Ford Kuga recalls

On affected vehicles the Exhaust Gas Recirculation (EGR) valve may fail leading to weak acceleration engine vibration a no start condition or a loss of power.

Fix: Replace the EGR valve.

• KUGA: 292 vehicles · built 5 Feb 2025 to 4 Jun 2025
• KUGA: 22 vehicles · built 10 Jun 2025 to 11 Jun 2025

Affected vehicles may experience erratic behaviour of the Glare Free High Beam function under certain circumstances.

Fix: Update the Advanced Driver Assistance Systems Electronic Control Unit software.

9,702 vehicles · built 23 Sep 2025 to 14 Apr 2026

Affected vehicles may have been repaired using a coolant pump with a potential issue. This issue may lead to incorrect engine timing resulting in an engine failure causing a sudden loss of power without prior warning. The engine cannot be restarted.

Fix: Check and replace the water pump and timing belt if necessary.

• KUGA: 1 vehicle · built 11 Mar 2020 to 11 Mar 2020
• KUGA: 1 vehicle · built 5 Jun 2020 to 5 Jun 2020
• KUGA: 3 vehicles · built 1 Dec 2021 to 9 Dec 2021
• KUGA: 1 vehicle · built 19 Jan 2022 to 19 Jan 2022

Affected vehicles may experience a loss of emergency call system (eCall) functionality which impacts both automatic and manual eCall events.

Fix: Update the Telematics Control Unit software to the latest level.

• KUGA: 700 vehicles · built 17 Dec 2019 to 25 Feb 2022
• KUGA: 604 vehicles · built 1 Mar 2022 to 30 May 2022
• KUGA: 1,819 vehicles · built 30 May 2022 to 21 Oct 2022
• KUGA: 3,976 vehicles · built 4 Oct 2022 to 9 Feb 2024

On affected vehicles the software repair for previous recall 25C79 may not have been delivered properly and the Powertrain Control Module software may deliver lower power output than intended.

Fix: Update the Powertrain Control Module software and perform an additional verification process to ensure the configuration has been installed correctly.

19 vehicles · built 24 Jul 2019 to 13 Mar 2020

On affected vehicles the high voltage battery may have some cells that could potentially develop a short circuit leading to a Stop Safely Now message and possible loss of motive power or battery thermal venting.

Fix: Update the vehicle's Battery Energy Control Module software.

• KUGA: 7,659 vehicles · built 12 Jun 2023 to 29 Feb 2024
• KUGA: 13,204 vehicles · built 9 May 2024 to 31 May 2025
• KUGA: 1 vehicle · built 10 Jul 2025 to 10 Jul 2025
• KUGA: 3,603 vehicles · built 26 Nov 2019 to 16 Mar 2021
• KUGA: 2,193 vehicles · built 5 Jun 2020 to 22 Dec 2020
• KUGA: 674 vehicles · built 1 Dec 2020 to 20 Apr 2021
• KUGA: 1,062 vehicles · built 16 Mar 2021 to 17 Jun 2021
• KUGA: 1,285 vehicles · built 2 Jun 2021 to 21 Oct 2021
• KUGA: 586 vehicles · built 10 Sep 2021 to 29 Oct 2021
• KUGA: 2,680 vehicles · built 25 May 2021 to 16 Feb 2022
• KUGA: 566 vehicles · built 2 Feb 2022 to 31 Mar 2022
• KUGA: 1,178 vehicles · built 28 Feb 2022 to 31 May 2022
• KUGA: 5,916 vehicles · built 1 Jun 2022 to 24 Oct 2022
• KUGA: 6,632 vehicles · built 7 Aug 2019 to 28 Nov 2023
• KUGA: 1 vehicle · built 10 Jun 2020 to 10 Jun 2020
• KUGA: 11 vehicles · built 1 Mar 2023 to 9 Jan 2024
• KUGA: 2,005 vehicles · built 10 May 2024 to 26 Jun 2025
• KUGA: 63 vehicles · built 20 Jun 2025 to 26 Sep 2025
• KUGA: 130 vehicles · built 25 Oct 2025 to 19 Jan 2026
• KUGA: 2 vehicles · built 3 Jun 2025 to 3 Jun 2025
• KUGA: 9 vehicles · built 27 Jun 2025 to 17 Sep 2025
• KUGA: 6 vehicles · built 19 Jan 2026 to 27 Feb 2026

On affected vehicles the cylinder head may have loose ball plugs. This condition may result in a rapid oil leak if a ball plug comes out of the cylinder head.

