Ford is recalling nearly 43,000 SUVs because of gas leaks that can lead to fires, but remedies can't fix the leaks

DETROIT – Ford is recalling nearly 43,000 small SUVs because fuel can leak from fuel injectors onto hot engine surfaces, increasing the risk of fire. However, the recall remedy does not include repair of the fuel leaks.

The recall affects certain 2022 and 2023 model year Bronco Sport SUVs and 2022 Escape SUVs. All have 1.5-liter engines.

In documents filed with U.S. safety regulators, Ford says fuel injectors can break and gasoline or fumes can build up near ignition sources, potentially starting fires.

Dealers install a hose to allow gasoline to flow from hot surfaces to the ground beneath the vehicle. They will also update the engine control software to detect a pressure drop in the fuel injection system. In this case, the software disables the high-pressure fuel pump, reducing engine power and lowering engine compartment temperatures, according to documents posted Wednesday on the National Highway Traffic Safety Administration website.

Owners should be notified by letter from April 1st.

The company says in its filings that it has reports of five underhood fires and 14 warranty fuel injector replacements, but no reports of accidents or injuries.

In an email, Ford said it will not replace the injectors because the problem only occurs in about 1% of SUVs. The new software will also trigger a warning light on the dashboard and allow customers to drive to a safe location, stop the vehicle and request service, the company said.

The company also announced that it will extend the warranty for cracked injectors so that owners who experience the problem can receive replacements. Ford said repairs are already available and warranty extension details will be available in June.

The company said the recall is an expansion of a 2022 recall for the same issue. The repair has already been tested on vehicles involved in the previous recall and Ford said there were no known problems.

Ford also said it doesn't recommend only parking the SUVs outdoors because there is no evidence that fires occur when vehicles are parked with engines turned off.

Michael Brooks, executive director of the nonprofit Center for Auto Safety, called Ford's solution to the fuel leaks a “Band-Aid recall” and said the company was trying to avoid the cost of repairing the fuel injectors.

A 1% failure rate is high, he said, and despite the repairs, motorists could still be forced to exit the highway at low speeds, putting them at risk of accidents.

NHTSA, he said, should do more to ensure recalls address the root causes of vehicle problems rather than making more cost-effective repairs.

In the past, NHTSA has said it does not have the authority to pre-approve recall repairs. But in a statement Wednesday, the agency said it would “closely track its performance based on field data.” The agency said owners who have questions should contact their dealer or Ford.

Brooks said Congress should change the law to allow the agency to require “more than just the stamp that NHTSA currently applies” to recalls.

He said the agency has recently become more aggressive in investigating recall solutions. “This is an after-the-fact investigation that does not improve the corrections, but rather drags out the process even further and leaves consumers in limbo,” he said.