HUNDREDS of thousands of Ford drivers are being warned about a dangerous defect that could cause their vehicles to suddenly lose control.
The issue affects over 850,000 vehicles across the US, triggering a sweeping federal recall.
Ford is recalling over 850,000 vehicles in the US due to a fuel pump defect (stock image)[/caption]
The issue, more likely in hot weather or with low fuel, increases the risk of a crash (stock image)[/caption]
The National Highway Traffic Safety Administration said the problem stems from a fuel pump defect that can cause the engine to stall while driving.
Ford confirmed the affected vehicles were built between July 2021 and July 2022, with some models extending into late 2022.
The company is still working on a fix and has not yet released a repair solution.
NHTSA has said the faulty pump can suddenly cut fuel flow, especially in hot weather or when fuel levels are low, sharply increasing the risk of a crash.
Before stalling, drivers may notice rough idling, misfiring, reduced engine power, or a check engine light.
According to Ford, the problem traces back to a supplier in Chihuahua, Mexico, which made changes to the fuel pump design in June 2021.
An internal review from Ford found that internal contamination and tight component spacing in the pump chamber triggered the failure, as reported by Reuters.
The company’s Critical Concern Review Group launched an investigation after identifying a pattern of warranty claims tied to sudden power loss.
As of June 2025, Ford had logged 1,860 warranty reports related to the defect.
Federal safety officials have also received six consumer complaints about vehicles losing power.
No crashes, fires, injuries, or property damage have been reported so far, Ford said.
The recall has affected a wide range of models, including the Ford F-150, Bronco, Explorer, Expedition, Mustang, and several Super Duty pickups.
Luxury SUVs like the Lincoln Aviator and Navigator are also impacted.
In total, 11 different models are being recalled.
Affected Ford Models
- 2021-2023 Ford F-550 SD (5,039 vehicles)
- 2021-2023 Ford F-450 SD (4,393 vehicles)
- 2021-2023 Ford F-350 SD (30,781 vehicles)
- 2021-2023 Ford F-250 SD (73,183 vehicles)
- 2021-2022 Lincoln Navigator (14,358 vehicles)
- 2021-2023 Lincoln Aviator (24,073 vehicles)
- 2021-2022 Ford Mustang (24,790 vehicles)
- 2021-2022 Ford F-150 (455,261 vehicles)
- 2021-2023 Ford Explorer (76,089 vehicles)
- 2022 Ford Expedition (32,470 vehicles)
- 2021-2023 Ford Bronco (109,881 vehicles)
Source: WFMJ
Ford estimates that about 10 percent of the recalled vehicles may actually have the defect.
Dealers were alerted of the recall on July 8.
Owners are set to receive interim letters between July 14 and July 18, letting them know their vehicle is part of the recall, per NBC affiliate WFMJ.
Once a repair is available, Ford will send another notice so drivers can book a free service appointment at their dealership.
Until then, the company advises owners to stay alert for warning signs and avoid running the tank too low, especially during summer.
Ford previously issued another recall of more than 200,000 vehicles in July after discovering a glitch that affected the backup cameras.
The defect can cause the display to freeze or go dark, potentially leading to crashes and renewing concerns over vehicle safety.
Luxury SUVs like the Lincoln Aviator and Navigator are also impacted (stock image)[/caption]