Fix: Replace the cylinder head.

3 vehicles · built 16 Sep 2024 to 12 Dec 2024

On affected vehicles a software problem may result in issues with the rear-view camera that reduce the driver’s view or with it remaining on after a reversing event.

Fix: Update the vehicle software to the latest level.

• KUGA: 1 vehicle · built 11 Mar 2019 to 11 Mar 2019
• KUGA: 2 vehicles · built 29 Mar 2019 to 29 Mar 2019
• KUGA: 2 vehicles · built 9 Sep 2019 to 12 Sep 2019
• KUGA: 2 vehicles · built 4 Dec 2019 to 17 Dec 2019
• KUGA: 284 vehicles · built 2 Jan 2020 to 29 May 2020
• KUGA: 110 vehicles · built 29 May 2020 to 2 Oct 2020
• KUGA: 39 vehicles · built 6 Oct 2020 to 17 Nov 2020
• KUGA: 227 vehicles · built 14 Oct 2020 to 19 Feb 2021
• KUGA: 68 vehicles · built 25 Feb 2021 to 1 Jun 2021
• KUGA: 33 vehicles · built 18 Jun 2021 to 7 Sep 2021
• KUGA: 28 vehicles · built 8 Sep 2021 to 22 Oct 2021
• KUGA: 19 vehicles · built 27 Oct 2021 to 2 Feb 2022
• KUGA: 8 vehicles · built 19 Jan 2022 to 28 Feb 2022
• KUGA: 14 vehicles · built 9 Mar 2022 to 12 May 2022
• KUGA: 14 vehicles · built 13 Jun 2022 to 30 Sep 2022
• KUGA: 16 vehicles · built 5 Oct 2022 to 5 Jul 2023

Certain Kuga S-Max and Galaxy vehicles equipped with a 2.5L HEV/PHEV Engine may not have the remedy for Safety Recall 23S27 installed correctly but were recorded as having received the repair successfully. Because the correct software update may not have been installed on these vehicles the underlying condition specified in Safety Recall 23S27 potential under hood fire may still exist.

Fix: Dealers are to update the Powertrain Control Module (PCM) software.

547 vehicles · built 9 Jan 2021 to 9 Dec 2022

On affected vehicles the remedy software for a previous recall which was needed to mitigate a potential fire risk may not have been installed correctly.

Fix: Update the Power Control Module software and perform an additional verification process to ensure the software has been installed correctly.

• KUGA: 7 vehicles · built 29 Feb 2020 to 30 Apr 2020
• KUGA: 501 vehicles · built 25 Jul 2019 to 2 Jun 2020
• KUGA: 152 vehicles · built 4 Jun 2020 to 13 Oct 2020
• KUGA: 53 vehicles · built 7 Oct 2020 to 13 Nov 2020
• KUGA: 395 vehicles · built 20 Oct 2020 to 23 Feb 2021
• KUGA: 81 vehicles · built 12 Mar 2021 to 1 Jun 2021
• KUGA: 23 vehicles · built 2 Jun 2021 to 8 Sep 2021
• KUGA: 99 vehicles · built 10 Sep 2021 to 29 Oct 2021
• KUGA: 124 vehicles · built 27 Oct 2021 to 17 Jan 2022
• KUGA: 202 vehicles · built 17 Jan 2022 to 1 Mar 2022
• KUGA: 360 vehicles · built 1 Mar 2022 to 31 May 2022
• KUGA: 185 vehicles · built 31 May 2022 to 20 Sep 2022
• KUGA: 802 vehicles · built 4 Oct 2022 to 12 Jan 2023

On affected vehicles software from a previous recall may not have been installed correctly. Vehicles may have Hybrid Powertrain Control Module (HPCM) software that can result in a forced neutral condition while driving.

Fix: Update and verify the software.

