The Ford Puma, a popular light SUV in Australia, has been hit with a significant recall in 2025, affecting over 5,000 vehicles due to a manufacturing defect that could lead to fuel leaks and potential fires. Launched in 2020 as a stylish, fuel-efficient crossover based on the Ford Fiesta platform, the Puma has been lauded for its engaging driving dynamics, practical “MegaBox” storage, and mild-hybrid powertrains. Priced from $30,840 (MRLP) for the base model to $37,390 for the ST-Line V, it recorded 4,355 sales in 2023, ranking it among the top compact SUVs. However, the recent recall, announced on June 5, 2025, has raised concerns among owners, particularly as it involves a serious safety issue. This article explores the details of the recall, the Puma’s features and market position, the implications for Australian drivers, and the broader context of Ford’s reliability challenges, followed by three frequently asked questions.
The 2025 Ford Puma Recall: A Fire Risk
Recall Details
Ford Australia issued a recall for 5,131 Puma vehicles manufactured between 2019 and 2022, citing a manufacturing defect in the fuel line sleeve. According to the recall notice lodged with the Department of Infrastructure, “the fuel line sleeve may chafe against the support bracket and become damaged,” potentially causing fuel leaks. If a leak occurs in the presence of an external ignition source, it could result in a vehicle fire, increasing the risk of injury or death to occupants, other road users, or bystanders, as well as property damage. Additionally, a fuel leak could lead to a loss of motive power, further elevating safety risks during driving.
The affected vehicles span the Puma’s petrol and mild-hybrid variants, covering models like the base Puma, ST-Line, and ST-Line V. Ford is contacting owners to schedule free repairs at authorized dealerships, where technicians will inspect and replace the fuel line sleeve, reroute it, and add securing clips to prevent further chafing. The repair is expected to take approximately one hour, and Ford has emphasized that owners should act promptly to address the issue. The recall notice, reported by CarExpert and other outlets, underscores the severity of the defect, with a red-chevron-bordered warning highlighting the fire risk.
Historical Context
This is not the first recall for the Ford Puma. In 2023, Ford recalled 307 Pumas in Australia due to an incorrectly configured Restraint Control Module (RCM), which could prevent airbags and seatbelt pretensioners from functioning properly in a crash, increasing injury risks. The issue required a software update, and affected vehicles were repaired free of charge. Earlier recalls in 2020 addressed hybrid battery connection issues and driver’s airbag retention springs, both of which posed safety risks, including potential fires from loose battery connections. Globally, a 2022 recall affected 55,375 Pumas, Fiestas, Focuses, and Kugas in Europe due to a damaged engine oil separator that could leak oil, increasing fire risks in the engine compartment. These recurring issues suggest ongoing challenges in Ford’s manufacturing and quality control processes.
Owner Response and Sentiment
The 2025 recall has sparked concern among Puma owners, with some expressing frustration on platforms like X, where posts highlight the fire risk as a “serious worry” for a relatively new vehicle. One user noted, “Just got my Puma, now worried about it catching fire—Ford needs to sort this out quick.” Owners are advised to check their vehicle’s VIN on Ford Australia’s website or the government’s Vehicle Recalls portal (vehiclerecalls.gov.au) to confirm if their Puma is affected. While Ford’s proactive communication and free repairs have been praised, the lack of an immediate fix timeline for some owners has caused unease, reminiscent of the 2020 Ford Kuga PHEV recall, where owners were instructed not to charge their vehicles until repairs were available.
Ford Puma’s Features and Market Appeal
Design and Practicality
The Ford Puma, introduced in Australia in 2020, is a compact crossover that blends sporty styling with practicality. Built on the Fiesta’s platform, it offers agile handling and a fun-to-drive character, earning praise from reviewers like Top Gear for its “engaging driving dynamics” and “responsive steering.” Its standout feature is the “MegaBox,” a 68-liter rubber-lined storage compartment beneath the boot floor, bringing total cargo capacity to 456 liters (1,216 liters with seats folded), surpassing rivals like the Hyundai Kona (407 liters). The MegaBox’s drain plug allows for easy cleaning, making it ideal for muddy gear or wet equipment, a practical feature for Australian lifestyles that often involve outdoor activities.
The Puma’s exterior, updated in 2024 with a revised grille and LED headlights, exudes a modern, sleek aesthetic. The interior, however, has drawn criticism for its “utilitarian” plastics and dated infotainment system compared to competitors like the Mazda CX-3. The 2024 facelift introduced a 12-inch touchscreen and a 12.8-inch digital cluster, improving connectivity with wireless Apple CarPlay and Android Auto, though the removal of physical climate controls has frustrated some users.
