“They Said It Was Safe”: Ford’s Massive Recall Over 600,000 SUVs Sparks Fire Fears Under the Hood (and Drivers Are Furious)

In a significant development, Ford has issued a recall impacting over 600,000 vehicles, sparking concern among drivers nationwide. This recall, which affects some of Ford’s most popular models, is due to a defect that could potentially lead to underhood fires. Specifically, the Ford Escape from model years 2020 to 2022 and the Bronco Sport from 2021 to 2024 are at the center of this safety alert. Both models are equipped with a 1.5-liter EcoBoost three-cylinder engine. This action is part of an ongoing initiative by the National Highway Traffic Safety Administration (NHTSA) and Ford to address persistent fuel injector issues. Despite previous recalls and software upgrades, the problem continues to pose a risk, prompting this latest recall effort.

Understanding the Reason for the Recall

The current recall is attributed to a specific issue with the XL3 high-pressure fuel injector, initially supplied by Dumarey Flowmotion Technologies of Italy. Fuel injectors bearing part numbers HX7G-9F597-BB and HX7G-9F597-BC are prone to cracking over time. This defect increases the risk of gasoline leaking into the engine’s cylinder head, posing a serious fire hazard.

The potential danger arises when fuel or vapors escape through a drain hole and come into contact with hot engine surfaces. To date, there have been eight reported cases of underhood fires linked to this defect in the U.S. Fortunately, these incidents have not resulted in injuries. However, the fact that six of the affected vehicles had already undergone previous software updates raises questions about the effectiveness of earlier recall measures.

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Ford’s Affected Models Being Recalled

The recall affects all Ford vehicles equipped with the 1.5L EcoBoost engine, specifically targeting two popular models:

• Ford Escape (Model years 2020, 2021, and 2022 manufactured in the U.S.)
• Ford Bronco Sport

Both the Ford Escape and Bronco Sport are among the brand’s best-selling vehicles. However, it is the trims featuring the 1.5L turbocharged three-cylinder engine that are primarily impacted by this recall. Other trims with 2.0L EcoBoost or 2.5L hybrid engines remain unaffected.

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How Has Ford Reacted to This Particular Recall?

Ford is taking proactive measures to address the serious mechanical issue associated with the cracked injectors. The company plans to update the engine control software, a strategy previously implemented during recalls in 2022, 2024, and March 2025. This software update aims to detect potential fuel leaks, limit engine temperatures, and reduce the risk of fire while Ford considers a more comprehensive mechanical solution.

Affected Ford drivers have been notified via initial letters sent between August 18 and August 22, 2025. These notifications detail the issue, and a second letter outlining the final remedy will follow once it becomes available. The recall is identified by reference number 25S76. Ford vehicle owners can determine if their model is affected by using the vehicle identification number (VIN).

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Understanding the Larger Impact of This Recall for Ford

The recent recall is part of a challenging period for Ford, following a July recall of 132,000 vehicles due to detaching trim pieces. With over 700,000 vehicles affected in this latest recall, the company faces significant financial implications and reputational challenges. Safety is a primary concern for most Ford drivers, and the potential fire hazard presents a serious risk.

For now, Ford is addressing the issue by providing free software updates, with a full repair to follow. This approach underscores Ford’s commitment to resolving the problem and ensuring customer safety. For additional information, the NHTSA’s 25V-467 recall provides further details on this case.

As Ford navigates the complexities of this recall, drivers and industry observers alike will be watching closely to see how the company responds to these challenges. Will Ford’s efforts to implement long-term solutions restore confidence among its loyal customer base?