Ford Motor Company has issued more safety recalls in the first half of 2025 than any other car company has over the course of a year, according to the National Highway Traffic Safety Administration (NHTSA). With the company’s latest recall involving gasoline fuel systems, Ford has issued 89 safety recalls in 2025 alone. The next highest annual recall number is from General Motors, which issued 77 in 2014.
Throughout June 2025, the company issued 19 recalls. These included recalls for the rearview camera on certain F-150 trucks (among others), which may not display; the service brakes on certain 2025 F-550 SD, F-450 SD, F-350 SDE, and F-250 SD trucks, which may cause the loss of brake function; and the instrument panel on certain 2025 Ranger trucks, which may not properly display warning lights or gauges.
Ford's response
“We know that we need to take care of our customers, and that's what we do,” Mike Levine, director of Ford Blue Product Communications, Supply Chain, and Quality and Safety Communications told Fleet Maintenance. “Part of it is also that we've been spending more time to improve our quality, and by doing so, we're going back into current production vehicles, and we're testing components to make sure that they meet customer requirements.”
Through these recalls, Levine said that the company was not only rectifying safety or quality issues with vehicles, but also “rolling out changes in real time in production to improve the quality of the vehicles as well.”
He went on to specify that 33 of the recalls from 2025 have been for software audits for vehicles that were previously recalled, stating that less than 5% of the vehicles from the original vehicles had software that wasn’t properly updated.
“… the rest of the recalls that we've been doing are around the safety items that we discover,” Levine stated.
The most recent recall
Ford’s most recent recall, No. 25V455000, potentially impacts 850,318 vehicles and is due to low-pressure fuel pumps that can fail, causing engines to stall. More specifically, it covers certain 2021-2023 Bronco, Explorer, Lincoln Aviator, F-250 SD, F-350 SD, F-450 SD, F-550 SD, 2021-2022 Lincoln Navigator, Mustang, F-150, and 2022 Expedition vehicles.
The fuel-pump problem is reportedly due to issues with two of Ford’s suppliers. The company’s Critical Concern Review Group (CCRG) first opened an investigation into Fuel Delivery Modules (FDMs) on certain 2021-2022 MY vehicles in September 2022, when the company saw an increase in warranty claims and part returns for some FDMs. After doing a teardown analysis, the Group found that the jet pump orifices on some of the returned FDMs were blocked by contamination—but seeing that the initial supplier had taken steps to fix the problem for those FDMs, thus decreasing failures, CCRG closed the investigation in July 2023.
One year later, NHTSA opened a preliminary evaluation after additional complaints surfaced about some 2021 MY Ford Broncos losing power due to low-pressure fuel pump failure. After an initial response on Sept. 23, 2024, Ford’s CCRG discovered in July 2025 that the impacted vehicles were all produced between July 2021 and July 2022.
This led to the Ford Product Development and Ford Supplier Technical Assistance teams reviewing their supplier’s manufacturing process for those vehicles, where they found two key elements. First, the supplier had changed the jet pump process to accommodate the increase in vehicle build complexity in June 2021, according to NHTSA’s report.
Second, another Tier 3 supplier for the GEN 4.6 fuel pump pumping chamber “was not statistically capable for internal clearances and utilizing the full tolerance range of the supplier specifications,” the report said. Reportedly, the low clearances led to more internal friction in the part, as well as sensitivity to vapor lock for vehicles produced in early July 2021 throughout July 2022. Afterwards, Ford connected 1,860 warranty claims, 28 field reports, and 57 customer service reports to the issue.
Ultimately, Ford concluded that vehicles produced from July 1, 2021 through July 31, 2022, had a projected fuel delivery module failure rate of 8.9 R/1000 at 10 years/150,000 miles of vehicle service, according to NHTSA. This led to the company’s 89th recall in 2025.
Notification letters about the recall will be mailed out on July 14, 2025. While Ford doesn’t yet have a fix for the problem, a second round of letters will be sent out once one is identified so drivers can get their trucks fixed free of charge.
About the Author
Alex Keenan
Alex Keenan is an Associate Editor for Fleet Maintenance magazine. She has written on a variety of topics for the past several years and recently joined the transportation industry, reviewing content covering technician challenges and breaking industry news. She holds a bachelor's degree in English from Colorado State University in Fort Collins, Colorado.