2023 Ford Bronco Sport fuel system problems

What is wrong

Ford Motor Company (Ford) is recalling certain 2021-2024 Bronco Sport and 2020-2022 Escape vehicles equipped with 1.5L engines. A fuel injector may crack and leak fuel inside the engine compartment.

Risk

A fuel leak in the presence of an ignition source, such as hot engine or exhaust components, can increase the risk of a fire.

Remedy

Dealers will update the engine control software. In addition, dealers will replace the high-pressure fuel rail assembly and fuel injectors, free of charge. As an interim repair, dealers will update the engine control software, free of charge. Interim owner notification letters notifying owners of the safety risk were mailed August 29, 2025. Second letters will be sent once the final remedy is available, anticipated in July 2026. 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 recall numbers 22V‑859, 24V187, and 25V165. Vehicles previously remedied under 22V‑859, 24V187, and 25V165 will need to have the new final remedy performed once it is available.

Recall number 25V467000 · Recall details

What is wrong

Ford Motor Company (Ford) is recalling certain 2020-2022 Escape and 2021-2023 Bronco Sport vehicles previously repaired incorrectly under recall numbers 22V‑859 or 24V‑187. A fuel injector may crack and leak fuel inside the engine compartment.

Risk

A fuel leak in the presence of an ignition source such as hot engine or exhaust components, can increase the risk of a fire.

Remedy

Dealers will update the powertrain control module (PCM) software, free of charge. Owner notification letters were mailed April 22, 2025. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 25S21.

Recall number 25V165000 · Recall details

What is wrong

Ford Motor Company (Ford) is recalling certain 2022-2023 Bronco Sport and 2022 Escape vehicles equipped with 1.5L engines. A fuel injector may crack and leak fuel inside the engine compartment.

Risk

A fuel leak in the presence of an ignition source such as hot engine or exhaust components, can increase the risk of a fire.

Remedy

Dealers will update the engine control software to include fuel injector leak detection and install a drain tube, free of charge. Owner notification letters were mailed on April 24, 2024. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 24S16. This recall is an expansion of previous recall number 22V‑859.

Recall number 24V187000 · Recall details

What is wrong

Ford Motor Company (Ford) is recalling certain 2020-2023 Escape and 2021-2023 Bronco Sport vehicles equipped with 1.5L engines. A fuel injector may crack and leak fuel inside the engine compartment.

Risk

A fuel leak in the presence of an ignition source such as hot engine or exhaust components, can increase the risk of a fire.

Remedy

Dealers will update the engine control software to include fuel injector leak detection and install a drain tube, free of charge. Interim owner notification letters informing owners of the safety risk were mailed January 9, 2023. Remedy parts are expected to be available in 1st Quarter of 2023. Owner notification letters were mailed February 28, 2023. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 22S73. This recall includes all vehicles previously recalled under 22V‑191. Vehicles previously remedied under 22V‑191 will need to have the new remedy performed.

Recall number 22V859000 · Recall details

On April 11, 2024, the federal safety agency’s Office of Defects Investigation (“ODI”) opened this Recall Query (“RQ”) to investigate the adequacy of, including various safety concerns associated with, the remedy program in recalls 22V‑859 (filed Nov. 18, 2022) and 24V‑187 (filed Mar. 8, 2024). The vehicle population associated with these recalls includes certain MY 2020-2022 Ford Escape vehicles and MY 2021-2023 Ford Bronco Sport vehicles equipped with 1.5L engines. The safety defect in each recall involves high-pressure fuel injectors that are susceptible to cracking, allowing liquid fuel and fuel vapor to migrate onto hot surfaces within the engine compartment potentially resulting in underhood vehicle fires. The remedy programs described in recalls 22V‑859 and 24V‑187 are identical and involve both a software component and a hardware component. Specifically, Ford developed an updated engine control software designed to detect a pressure drop in the high-pressure fuel rail, provide instrument cluster messaging to the driver, invoke a strategy to disable the high-pressure fuel pump, derate the engine output, and lower the temperatures of possible ignition sources within the engine compartment. Additionally, Ford would install a tube into the engine’s cylinder head drain hole to shunt spilled liquid fuel past the various hot surfaces within the engine compartment and ultimately discard the spilled liquid fuel onto the roadway. ODI identified various safety concerns with this remedy program, which, among other things, notably did not include repairing or replacing the defective part and potentially did include the introduction of new safety defects (like fuel spilling near the spark plugs and fuel spilling onto the public roadway). the federal safety agency opened this investigation to evaluate these concerns with the remedy program, including whether the vehicles were still susceptible to underhood fires even post-remedy. As described in more detail in the Additional Summary posted simultaneously with this resume, ODI conducted a thorough investigation that included analyzing data and other materials received in response to two Information Requests, as well as inspections of post-remedy vehicles that experienced an underhood fire. ODI and Ford worked to identify and locate vehicles that experienced post-remedy fires and conduct joint vehicle inspections. ODI’s investigation also prompted Ford to initiate a more in-depth evaluation of the defect, including Ford’s conducting component level testing of high-pressure fuel injectors. ODI met with Ford on several occasions throughout this investigation to jointly conduct certain of these described tasks and to discuss test results. A collateral issue surfaced as a result of this investigation: in March 2025, Ford realized that despite relevant repairs having been recorded as successfully completed, approximately 33,576 vehicles subject to recalls 22V‑859 and 24V‑187 did not have the software component of the remedy program installed correctly. Thus, on March 27, 2025, Ford filed a new related recall (25V‑165) for these vehicles, notifying the federal safety agency and the public that they were still at risk of experiencing an underhood vehicle fire due to cracked fuel injectors despite the consumer having had their vehicle remedied pursuant to one of the two earlier recalls. In June 2025, Ford committed to implementing a new remedy program to repair the vehicles. On July 11, 2025, Ford documented this commitment in a new recall filing (25V‑467), which explains that Ford’s upcoming remedy program will involve proactive replacement of all high-pressure fuel injectors within the recall population. In view of the recall action taken by Ford, ODI is closing this Recall Query, which was opened given the federal safety agency’s concerns that the initial remedy programs of the software to detect the pressure drop plus installation of the drain tube did not constitute an adequate repair. The agency reserves the right to take additional action if warranted by future circumstances.

RQ24008