Ford Motor Company has issued a widespread recall impacting over 850,000 units from its 2021-2023 model years, encompassing popular Ford and Lincoln vehicles. This action addresses a critical defect in the low-pressure fuel pump system, which poses a risk of engine stall due to insufficient fuel supply. The concern could manifest as diminished power or erratic engine operation before complete failure. This latest recall highlights ongoing challenges for the automaker in addressing component reliability across its diverse product lineup.
The issue stems from internal contamination within the low-pressure fuel pump jet, leading to compromised fuel flow and pressure. This vulnerability increases the susceptibility to 'vapor lock,' a condition where fuel vaporizes prematurely, disrupting normal engine function. Initial symptoms reported by vehicle owners include a noticeable decrease in power or rough engine performance, such as misfires, preceding a complete fuel pump malfunction.
The recall extends to a broad range of Ford's well-known and top-selling models. These include the Ford Bronco, Explorer, Mustang, and F-150, with the latter alone constituting more than half of the total affected units. Furthermore, the recall encompasses the Ford Super Duty, Expedition, Lincoln Aviator, and Lincoln Navigator. The diverse array of vehicles impacted underscores the widespread nature of the faulty component.
Ford's internal investigation into this anomaly commenced in September 2022 when their Critical Concern Review Group (CCRG) observed an uptick in warranty claims related to fuel delivery modules in certain 2021-2022 models. These specific vehicles were identified as containing a particular variant of the low-pressure fuel pump and jet pump assembly. Despite previous corrective measures implemented by the supplier between December 2021 and September 2022 aimed at reducing contamination, the problem persisted.
Although the CCRG concluded its initial inquiry in July 2023, believing the supplier's actions had resolved the issue, new concerns arose. The National Highway Traffic Safety Administration (NHTSA) initiated its own evaluation in April 2025 following six consumer complaints concerning power loss in 2021 Bronco models. A renewed investigation by Ford in May revealed a correlation between increased warranty claims and warmer weather conditions and summer months, suggesting environmental factors might exacerbate the defect. The company later pinpointed changes in the jet pump production process from July 2021, which resulted in reduced clearances, as the underlying cause. As of early June, Ford has documented 1,860 warranty claims, 57 customer service reports, and 28 field reports directly linked to this issue. Fortunately, the manufacturer has not received any reports of accidents or injuries stemming from the defect.
Ford is currently working diligently to develop a definitive remedy for the affected vehicles, with a solution still in progress. Once a fix is available, vehicle owners will receive mailed notifications instructing them to bring their vehicles to an authorized dealership for the necessary repairs. Initial owner notifications are anticipated to be dispatched within the coming week, ensuring timely communication regarding this safety campaign.