Dive Brief:
- Ford Motor Co. recalled 33,576 Bronco Sport and Escape models for fuel injectors that may crack and leak fuel onto hot engine components and increase the risk of fire, according to the National Highway Traffic Safety Administration.
- The recall covers 2021-2023 Bronco Sport and 2020-2022 Escape SUVs equipped with 1.5 liter turbocharged, three-cylinder EcoBoost engines. Some of these models were included in two prior recalls in November 2022 and March 2024.
- To address the recall, dealers will update the vehicles’ powertrain control module software to the latest version, free of charge. Owner notification letters are expected to be mailed beginning April 24.
Dive Insight:
The March 2024 recall included roughly 42,650 2022-2023 Bronco Sport and 2022 Escape models. Dealers performed an engine control software update that added fuel injector leak detection capabilities. A drain tube was also installed to channel raw fuel away from underhood components.
The revised PCM software is meant to detect a pressure drop in the high-pressure fuel rail and warn drivers of a potential problem via the instrument cluster. The software is also designed to disable the vehicle’s fuel pump and lower engine power output to further reduce fire risk.
However, Ford acknowledged that some of the Bronco Sport and Escape models included in last year’s recall may have had the incorrect software version installed, according to the NHTSA. Ford said the errors may have been recorded in its internal system as the correct software updates.
The automaker cited an issue with its dealer service equipment for the software update error. Dealers performed the PCM software update using a factory-authorized service tool, but the equipment failed to update all vehicles to the correct version as intended, according to the NHTSA.
Ford is now determining which software versions have been installed during production and by its dealers for last year’s recall. To ensure that the recall is properly addressed, the software update will be validated by service technicians before the field service action is closed.
In addition to the increased risk of fire, drivers of these vehicles may experience a fuel odor around the vehicle, or notice smoke or flames originating from the engine compartment, which highlights the elevated safety risk that spurred a third recall.
Ford is aware of four underhood fires in Bronco Sport and Escape models, but has been unable to confirm if they were due to a leaking fuel injector, according to the NHTSA. The automaker is not aware of any accident or injuries related to the recall.
Recall timeline
Ford’s Critical Concern Group was notified of the problem Nov. 26, 2024, which was identified after an audit was requested for software previously installed in Ford vehicles. However, an initial review of field service actions found insufficient data to confirm that the vehicles’ received the correct update and the invesgitation was expanded.
The automaker informed the NHTSA of its findings on Dec. 19, 2024. In February, Ford performed an audit of software installed in each vehicle to identify the exact number requiring the update. As a result of the audit, Ford’s Field Review Committee approved the recall on March 7.
Ford implemented a fuel injector production change in late 2022 to eliminate stresses that could lead to cracking, according to the NHTSA. The automaker also extended the warranty on the injectors for 15 years or 150,000 miles and will replace any defective parts in this timeframe free of charge.
For the models recalled in March 2024 recall, the original fuel injector design and PCM software was taken out of production on Jan. 13, 2023. Model year 2022 Escape SUVs were taken out of production a month earlier in December.
