Ford Announces Major Safety Recall Affecting Nearly 850,000 Vehicles Nationwide Due to Engine Stalling Concerns
Automotive giant addresses fuel pump defect that could cause sudden engine failure and increase crash risk across multiple popular vehicle models
July 10, 2025 – Ford Motor Company has announced a comprehensive safety recall affecting approximately 843,000 vehicles across the United States due to a critical defect in low-pressure fuel pumps that could result in engine stalling while driving. The recall, coordinated with the National Highway Traffic Safety Administration (NHTSA), addresses a significant safety concern that could potentially increase the risk of vehicular accidents due to sudden loss of engine power.
Nature of the Defect and Safety Implications
The recall centers on a malfunction in the vehicles’ low-pressure fuel pump systems, which are essential components for delivering fuel from the tank to the engine. When these pumps fail, they can cause complete engine shutdown while the vehicle is in operation, creating dangerous situations for drivers and passengers, particularly when traveling at highway speeds or in heavy traffic conditions.
According to NHTSA documentation, the fuel pump failure can manifest in several ways before complete engine shutdown occurs. Drivers may experience preliminary warning signs including poor engine performance, engine misfiring, rough idling, reduced power output, or the illumination of check engine warning lights on the vehicle’s dashboard. These symptoms serve as early indicators that the fuel pump system may be compromising engine function.
The safety administration has noted that fuel pump failures are more likely to occur under specific conditions, particularly when fuel levels are low or during periods of hot weather. This information is crucial for affected vehicle owners who may be able to minimize their risk by maintaining adequate fuel levels and being particularly vigilant during summer months or in regions with elevated temperatures.
Consumer Complaints and Defect Prevalence
The NHTSA has received six formal consumer complaints specifically relating to loss of engine power attributed to fuel pump failure. These complaints provided the initial evidence that prompted the broader investigation into the defect and ultimately led to the recall announcement. The federal safety agency estimates that approximately 10 percent of the vehicles included in the recall actually possess the defective fuel pump components.
While the number of reported incidents may seem relatively small compared to the total number of vehicles being recalled, safety regulators emphasize that even a small percentage of failures can represent significant safety risks given the potential consequences of sudden engine shutdown during vehicle operation.
Affected Vehicle Models and Production Years
The recall encompasses a wide range of Ford and Lincoln vehicles spanning multiple model years, reflecting the extensive use of the problematic fuel pump components across Ford’s vehicle lineup. The affected models include some of the company’s most popular and best-selling vehicles, amplifying the potential impact of the recall.
Ford Bronco models from the 2021-2023 model years are included in the recall, affecting one of the company’s most successful recent product launches. The Bronco’s return to the market after a lengthy hiatus has been a significant success story for Ford, making this recall particularly notable for the brand.
The recall also affects Ford Expedition models from 2022, Ford Explorer vehicles from 2021-2023, and Ford Mustang models from 2021-2022. These represent core elements of Ford’s passenger vehicle portfolio, including both family-oriented SUVs and the iconic sports car that has been a cornerstone of Ford’s brand identity for decades.
Lincoln luxury vehicles are also significantly impacted, with Lincoln Aviator models from 2021-2023 and Lincoln Navigator models from 2021-2022 included in the recall. This affects Ford’s premium brand and represents a particular concern for customers who expect the highest levels of reliability and performance from luxury vehicles.
Ford’s commercial and work truck lineup is extensively affected, with F-150 pickups from 2021-2022 included in the recall. The F-150 has been America’s best-selling truck for decades and remains crucial to Ford’s financial performance and market position. Additionally, the recall extends to Ford’s Super Duty truck line, including F-250 SD, F-350 SD, F-450 SD, and F-550 SD models from 2021-2023.
Company Response and Remediation Efforts
Ford has issued a comprehensive statement addressing the recall and outlining the company’s approach to resolving the issue. The automotive manufacturer has acknowledged the seriousness of the defect and its potential safety implications while emphasizing its commitment to customer safety and satisfaction.
“Ford is recalling approximately 843,000 vehicles in the US due to a low-pressure fuel pump failure,” the company stated in its official announcement. “This concern may result in poor engine performance (misfiring or running rough), a check engine light, reduced power, or an engine stall while driving.”
The company has been transparent about the safety implications, stating that “an engine stall while driving increases the risk of a crash.” However, Ford has also emphasized that the company is not currently aware of any reports of accidents or injuries directly related to this particular defect, which may provide some reassurance to affected vehicle owners.
Importantly, Ford has acknowledged that a permanent remedy for the fuel pump issue is still under development. The company stated that “a remedy for this issue is currently under investigation,” indicating that affected vehicle owners may need to wait for Ford to complete its engineering analysis and develop an appropriate repair solution.
Customer Notification Process
The NHTSA has announced that owners of affected vehicles can expect to receive official recall notices in the coming days. These letters will provide detailed information about the recall, including specific instructions for vehicle owners and information about how to obtain repairs once a remedy becomes available.
The recall notices will likely include vehicle identification number (VIN) information to help owners determine whether their specific vehicle is affected by the recall. Given the large number of vehicles involved and the multiple model years affected, the VIN-specific information will be crucial for ensuring that only vehicles with the problematic fuel pump components are brought in for repair.
Ford’s Broader Recall History and Industry Context
This latest recall represents part of a broader pattern of safety recalls for Ford Motor Company, which has experienced significant recall activity in recent years. The company issued six separate recalls in June 2025 alone, affecting a total of 534,755 vehicles and impacting some of America’s best-selling vehicle models.
Ford’s recall activity has been particularly notable within the automotive industry, with the company leading all manufacturers in recall frequency during 2022 and 2023. While Ford dropped to third place in recall rankings during 2024, the company has again emerged as the industry leader in recall activity for 2025.
The financial impact of recalls has been substantial for Ford, with CEO Jim Farley revealing during a 2024 earnings call that the company spends approximately $4.8 billion annually on recall-related expenses. This figure includes costs associated with parts, labor, customer notifications, and administrative expenses related to recall management.
Consumer Safety Recommendations
While Ford continues to develop a permanent solution for the fuel pump defect, affected vehicle owners should remain vigilant for warning signs that may indicate impending fuel pump failure. The NHTSA and Ford recommend that drivers pay attention to symptoms such as rough engine operation, reduced power, engine misfiring, or check engine warning lights.
Given that fuel pump failures are more likely to occur when fuel levels are low or during hot weather conditions, affected vehicle owners may want to consider maintaining higher fuel levels than usual and exercising additional caution during summer months or in hot climates.
Conclusion
Ford’s announcement of this major safety recall affecting nearly 850,000 vehicles underscores the ongoing challenges automotive manufacturers face in ensuring product safety and reliability. While the company works to develop a permanent solution for the fuel pump defect, affected vehicle owners should remain alert for warning signs and prepare to respond to official recall notices that will be arriving in the coming days.
The recall represents a significant undertaking for Ford, both in terms of the number of vehicles affected and the breadth of models included. The company’s handling of this recall and its success in developing and implementing an effective remedy will likely be closely watched by industry observers, regulators, and consumers alike.
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