Ford recalls 850k vehicles: Mexico supplier fuel pump mishaps

Ford is recalling 850k vehicles all thanks to Mexico supplier fuel pump mishaps causing vehicles to stall.

Ford recalls 850k vehicles

The recall document on NHTSA.gov states:

NHTSA Campaign Number: 25V455000

Manufacturer Ford Motor Company

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 850,318

These vehicles include: 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.

Owners will be mailed letters starting on July 14, 2025 and a second letter with the remedy will be mailed at a later date.

Mexico supplier fuel pump

The recall chronology report details exactly what happened between Ford, NHTSA investigators and two different Mexico parts suppliers.

“In September 2022, Ford’s Critical Concern Review Group (CCRG) opened an investigation into an
increase in warranty claims and part returns related to Fuel Delivery Modules (FDM) on certain 2021- 2022 Model Year (MY) vehicles. The FDMs on these vehicles contained a specific variant of lowpressure fuel pump and jet pump.

Teardown analysis indicated that jet pump orifices on some returned parts were blocked by
contamination. The source of contamination was not confirmed. The CCRG reviewed the available
warranty data and noted that the rate of failures had decreased significantly after the supplier
implemented several corrective actions from December 2021 through September 2022 to reduce
contamination and production variation.

In July 2023, the CCRG reviewed the warranty data after the monitor period to confirm that the
supplier’s corrective actions had successfully resolved this concern in the field. Based on the available warranty data, Ford closed the investigation because the field data showed that the rate of failures was low and the failure could be progressive in nature. Ford was not aware of any accidents, fires, injuries or property damage attributed to failure of the FDM.

On July 29, 2024, the National Highway Traffic Safety Administration (NHTSA) opened Preliminary
Evaluation (PE) 24-019 in response to six consumer complaints alleging loss of motive power as a result of low-pressure fuel pump failure in 2021 MY Ford Bronco vehicles. Ford’s response was provided on September 23, 2024.

On April 3, 2025, Ford’s Critical Concern Review Group (CCRG) opened an investigation to update the warranty claims, field reports and affected population associated with PE24-019. On May 22, 2025, the CCRG determined that the number of warranty claims had increased during summer months and in warm weather states. Connected vehicle data was utilized to further understand the conditions, such as fuel tank fill levels and diagnostic trouble codes, leading to further understanding of the root cause.

On June 9, 2025, the CCRG reviewed vehicle production dates for warranty claims to determine whether something had changed in the supplier’s manufacturing process. The CCRG discovered that vehicles were all produced between July 2021 and July 2022. On June 9, 2025, through June 10, 2025, Ford Product Development (PD) and Ford Supplier Technical Assistance (STA) conducted a review of the supplier’s manufacturing process for the parts used on these vehicles. Ford found that the supplier had made changes to the jet pump process to accommodate an increase in build complexity in June 2021 and identified that a tier 3 supplier for the GEN 4.6 fuel pump pumping chamber was not statistically capable for internal clearances and utilizing the full tolerance range of the supplier specifications. The low clearances resulted in an increase of internal friction and sensitivity to vapor lock beginning in early July 2021.

As of June 6, 2025, 1,860 warranty claims (received from September 2, 2021 to May 31, 2025) have been identified related to the investigation. As of June 24, 2025, 28 field reports (received from January 5, 2022 to March 31, 2025) and 57 customer service reports (received from October 18, 2021 to May 22, 2025) have been identified related to the concern. Vehicles produced from July 1, 2021, through July 31, 2022, have a projected fuel delivery module failure rate of 8.9 R/1000 at 10 years/150,000 miles of vehicle service.

On June 30, 2025, Ford’s Field Review Committee reviewed the concern and approved a field action.

Ford is not aware of any reports of accident or injury related to this condition.”

Owners should contact Ford or search for their vehicle on NHTSA.gov for more information on recalls.