Ford Fuel Pump Recall Canada US: What Every Owner of 2021-2023 Ford and Lincoln Models Must Know

The bottom line: Ford is recalling over 957,000 vehicles in the U.S. and Canada combined due to a low-pressure fuel pump that may fail, causing the engine to stall while driving — a serious safety risk that increases your chance of a crash. The recall covers 2021-2023 Ford Bronco, Explorer, F-150, Super Duty trucks, Mustang, and Lincoln Aviator and Navigator models. As of July 2025, the repair is still under development, and Ford will mail two sets of letters: a first notification about the risk, and a second when the fix is available. If you own one of these vehicles, you should check your VIN immediately and watch for warning signs like a rough-running engine, a check engine light, or sudden loss of power.

This article explains exactly what is happening, which vehicles are affected, what symptoms to watch for, and what you can do right now to stay safe — including how to find a reliable replacement fuel pump if you need one.

The Recall In Detail

Ford Fuel Pump Recall Canada US: The Numbers

Transport Canada issued recall number 2025-366 on July 8, 2025, affecting 107,534 vehicles in Canada. In the United States, the National Highway Traffic Safety Administration (NHTSA) recall 25V-455 covers 850,318 vehicles. Combined, this is nearly 960,000 vehicles across both countries.

Ford estimates that about 10% of the recalled vehicles in the U.S. actually have the fuel pump defect. The NHTSA opened an investigation (PE24019) after receiving six consumer complaints about loss of power due to pump failure. As of the recall date, Ford reported no accidents or injuries related to this issue.

Which Vehicles Are Affected?

The recall covers specific model years of Ford and Lincoln vehicles. Here is the complete list based on the official Transport Canada and NHTSA documents:

Ford Models:

  • 2021-2022 Ford Bronco
  • 2022 Ford Expedition
  • 2021-2022 Ford Explorer
  • 2021-2022 Ford F-150
  • 2021-2023 Ford F-250 Super Duty
  • 2021-2023 Ford F-350 Super Duty
  • 2021-2023 Ford F-450 Super Duty
  • 2021-2023 Ford F-550 Super Duty
  • 2021-2022 Ford Mustang
  • 2021-2022 Ford Police Interceptor Utility (Explorer)

Lincoln Models:

  • 2021-2023 Lincoln Aviator
  • 2021-2022 Lincoln Navigator

The supplier of the faulty fuel pumps has been identified as Phinia Inc.

What Is The Problem?

The issue is with the low-pressure fuel pump inside the fuel tank. According to the NHTSA and Transport Canada, the pump can fail due to internal contamination of the jet pump and reduced internal clearances that increase friction. When the pump fails, fuel stops flowing from the tank to the engine, and the engine stalls.

Key conditions that make the failure more likely:

  1. Low fuel level — the problem is more likely when your tank is nearly empty
  2. Warm weather or hot fuel — high temperatures increase the risk of pump failure

The manufacturing defect was traced to a change in the jet pump production process that occurred in June 2021. The supplier modified the process, which resulted in internal gaps in the fuel pump chamber falling below the required specifications. The issue was corrected in July 2022 when the supplier added two new vacuum pumps to reduce contamination during production.

What Symptoms Should You Watch For?

Before the fuel pump fails completely, you may notice the following warning signs:

  • Rough engine idle or misfiring — the engine may run unevenly
  • Check engine light — this light may illuminate on your dashboard
  • Reduced engine power — your vehicle may feel sluggish or lack power during acceleration
  • Extended cranking time — the engine may take longer than usual to start
  • The engine may not start at all — in some cases, the car simply won't crank
  • Sudden loss of engine power while driving — this is the most dangerous symptom, as it can happen without warning

What Is Ford Doing About It?

The repair is still under development. Here is the timeline of what Ford has done and plans to do:

  • July 14, 2025: Ford began mailing interim notification letters to all affected owners. These letters warn about the safety risk and advise owners to take their vehicle to a dealership.
  • Second quarter of 2026: Ford expects to have the remedy available. At that point, a second letter will be mailed with instructions for the free repair.
  • For Super Duty models specifically: The dealer will replace the fuel pump entirely.
  • For other models: The fix involves updating the powertrain control module (PCM) software.

Important: There is no charge to the owner for any of these repairs. Ford will cover all costs.

