The government, through the National Highway Traffic Safety Administration (NHTSA), has issued a massive new recall for over 59,000 Ford cars and SUVs. This comes after the NHTSA warned that a faulty engine block heater could crack and leak coolant, causing engine fires.
The issue stems from a manufacturing flaw that allows coolant to leak into electrical components, which could cause a short circuit and fire risk, whether the car is parked, turned off, or in motion.
According to filings with the NHTSA, the recall affects several Ford and Lincoln models that are equipped with 2.0-liter or 2.3-liter engines and optional engine block heater systems designed to warm engines in cold weather. Here are the models and the number of units affected:
- 2020–2023 Ford Explorer (15,216 vehicles)
- 2019–2024 Ford Ranger (12,701 vehicles)
- 2021–2024 Ford Bronco (8,107 vehicles)
- 2022–2024 Ford Maverick (4,277 vehicles)
- 2016–2018 Ford Explorer (4,517 vehicles)
- 2016–2019 Lincoln MKC (4,235 vehicles)
- 2021–2024 Ford Bronco Sport (4,020 vehicles)
- 2020–2022 Ford Escape (3,723 vehicles)
- 2019–2020 Ford Fusion (1,334 vehicles)
- 2020–2022 Lincoln Corsair (876 vehicles)
The Ford’s internal recall number for all the 59,006 affected vehicles is 25SA4, and the NHTSA campaign number is 25V685.
What’s Causing the Fire Risk in Ford’s Recalled Vehicles
According to NHTSA documents, the engine block heater, a small device that pre-warms the engine to improve cold-weather starts, can develop cracks in its solder joints over time. Through these cracks, the coolant may seep into the electrical connector, where it can evaporate, leaving behind conductive salt deposits.
These deposits can create a short circuit when the heater is plugged into a 110-volt outlet. The short can cause smoke, melting, or even an under-hood fire, especially if the outlet lacks a functional circuit breaker or ground fault interrupter (GFCI).
As of September 2025, Ford has received 46 reports of fires, mostly from Canada, where block heaters are most common. Luckily, there are no reports of injuries or crashes related to the defect.
Ford’s Guidance to Owners
Ford has advised all affected vehicle owners to stop plugging in their engine block heaters until the defect is repaired. The company plans to start sending notification letters to owners as of October 20, 2025. It will also send follow-up letters once redesigned parts are available, probably by February 2026.
Ford will perform all repairs and replace all faulty block heaters with new, redesigned components free of charge.
Owners are advised to look out for these warning signs that could lead to failure:
- Coolant paddles under the vehicle or in the garage.
- Loss of cabin heat or engine overheating.
- Smoke or a burning smell coming from the hood.
- Low coolant alerts on the dashboard.
Owners can find out whether their vehicle is affected by calling Ford customer service at 1-866-436-7332, visiting a Ford or Lincoln dealership, or entering their Vehicle Identification Number (VIN) at NHTSA.gov/recalls.
Ford Leads U.S. Automakers in Recalls This Year
The latest recall is part of what has already been a record-setting year for Ford recalls. This year, Ford has issued roughly 60% of all auto recalls in the U.S., affecting over 5 million vehicles. No other automaker has recalled so many vehicles in the U.S.
According to Ryan Maher, CEO of BizzyCar, recalls have become rampant nowadays due to the complexity of modern vehicles. Additionally, the recalls are necessary because defects involving safety-critical systems, such as brakes, fuel, and electronics, must be solved promptly to prevent accidents.
Steps Owners Should Take Immediately
While the defect primarily affects vehicles in regions with cold climates, such as Canada, where block heaters are commonly used, Ford has advised its owners to check their recall status to ensure their vehicle is among the affected. Drivers are also advised to avoid plugging in the heater until the repairs are made available.