American car giants, Ford is recalling 694,271 crossover SUVs in the United States due to a fuel leak issue that poses a potential fire risk, according to a report by the U.S. National Highway Traffic Safety Administration (NHTSA). The recall affects certain 20212024 Bronco Sport and 20202022 Escape models equipped with 1.5-litre engines. The NHTSA stated that fuel injectors in these vehicles may crack and leak fuel into the engine compartment, which could lead to fires. Symptoms include a strong fuel odor, dashboard warning lights, smoke, or even visible flames. The vehicles being recalled include units that were previously repaired under earlier campaigns in 2022 and 2024, as well as newer models that share the same engine and software. Ford acknowledged the issue in a statement, estimating the cost of the expanded recall at approximately $570 million, which will be reflected in its second quarter 2025 financial results. The NHTSA estimates that 0.3% of the recalled vehicles may actually have the defect. The agency had raised concerns last year that Ford's prior fix, primarily a software update, did not adequately resolve the root cause of the problem. The recall comes after Ford reassessed the effectiveness of its previous remedies and found that eight vehicles had experienced under-hood fires due to cracked fuel injectors, despite having undergone repairs. Six of those vehicles had not received the updated engine software. The injectors were manufactured by Italy-based Dumarey Flowmotion Technologies. As a temporary solution, Ford has introduced a software update to detect fuel injector leaks, reduce engine power, and cut off fuel supply. The company is continuing to develop a more permanent mechanical remedy. Earlier recommendations also included installing a drain tube to redirect leaking fuel away from ignition sources, but Ford has now moved to expand those efforts in light of the continued fire risk.
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