How To Check If Your Vehicle Is Affected

The easiest way to know if your car is part of this recall is to check your Vehicle Identification Number (VIN). You can do this on the following websites:

  • Transport Canada: Go to the Motor Vehicle Safety Recalls Database at wwwapps.tc.gc.ca
  • NHTSA: Go to www.nhtsa.gov/recalls and enter your 17-digit VIN
  • Ford Customer Service: Call 1-800-565-3673 (Canada) or 1-866-436-7332 (U.S.)

Ford's internal recall number for this action is 25S75. The NHTSA campaign number is 25V-455.

What Is The Safety Risk?

The safety risk is straightforward: a sudden loss of engine power while driving can cause a crash. If your engine stalls, you lose power steering and power brakes, making it much harder to control the vehicle. This is especially dangerous at highway speeds or in heavy traffic.

The NHTSA investigation noted that some consumers reported the failure happened "without warning" while driving, and the engine could not be restarted. This is why it is critical to pay attention to the early warning signs like a check engine light or rough running.

What Should You Do Right Now?

Step 1: Check your VIN immediately using the links above. If your vehicle is affected, you are at risk.

Step 2: Do not ignore the check engine light. If it comes on, and especially if you notice rough running or loss of power, do not drive the vehicle. Have it towed to a dealer.

Step 3: Keep your fuel tank above a quarter full. Since the failure is more likely at low fuel levels, keeping your tank fuller reduces the risk.

Step 4: Watch for the mail from Ford. The interim notification was sent starting July 14, 2025. If you haven't received it yet, check your VIN anyway.

Step 5: When the second letter arrives with the repair instructions, schedule an appointment with your dealer immediately.

A Special Note On Other Ford Fuel Pump Recalls

This is not the only fuel pump recall Ford has issued recently. If you own a diesel-powered Super Duty truck, you should also be aware of:

  • Recall 2024-780 (NHTSA 24V-957): Affected 2020-2022 F-250 through F-550 Super Duty trucks and 2021-2022 F-650/F-750 trucks with the 6.7L diesel engine. The high-pressure fuel pump could fail due to biodiesel deposits. The fix was a PCM software update.
  • Recall 2026-122 (NHTSA 26V-158): A follow-up to the above recall. Some vehicles repaired under the first recall were not fixed correctly, requiring a second repair. This affects about 7,105 vehicles.

Make sure to check your VIN for all of these recalls, not just the low-pressure fuel pump one.

Why You Should Consider A Reliable Aftermarket Fuel Pump

If you own a Ford or Lincoln model that falls outside the recall years, or if you have already experienced a fuel pump failure and want a long-term solution, you may need to replace the pump yourself. The OEM replacement parts can be expensive, and the recall fix is still months away for many owners.

KEMSO Fuel Pumps offer a high-quality, reliable, and affordable alternative. Here is why KEMSO stands out:

  • High Performance: KEMSO fuel pumps are designed to deliver exceptional flow rates, with models like the 340LPH pump capable of supporting up to 700-800 horsepower. They are compatible with both gasoline and E85 ethanol blends.
  • OEM Replacement: Each pump is manufactured to meet or exceed OEM specifications, making it a direct drop-in replacement for your factory pump. KEMSO pumps are individually tested for flow and pressure performance.
  • Lifetime Warranty: Every KEMSO pump comes with a lifetime warranty. This is a significant advantage over many aftermarket brands that offer only 1-2 year warranties.
  • American Support: KEMSO is based in Houston, Texas, with a customer service team staffed by U.S. technicians.
  • Wide Compatibility: KEMSO offers pumps for a vast range of vehicles, including Ford, Lincoln, Honda, BMW, Subaru, and many more.

If you are looking for a fuel pump that combines quality, performance, and peace of mind, visit KEMSO Racing at https://www.kemsoracing.com/ to find the perfect pump for your vehicle. Whether you need a replacement for a failed pump or an upgrade for better performance, KEMSO has a solution backed by a lifetime warranty.

Final Thoughts

The Ford fuel pump recall in Canada and the US is a serious safety issue affecting nearly a million vehicles. If you own a 2021-2023 Ford Bronco, Explorer, F-150, Super Duty, Mustang, or Lincoln Aviator or Navigator, check your VIN immediately. The warning signs are real, and the risk of a sudden stall is dangerous.

Until the recall remedy is available — expected in the second quarter of 2026 — keep your tank above a quarter full, watch for the check engine light and rough running, and do not ignore any loss of power. If you need a replacement pump now, consider KEMSO for a reliable, high-performance, and lifetime-warranted solution.

For more information on high-quality fuel pumps and to browse the full product lineup, visit:
https://www.kemsoracing.com/


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