- The Root Cause of the Recall
- Affected Models
- Warning Signs Drivers Should Watch For
- Inside Ford’s Investigation
- Severity of the Problem
- Ford’s Response
- Why This Recall Stands Out
- Guidance for Vehicle Owners
In an urgent move signaling the gravity of the situation, Ford has announced a recall of over 59,000 vehicles and issued a stop-sale order after confirming 46 engine fire incidents linked to a malfunction in the engine block heater system. The fires have caused widespread concern among owners, particularly in Canada, where the issue has surfaced more frequently during cold weather.
The Root Cause of the Recall
The problem arises from a defective engine block heater installed in several Ford and Lincoln models.
This heater may leak coolant through its element pins, creating a safety hazard.
Over time, electrically conductive salt deposits accumulate as the coolant evaporates inside the heater.
These deposits can corrode wiring connections or form a “salt bridge,” leading to a resistive short circuit—a serious fire risk when the heater is plugged in.
Affected Models
The recall covers a broad range of vehicles, making it one of Ford’s major campaigns in 2025:
Bronco (2021–2024)
Bronco Sport (2021–2024)
Escape (2020–2022)
Maverick (2022–2024)
Fusion (2019–2020)
Ranger (2019–2024)
Explorer (2016–2018, 2020–2023)
Lincoln Corsair (2020–2022)
Lincoln MKC (2016–2019)
Warning Signs Drivers Should Watch For
Owners are urged to remain alert for these indicators of trouble:
Coolant puddles under the vehicle or in the garage.
Unusual smoke or a burning odor from under the hood.
Loss of cabin heat or signs of engine overheating.
A low coolant warning displayed on the instrument panel.
Inside Ford’s Investigation
Ford launched its internal investigation last January after a cluster of fire reports. Engineers conducted X-rays and CT scans of defective heaters, revealing cracks and voids in the solder joints of the heating elements. Despite extensive testing, the company has not yet identified the fundamental manufacturing cause of the issue.
Severity of the Problem
At least 46 confirmed vehicle fires have been linked to the defect.
The majority of cases were in Canada, where engine block heaters are commonly used during freezing temperatures.
Ford recorded six customer complaints, 30 legal claims, and 21 official reports from Transport Canada related to this issue.
Ford’s Response
The automaker immediately issued a stop-sale order affecting all impacted vehicles.
Owners have been instructed to avoid using their engine block heaters until repairs are completed.
The replacement program is scheduled for February 2026, unfortunately after the winter season.
Ford emphasized in its statement that it is treating customer safety as its top priority and will continue to monitor affected vehicles closely.
Why This Recall Stands Out
With this latest recall, Ford has reached its 115th recall campaign of 2025—a record-high pace that continues to raise questions about quality control and reliability. Although only about one percent of the recalled vehicles are estimated to have the actual defect, the potential for underhood fires makes this situation exceptionally serious.
Guidance for Vehicle Owners
Experts recommend owners take the following immediate precautions:
Unplug any block heaters immediately if installed in one of the affected models.
Contact your local Ford dealer for assistance or to verify recall eligibility.
Stay alert for updates from the automaker regarding part availability and repair scheduling.
This incident rekindles Ford’s long-standing struggle with fire-related recalls, echoing past cases involving the Bronco, Escape, and Expedition lines. Despite continuing efforts to improve design and production consistency, thermal and electrical safety remains a weak link in some of Ford’s vehicles.
Beyond being a corporate embarrassment, this recall underscores a broader challenge in the auto industry: managing electronic and thermal system integrity in vehicles built for diverse climates. Small design flaws—especially in components meant for extreme weather—can lead to major safety hazards, proving that even minor parts like the engine block heater can ignite serious consequences for both carmakers and consumers alike.
