Ford Motor Company (NYSE:F)* is recalling model year 2021-2023 Bronco, Explorer, Lincoln Aviator, F-250 SD, F-350 SD, F-450 SD, F-550 SD, 2021-2022 Lincoln Navigator, Mustang, F-150, and 2022 Expedition vehicles. The Mexican made low-pressure fuel pump from Phinia Inc. may fail, which can result in an engine stall while driving. The driver may experience poor engine performance – misfiring or rough running – a check engine light or a reduction in engine power. Fuel pump failure is more likely to occur in low fuel or warm weather with hot fuel in the fuel tank. The recall was prompted in part by data from the National Highway Traffic Safety Administration (NHTSA).
“Fuel pump failure can result in an engine stall while driving, increasing the risk of a crash,” Ford told NHTSA in the mandatory safety defect recall filing made public by NHTSA earlier this week. “Loss of fuel pressure and flow from the low-pressure fuel pump can be due to internal contamination of the jet pump, specifically in low fuel conditions, and reduced fuel pump internal clearances that result in an increase of internal friction and sensitivity to vapor lock,” Ford said.
Vehicles affected by Ford Motor Stalling Recall Number 25S75 or NHTSA recall or campaign number 25V455 or 25V-455. July 2025.
Prior to fuel pump failure, the customer may experience poor engine performance (misfiring or running rough), a Check Engine light, or a reduction in engine power. Fuel pump failure is more likely to occur with low fuel and warm weather and hot fuel conditions in the tank.
The repair remedy for the safety defect is under development. Owner notification letters are not expected to be mailed until 14 July 2025. Second letters will be sent once the remedy is available. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 25S75. Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 888-327-4236 or go to nhtsa.gov about NHTSA recall or campaign number 25V455 or 25V-455.
Chronology
- September 2022: Ford’s Critical Concern Review Group (CCRG) opened an investigation into an increase in warranty claims and part returns related to Fuel Delivery Modules (FDM) on certain 2021-2022 Model Year (MY) vehicles. The FDMs on these vehicles contained a specific variant of low-pressure fuel pump and jet pump. Teardown analysis indicated that jet pump orifices on some returned parts were blocked by contamination. The source of contamination was not confirmed. The CCRG reviewed the available warranty data and noted that the rate of failures had decreased significantly after the supplier implemented several corrective actions from December 2021 through September 2022 to reduce contamination and production variation.
- July 2023: CCRG reviewed the warranty data after the monitor period to confirm that the supplier’s corrective actions had successfully resolved this concern in the field. Based on the available warranty data, Ford closed the investigation because the field data showed that the rate of failures was low and the failure could be progressive in nature. Ford was not aware of any accidents, fires, injuries or property damage attributed to failure of the FDM.
- 29 July 2024: the National Highway Traffic Safety Administration (NHTSA) opened Preliminary Evaluation (PE) 24-019 in response to six consumer complaints alleging loss of motive power as a result of low-pressure fuel pump failure in 2021 MY Ford Bronco vehicles. Ford’s response was provided on 23 September 2024.
- 2 April 2025: Ford’s Critical Concern Review Group (CCRG) opened an investigation to update the warranty claims, field reports and affected population associated with PE24-019.
- 22 May 2025: CCRG determined that the number of warranty claims had increased during summer months and in warm weather states. Connected vehicle data was utilized to further understand the conditions, such as fuel tank fill levels and diagnostic trouble codes, leading to further understanding of the root cause.
- 9 June 2025: CCRG reviewed vehicle production dates for warranty claims to determine whether something had changed in the supplier’s manufacturing process. The CCRG discovered that vehicles were all produced between July 2021 and July 2022.
- 9 June through 10 June 2025: Ford Product Development (PD) and Ford Supplier Technical Assistance (STA) conducted a review of the supplier’s manufacturing process for the parts used on these vehicles. Ford found that the supplier had made changes to the jet pump process to accommodate an increase in build complexity in June 2021 and identified that a tier 3 supplier for the GEN 4.6 fuel pump pumping chamber was not statistically capable for internal clearances and utilizing the full tolerance range of the supplier specifications. The low clearances resulted in an increase of internal friction and sensitivity to vapor lock beginning in early July 2021.
- As of 6 June 2025: 1860 warranty claims (received from 2 September 2021 to 31 May 2025) have been identified related to the investigation. As of 24 June 2025, 28 field reports (received from 5 January 2022 to 31 March 2025) and 57 customer service reports (received from 18 October 2021 to 22 May 2025) have been identified related to the safety defect. Vehicles produced from 1 July 2021, through 31 July 2022, have a projected fuel delivery module failure rate of 8.9 R/1000 at 10 years/150,000 miles of vehicle service.
- 30 June 2025: Ford’s Field Review Committee reviewed the concern and approved a field action. Ford is not aware of any reports of accident or injury related to this safety defect.
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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 Motor Recalls 850,000 Vehicles for Sudden Stalling
Ford Motor Company (NYSE:F)* is recalling model year 2021-2023 Bronco, Explorer, Lincoln Aviator, F-250 SD, F-350 SD, F-450 SD, F-550 SD, 2021-2022 Lincoln Navigator, Mustang, F-150, and 2022 Expedition vehicles. The Mexican made low-pressure fuel pump from Phinia Inc. may fail, which can result in an engine stall while driving. The driver may experience poor engine performance – misfiring or rough running – a check engine light or a reduction in engine power. Fuel pump failure is more likely to occur in low fuel or warm weather with hot fuel in the fuel tank. The recall was prompted in part by data from the National Highway Traffic Safety Administration (NHTSA).
“Fuel pump failure can result in an engine stall while driving, increasing the risk of a crash,” Ford told NHTSA in the mandatory safety defect recall filing made public by NHTSA earlier this week. “Loss of fuel pressure and flow from the low-pressure fuel pump can be due to internal contamination of the jet pump, specifically in low fuel conditions, and reduced fuel pump internal clearances that result in an increase of internal friction and sensitivity to vapor lock,” Ford said.
Vehicles affected by Ford Motor Stalling Recall Number 25S75 or NHTSA recall or campaign number 25V455 or 25V-455. July 2025.
Prior to fuel pump failure, the customer may experience poor engine performance (misfiring or running rough), a Check Engine light, or a reduction in engine power. Fuel pump failure is more likely to occur with low fuel and warm weather and hot fuel conditions in the tank.
The repair remedy for the safety defect is under development. Owner notification letters are not expected to be mailed until 14 July 2025. Second letters will be sent once the remedy is available. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 25S75. Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 888-327-4236 or go to nhtsa.gov about NHTSA recall or campaign number 25V455 or 25V-455.
Chronology
*AutoInformed on
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.