American automaker Ford is recalling 694,271 crossover SUVs in the United States due to a fuel leak issue that poses a potential fire hazard, according to the U.S. National Highway Traffic Safety Administration (NHTSA).
The recall affects specific models of the 2021–2024 Bronco Sport and 2020–2022 Escape equipped with 1.5-liter engines. The NHTSA reported that the vehicles’ fuel injectors may crack and leak fuel into the engine compartment, increasing the risk of under-hood fires. Warning signs include a strong fuel smell, dashboard alerts, smoke, or visible flames.
The recall includes vehicles that were previously repaired under earlier campaigns in 2022 and 2024, as well as newer models using the same engine and software systems.
In a statement, Ford acknowledged the issue and estimated the cost of the expanded recall at approximately $570 million, which will be recorded in its second-quarter 2025 financial results.
The NHTSA estimates that about 0.3% of the recalled vehicles are likely to exhibit the defect. The agency had raised concerns last year that Ford’s earlier fix—a software update—did not sufficiently address the root cause.
Ford reevaluated the effectiveness of its previous repairs after eight vehicles experienced engine compartment fires due to cracked fuel injectors. Notably, six of those vehicles had not received the updated engine software.
The affected fuel injectors were manufactured by Dumarey Flowmotion Technologies, an Italy-based supplier.
As an interim measure, Ford is deploying a new software update designed to detect potential injector leaks, reduce engine power, and cut off fuel supply if necessary. The company is also working on a permanent mechanical solution.
Previously, Ford advised installing a drain tube to divert leaking fuel away from ignition sources. With this latest recall, the company plans to expand those efforts in response to the ongoing safety concern.
