New Recall 25S62 released 8/4/25 to dealers for 2024-2025 BS and Escapes with the 1.5L; delivery hold for new vehicles.

[rugedraw]

REASON FOR THIS SAFETY RECALL: Some affected vehicles were repaired with service replacement cylinder heads or long blocks that may have a loose ball plug or ball plugs. This condition may result in a rapid oil leak if a ball plug comes out of the cylinder head. An oil leak in the presence of an ignition source, such as hot engine or exhaust components, can increase the risk of a fire. In addition, the loss of oil can result in engine seizure and loss of motive power, increasing the risk of a crash.

SERVICE ACTION: Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to inspect the cylinder head serial number; ONLY if the serial number on the cylinder head matches one on the suspect parts list, replace the engine cylinder head. This service must be performed on all affected vehicles at no charge to the vehicle owner. For new vehicle storage guidelines, refer to EFC13033, Storage Guidelines for New Vehicles. To assist vehicle owners to have this repair completed, dealers should: • Arrange to pick up the owner’s vehicle and drive it to the dealership for repairs o Re-deliver the owner’s vehicle after repairs have been completed. • Pick-Up & Delivery should be made available for all customers. Refer to the Rental and Claiming sections for further details.

The letters to advise affected vehicles will start going out to owners starting 8/18/25. Only 2,977 vehicles in the US market affected.

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[rocks]

Amazing! WTF!

 

[wireman]

Another 1.5L issue. I guess at least they are taking care of it.

 

[rocks]

Another 1.5L issue. I guess at least they are taking care of it.

I never had confidence in the 1.5 in an OBX I had.

 

[wireman]

I never had confidence in the 1.5 in an OBX I had.

I had 3 Escapes with the 2.0 and never an issue. Only way for me. JMO

 

[Sixxgunscott]

New Guy here....interesting that the published bulletins do not list the affected parts Serial Numbers. Is the Cylinder Head Serial Number visable when inspecting by only opening the hood. Also, interesting is that the bulletin only listed one days production of 2024 BS in Hermasillo, Mexico - "December 09, 2023 through December 09, 2023.".

 

[rugedraw]

New Guy here....interesting that the published bulletins do not list the affected parts Serial Numbers. Is the Cylinder Head Serial Number visable when inspecting by only opening the hood. Also, interesting is that the bulletin only listed one days production of 2024 BS in Hermasillo, Mexico - "December 09, 2023 through December 09, 2023.".

They're listed. I'll post it later.

Edit:

 

[RidingTheBronco]

REASON FOR THIS SAFETY RECALL: Some affected vehicles were repaired with service replacement cylinder heads or long blocks that may have a loose ball plug or ball plugs. This condition may result in a rapid oil leak if a ball plug comes out of the cylinder head. An oil leak in the presence of an ignition source, such as hot engine or exhaust components, can increase the risk of a fire. In addition, the loss of oil can result in engine seizure and loss of motive power, increasing the risk of a crash.

SERVICE ACTION: Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to inspect the cylinder head serial number; ONLY if the serial number on the cylinder head matches one on the suspect parts list, replace the engine cylinder head. This service must be performed on all affected vehicles at no charge to the vehicle owner. For new vehicle storage guidelines, refer to EFC13033, Storage Guidelines for New Vehicles. To assist vehicle owners to have this repair completed, dealers should: • Arrange to pick up the owner’s vehicle and drive it to the dealership for repairs o Re-deliver the owner’s vehicle after repairs have been completed. • Pick-Up & Delivery should be made available for all customers. Refer to the Rental and Claiming sections for further details.

The letters to advise affected vehicles will start going out to owners starting 8/18/25. Only 2,977 vehicles in the US market affected.

For the record, I think the Ford Pass app reports any recalls for your specific vehicle. I keep checking the app when these recalls get posted, noting yet.

 

[rugedraw]

For the record, I think the Ford Pass app reports any recalls for your specific vehicle. I keep checking the app when these recalls get posted, noting yet.

I'm not sure how good or bad of a job fordpass does of doing that, but I get this from Ford's PTS dealer website where dealers are advised of these things before the general public gets notified via Fordpass, mail or whatever other methods they use.

 

[thegadgetfish]

Not a great start for the newer 1.5Ls. Seems like the badlands is still the way to go for reliability.

 

[kenmitch]

Not a great start for the newer 1.5Ls. Seems like the badlands is still the way to go for reliability.

That's what I was thinking when I read this. I did consider a lesser model until I realized that no way in Haiti's was a buying a vehicle with 1/2 a V-6 in it...Jokes aside I tend to have Tim the toolman Taylor syndrome.

 

[kenmitch]

On another note, I wonder if all the auto manufacturers have been infiltrated by tree hugging, global warming , EV lovers purposely sabotaging ICE vehicles.

 

[TrueNorthSport]

They're listed. I'll post it later.

Edit:

Hello, can someone explain what a "ball plug " is and can we assume that only a small number of BSs , built in a single day at the Mexican factory are affected ?

Cheers

 

[Dude]

Hello, can someone explain what a "ball plug " is and can we assume that only a small number of BSs , built in a single day at the Mexican factory are affected ?

Cheers

What is a ball plug in terms of cylinder head manufacturing

[ChatGPT] In cylinder head manufacturing, a ball plug is typically a small spherical or ball-shaped metal plug used to seal an internal drilled passage within the cylinder head—most often in coolant or oil galleries.

Here’s why and how it’s used:

Purpose

• When cylinder heads are cast and machined, internal passages (for coolant flow, oil lubrication, or sometimes fuel injection) are often created by drilling from the outside in.
• These drilled holes allow tooling to reach internal channels, but they must be sealed after machining so fluids don’t leak out.
• A ball plug is pressed into the hole to permanently block it.

Design & Materials

• Usually made of steel, aluminum, or brass, depending on the cylinder head material.
• Spherical shape allows for uniform expansion when pressed in, providing a tight, leak-proof seal.
• Can be solid or hollow depending on application.

Installation

• The ball is pressed into the drilled opening slightly larger than the ball’s diameter.
• Pressing deforms the ball slightly, locking it in place.
• In some cases, a sealant or staking method is added for extra security.

Examples in Cylinder Heads

• Coolant jacket gallery plugs – sealing the end of a drilled coolant passage.
• Oil passage plugs – closing off lubrication drill points to direct oil flow only where needed.
• Sometimes also called a ball plug closure, drill ball plug, or ball expansion plug in manufacturing manuals.

If you’d like, I can also sketch you a cutaway diagram of a cylinder head showing exactly where and how a ball plug is used in sealing coolant/oil galleries. That would make it visually clear.

Just remember … ChatGPT does not always know truth

As far as how many Bronco Sports are impacted, I have no reason to doubt Ford’s analysis of the impacted vehicles

 

[rugedraw]

Hello, can someone explain what a "ball plug " is and can we assume that only a small number of BSs , built in a single day at the Mexican factory are affected ?

Cheers

The one day of production seems strange to me, too. It could be a typo that will be corrected in a revised version of the recall, but it could be that was the one and only day the affected part numbers were used on the assembly line. I have no way of knowing for sure which is the case.

The instructions do not require for an inspection of the ball plug or anything. The tech instructions call for the tech to remove the air cleaner box to be able to see the p/n on the cylinder head. If it is one of the ones on the list, there is nothing further to do. It calls for the head to be replaced; no questions asked.

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