Ford Motor Company has issued a significant safety recall affecting 850,318 Ford and Lincoln vehicles across the United States due to potentially faulty low-pressure fuel pumps that could cause engines to stall while driving. This recall, announced on July 8, 2025, represents one of the largest automotive safety actions of the year and underscores growing concerns about fuel system reliability in modern vehicles.
The recall affects a wide range of popular Ford and Lincoln models manufactured between 2021 and 2023, including some of Ford’s best-selling vehicles such as the F-150 pickup truck, Bronco SUV, and Explorer. The safety issue stems from fuel pumps that may fail while in use, causing the engine to stall, which significantly increases the risk of accidents, particularly when vehicles lose power unexpectedly during highway driving or in heavy traffic conditions.
Understanding the Technical Problem
How Fuel Pump Failures Occur
To understand the severity of this recall, it’s important to grasp how fuel pumps function in modern vehicles. The low-pressure fuel pump serves as the critical first stage in delivering gasoline from the tank to the engine. When this component fails, vehicles may lose fuel pressure and flow from the fuel tank, effectively starving the engine of the fuel it needs to continue running.
The failure mechanism in these Ford vehicles involves two primary issues. First, contamination of the jet pump in low-fuel situations can block the fuel delivery system. Second, reduced fuel pump internal clearances can increase internal friction and sensitivity to vapor lock, particularly problematic in warm weather conditions when fuel temperatures rise.
Warning Signs for Vehicle Owners
Ford has identified several warning signs that may indicate impending fuel pump failure. Vehicle owners should be particularly alert for poor engine performance, such as misfiring or running rough, or a reduction in engine power. Additionally, drivers may notice the check engine light illuminating on their dashboard, which could signal fuel system problems among other potential issues.
The automaker has also noted that fuel pump failure is more likely to occur under low fuel or warm weather and hot fuel conditions in the fuel tank. This means drivers in warmer climates or those who frequently operate their vehicles with low fuel levels face higher risks of experiencing this potentially dangerous failure.
Affected Vehicle Models and Timeline
Complete List of Recalled Vehicles
The recall encompasses multiple vehicle lines across Ford’s popular model range. The affected vehicles include:
| Vehicle Model | Model Years | Type |
|---|---|---|
| Ford Bronco | 2021-2023 | SUV |
| Ford Explorer | 2021-2023 | SUV |
| Ford F-150 | 2021-2022 | Pickup Truck |
| Ford F-250 Super Duty | 2021-2023 | Heavy-Duty Truck |
| Ford F-350 Super Duty | 2021-2023 | Heavy-Duty Truck |
| Ford F-450 Super Duty | 2021-2023 | Heavy-Duty Truck |
| Ford F-550 Super Duty | 2021-2023 | Heavy-Duty Truck |
| Ford Expedition | 2022 | Full-Size SUV |
| Ford Mustang | 2021-2022 | Sports Car |
| Lincoln Aviator | 2021-2023 | Luxury SUV |
| Lincoln Navigator | 2021-2022 | Full-Size Luxury SUV |
Statistical Impact and Risk Assessment
While the recall affects over 850,000 vehicles, Ford estimates that 10% of the recalled vehicles in the U.S. have this fuel pump risk. This means approximately 85,000 vehicles may actually experience the fuel pump failure, though all affected models require attention as a precautionary measure.
Importantly, Ford isn’t aware of any accidents or injuries related to this recall, which suggests the company acted proactively based on internal data analysis and consumer complaints rather than waiting for serious incidents to occur.
Investigation Background and Supplier Issues
Timeline of Discovery
The fuel pump issue has a complex history that demonstrates how automotive problems can evolve over time. Ford first uncovered this issue in September 2022, when an internal Critical Concern Review Group opened an investigation into an increase in warranty claims and parts returns for fuel delivery modules on affected model years.
Initially, Ford’s investigation seemed to resolve the problem. An investigation into Ford’s Mexican supplier, Phinia, detailed an improvement in part quality after several corrective actions. This internal investigation was closed in July 2023, after Ford recorded a lower rate of warranty claims.