• KUGA: 3 vehicles · built 28 Feb 2020 to 11 May 2020
• KUGA: 2 vehicles · built 6 Jul 2020 to 9 Jul 2020
• KUGA: 3 vehicles · built 29 Jan 2021 to 11 Feb 2022
• KUGA: 1 vehicle · built 13 May 2021 to 13 May 2021
• KUGA: 2 vehicles · built 14 Jan 2022 to 24 Jan 2022
• KUGA: 1 vehicle · built 10 Feb 2022 to 10 Feb 2022
• KUGA: 3 vehicles · built 7 Jul 2022 to 9 Sep 2022

Affected vehicles may develop a crack in the Diesel Particulate Filter (DPF).

Fix: Update software to prevent a cracked DPF. Test and replace DPFs that are already cracked.

• KUGA: 47 vehicles · built 8 Jan 2020 to 27 Jul 2020
• KUGA: 567 vehicles · built 5 Mar 2021 to 17 Jun 2021
• KUGA: 205 vehicles · built 3 Jul 2021 to 10 Sep 2021
• KUGA: 5 vehicles · built 24 Feb 2022 to 28 Feb 2022
• KUGA: 1,502 vehicles · built 28 Feb 2022 to 9 Jun 2022
• KUGA: 1,820 vehicles · built 31 May 2022 to 30 Sep 2022
• KUGA: 1,892 vehicles · built 12 Nov 2019 to 24 Jun 2020
• KUGA: 1,515 vehicles · built 4 Jun 2020 to 7 Oct 2020
• KUGA: 504 vehicles · built 8 Oct 2020 to 23 Dec 2020
• KUGA: 2,848 vehicles · built 14 Oct 2020 to 26 Feb 2021

A small number of vehicles on which the fuel injectors may crack and leak. In the event of an injector failing this may result in fuel accumulating on the top of the engine. The accumulation of fuel could become the catalyst for a fire due to the proximity to the exhaust system and lack of an escape route for the leaking fuel.

Fix: The dealer will fit a specially developed drain tube which will safely drain any leaking fuel away from hot surfaces like the cylinder head or exhaust. Also the vehicle software will be updated which will allow any drop in fuel pressure to be detected. This software will reduce the power of the engine if a drop in fuel pressure is detected and a warning light will be illuminated in the instrument cluster.

1,136 vehicles · built 24 Nov 2022 to 19 Jan 2023

Engine failure that may lead to a breach of the engine oil sump or engine block

Fix: Software update

• KUGA: 26 vehicles · built 31 Jul 2019 to 16 Mar 2021
• KUGA: 3,456 vehicles · built 8 Jan 2020 to 22 Jul 2020
• KUGA: 1,989 vehicles · built 5 Jun 2020 to 22 Dec 2020
• KUGA: 890 vehicles · built 1 Dec 2020 to 18 Oct 2022
• KUGA: 1,161 vehicles · built 8 Mar 2021 to 17 Jun 2021
• KUGA: 1,879 vehicles · built 1 Jun 2021 to 21 Oct 2021
• KUGA: 787 vehicles · built 10 Sep 2021 to 29 Oct 2021
• KUGA: 2,944 vehicles · built 20 Sep 2021 to 16 Feb 2022
• KUGA: 582 vehicles · built 27 Jan 2022 to 31 Mar 2022
• KUGA: 2,591 vehicles · built 28 Feb 2022 to 31 May 2022
• KUGA: 6,606 vehicles · built 10 May 2022 to 26 Oct 2022
• KUGA: 1,851 vehicles · built 4 Oct 2022 to 16 Dec 2022
• KUGA: vehicle count not given · built 8 Jan 2020 to 16 Dec 2022

The steering gear could potentially develop excessive movement. Over time a wear condition may manifest in an audible noise increased steering efforts and the steering wheel not returning to the centre position. In rare circumstances if the issue of noise increased steering efforts and the steering wheel not returning to the centre position are not addressed the excessive movement in the steering gear may lead to the pinion shaft becoming disconnected from the steering rack.

Fix: Replace affected components.

