Ford recall 16V777 covers 329,265 2010-2012 Escape and Mariner vehicles with Fuel Delivery Module flanges that crack. Repair is free at any franchised Ford dealer.
Ford is recalling 329,265 2010-2012 Escape and Mercury Mariner vehicles because the Fuel Delivery Module on 3.0L engines can crack and leak fuel. A fuel leak near an ignition source increases the risk of fire, and Ford dealers will complete the recall repair free of charge.
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What's wrong?
The fuel delivery module on 2010-2012 Escape and Mariner vehicles with the 3.0L engine sits at the fuel tank and helps move gasoline from the tank toward the engine. Its fuel supply port is the outlet that carries fuel into the line, so the port and its plastic flange have to hold pressure without leaking.
On affected vehicles, the wall of that fuel supply port is thinner than Ford used in similar fuel module applications. The plastic material, POM acetal, is vulnerable to creep fatigue, which means it slowly deforms and cracks after exposure to heat and fuel pressure over time. Field data tied the cracking pattern strongly to hotter states.
Before failure, owners can notice a fuel smell near the vehicle or see fuel on the ground under the fuel tank. Those signs point to a leak at the fuel delivery module and need dealer attention.
Who's affected?
Scope spans the Escape and Mariner across the 2010-2012 model years, with both nameplates tied to the same fuel-pump component.
| 2011 Ford Escape | fuel system |
|---|---|
| 2010 Ford Escape | fuel system |
| 2010 Mercury Mariner | fuel system |
| 2011 Mercury Mariner | fuel system |
| 2012 Ford Escape | fuel system |
| Units affected | 329,265 |
| Field incidents | NHTSA has logged no field incidents to date. |
The year and model narrow the scope, but the VIN decides. Check your VIN to confirm whether your specific SUV is included.
What's the safety risk?
Fuel leaking from the FDM raises fire risk if it reaches an ignition source. Treat fuel odor or visible fuel under the tank as a warning to stop and call the dealer, and keep ignition sources away from the vehicle. Repair is free at any franchised Ford dealer.
What should I do?
- Check your VIN to confirm your 2010-2012 Ford Escape or Mercury Mariner with a 3.0L engine is included in this recall.
- Contact a franchised Ford dealer to schedule the free Fuel Delivery Module flange replacement that repairs the fuel leak risk.
- Bring the recall notice if Ford mailed one. If not, reference recall number 16V777 when you call.
- Avoid driving with a known fuel leak, and keep ignition sources away from any fuel leak until the repair is complete.
What happens at the repair
At the dealer, a Ford technician replaces the Fuel Delivery Module flange with one that has a redesigned fuel supply port. The recall repair is free, and parts and labor are covered. For owner-paid repairs completed before the recall notice, Ford's general reimbursement plan covered eligible remedy costs through June 30, 2017. Bring documentation if you need the service desk to review prior repair paperwork, or contact Ford customer service about the closed reimbursement window.
| Reimbursement | Reimbursement available |
|---|
Timeline
| October 25, 2016 | Dealer notification began |
|---|---|
| October 25, 2016 | Dealer notification ended |
| October 26, 2016 | NHTSA published the recall |
| December 12, 2016 | Interim owner notification (was planned for this date) |
| November 6, 2017 | Owner notification mailed |
Frequently asked questions
What is recall 16V777?
Recall 16V777 covers 329,265 2010-2012 Ford Escape and Mercury Mariner vehicles with a 3.0L engine. The fuel delivery module flange can crack and leak fuel. Ford dealers replace the flange with a redesigned part for free.
What should I do if my 2010-2012 Ford Escape or Mercury Mariner is on this recall?
Check your VIN to confirm your specific vehicle is included in recall 16V777. If it is, call a franchised Ford dealer and ask for the fuel delivery module flange replacement. Reference Ford recall number 16S41 when you call. The repair is free.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost. For recall 16V777, a franchised Ford dealer replaces the fuel delivery module flange with a redesigned part free of charge.
What is the safety risk?
The safety risk is fire. A cracked fuel delivery module flange can leak fuel, and a fuel leak near an ignition source increases the risk of a fire. If you smell fuel or see a leak, avoid driving and call a Ford dealer for guidance.
What if I bought my Escape or Mariner used?
The free repair still applies. Recall coverage follows the vehicle, not the first owner. Check your VIN to confirm whether your specific Escape or Mariner is included, then contact a franchised Ford dealer and reference recall 16V777 or Ford recall number 16S41.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/16V777000 |
|---|---|
| Ford customer service | 1-866-436-7332 |
| NHTSA recall # | 16V777 |
| NHTSA recall # (full) | 16V777000 |
Source documents
-
Download Recall Document (PDF) (PDF) - Download Misc. Document (PDF)
- Download Recall Document (PDF) (PDF)
- Download Owner Notification Letter (PDF)
- Download Owner Notice (PDF)
- Download Recall Report (PDF)
- Download Quarterly Report (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 31, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →