,000
Ford Motor Company (NYSE: Ford) is recalling 2021-2024 Bronco Sport and 2020-2022 Escape vehicles equipped with 1.5-liter engines. A fuel injector may crack and leak fuel inside the engine compartment and cause a fire. This is an ongoing safety problem related to NHTSA Recall numbers 22V859, 24V187, 25V165. It’s the latest in a growing series of Ford recalls that were not properly repaired the first time because of software programming errors, requiring a recall of the recall, so to speak. The injectors were supplied by Dumarey Flowmotion Technologies S.R.L. of Italy. (read AutoInformed.com on: Ford Recalls Previous Bronco and Escape Fire Recalls)
The fix is currently under development. As an interim repair, dealers will update the engine control software, free of charge. Owner notification letters notifying owners of the safety risk are not expected to be mailed until 18 August 2025. Second letters will be sent once the remedy is available, according to documents released by the National Highway Safety Administration today.
Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 25S76.
This recall expands and replaces previous NHTSA recall numbers 22V859, 24V187, and 25V165. Vehicles previously remedied under 22V859, 24V187, and 25V165 will need to have the new final remedy performed once it is available. Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 888-327-4236 or go to nhtsa.gov.
Chronology
On 1 March 2024 Ford’s Field Review Committee (FRC) approved Field Service Action (FSA) 22S73/22V859 on November 10, 2022, and FSA 24S16/24V187 on March 1, 2024, to address the risk of underhood fire due to fuel leaks from cracked injectors in Escape and Bronco Sport with 1.5L Dragon GTDI engines. The remedy for both recalls updates the engine control software to allow for detection of a cracked fuel injector and invokes a strategy to disable the high-pressure fuel pump, derate engine power output and reduce temperatures of possible ignition sources in the engine compartment. The remedy also includes installation of a tube for additional robustness to allow fuel to drain from the cylinder head drain hole, away from surfaces which may initiate combustion. Ford’s FRC also approved FSA 25S21/25V165 on March 7, 2025, to address a subset of vehicles that did not properly receive the software portion of the recall remedy when having FSA 22S73/22V859 or 24S16/24V187 performed.
On April 11, 2024, the National Highway Traffic Safety Administration (NHTSA) opened a Recall Query (RQ24-008) to assess the “adequacy and safety consequences” of the 24S16/24V187 remedy. NHTSA’s communication noted they believe that “the remedy program does not address the root cause of the issue and does not proactively call for the replacement of defective fuel injectors prior to their failure.”
Ford provided its response to RQ24-008 on May 21, 2024, and June 21, 2024. On September 26, 2024, NHTSA requested additional information through a supplemental information request associated with RQ24-008 and Ford provided a response to this request one month later.
On July 23, 2024, Ford’s Critical Concern Review Group (CCRG) opened an investigation into a vehicle that had experienced an underhood fire subsequent to receiving the 22S73/22V859 remedy. Ford repurchased this vehicle and conducted component testing, which identified a cracked injector. “Fire damage to the vehicle prevented a conclusive determination that the cracked injector was the cause of the fire,” Ford said.
From August 2024 through May 2025, Ford continued efforts to verify the effectiveness of the 22S73/22V859 and 24S16 /24V187 remedies through inspection of vehicles that had experienced underhood fires post-remedy. Ford inspected additional vehicles and identified one vehicle with an injector that showed evidence of slight weeping. Ford believes this low leak rate would be insufficient to result in a fire. Ford confirmed that this vehicle had not received the software portion of the recall remedy and was part of the FSA 25S21/25V165 population. “Ford also recovered injectors that had been replaced in warranty to better understand injector cracking occurrence rate and injector leak rates.”
Between April and May 2025, Ford learned more about corrosion’s role as a contributing factor to injector cracking through further analyses of returned injectors. Ford analyzed potential corrosion contributing factors, injector leak testing results, remedy software operation, and drive cycle conditions. To evaluate the adequacy of the remedy, Ford also reviewed data on how the size of an injector crack could impact the amount of fuel that could leak to the roadway for vehicles equipped with and without the software and drain tube recall remedy.
On May 29, 2025, Ford had a meeting with NHTSA in which NHTSA provided a full technical briefing about their concerns with the 22S73/22V859 and 24S16/24V187 remedy. Ford had a follow-up meeting with NHTSA on June 10, 2025, where Ford presented their latest findings on issue root cause, the current and projected occurrence rate of injector cracking, potential for fuel leakage on roadways, and evidence demonstrating the effectiveness of the remedy at preventing underhood fires. As part of this review, Ford and NHTSA discussed whether the remedy fully addressed the combination of risks related to fires and fuel spillage on roadways resulting from cracked injectors.
On July 7, 2025, Ford’s Field Review Committee reviewed the concern and approved a field action to administer a safety recall with a to-be-determined remedy for vehicles previously recalled under 22S73/22V859 and 24S16/24V187, as well as an additional population of vehicles produced with the 1.5L engine and the updated engine control software.
Ford has identified injector cracking on 8 vehicles experiencing underhood fire, 6 of which did not have updated engine control software. Ford claims is aware of no allegations of injuries associated with these 8 fires.
About Ken Zino
Ken Zino, editor and publisher of AutoInformed, is a versatile auto industry participant with global experience spanning decades in print and broadcast journalism, as well as social media. He has automobile testing, marketing, public relations and communications experience. He is past president of The International Motor Press Assn, the Detroit Press Club, founding member and first President of the Automotive Press Assn. He is a member of APA, IMPA and the Midwest Automotive Press Assn. He also brings an historical perspective while citing their contemporary relevance of the work of legendary auto writers such as Ken Purdy, Jim Dunne or Jerry Flint, or writers such as Red Smith, Mark Twain, Thomas Jefferson – all to bring perspective to a chaotic automotive universe. Above all, decades after he first drove a car, Zino still revels in the sound of the exhaust as the throttle is blipped during a downshift and the driver’s rush that occurs when the entry, apex and exit points of a turn are smoothly and swiftly crossed. It’s the beginning of a perfect lap. AutoInformed has an editorial philosophy that loves transportation machines of all kinds while promoting critical thinking about the future use of cars and trucks. Zino builds AutoInformed from his background in automotive journalism starting at Hearst Publishing in New York City on Motor and MotorTech Magazines and car testing where he reviewed hundreds of vehicles in his decade-long stint as the Detroit Bureau Chief of Road & Track magazine. Zino has also worked in Europe, and Asia – now the largest automotive market in the world with China at its center.