Ford Motor Company is initiating a recall affecting a significant number of its popular vehicle models due to a potential fire hazard associated with a faulty engine block heater. The recall, submitted to the National Highway Traffic Safety Administration (NHTSA), encompasses over 59,000 vehicles, including various model years of the Ford Explorer, Bronco, Bronco Sport, Maverick, Ranger, Escape, Fusion, as well as Lincoln Corsair and MKC. Owners of affected vehicles are advised to avoid plugging in the engine block heater until repairs are completed.
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The defect centers on the engine block heater’s potential to develop a coolant leak through its element pins. This leakage can lead to a resistive short circuit when the heater is plugged into a power source. The resulting short circuit increases the risk of an underhood fire, particularly if the vehicle is connected to a 110-volt electrical supply that lacks a functional circuit breaker or Ground Fault Circuit Interrupter (GFCI). The problem stems from solder joints within the engine block heater that may develop cracks, allowing coolant to seep into the interface between the heater and the power cord. Over time, this coolant can evaporate, leaving behind conductive salt deposits that form a “salt bridge” or corrode electrical connections, creating a path to ground and potentially causing the short circuit.
Drivers may notice warning signs such as coolant spots on the ground, a loss of cabin heat, engine overheating, or a low coolant level warning indicator. Additionally, heat damage to the heater’s electrical wiring and connector, along with unusual odors or smoke, could indicate the presence of the defect. The supplier for the affected engine block heaters is Phillips and Temro Industries.
The recall covers the following specific models and production dates:
* 2020-2023 Ford Explorer: 15,216 vehicles produced from October 19, 2018, to December 22, 2023.
* 2021-2024 Ford Bronco: 8,107 vehicles produced from October 1, 2020, to December 28, 2024.
* 2016-2018 Ford Explorer: 4,517 vehicles produced from October 20, 2014, to September 15, 2018.
* 2022-2024 Ford Maverick: 4,277 vehicles produced from May 10, 2021, to November 8, 2024.
* 2019-2024 Ford Ranger: 12,701 vehicles produced from June 4, 2018, to November 19, 2024.
* 2020-2022 Ford Escape: 3,723 vehicles produced from November 20, 2018, to November 28, 2022.
* 2021-2024 Ford Bronco Sport: 4,020 vehicles produced from February 5, 2020, to November 8, 2024.
* 2019-2020 Ford Fusion: 1,334 vehicles produced from December 6, 2017, to January 30, 2020.
* 2020-2022 Lincoln Corsair: 876 vehicles produced from January 30, 2019, to November 22, 2022.
* 2016-2019 Lincoln MKC: 4,235 vehicles produced from February 9, 2015, to August 2, 2019.
Ford began investigating the issue in January 2025 after concerns about potential engine block heater fires were raised. Through subsequent testing and analysis of returned parts, the company and its supplier confirmed the defect. While Ford is aware of 6 customer complaints, 21 Transport Canada log claims, and 30 legal claims alleging vehicle fires attributed to the block heater, the majority of these incidents have occurred in Canada. Currently, Ford is not aware of any accidents or injuries directly resulting from this condition.
Owners of affected vehicles will be notified by mail. The remedy involves replacing the suspect engine block heater with a newly designed component at no cost to the owner. Ford expects to notify dealers about the recall on October 15, 2025, with interim owner notifications to begin on October 20, 2025. Mailing of remedy notification letters is scheduled to commence on February 2, 2026. Vehicle Identification Numbers (VINs) will be searchable for recall applicability starting October 15, 2025. Until the replacement is performed, owners are strongly advised not to plug in their vehicle’s engine block heater and to park their vehicles outside due to the fire risk.
Article by Mel Anara, based upon information from Ford Motor Company
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