According to the National Highway Traffic Safety Administration (NHTSA), Ford issued a major recall due to low-pressure fuel delivery module (FDM) failures that may lead to engine stalling while driving, significantly increasing the risk of a crash.
The recall affected 850,000 vehicles, including certain 2021-2023 Bronco, Explorer, Lincoln Aviator, F-250, F-350, F-450, and F-550 Super Duty pickups; 2021-2022 F-150, Mustang, and Lincoln Navigator; and 2022 Expedition SUV.
The problem stems from the internal contamination of the FDM’s jet pump, which likely occurs when the fuel level is low. According to the recall report, drivers of the affected vehicles experienced poor engine performance, such as rough running or misfiring, as well as reduced power and a blinking check engine light.
Currently, Ford doesn’t have a remedy available to address the issue. They are still working on it and notifying affected owners of the safety risk. Continue reading the article to reveal the complete story behind this massive Ford Super Duty Fuel Pump Recall.
What is a Fuel Delivery Module and How Does it Work?
Before getting to the topic, let’s discuss the fuel delivery system and how it works.
A fuel delivery module is an assembly located in the fuel tank responsible for delivering fuel from the fuel tank to the engine at the correct pressure and volume. The module contains some essential components, including a fuel pump, fuel filter, fuel reservoir, fuel level sensor, and valves.
How FDM works:
- It works by pumping fuel from the tank. While passing through the fuel delivery module, the integrated filter removes any impurities from the fuel.
- The fuel passes through a reservoir, which ensures a stable supply of fuel to the pump.
- Then, the fuel is delivered to the fuel rail at the right pressure, controlled by a pressure regulator.
- The fuel is delivered to the engine for combustion.
- The fuel level sensor is monitoring the fuel level, and the data is transmitted to the vehicle’s computer.
- Modern FDMs come with demand-controlled fuel supply systems that adjust the fuel delivery based on engine requirements, reducing emissions.
What Ford Vehicles Were Affected in the Recall?
The massive 850,000 recall due to a defective fuel pump includes:
- 2021-2023 Bronco, Explorer, Lincoln Aviator, F-250, F-350, F-450, and F-550 Super Duty pickups
- 2021-2022 F-150
- Mustang and Lincoln Navigator
- 2022 Expedition SUV
According to the recall report, an estimated 10% of the recalled vehicles are suspected of having defective fuel delivery modules.
If you want to learn about other major recalls affecting the Ford Explorer, check out this recall report.
What Caused the Ford Super Duty Fuel Pump Recall?
According to the recall report, Ford has recalled 850,000 vehicles due to a failure in the fuel delivery module. The internal contamination of the FDM’s jet pump caused the issue, increasing internal friction and sensitivity to vapor lock.
The problem is more likely to occur when the fuel level is low or in warm weather, which leads to an increase in the fuel temperature in the tank.
Other Potential Reasons Behind the Faulty Fuel Delivery Module
Here are some most common and less common reasons behind the faulty fuel delivery module.
Most Common Reasons
- Corrosion: The fuel delivery module is present on the vehicle’s frame, exposing it to debris, dirt, and water. When the module comes in contact with any of these things, it leads to oxidation of the aluminium casing, resulting in overall component failure.
- Wiring and Electrical Issues: One of the most common causes is wiring issues, such as poor grounding, bad connectors, or blown fuses. These issues can prevent the module from receiving or sending the proper signals, forcing it to fail.
- Overheating: Sometimes, high operating temperatures can damage the module’s internal components.
Less Common Reasons
- Malfunctioning Fuel Pump: One of the least common causes is a malfunctioning fuel pump. When a fuel pump draws too much electric current, it can put a strain on the FDM, leading to its failure.
- Defective Module: Sometimes, there may be a manufacturing defect in the module, causing the issue.
- Excessive Vibration: While driving, the module feels vibration from the road due to its placement. If it’s feeling excessive vibration, it can cause internal damage and lead to FDM failure.
Warning Signs of Fuel Delivery Module Failure
Here are some of the most common warning signs of fuel delivery module failure.
