Key Details and Main Themes
1. Defective Fuel Delivery Modules (FDMs) Causing Engine Stalling
Core Problem: Ford has recalled 850,000 vehicles due to "low-pressure fuel delivery module (FDM) failures that have led to engine stalling while driving."
Root Cause: The problem is attributed to "internal contamination of the FDM’s jet pump" and "reduced fuel pump internal clearances that result in an increase of internal friction and sensitivity to vapor lock."
Contributing Factors: FDM failures are more likely to occur "when the fuel level is low, or in warm weather that increases the temperature of the fuel in the tank."
Symptoms: Drivers may experience "poor engine performance, such as rough running or misfiring, as well as reduced power and a check engine light."
2. Affected Vehicles and Scope
Recalled Models: The recall includes "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."
Production Dates: All warranty claims are for vehicles produced between "July 2021 and July 2022."
Estimated Defective Rate: An "estimated 10% of the recalled vehicles are suspected of having defective FDMs."
3. Investigation and Supplier Involvement
Timeline of Discovery:September 2022: Ford’s Critical Concern Review Group (CCRG) began investigating FDM failures due to high warranty claims.
December 2021 - September 2022: The supplier, Phinia, implemented "several corrective actions... to reduce contamination and production variation," leading Ford to initially close its investigation in July 2023.
July 29, 2024: NHTSA’s Office of Defects Investigation (ODI) opened a preliminary evaluation after receiving consumer complaints.
April 3, 2025: Ford’s CCRG reopened its investigation, noting a higher number of warranty claims in summer months and warm-weather states.
June 9 and 10: A review of Phinia's manufacturing process revealed a change in the jet pump process in early June 2021 to "accommodate an increase in build complexity."
Supplier Details: The FDM was sourced from "Auburn Hills, Michigan-based Tier 1 supplier Phinia and manufactured at a facility in Mexico."
Tier 3 Supplier Issue: Ford identified that an "unnamed Tier 3 supplier of the FCM’s pumping chamber did not manufacture the part to Phinia’s specifications," contributing to low clearances and sensitivity to vapor lock.
