Ford Vehicle Recall Report Due to Fuel Pump Issue
According to the recall report, the issue is related to internal contamination of the FDM jet pump that occurs at low fuel levels. The report also notes reduced internal clearances of the fuel pump, leading to increased internal friction and greater susceptibility to vapor lock.
Drivers of recalled vehicles may experience poor engine performance: rough running or misfires, reduced power, and illumination of the “check engine” indicator. FDM faults most often occur at low fuel levels or in warm weather, which raises the temperature of the fuel in the tank.
Investigation History
September 2022 — Ford’s Critical Concern Review Group (CCRG) initiated an investigation following a large number of warranty claims and part returns related to the fuel delivery system on 2021-2022 model year vehicles.
Disassembly analysis revealed contamination of the jet pump openings on some parts, although the contamination source was not confirmed at that time.
The FDM supplier is Phinia (Auburn Hills, Michigan), with manufacturing located in Mexico.
Corrective Actions
From December 2021 through September 2022, Phinia implemented several measures to reduce contamination and stabilize production, resulting in a significant decrease in fuel pump failures.
In July 2023, Ford closed the investigation, assessing that the failure rate had become low and failures were progressive in nature.
Recent Developments
July 29, 2024 — NHTSA initiated a preliminary evaluation after receiving six complaints from 2021 Ford Bronco owners citing engine power loss.
Ford submitted responses to NHTSA on September 23, 2024.
April 3, 2025 — CCRG reopened the investigation, reviewing warranty claims, field reports, and the number of affected vehicles.
It was found that complaints increase in summer and warm states.
The company is collecting data from connected vehicles, analyzing fuel levels and diagnostic codes to identify the root cause.
Manufacturing Details
All affected vehicles were produced between July 2021 and July 2022.
In June 2021, Phinia revised the jet pump manufacturing process to address assembly complexity.
It was discovered that an unnamed supplier of the FCM pump chamber did not meet specifications, leading to reduced clearances, increased friction, and susceptibility to vapor lock.
As a result, on June 30, Ford approved a recall of approximately 850,000 vehicles.
Statistics and Next Steps
Approximately 10% of recalled vehicles have defective FDM.
As of June 6, 2025, Ford received 1,860 warranty claims from September 2021 through May 2025, including 28 field reports and 57 customer complaints.
No crashes or injuries related to this issue have been reported.
Ford is currently working on a fix; the implementation date has not been announced.
Overall Context of Ford Recalls in 2025
This is Ford’s 89th recall in 2025 and the second largest after a May recall of over 1 million vehicles due to rearview camera software issues.
The total number of Ford recalls this year exceeds the combined recalls of General Motors, Stellantis, Toyota, Honda, Hyundai, Volkswagen, and Tesla.
The company states it is actively improving vehicle quality, considering the increasing complexity and number of software features.
“Over the past two years, Ford has more than doubled its team of safety and technical experts and significantly increased failure testing of critical systems such as powertrains, steering, and brakes,” said spokesman Mike Levine.