Ford Recalls Kuga, Bronco and Escape Over Fuel Injector Defect

Ford has announced a recall of nearly 858,000 vehicles due to a fuel injector defect that may cause fires. Learn which models are affected and why.

Ford has launched one of its largest recalls in recent years, affecting nearly 858,000 vehicles worldwide due to a potentially dangerous defect in the 1.5-liter EcoBoost engine. The issue involves fuel injectors that may crack, leading to fuel leaks and an increased risk of underhood fires.

The recall covers popular models including the Ford Kuga, Bronco, and Escape, produced between November 2018 and the end of May 2024. In Europe, the Kuga accounts for the largest share of affected vehicles, while in the United States and several other markets the focus is on the Escape and Bronco Sport. In Germany alone, more than 19,000 vehicles are subject to inspection under the oversight of the federal motor authority.

According to regulatory filings, the problem originates from possible cracks in the high-pressure fuel injector. If the injector loses its seal, gasoline can leak onto the top of the engine. Combined with the high temperatures of nearby exhaust components, this creates a serious fire hazard and prompted Ford to initiate a global service campaign.

The automaker has acknowledged that the issue has been under investigation for several years. Earlier measures included software updates and the installation of drainage components intended to mitigate the risk. However, the current campaign effectively expands and replaces those earlier recalls, indicating that previous fixes did not fully resolve the problem. Ford has confirmed it is aware of at least eight underhood fire incidents linked to the defect, with no reported injuries.

A final set of technical remedies has not yet been announced. Dealers are expected to either replace the faulty injectors or modify the fuel system to reduce the likelihood of fuel leakage. The recall has been formally registered with regulators, and owners are advised to contact authorized service centers and reference campaign code 25S76.

The financial impact is also significant. Ford estimates the cost of the recall at around $570 million, underscoring the scale of the issue. Analysts suggest the campaign may lead to tighter quality controls for EcoBoost engines, as regulatory scrutiny around fire risks continues to intensify.