Ford Escape and Bronco Sport Vehicles May Still Be at Risk of Under Hood Fires

On 2025-03-28 12:43:49

A critical issue has been identified in certain 2020-2022 Ford Escape and 2021-2023 Ford Bronco Sport vehicles, previously repaired under recall numbers 22V-859 or 24V-187. The problem lies in a faulty fuel injector that could lead to cracking and fuel leaks inside the engine compartment, potentially resulting in underhood fires.

The chronology of events leading up to this defect decision is as follows:

  • November 26, 2024: An issue regarding incomplete software recall remedies was brought to Ford's Critical Concern Group (CCRG) for review. This issue was initially identified in a Quality Office forum, where an audit was requested for software part numbers applied to vehicles remedied under a sample of field service actions (FSAs).

  • December 2024: A cross-functional team was formed to audit all software FSAs that used the FDRS service tool, with its first focus being on safety and compliance FSAs. Templates were created to track software lineage part numbers.

  • December 19, 2024: Ford informed NHTSA of this concern, confirming that the service tool data showed a mismatch between the software state on the service tool and the FSA software release for some vehicles.

  • January 2025: The cross-functional team created database records to store all software lineage part numbers for previously launched FSAs. The team then began auditing the current software level for every VIN repaired under several previously launched FSAs.

  • February 27, 2025: The cross-functional team completed the audit of recalls 24S16 and 22S73, concluding that only 97.7% and 91.6%, respectively, of the repairs conducted under these recalls had the correct software installed.

  • March 7, 2025: Ford's Field Review Committee reviewed the concern and approved a field action.

 

According to Ford's records, certain 2021-2023 Bronco Sport and 2020-2022 Escape vehicles did not have the remedy for Safety Recall 24S16 / 24V-092 and/or 22S73 / 22V-191 installed correctly but were recorded as having been repaired successfully. As a result, the underlying condition specified in these safety recalls may still exist, and a fuel injector may crack, leading to fuel and/or fuel vapor migrating to and accumulating near ignition sources, potentially resulting in under hood fires.

 

To address this issue, dealers will update the powertrain control module (PCM) software free of charge. Owner notification letters are expected to be mailed on April 24, 2025. Ford's number for this recall is 25S21, and the NHTSA campaign number is 25V-165.

Although Ford is not aware of any reports of accidents or injuries related to this condition, there have been four reported under hood fires in the affected population. However, it has not been confirmed whether these fires are related to a cracked fuel injector.