Ford has had a very rocky 2025 when it comes to reliability and quality with the Dearborn auto giant already exceeding the amount of recalls it was forced to issue last year within the first few months of 2025.

This tidal wave of recalls has caused Ford to take heat from consumers and dealerships but it appears the misery is not over yet with the National Highway Traffic Safety Administration (NHTSA) announcing a new recall that affects nearly 700,000 SUVs due to a fire risk.

Recall focuses on the fuel injectors

This latest recall targets 694,271 SUVs and applies to the 2020-2022 Ford Escape and the 2021-2024 Bronco Sport. These SUVs could have been equipped with faulty fuel injectors that can crack. These cracked injectors can leak fuel into the engine compartment with the leaked fuel potentially causing an engine fire. This recall is also separate from a recall announced last week that focused on faulty fuel pumps that were installed into various SUV models as well as the Ford Mustang.

According to the NHTSA report, an internal committee at Ford had first reviewed the issue on 1.5-liter engines in March last year, suggesting that an update to the engine control software and the installation of a drain tube would resolve the issue. The tube was supposed to help divert leaked fuel away from potential danger spots while an accompanying software update would activate a warning light when pressure in the fuel rails was low.

Only around 42,000 vehicles were covered by the recall at the time. That only lasted a month before the NHTSA opened a recall query and determined the solutions failed to address the problem and forced the agency to release this latest recall.

Ford faces a double-edged sword

Unlike other recalls, Ford is facing a proverbial double-edged sword with this one. The good news is that only 0.3% of the Bronco and Escapes bundled into the recall are supplied with the faulty injectors and no injuries have been reported.

However, this is balanced out by Ford not having a permanent solution to the problem as of this writing. This will help create a big hit in the company’s pocketbook as well with the company releasing a statement to Reuters saying “We estimate the aggregate cost of the action, based on the remedy options we are evaluating, to be about $570 million and will be reflected in our second quarter 2025 results,” Ford said.