Ford has announced a major recall affecting more than 850,000 vehicles across the US, following the discovery of a dangerous fuel pump defect.

According to the National Highway Traffic Safety Administration, the issue can cause sudden engine stalls while driving, especially in hot conditions or when fuel levels are low.

The recall applies to 11 different models manufactured between July 2021 and July 2022, with some extending into late 2022 production.

Ford has not yet released a permanent fix, but interim safety notices will be mailed to affected owners beginning July 14.



The root of the problem stems from a fuel pump component manufactured by a supplier in Chihuahua, Mexico.

Ford’s internal review traced the failure to tight internal spacing and contamination in the redesigned pump chamber.

These changes, implemented in mid-2021, can lead to a sudden disruption in fuel delivery under certain conditions.


The company’s Critical Concern Review Group launched a full investigation after spotting a pattern of power loss claims under warranty.

The issue has not yet led to any reported crashes, fires, injuries, or property damage, Ford said in a statement to regulators.

However, the NHTSA has received six consumer complaints citing a sudden loss of vehicle power. Drivers are advised to stay alert for early warning signs, such as rough idling, misfires, or a check engine light appearing unexpectedly.



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Ford estimates that only about 10% of the recalled vehicles actually contain the defective component, though all units in the affected group will be notified.

Models involved in the recall include high-volume vehicles such as the F-150, Explorer, and Bronco, as well as luxury Lincoln SUVs.

Specifically, the F-150 accounts for more than half of the recalled units, with over 455,000 trucks built during the recall window.



A full list also includes various Super Duty trucks, the Mustang, and both the Lincoln Navigator and Aviator. Dealers were officially notified on July 8 and are preparing for an increase in service traffic.

Although no official repair has been finalized, owners will receive two mailings: the first in mid-July explaining the risk, and the second later this year when a fix becomes available.

Ford emphasized that all repairs will be free once the final procedure is confirmed and distributed. Until then, drivers are urged to avoid running fuel tanks low and to be cautious in high-temperature environments.



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The company is closely monitoring additional reports and evaluating possible remedies. The recall follows another major Ford safety issue earlier this month, when over 200,000 vehicles were recalled due to a backup camera glitch.

In that instance, the display could freeze or go dark, increasing the risk of crashes during reversing. Ford’s recent pattern of electrical and mechanical issues has raised broader questions about quality control across its product lines.

While this recall has not yet led to physical harm, the scale of potential failure has alarmed both regulators and consumers.

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Have you experienced a sudden stall or power loss in one of the recalled Ford models? We want to hear from you—share your experience in the comments below and let us know if you’ve already received your recall letter.