In recall 24V634, Ford is recalling 24 2023-2025 Mustang, Escape, Explorer, and Corsair vehicles for missing fuel-injector O-ring support discs.
Ford is recalling 24 vehicles from the 2023-2025 Mustang, Escape, Explorer, and Corsair model lines because the fuel injectors were assembled without O-ring support discs, which can let fuel leak. A fuel leak near an ignition source increases fire risk, and Ford dealers will complete the repair free of charge.
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What's wrong?
On affected 2023-2025 Mustang, Escape, Explorer, and Corsair vehicles, the direct fuel injector meters fuel into the engine in a fine spray. Each injector uses an O-ring, a small rubber seal, and an O-ring support disc that helps keep that seal seated while fuel pressure rises and falls. The seal has to stay in position so gasoline stays inside the injector and fuel rail.
The problem is assembly, not owner wear. During supplier production, the support disc was left out of some injectors. Without that disc, the O-ring is not supported the way Ford designed it. Fuel can leak past the seal instead of staying contained in the fuel system.
Owners can notice a fuel odor inside or outside the vehicle. The engine can also be hard to start if the injector seal is not holding fuel pressure correctly. Those signs mean the fuel system needs dealer attention, because the affected injector was built without the support part that keeps the seal in place.
Who's affected?
Covers Mustang, Escape, Explorer, and Corsair vehicles from the 2023, 2024, and 2025 model years, all tied to the same direct fuel injector part.
| 2024 Ford Mustang | fuel system |
|---|---|
| 2024 Ford Escape | fuel system |
| 2023 Ford Escape | fuel system |
| 2025 Ford Explorer | fuel system |
| 2023 Lincoln Corsair | fuel system |
| Units affected | 24 |
| Field incidents | NHTSA has logged no field incidents to date. |
A matching year and model does not guarantee inclusion. Check your VIN to confirm whether this recall applies to your specific vehicle.
What's the safety risk?
A fuel leak in the presence of an ignition source increases the risk of a fire. Fuel odor inside or outside the vehicle, or trouble starting, is a warning sign to schedule the recall repair promptly and ask the dealer for guidance before driving farther. Repair is free at any franchised Ford dealer.
What should I do?
- Check your VIN to confirm your 2023-2025 Ford Mustang, Escape, Explorer, or Lincoln Corsair is included in this recall.
- Contact a franchised Ford dealer to schedule the free fuel injector O-ring and support-disc repair that addresses the fuel leak risk.
- Bring the recall notice if Ford mailed one. If not, reference recall number 24V634 and Ford recall 24S54 when you call.
- Keep the vehicle away from open flames and ignition sources until the repair is complete.
What happens at the repair
At the dealer, a Ford technician installs new fuel injector O-rings and O-ring support discs. The repair is open, and parts and labor are free under recall 24V634. This corrects injectors that were assembled without the support discs that help seal the injector area. If you already paid for this fuel injector O-ring repair before the recall notice, Ford's standard reimbursement plan covers eligible documented expenses. Bring your repair invoice and payment records to the service desk, or contact Ford customer service to start the reimbursement claim.
| Reimbursement | Reimbursement available |
|---|
Timeline
| August 23, 2024 | NHTSA published the recall |
|---|---|
| August 26, 2024 | Dealer notification began |
| August 26, 2024 | Dealer notification ended |
| September 30, 2024 | VIN-searchable in NHTSA's database — Check your VIN to see whether this recall applies to your specific vehicle. |
| September 30, 2024 | Interim owner notification (was planned for this date) |
| October 7, 2024 | Owner notification mailed |
Frequently asked questions
What is recall 24V634?
Recall 24V634 covers 24 2023-2025 Ford and Lincoln vehicles with fuel injectors assembled without O-ring support discs. That defect can cause a fuel leak, and a fuel leak near an ignition source increases fire risk. Ford dealers will install new fuel injector O-rings and support discs for free.
What should I do if my 2023-2025 Ford Mustang, Escape, Explorer, or Lincoln Corsair is on this recall?
Check your VIN to confirm your specific vehicle is included in recall 24V634. If it is, contact a franchised Ford dealer to schedule the fuel injector O-ring and support disc repair. Reference Ford recall number 24S54 when you call. The repair is free.
Is the recall repair free?
Yes. Federal recall law requires manufacturers to repair recall defects at no cost, and Ford's remedy says dealers will install new fuel injector O-rings and O-ring support discs free of charge.
What is the safety risk?
The safety risk is fire. Ford says the affected fuel injectors were assembled without O-ring support discs, which can allow a fuel leak. If leaked fuel reaches an ignition source, the risk of a fire increases.
When were owners notified about recall 24V634?
Ford mailed owner notification letters on October 7, 2024. If you bought the vehicle used or never received the letter, check your VIN and reference recall 24V634 or Ford recall number 24S54 when you contact the dealer.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/24V634000 |
|---|---|
| Ford customer service | 1-866-436-7332 |
| NHTSA recall # | 24V634 |
| NHTSA recall # (full) | 24V634000 |
Source documents
-
Download Quarterly Report (PDF) - Download Recall Document (PDF) (PDF)
- Download Owner Notice (PDF)
- Download Owner Notification Letter (PDF)
- Download Recall Acknowledgement (PDF)
- Download Recall Report (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 20, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →