Ford’s recall woes appear far from over. Since the beginning of the year, the automaker has issued 90 recalls in the United States—more than any other car manufacturer. The latest recall, involving Ford Bronco Sport and Escape models, could cost the company more than half a billion U.S. dollars.
This is the third recall for the same issue
Only 1.5-litre turbocharged 4-cylinder engines are affected
A total of 70,618 vehicles are impacted in Canada
This week, Ford announced a recall of more than 700,000 vehicles globally due to a serious fire risk—an issue the company has already attempted to address multiple times. In Canada, 70,618 units are affected.
In the U.S., the recall involves 339,044 Bronco Sport SUVs (model years 2021 to 2024) and 355,227 Ford Escapes built between 2020 and 2022, all equipped with the 1.5-litre turbocharged 4-cylinder engine. Canadian model breakdowns have not been disclosed. The issue stems from a fuel injector that may crack, leading to a fuel vapour leak into the engine compartment. These vapours can then come into contact with hot surfaces, such as the turbocharger or exhaust system, potentially causing a fire.
Ford Bronco Sport 2021-2024Since this issue first emerged in November 2022, Ford has implemented several measures, including installing a fuel drain tube and updating engine software to detect cracked injectors and shut off the fuel pump if needed. However, some vehicles never received this software update, prompting another recall in March 2025.
Meanwhile, the U.S. National Highway Traffic Safety Administration (NHTSA) launched its own investigation and determined that Ford’s remedies were inadequate. It mandated an official recall with full replacement of the defective injectors. The result: a return to square one and a comprehensive recall of all affected units.
Ford Escape 2020-2022Ford has acknowledged that corrosion plays a key role in the injector failures but has not confirmed whether all injectors will be replaced. For now, the company is rolling out software updates to vehicles that have yet to receive them. However, it increasingly looks like Ford will have no choice but to order millions of new injectors to comply with regulatory demands. As is often the case, Canada is expected to follow the U.S. lead on the matter.
Here is the official Transport Canada recall number 25S76:
Recall Description:
Issue: On certain vehicles, a fuel injector may crack. If this happens, fuel could leak into the engine compartment.
Note: This recall only affects vehicles equipped with a 1.5 L EcoBoost engine. This recall replaces Transport Canada recalls 2022-658, 2024-160 and 2025-134.
Safety Risk: A fuel leak can create the risk of a fire.
Corrective Actions: Ford will notify owners by mail. As an interim repair, a dealer will update the engine control software to detect fuel injector leaks. Owners that have already received this software update will be informed that the interim repair is not required. Once the final repair is available, you will need to return to a dealership. The final corrective actions for this recall are under development.
