Ford Motor Company is once again in the spotlight—and not for the right reasons. The American automaker, already leading the nation in vehicle recalls for 2025, has just announced another massive safety issue that could cost it a staggering $570 million. This time, the recall involves nearly 700,000 vehicles: specific models of the Ford Bronco Sport and Ford Escape, both equipped with a 1.5-liter EcoBoost engine.

In total, 694,271 vehicles are affected by this latest safety campaign, which covers pre-facelift versions of the Bronco Sport and Escape SUVs built through the 2024 model year. The recall is related to a fuel injector defect that poses a serious fire hazard.

What’s the Issue? A Serious Fire Risk

The defect centers around high-pressure fuel injectors supplied by Dumarey Flowmotion Technologies, an Italian parts manufacturer. In the affected SUVs, these injectors can crack and leak fuel. Since the fuel system operates under high pressure, even a small leak can lead to dangerous results. Fuel dripping onto hot engine components, especially near the turbocharger or exhaust manifold, could easily ignite and cause an underhood fire.

As of July 2025, Ford has confirmed at least eight vehicle fires tied to this issue in the United States alone. Alarmingly, six of those vehicles had not received previous software updates that were intended to detect potential fuel system leaks. Even more concerning: two vehicles that had received the update still caught fire. This clearly shows that earlier attempts to fix the problem did not go far enough.

Why Is This Recall So Expensive?

The $570 million price tag is expected to be a direct hit to Ford’s bottom line and will be reflected in the company’s Q2 2025 earnings report, which is scheduled for July 30. This figure includes the costs of recall notifications, repairs, parts replacements, labor, and potential legal exposure.

It’s worth noting that only two other Ford recalls in 2025 have covered more vehicles, one affecting 850,000+ vehicles and another massive recall impacting 1,075,299 vehicles. That larger campaign includes popular models like the Ford Ranger, F-150, F-Series Super Duty, Edge, Mustang, and even luxury vehicles under the Lincoln brand like the Corsair and Navigator.

A Look Back: Ford’s Ongoing Quality Challenges

Ford CEO Jim Farley has repeatedly emphasized that “quality is job one” at the company. However, the repeated wave of recalls tells a different story. With over 90 recalls issued already this year alone, Ford is facing increasing pressure to improve its manufacturing and quality assurance processes.

This latest recall adds to a growing list of field service actions (FSAs) that are frustrating both customers and investors. What makes matters worse is that a permanent fix for the faulty fuel injectors is still under development. That means affected owners might be waiting for a long-term solution, all while being exposed to risk.

Which Vehicles Are Affected?

Only certain models are involved in this recall. Specifically:

• Ford Bronco Sport and Ford Escape SUVs
• Equipped with the 1.5-liter EcoBoost “Dragon” engine
• Built through the 2024 model year

If your SUV uses the 2.0-liter EcoBoost or the 2.5-liter hybrid engine, you’re in the clear. Those versions are not affected by this particular recall.

The 1.5-liter Dragon engine has a history within Ford’s global vehicle lineup. It was first used in the seventh-generation Ford Fiesta, and later found in vehicles like the Focus, Puma ST, and even the Fiesta Rally3, a race car designed to compete in the Group Rally3 category.

In the Bronco Sport and Escape, this engine produces 181 horsepower and 190 lb-ft of torque, which is delivered through an 8-speed automatic transmission. Depending on the configuration, the powertrain sends force to either the front wheels or all four.

What Happens Next for Owners?

While Ford continues to work on a full repair solution, owners of affected vehicles should stay alert. Affected owners can expect to receive a recall notice by mail soon, advising them to bring their vehicle to a Ford dealership for inspection and, when available, the corrective action.

In the meantime, if you smell fuel or suspect a leak, Ford recommends parking the vehicle outside and away from structures and contacting a dealer immediately.

As always, repairs under safety recalls are free of charge to vehicle owners.

Final Thoughts: A Growing Problem for Ford

This isn’t just a technical issue—it’s a reputation issue. With more than 90 recalls in 2025 so far, and massive costs piling up, questions are being raised about Ford’s engineering oversight, supplier management, and quality control processes. As consumers, trust in a brand plays a major role in purchase decisions. News like this may make some drivers think twice before choosing a Ford vehicle.

With the $570 million figure looming over its upcoming earnings call, Ford’s leadership will undoubtedly face tough questions—from shareholders, regulators, and drivers alike.

Stay tuned for updates following Ford’s Q2 2025 earnings report on July 30.

For Vehicle Owners: How to Check If Your SUV Is Affected

• Visit the NHTSA recall website
• Enter your 17-digit VIN (Vehicle Identification Number)
• See if your car is listed under the current recall campaign

You can also contact your local Ford dealership or call Ford Customer Service for more information.

Bottom Line: Ford is recalling nearly 700,000 SUVs over a serious fire risk caused by defective fuel injectors. The fix is still in progress, and the total cost is expected to reach $570 million, further straining Ford’s efforts to rebuild consumer trust in its product quality.

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