Ford pickup, Bronco, and big SUV owners, heads up! Ford Motor Company (Ford) is recalling certain 2021-2023 Bronco, Explorer, Lincoln Aviator, F-250 SD, F-350 SD, F-450 SD, F-550 SD, 2021-2022 Lincoln Navigator, Mustang, F-150, and 2022 Expedition vehicles. The low-pressure fuel pump may fail, which can result in an engine stall while driving. An engine stall increases the risk of a crash. 850,318 of these rigs are under recall in the Ford fuel pump failure issue.
Ford fuel pump failure remedy
The remedy is under development. Letters notifying owners of the safety risk were expected to be mailed July 14, 2025. Second letters will be sent once the remedy is available. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 25S75.
Background goes back a ways
Back in 2022, Ford started looking into a rise in fuel system issues in some of their 2021 – 2022 vehicles. Owners were filing more warranty claims and returning faulty parts, especially related to the Fuel Delivery Module (FDM), which includes a low-pressure fuel pump and a jet pump.
What’s the problem?
Ford found that some of these fuel pumps had blockages due to contamination (basically, stuff got inside that shouldn’t have been there), though they weren’t sure where it came from. The company that made the parts made some fixes in late 2021 through 2022, and things seemed to improve—fewer vehicles were having problems.
Ford thinks it’s off the hook
By July 2023, Ford thought the issue was under control. They saw the number of failures drop and figured the problem was fixed. No accidents, fires, or injuries were tied to the issue, so they officially closed the investigation.
But wait… there’s more
In July 2024, the National Highway Traffic Safety Administration (NHTSA) opened a new investigation after getting six complaints about 2021 Ford Bronco losing power—again pointing to the fuel pump.
Ford took another look. In April 2025, they reopened their internal investigation and started digging into more recent data. By May 2025, they noticed the failures were happening more often during hot months and in warm-weather states. They used data from connected vehicles to analyze what conditions were triggering problems (like fuel tank levels and engine codes).
Ford’s findings
By checking production dates and digging into the parts supplier’s manufacturing changes, Ford discovered something important:
- Vehicles built between July 2021 and July 2022 were most affected.
- In June 2021, the supplier changed how they made part of the fuel pump to handle more complicated builds.
- One of their sub-suppliers wasn’t meeting proper specs, which made the pump more prone to friction and vapor lock (a condition where fuel can’t reach the engine properly, especially in heat).
The numbers:
- 1,860 warranty claims (as of June 6, 2025)
- 28 field reports and 57 customer complaints related to the issue
- Vehicles from July 2021 to July 2022 have an estimated failure rate of 8.9 per 1,000 vehicles over 10 years or 150,000 miles.
Finally, Ford calls for a fix
On June 30, 2025, Ford’s internal review team approved a field action, recall campaign, to address the problem. So far, Ford says there have been no reported crashes or injuries tied to the issue.
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Ford is becoming the laughing stock of the auto industry!
Thank you for the news, Russ and Tina! 🙂 Thankfully, DW’s car is considerably older than the recalled vehicles. 🙂 Hava a great day and safe travels!
I got a recall letter yesterday for my 2022 F-250. No fix yet, but it says: “Ford has not issued instructions to stop driving your vehicle under this safety recall.” It also says: “Prior to fuel pump failure, you may experience poor engine performance (misfiring or running rough), a check engine light, or a reduction in engine power. Fuel pump failure is more likely to occur under low fuel or warm weather and hot fuel conditions in the fuel tank.”
Hopefully that means failures are rare, and we get some warning before the pump fails entirely so we can pull off the road safely. I imagine they have their best and brightest working on it, so hopefully we see a fix soon.
Vapor lock?? I thought that disappeared with fuel injection!
Vehicle recalls used to be big news. Now it happens every month or so. Last year Ram DEF systems. Last month GM crankshaft failures. This month Ford fuel pumps. Who is next? The old stuff we drive looks better every day.