Ford Motor Company has issued a major recall involving 850,318 vehicles due to a defect related to the fuel pump system. This safety recall includes several well-known Ford and Lincoln models produced between 2021 and 2023. The core issue centers around the low-pressure fuel pump, which could fail unexpectedly and disrupt the engine’s fuel supply. This malfunction may cause the vehicle to lose power or stall while driving, posing a serious safety risk to occupants and others on the road.
According to official recall documents, internal contamination within the low-pressure fuel pump jet can significantly restrict fuel flow and pressure. This issue also increases the engine’s susceptibility to vapor lock, which may cause the vehicle to misfire, run roughly, or perform poorly before complete failure of the pump occurs. Among the models affected are the popular Ford F-150, which accounts for the majority of the recalled vehicles, as well as other major nameplates like the Bronco, Explorer, Mustang, and Super Duty. Lincoln models included in the recall are the Aviator and Navigator.
The issue first came to Ford’s attention in September 2022, when its Critical Concern Review Group (CCRG) began looking into a rising number of warranty claims concerning fuel delivery modules in some 2021–2022 models. These vehicles were equipped with a specific type of low-pressure fuel pump and accompanying jet pump. A subsequent teardown and analysis revealed that contaminants were obstructing the jet pump orifices. Although the root source of the contamination couldn’t be confirmed at the time, the supplier initiated several corrective measures between December 2021 and September 2022, which seemed to reduce the number of claims.
By July 2023, Ford closed its initial investigation, believing the problem had been addressed. However, the situation resurfaced in April 2025 when the National Highway Traffic Safety Administration (NHTSA) began reviewing consumer complaints, particularly about 2021 Bronco models experiencing power loss. Ford re-opened its inquiry and discovered that warranty claims were rising again, especially in warmer regions and during the summer season. In May 2025, engineers traced the root of the issue to changes the supplier had made in July 2021 that resulted in tighter clearances in the jet pump, contributing to the malfunction.
As of early June 2025, the company has logged nearly 1,900 warranty claims, along with dozens of customer and field reports. Fortunately, no accidents or injuries have been linked to the defect so far. While Ford has acknowledged the problem, it currently does not have a finalized solution. The company is developing a remedy and plans to notify affected vehicle owners by mail. Initial notifications are expected to begin going out next week, instructing owners to bring their vehicles to dealerships for inspection and repair once a fix is available.