Since the beginning of 2025, Ford has initiated a total of 90 recall campaigns in the United States, becoming the automaker with the most recalls in the history of the country’s automotive industry.
Ford’s latest recall involves 694,271 vehicles, including the 2021-2024 Ford Bronco Sport and 2020-2022 Escape models, all equipped with the 1.5L EcoBoost 3-cylinder turbocharged engine. This engine has been the subject of multiple technical complaints.
This is Ford’s third recall due to fuel injector issues, adding to an ongoing technical debacle that began in 2022. In its latest announcement, Ford stated that the fuel injectors may crack, leading to potential fuel leaks in the engine compartment. This poses a fire hazard if left unattended.
Ford estimates that this recall will cost approximately $570 million. Currently, the American automaker has yet to present a comprehensive technical solution to replace the faulty injectors but will offer a software update for the engine control system. This update will enable the early detection of fuel leaks and notify drivers through the instrument cluster.
Customers can visit Ford or Lincoln dealerships to receive the free software installation. This solution also applies to vehicles previously recalled in earlier campaigns.
Ford first acknowledged the injector issue in November 2022 when it recalled over 520,000 vehicles due to fuel leak concerns. The initial remedy involved software updates and the addition of a secondary tube to divert leaked fuel away from the engine compartment.
However, by March 2024, Ford expanded the recall to include over 42,000 additional vehicles. In March 2025, another 33,000 vehicles were added to the recall list due to improper repair techniques. These measures were considered temporary and did not address the root cause of the problem.
In response to increasing consumer and media pressure, the National Highway Traffic Safety Administration (NHTSA) launched a comprehensive investigation in April 2025 into Ford’s handling of previous recalls.
According to the NHTSA, Ford failed to proactively replace the faulty injectors and instead offered temporary solutions. As a result of this investigation, Ford initiated its third recall expansion, including the recently launched 2024 Bronco Sport models.
Despite the large-scale recall, Ford estimates that only about 0.3% of the affected vehicles are likely to experience the issue. The company has discontinued the use of these injectors in the Escape since December 2022 and in the Bronco Sport since February 2024, replacing them with improved components.
However, the recurrence of recalls in 2025 raises significant questions about Ford’s product quality control and technical responsiveness to critical issues.
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