• KUGA: 2,302 vehicles · built 14 Jan 2021 to 14 Apr 2021
• KUGA: 2,740 vehicles · built 12 Feb 2021 to 16 Jun 2021
• KUGA: 110 vehicles · built 2 Jun 2021 to 9 Jul 2021
• KUGA: 1 vehicle · built 16 Sep 2021 to 16 Sep 2021
• KUGA: 1 vehicle · built 25 May 2021 to 25 May 2021
• KUGA: vehicle count not given · built 14 Jan 2021 to 16 Sep 2021

In the event of a fuel injector failing this will potentially cause a fuel leak.

Fix: A drain tube will need to be installed to allow safe passage of the fuel away from hot surfaces in the event of a leak occurring. Also the dealer will perform a PCM software update that will reduce the engine power if a drop in fuel pressure is detected and a warning light will be illuminated to make the user aware.

13,671 vehicles · built 25 Jul 2019 to 14 Dec 2022

A small number of vehicles may be fitted with tyres that do not meet the high specification expected.

Fix: Conduct a visual inspection of the summer tyres to identify known and specific build codes. If after inspecting the vehicle a tyre(s) is identified as one of the known specific build numbers that falls in the suspect build range the Dealer will replace the affected tyre free of charge.

142 vehicles · built 23 Jun 2022 to 1 Jul 2022

Some Kuga vehicles with a panoramic roof may have a fixed glass panel with poor adhesion to the roof frame assembly. As a result there is a possibility that the fixed glass panel could detach during driving causing a hazard to vehicle occupants and other road users.

Fix: Check the panoramic roof frame If an affected date is present the fixed glass roof panel will need to be removed to inspect the integrity of the adhesive. If the adhesive is found to be compromised a new roof frame assembly will need to be installed.

2,359 vehicles · built 19 Apr 2021 to 19 Nov 2021

The lower front seatbelt bolt may not be correctly tightened to specification.

Fix: Inspect and re-torque the front lower seatbelt bolts to specification

35 vehicles · built 19 Nov 2019 to 26 Apr 2021

It may be possible that the eCall feature will stop functioning due to a malfunction.

Fix: The Telecommunication Module will need to be replaced

9,388 vehicles · built 9 Feb 2022 to 14 Jun 2022

Under certain operating conditions an oil and/or fuel vapour leak in the presence of an ignition source may result in an engine compartment or vehicle fire localized melting or smoke.

Fix: Modification of the engine undertray and active grill assemblies.

16,155 vehicles · built 8 Jan 2020 to 1 Jul 2022

Certain vehicles could have an engine oil separator that may have been damaged prior to engine assembly.

Fix: Inspect the engine oil separator and if found to be damaged and/or leaking a replacement engine oil separator must be installed

9,818 vehicles · built 13 Feb 2020 to 25 Feb 2022

Vehicles may have an issue with the current software that controls the functionality of the eCall system.

Fix: Carry out a software update.

100 vehicles · built 15 Jul 2019 to 12 Feb 2021

The Fuel Operated Heater could start inadvertently

Fix: New SYNC system software must be applied.

1 vehicle · built 1 Nov 2019 to 8 Jun 2020

The HV battery pack can overheat and result in the venting of hot gas which can ignite vehicle components or in extreme cases the entire vehicle.

Fix: To prevent a vehicle fire the vehicles should not be charged using the external charging cable and the vehicles should only be driven using the default Auto EV mode only.

5,046 vehicles · built 1 Jul 2019 to 7 Sep 2020

The High Voltage Battery Control Charger Module (BCCM) connector may be damaged

Fix: An inspection of the BCCM is required to confirm an undamaged connector. If a failed inspection occurs the vehicle must be reworked with a replacement BCCM and charge cable.

30,202 vehicles · built 1 Jul 2019 to 31 Jul 2020

A number of vehicles fitted with a 1.0 1.5 or 1.6 Ecoboost engine and 6-speed manual transmission could suffer clutch pressure plate fracture. This results in clutch smell reduced vehicle speed and performance. In the unlikely event of clutch pressure plate fracture a noise (thud / bang) could be heard from the vicinity of the transmission in extreme cases resulting in clutch / transmission fragments being released and striking under hood components creating a risk of smoke and fire from the under hood area.

