DETROIT - Ford has issued a recall for more than 850,000 vehicles across various 2021-2023 models due to a potential defect in the fuel delivery module that could lead to an engine stall while driving.

The recall affects an estimated 850,318 vehicles, with about 10% of those estimated to have the defect. The issue stems from a low-pressure fuel pump failure caused by internal contamination of the jet pump, particularly in low fuel conditions, and reduced internal clearances that increase friction and sensitivity to vapor lock.

 Affected models include:

  • 2021-2023 Ford F-550 SD (5,039 vehicles)
  • 2021-2023 Ford F-450 SD (4,393 vehicles)
  • 2021-2023 Ford F-350 SD (30,781 vehicles)
  • 2021-2023 Ford F-250 SD (73,183 vehicles)
  • 2021-2022 Lincoln Navigator (14,358 vehicles)
  • 2021-2023 Lincoln Aviator (24,073 vehicles)
  • 2021-2022 Ford Mustang (24,790 vehicles)
  • 2021-2022 Ford F-150 (455,261 vehicles)
  • 2021-2023 Ford Explorer (76,089 vehicles)
  • 2022 Ford Expedition (32,470 vehicles)
  • 2021-2023 Ford Bronco (109,881 vehicles)

The vehicles involved were produced between July 1, 2021, and July 31, 2022, with some Lincoln Aviator models extending to Dec. 21, 2022, and Ford Bronco models to July 30, 2022.

Ford states that a loss of fuel pressure can lead to an engine stall, increasing the risk of a crash. Drivers may experience warning signs such as poor engine performance (misfiring or running rough), a check engine light or a reduction in engine power before a complete failure. The company notes that fuel pump failure is more likely to occur in low fuel or warm weather conditions.

The defect has been traced to a supplier in Chihuahua, Mexico. An investigation by Ford's Critical Concern Review Group (CCRG) found that changes made by the supplier in June 2021 to accommodate increased build complexity, along with issues with a Tier 3 supplier for the fuel pump pumping chamber, led to the problem.

As of June 6, 2025, Ford had identified 1,860 warranty claims related to the issue. The company says it is not aware of any accidents, fires, injuries, or property damage attributed to this condition.

The remedy for the defect is currently under development. Once available, owners will be notified by mail to take their vehicles to a Ford or Lincoln dealer for free repair.

Dealers were notified of the recall July 8, 2025. Interim owner notification letters are expected to be mailed between July 14 and July 18, 2025. The date for remedy owner notification letters will be announced once the repair solution is finalized.

Owners can contact Ford’s toll-free line at 1-866-436-7332 or a local Ford or Lincoln dealer for specific information regarding their vehicles.