Ford Issues Massive Fuel-Pump Recall Affecting 850,000 Vehicles

In July 2025, Ford issued a major safety recall affecting 850,318 vehicles because of a defect in the low-pressure fuel pump that can cause engine stalls. According to Ford’s report to the National Highway Traffic Safety Administration (NHTSA), the problem is serious: fuel pressure and flow may drop, starving the engine, and in some cases, the vehicle may stall while driving, dramatically increasing the risk of a crash.

Defects that substantially affect a vehicle’s safety are one of the three main types of defects that can lead to lemon law claims if they can’t be satisfactorily repaired. Learn about this recent massive Ford recall below, and call Nita Lemon Law Firm if you are having problems with a defective vehicle and need to speak with an experienced and successful California lemon law attorney.

Which Vehicles Are Affected?

The recall covers a wide range of 2021–2023 Ford and Lincoln models, including:

• Ford SUVs / Trucks: Bronco (2021–23), Explorer (2021–23), Super Duty F-250, F-350, F-450, F-550 (2021–23), F-150 (2021–22), and the 2022 Expedition.

• Lincoln Models: Aviator (2021–23) and Navigator (2021–22).

• Ford Mustang: 2021–2022.

The root cause appears to involve internal contamination of the jet pump within the low-pressure fuel module. In some cases, the clearances inside the fuel pump are reduced, increasing friction and making the pump more vulnerable, especially under low-fuel or hot-fuel conditions.

Drivers may observe warning signs before a failure, such as misfires, rough running, reduced engine power, or the check engine light turning on. According to Ford and NHTSA, failure is more likely when the fuel tank is nearly empty or on warm days when fuel inside the tank is hot.

An engine stall while driving is inherently dangerous. If it happens at highway speeds, it could lead to loss of control, especially in traffic, and raise the risk of a crash. As of the date of the recall, no accidents or injuries have been reported. But the potential is serious enough that Ford has moved to alert owners and develop a fix.

At present, a permanent remedy is under development. Ford began mailing initial “interim” letters to affected owners starting July 14, 2025, informing them of the safety risk. A second round of letters will go out when the final repair or replacement fix is ready.

If you own one of the affected vehicles, you can contact Ford at 1-866-436-7332 for more information, using recall number 25S75.

How This Recall Could Trigger a California Lemon Law Claim

A recall does not automatically mean your car is a “lemon,” but a serious, uncorrected recall defect, especially one that causes stalling or safety risks, may form the basis of a lemon law case if the problem persists despite repair attempts.

Under California’s Lemon Law (officially the Song–Beverly Consumer Warranty Act), a “lemon” is a vehicle that has a substantial defect covered by warranty that cannot be repaired after a reasonable number of attempts. The law is reinforced by the Tanner Consumer Protection Act, which provides legal presumptions for what counts as “reasonable.” For example, if a defect affects safety, just two repair attempts may suffice; for non-dangerous defects, four attempts or a cumulative 30+ days out of service within 18 months or 18,000 miles may trigger the presumption that the car is a lemon.

If your vehicle qualifies as a lemon, the manufacturer must either replace the vehicle or repurchase it. If you choose a refund, the amount includes what you paid (including certain fees) minus a “usage offset” based on how many miles you drove before the first reported defect. You’re also entitled to costs tied to the defect, like towing, rental car use, and other incidental damages. If you prevail in a lemon law claim, the manufacturer must pay your attorney’s fees and other legal costs.

Filing a Lemon Law Claim Under the New “Opt-In” Procedure

Ford is one of the manufacturers that has opted in to California’s new lemon law procedures under Assembly Bill 1755 (AB 1755) and Senate Bill 26 (SB 26). Because Ford opted in, if you file a lemon law claim in California, your case must follow these updated procedures, which are different than traditional lemon law litigation.

Here’s how the new AB 1755 / SB 26 “opt-in” track works:

1. Pre-suit Written Demand: Before filing a lawsuit seeking civil penalties, you must first send written notice to Ford with details of your defect, VIN, repair history, and a requested remedy (refund or replacement). Ford has up to 30 days to acknowledge receipt of your notice and another 30 days to repair or replace your vehicle or provide a refund.

2. Mandatory Mediation: Once Ford responds, you must participate in mediation if your problem is not resolved. The law sets firm timeframes, and mediation must be scheduled and held within 90 to 150 days after Ford’s formal answer.

3. Streamlined Discovery: Under the opt-in process, discovery (the pre-trial fact-finding) is limited. You’ll exchange key documents early (repair invoices, contracts, warranty), and depositions are more constrained, which speeds things up but limits the amount of information you can get from Ford.

4. Quick Settlement / Performance: If Ford agrees to repurchase or replace, there are strict timelines for them to act. Ford must complete the remedy within 30 days, and delays may trigger penalties under the law.

5. Filing Deadlines: There’s a new statute of limitations under AB 1755. You must file within one year after your express warranty expires, or no later than six years from vehicle delivery, whichever is earlier (subject to some exceptions).

What Should You Do If You’re a Ford Owner Affected by the Recall?

1. Check Your VIN: Use Ford’s recall lookup or NHTSA’s website to confirm whether your vehicle is part of the 25S75 fuel pump recall. You should receive mailings from Ford, assuming your contact information is up-to-date.

2. Document Everything: Keep all repair orders, invoices, and correspondence. If your fuel system has been serviced or you’ve experienced symptoms (stalling, misfiring, etc.), record those details and dates.

3. Notify Ford in Writing: If you plan to pursue a lemon claim, prepare your written demand notice as required by AB 1755.

4. Talk to a Lemon Law Attorney: Given the scale and risk of this recall, legal counsel can represent you throughout the opt-in process and the many critical stages from mediation to settlement.

Contact Nita Lemon Law Firm in California Today

The Ford fuel pump recall is a big deal: over 850,000 vehicles are affected, and the defect could lead to engine stalls and significant safety risks. While Ford hasn’t yet rolled out a permanent fix, consumers don’t have to wait without options. Under California’s Song–Beverly Lemon Law, repeated failure to repair a serious defect like this fuel pump issue may entitle you to a buyback or replacement.

Because Ford has opted into California’s new AB 1755 / SB 26 lemon law procedure, affected consumers may benefit from a faster, more efficient process, but only if they follow the new rules. If you’re dealing with this recall, you should strongly consider talking to a lemon law attorney right away to protect your rights.

In California, contact Nita Lemon Law Firm in Los Angeles for a free consultation.