- Engine Misfires and Stalling: When the fuel delivery module fails, the fuel pump won’t produce the right amount of pressure, causing the engine to run low or misfire. There is also a possibility of engine stalling that increases the risk of an accident.
- Hesitation While Accelerating: When you feel hesitation while accelerating, it can be a sign that the module has failed. It mainly happens due to not sending the right amount of fuel for engine operation.
- Damaged Fuel Filter: A failed FDM can lead to unstable voltage delivery to the fuel pump. When it pushes too much fuel, it can strain the filter, decreasing its lifespan and performance.
- Loud Whining Noise: It’s normal to hear a faint humming noise coming from the fuel tank. But when it gets loud, it becomes concerning, as there may be something wrong with the fuel pump.
- Bad Mileage: If you notice that your vehicle is consuming fuel more than usual, you must understand that the FDM is faulty. You should have your fuel system inspected and fixed as soon as possible.
- Poor Engine Performance: One of the most common symptoms of a faulty FDM is poor engine performance. It’s simple to understand that your vehicle can’t perform best if it’s not receiving the right amount of fuel. Sometimes, your car doesn’t respond quickly or efficiently when you accelerate.
- Rough Idling: If you face difficulty in maintaining a smooth idle, it means the fuel delivery module is malfunctioning.
- Check Engine Light: If you notice a check engine light flashing on your vehicle’s dashboard, it is a clear indication of FDM failure.
History of Ford’s FDM Failing Investigation
The FDM failing is not a new thing in Ford vehicles. It all started in September 2022 when Ford’s Critical Concern Review Group first opened an investigation into failing FDMs after receiving a lot of warranty claims and parts returns related to the system on certain model year 2021-2022 vehicles.
The FDMs with warranty claims contained a specific variant of the low-pressure FDM and the unit’s jet pump. According to the analysis by Ford investigators, jet pump orifices on some returned parts were blocked by contamination.
However, the exact source of contamination was not clear at that time. The CCRG also reviewed warranty data and found that the rate of fuel pump failures significantly declined after its supplier implemented several corrective actions from December 2021 through September 2022.
Phinia, a Michigan-based Tier 1 supplier from Auburn Hills, was sourcing the FDM. In July 2023, another review of warranty data was conducted by Ford’s CCRG to confirm that Phinia’s corrective actions had successfully resolved the fuel pump contamination problem.
At that time, the automaker closed the investigation because field data showed a low rate of failures.
NHTSA Opened a Preliminary Evaluation of Fuel Pump Failures
On July 29, 2024, a preliminary evaluation of fuel pump failures was opened by the NHTSA’s Office of Defects Investigation after receiving six consumer complaints alleging loss of engine power in the 2021 Ford Bronco SUVs.
In response, Ford’s CCRG opened another investigation to update warranty claims, field reports, and the number of vehicles associated with the NHTSA’s preliminary evaluation. The investigation revealed that the number of warranty claims was higher in the summer months and warm-weather states.
The automaker also collected the vehicle data to better understand the cause of the high number of FDM problems. The CCRG also looked at fuel levels and diagnostic trouble codes to determine the root cause.
Reviewed the Vehicle Production Dates
In early June, the vehicle production dates were reviewed by the automaker’s CCRG to determine if the problem was related to changes in the manufacturing process. It was discovered that all the warranty claims were for vehicles produced between July 2021 and July 2022.
On June 9 and 10, the supplier’s manufacturing process was reviewed by Ford Product Development and Ford Supplier Technical Assistance for the fuel pump installed in the vehicles.
According to the report, Phinia had changed the jet pump process to accommodate an increase in build complexity. It was also found that an unnamed tier 3 supplier of the FCM’s pumping chamber did not manufacture the part to Phinia’s specifications, resulting in low clearances, increasing internal friction, and sensitivity to vapor lock.
This discovery led to the recall of the 850,000 vehicles on June 30.
Is it Safe to Drive a Car With a Faulty Fuel Delivery Module?
No, it is completely unsafe to drive a vehicle with a faulty fuel delivery module. It can lead to engine stalling, misfires, and rough idling, potentially causing a sudden loss of power while driving, which increases the risk of a crash.