Regulatory Involvement and Reopened Investigation
However, the situation became more complex when federal regulators became involved. NHTSA opened a preliminary evaluation into Ford’s fueling system in July 2024 after receiving six complaints alleging a loss of motive power in certain Bronco models. This regulatory scrutiny prompted Ford to take a closer look at the data.
The critical turning point came when Ford re-examined its warranty claim rate in May 2025 and realized it was increasing again, forcing the automaker to re-investigate its supplier and issue a recall on June 30. This timeline illustrates how automotive safety issues can resurface even after initial corrective actions appear successful.
Ford’s Response and Remedy Development
Current Status of Solutions
As of the recall announcement, a remedy is still under development, meaning Ford has not yet finalized the repair procedures that will address the fuel pump failures. This situation places the company in the challenging position of notifying owners about a safety risk while simultaneously working to develop an effective solution.
Ford plans to send out notification letters to affected owners starting Monday (July 14) to warn about the safety risks. However, owners will receive an additional letter with instructions to take their car to an authorized dealer for that service when the time comes, and the repair work will be provided at no charge to vehicle owners.
Owner Resources and Support
Ford has established multiple channels for affected vehicle owners to obtain information and support. Owners can contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 25S75. Additionally, vehicle owners can reach out to federal safety regulators through the NHTSA safety hotline at 1-888-327-4236 (TTY 1-888-275-9171), or go to www.nhtsa.gov. NHTSA’s number for the recall is 25V-455.
Broader Context of Ford’s Safety Record
Pattern of Recent Recalls
This fuel pump recall represents part of a concerning trend for Ford Motor Company. Ford has issued 89 recalls with the NHTSA so far this year, impacting more than 5 million vehicles, according to federal agency records. Even more striking, that’s more safety recalls within six months than any automaker has issued in a year, according to reporting by the Wall Street Journal.
This unprecedented recall activity raises questions about Ford’s quality control processes and supplier management systems. The high volume of recalls suggests either systemic issues in Ford’s manufacturing and design processes or a more proactive approach to addressing potential safety concerns before they result in accidents.
Previous Related Issues
The current fuel pump recall follows similar concerns from earlier in the year. The latest fuel pump-related recall follows a similar safety recall in January, involving 295,449 diesel-engine trucks with high-pressure fuel pumps. This pattern suggests that Ford may be experiencing broader challenges with fuel system components across multiple vehicle lines and powertrains.
Consumer Guidance and Safety Recommendations
Immediate Actions for Owners
Vehicle owners who suspect they may be driving affected models should take several immediate precautions. First, they should check whether their vehicle is included in the recall by visiting the NHTSA website or contacting Ford directly with their vehicle identification number (VIN).
While waiting for notification and repair procedures, owners should pay particular attention to vehicle performance. Any signs of engine misfiring, rough idling, reduced power, or illuminated check engine lights should prompt immediate attention from a qualified mechanic.
Driving Precautions
Given that fuel pump failures are more likely in certain conditions, owners of affected vehicles should consider maintaining higher fuel levels than usual and being especially cautious during warm weather driving. If possible, avoiding long trips or high-stress driving situations until repairs are completed would provide an additional safety margin.
Industry Implications and Future Outlook
The scale and timing of this recall highlight several important trends in the automotive industry. Modern vehicles’ increasing complexity creates more potential failure points, while regulatory agencies and manufacturers are taking more proactive approaches to safety issues. The involvement of international suppliers, such as Ford’s Mexican partner Phinia, also demonstrates how global supply chains can complicate quality control efforts.
For Ford specifically, the company faces the challenge of maintaining consumer confidence while addressing these widespread safety concerns. The automaker’s commitment to developing comprehensive solutions and providing free repairs demonstrates recognition of the seriousness of these issues.
Frequently Asked Questions
Q: How do I know if my Ford or Lincoln is affected by this recall? A: Check your vehicle’s VIN on the NHTSA website or call Ford customer service at 1-866-436-7332 with recall number 25S75.
Q: Can I still drive my vehicle if it’s part of the recall? A: While no accidents have been reported, Ford recommends monitoring for warning signs like engine misfiring, reduced power, or check engine lights and seeking immediate service if these occur.
Q: When will the repair be available? A: Ford is still developing the remedy and will notify owners when the solution is ready for implementation at dealerships.