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Ford recalls more than 40,000 Bronco Sport and Escape models for fuel leak

It’s an expansion of a much larger recall from 2022

APRIL 2024 — — Ford issued a recall for 42,652 examples of its 2022-2023 Bronco Sport and 2022 Escape SUVs to address a fuel leak caused by a cracked fuel injector. Vehicles equipped with 1.5-liter EcoBoost engines are included in the recall. The fix includes the installation of a drain tube to redirect any leaking fuel from the engine to the ground along with a software update that adds fuel injector leak detection to the engine control unit.

This might sound eerily familiar to owners of these particular vehicles. Back in November of 2022, Ford issued a much larger recall covering a similar range of Escape and Bronco Sport models that also included cracked fuel injectors, a flash of the ECU and a fuel drain tube. So, what’s the deal?

According to documents posted by the National Highway Traffic Safety Administration, “Ford’s Internal Combustion Engines Propulsion Thermal Systems Engineering (IPTSE) team had identified leaks during component-level injector flow testing on fuel injectors recovered from two Bronco Sport vehicles that had experienced underhood fires” that happened after the original recall “clean point.” In other words, these fires happened on vehicles produced after the date at which they were considered fixed.

These two vehicles had HX7G-9F597-BC fuel injectors, an improved design over the older HX7G-9F597-BB parts, and so therefore were not included in the original recall and did not receive the software update or the fuel drain tubes. “Ford’s decision not to include the updated engine control software on these vehicles was based on Ford’s assessment of the new injectors’ improved robustness,” according to documents posted on the NHTSA site. Ford is aware of five underhood fires on vehicles with these updated injectors but without the updated software and drain tube.

 2022-2023 Bronco Sport
2022 Ford Escape

Manufacturer: Ford Motor Company
Component(s): ENGINE, FUEL SYSTEM, GASOLINE; Engine Compartment Fire
Potential Number of Units Affected: 42,652
Report Receipt Date: May 26, 2023

MAY 2023 — Ford Motor Company (Ford) is recalling certain 2020-2023 Escape, 2022-2023 Maverick, and 2021-2023 Corsair vehicles equipped with 2.5L HEV or PHEV engines. In the event of an engine failure, engine oil and fuel vapor may be released into the engine compartment and accumulate near ignition sources such as hot engine or exhaust components, possibly resulting in an engine compartment fire.

Owners are advised to park and shut off the engine as quickly as possible if they hear unexpected engine noises, notice a reduction in vehicle power, or see smoke. The remedy is currently under development. Letters notifying owners of the safety risk are expected to be mailed June 12, 2023. Second letters will be mailed once the remedy is available. Ford’s number for this recall is 23S27.

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