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Ford Calls Back Escape, Bronco Once Again Due To Fuel Leakage And Fire Hazard

Image Source: Darren Brode / Shutterstock

Ford has broadened the recall of a fractured fuel injector which can enhance the danger of fire, as revealed by the NHTSA on Monday.

The initial recall, dated November 18, 2022, included 521,746 Escape and Bronco Sport small crossovers equipped with a 1.5-liter turbo-3 engine. This recall from 2022 was also an extension of a previous recall. This is now the third recall for the same problem affecting the same vehicles.

Some of the cars that were fixed during the original repair had an updated fuel injector design, yet Ford did not revise the engine control software to accommodate these new fuel injectors. This software would have identified a decrease in pressure in the fuel rail, warned the driver about an issue through the instrument cluster, reduced engine performance, and lowered ignition temperatures in the engine compartment where feasible. However, the new fuel injector could still fracture. This time, though, there would be no actions taken to minimize the heightened fire risk, and the driver would remain unaware until a fire occurs.

Ford disclosed five fires in this expanded recall group with the defective repair. The issue of cracked fuel injectors only affects the standard 1.5-liter turbo-3 engine. The recall affects 42,652 vehicles, including the 2022 Ford Escape and the 2022-2023 Ford Bronco Sport manufactured within a three-month span from October 2022 to early January 2023.

A fractured fuel injector can lead to fuel seeping rapidly onto the cylinder head, which may then flow onto hot surfaces close to the exhaust manifold or turbocharger. Fuel vapor on a hot surface can trigger a fire. Vehicle owners may detect fuel fumes inside or outside the car, witness smoke emanating from below the hood, and may receive a warning from the instrument cluster.

Ford has stated that they will enhance the engine control software to detect leaks and authorized service centers will attach a drain tube to redirect any leaked fuel away from the engine. The better solution would seem to be to replace the fuel injectors with models that are resistant to fractures.

Image Source: Darren Brode / Shutterstock

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