There are other common problems associated with FDM failure, such as poor fuel economy and loud whining from the fuel tank.
How Did Ford Fix the Issue?
Unfortunately, the remedy to resolve the FDM failure is still under development by Ford. However, the automaker is notifying affected owners of the safety risk in the interim. Ford will also send a letter once a fix is available.
Ford’s Safety Commitment
According to the NHTSA data, the Ford Super Duty fuel pump recall is the second-largest recall of the year, following a May recall of over 1 million vehicles for a faulty rear-view camera software.
In 2025, Ford issued the highest number of recalls, more than the combined total number of recalls of General Motors, Stellantis, Toyota, Honda, Tesla, Hyundai, and Volkswagen. However, the automaker responded to this increasing number of recalls, emphasizing its ongoing commitment to vehicle safety and quality improvements.
According to a Ford spokesperson, Mike Levine, the automaker has doubled its team of safety and technical experts in the past two years and significantly increased testing to failure on critical systems, such as powertrains, braking, and steering.
While the fuel pump recall is due to a mechanical issue, several of Ford’s other recalls were due to vehicle software errors. Therefore, finding and correcting software-related issues remains a high priority for the automaker.
Levine said the increase in recalls reflects Ford’s intensive strategy to quickly find and fix any hardware and software issues and go the extra mile.
Wrapping Up
Ford Super Duty fuel pump recall highlights the importance of addressing potential safety issues promptly. The risks associated with the recall, such as engine misfires, reduced power, or stalling, make it critical for affected owners to take the recall seriously.
Ford highest number of recalls in 2025 raised serious safety concerns over its vehicles. But the automaker’s push to improve vehicle quality by doubling the safety and technical experts team and conducting more rigorous testing may bring long-term benefits.
Ford’s massive recalls show how essential it is for automakers to adapt quickly and prioritize safety in both areas to protect drivers and maintain confidence in their cars.
Sources: Automotive Dive, CarParts, Reuters
Frequently Asked Questions
1. Which Ford Vehicles Were Affected by the 2025 Defective Fuel Pump Recall?
The recall affects an estimated 850,000 Ford vehicles, including certain 2021-2023 Bronco, Explorer, Lincoln Aviator, F-250, F-350, F-450, and F-550 Super Duty pickups. It also includes the 2021-2022 F-150, Mustang, and Lincoln Navigator, and the 2022 Expedition SUV.
2. What Causes the Fuel Pump Problem in These Ford Vehicles?
The issue is linked to internal contamination in the Fuel Delivery Module (FDM)’s jet pump. As a result, it increases friction inside the pump, making it more sensitive to vapor lock, especially when fuel levels are low or in warmer temperatures.
3. What Symptoms Should You Watch For If There is a Faulty FDM?
Drivers of affected vehicles may notice poor engine performance, misfiring, reduced power, and a check engine light.
4. How Many Vehicles Were Recalled Due to Fuel Delivery Module Failure?
Approximately 850,000 vehicles were recalled by Ford. However, it was estimated that around 10% of them may have defective fuel delivery modules.
5. Has Ford Reported Any Accidents or Injuries Related to the FDM Issue?
No, as of June 2025, Ford has not reported any crashes or injuries connected to the fuel pump issue. However, the automaker has received 1,860 warranty claims, 28 field reports, and 57 customer service reports.
6. What Should You Do If Your Vehicle is Affected in the Ford Super Duty Fuel Pump Recall?
You should check the NHTSA recall database or Ford’s official recall page using your Vehicle Identification Number (VIN).
7. Is a Fix or Repair Available for the Defective Fuel Pump Recall?
Ford is still developing a remedy for the defective fuel pump. The recall report does not provide a timeline for when repairs will be available, but updates will be issued by Ford and the NHTSA once the solution is finalized.
8. Why Does Ford Have So Many Recalls in 2025?
Ford says its higher number of recalls reflects a proactive safety strategy. The automaker has doubled its team of safety experts, increased testing on critical systems, and is taking action quickly when potential problems are identified. While this means more recalls in the short term, Ford argues it will improve long-term vehicle safety and reliability.
