Ford Recalls Over 12,000 Vehicles Due to Faulty Software Installations

Ford Motor Company is recalling more than 12,800 vehicles across two popular models after discovering that prior safety recall repairs were not properly completed, despite being recorded as successful. The affected vehicles, including specific model years of the Bronco Sport and Maverick, may still carry the original safety defect involving an insufficient software calibration that could result in engine stalls or failure to restart.

According to Ford’s report submitted to the National Highway Traffic Safety Administration, the issue impacts 11,620 units of the 2021–2024 Bronco Sport and 1,213 units of the 2022–2023 Maverick. The root cause stems from a malfunction in the Ford Diagnostic and Repair System (FDRS), which failed to install the intended software fix during earlier recall actions. This leaves vehicles vulnerable to sudden battery degradation events that could prevent restarting after an auto start/stop cycle or cause stalling at low speeds, potentially disabling key 12-volt systems like hazard lights.

Despite records showing the prior recall (24S24/24V267) had been resolved on these vehicles, Ford’s audit revealed mismatches between the intended and actually installed software. While 96% of affected vehicles received the correct software, the remaining units did not, prompting this follow-up recall action. No accidents or injuries related to the issue have been reported to date.

Ford identified the problem during an internal quality forum review in late 2024 and began a comprehensive audit of all software-related field service actions. This led to a detailed investigation and coordination with NHTSA. A new recall, 25S26 (NHTSA No. 25V-158), has now been issued, with notifications to dealers and vehicle owners scheduled between April 24 and May 1, 2025. Owners will be directed to dealerships for a free update of both the Body Control Module and Powertrain Control Module software. Ford will also validate proper software installation before closing out any service records.

Article by multiple RFHC contributors, based upon information from a safety recall report issued by Ford Motor Company to the National Highway Traffic Safety Administration (NHTSA).

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