Fix: To prevent the repeated heating /cooling events a new calibration has been developed for vehicles fitted with Engine Stop Start feature. The software with the additional feature sets the Instrument panel �Wrench light� and de-rates the engine performance if prolonged clutch slip is detected. The software feature includes a drive cycle strategy for latching the wrench light and engine performance de-rate if the customer should experience repeated clutch slip events. For vehicles that do not have Engine Stop Start feature an alternative clutch kit has been released.

66,497 vehicles · built 30 Jun 2016 to 28 May 2018

Affected vehicles fitted with a 1.0 1.5 or 1.6 Ecoboost engine and 6-speed manual transmission could suffer clutch pressure plate fracture. This results in clutch smell reduced vehicle speed and performance. In the unlikely event of clutch pressure plate fracture a noise (thud / bang) could be heard from the vicinity of the transmission in extreme cases resulting in clutch / transmission fragments being released and striking under hood components creating a risk of smoke and fire from the under hood area.

Fix: To prevent the repeated heating /cooling events a new calibration has been developed for vehicles fitted with Engine Stop Start feature. The software with the additional feature sets the Instrument panel �Wrench light� and de-rates the engine performance if prolonged clutch slip is detected. The software feature includes a drive cycle strategy for latching the wrench light and engine performance de-rate if the customer should experience repeated clutch slip events. For vehicles that do not have Engine Stop Start feature an alternative clutch kit has been released.

122,199 vehicles · built 1 Aug 2013 to 30 Jun 2016

The engine control module calibration may not adequately detect an overheat condition in certain 2.0L Duratorq Diesel engines. In extreme cases an overheated engine can result in a breach of the oil sump leading to loss of the engine oil.

Fix: Recall the vehicles that are likely to be affected and download revised software for the control module calibration that improves overheat detection and provides an instrument cluster warning indicator to the driver and engine de-rate strategy.

48,595 vehicles · built 13 Oct 2014 to 26 Sep 2015

Localized overheating of the engine cylinder head may cause the cylinder head to crack.This may cause a pressurized oil leak which in extreme circumstances could result in a fire in the engine compartment.

Fix: On affected vehicles Inspect engine and cooling system. Replace affected components and fit a Coolant Level Sensor along with associated software to provide and audible and visual warning to the driver.

15,228 vehicles · built 2 Jun 2010 to 20 Dec 2014

The airbag initiator may be defective and may prevent the side airbag(s) and/or knee airbag deploying in the event of an accident. In a collision the airbags not deploying could put the occupants at further risk.

Fix: Recall the 1943 vehicles that are likely to be affected to check and where necessary replace the side and knee protection airbags complete with initiators.

1,943 vehicles · built 28 Jul 2016 to 27 Dec 2016

In the event of a colision which deploys the front seat belt retractor pre-tensioner there is a possibility that the insulation material on the inner face of lower 'B' pillar trim could be subjected to a concentrated heat source that could ignite the insulation material resulting in fire.

Fix: Remove a section of the insulation material on both �B� pillar trims.

29,904 vehicles · built 17 Jul 2012 to 19 Jun 2014

The heated washer jets fitted to some Kuga vehicles may have jet heating elements that are not correctly sealed. There is a possibility that poor sealing could lead to corrosion due to water ingress and subsequent overheating of the jets. An overheating jet element will damage the nozzle housing and may cause local heat/fire damage to the cowl grille accompanied by smoke and burning smell.

Fix: Recall the vehicles that are likely to be affected and fit new washer jets.

4,382 vehicles · built 18 May 2010 to 31 Oct 2010

The heated washer jets may have jet heating elements which are not correctly sealed. There is a possibility that poor sealing could lead to corrosion due to water ingress and subsequent overheating of the jets. An overheating jet element will damage the nozzle housing and may cause local heat/fire damage to the cowl grille accompanied by smoke and burning smell.

Fix: Recall the vehicles that are likely to be affected and fit new washer jets.

20,358 vehicles · built 15 Jan 2008 to 17 May 2010

During engine warm up it is possible that the non return valve within the vacuum pump may stick. It is possible that if sufficient brake applications are made before the valve releases the vacuum stored within the brake booster will be used up and a hard brake pedal and longer stopping distances may result.

Fix: Recall the vehicles that are likely to be affected to fit a revised design of non return valve to the brake vacuum pump.

13,029 vehicles · built 1 Nov 2008 to 12 Mar 2009