Powertrains and Efficiency
The Puma is powered by a 1.0-liter three-cylinder EcoBoost petrol engine with mild-hybrid assistance, available in 92 kW/170 Nm (base) and 114 kW/200 Nm (ST-Line) outputs. Fuel economy ranges from 5.3–5.6 L/100 km, competitive with the Toyota Corolla Cross (4.7–5.4 L/100 km) and Hyundai Kona (6.0–6.9 L/100 km). The mild-hybrid system uses a 48-volt battery to boost low-end torque, improving acceleration (0-100 km/h in 9.0–9.8 seconds) and efficiency. A seven-speed dual-clutch automatic is standard, with a six-speed manual available in some markets. The Puma Gen-E, a fully electric variant launched in Europe in 2023, is not yet available in Australia, limiting its appeal in the growing EV market.
Safety and Reliability
The Puma holds a five-star ANCAP safety rating from 2019, with standard features like AEB, lane-keep assist, and traffic sign recognition. Higher trims add blind-spot monitoring and adaptive cruise control. However, its reliability score of 90.0% in What Car?’s survey ranks it 17th out of 22 small SUVs, with 22% of owners reporting issues like battery faults, brake problems, and infotainment glitches. The 2025 recall adds to these concerns, though Ford’s 5-year/unlimited km warranty and capped-price servicing ($299–$329 per service) provide some reassurance.
Implications for Australian Drivers
Safety and Practical Concerns
The fire risk recall is a significant issue for Puma owners, particularly in Australia’s hot, dry climate, where external ignition sources like bushfires or engine heat are a concern. The potential loss of motive power from fuel leaks could also be hazardous on rural highways or during peak traffic. Owners are urged to contact Ford dealerships immediately to schedule inspections, though some have reported delays due to parts availability, echoing issues faced during the 2020 Kuga PHEV recall. The recall’s impact on resale values remains uncertain, but past recalls have led to temporary dips in second-hand prices, as noted in owner forums.
Market Context
The Puma competes in a crowded light SUV segment against the Toyota Corolla Cross, Hyundai Kona, and MG ZS. Its 4,355 sales in 2023 placed it behind the Corolla Cross (8,283 units) but ahead of the Mazda CX-3 (3,978 units). The recall could dent consumer confidence, especially as competitors like Toyota boast stronger reliability reputations (RepairPal rating of 4.0/5.0 for the Corolla Cross vs. Ford’s 3.5/5.0). However, the Puma’s engaging drive, practical boot, and competitive pricing keep it appealing, particularly for urban buyers. The absence of a hybrid or electric option in Australia, unlike the Corolla Cross Hybrid or BYD Atto 3, may limit its growth as the market shifts toward electrified vehicles under the NVES.
Ford’s Response and Future Outlook
Ford Australia’s proactive recall communication and free repairs demonstrate a commitment to customer safety, but the company faces pressure to improve quality control. The Puma’s multiple recalls since 2020—covering battery connections, airbags, and now fuel lines—suggest systemic manufacturing issues. Ford’s transition to an EV-focused lineup, with the Puma Gen-E and Mustang Mach-E, could shift attention from petrol models, but Australia’s slow EV infrastructure growth means petrol and mild-hybrid Pumas remain critical. A potential 2026 facelift with enhanced safety features and a hybrid option could bolster its competitiveness, provided Ford addresses reliability concerns.
Broader Industry Trends
The Puma recall aligns with broader industry challenges, as seen in recent recalls for Ford’s Kuga PHEV (26,328 units globally in 2025) and Escape/Bronco Sport (33,576 units) due to battery and fuel injector issues. These incidents highlight the complexities of hybrid and mild-hybrid systems, where electrical and fuel components increase fire risks if not manufactured to specification. Competitors like Toyota and Hyundai have faced fewer fire-related recalls, giving them an edge in consumer trust. As Australia’s EV market grows—20% of 2024 sales were electrified—Ford must balance innovation with reliability to maintain its foothold.
Looking Forward
The 2025 Ford Puma recall, affecting over 5,000 vehicles in Australia due to a fuel line defect, underscores the challenges of ensuring safety in modern vehicles. While the Puma’s low price ($30,840–$37,390), solid mileage (5.3–5.6 L/100 km), and engaging powertrains (92–114 kW) make it a strong contender in the light SUV segment, its fire risk and history of recalls raise concerns. Ford’s swift response and free repairs are commendable, but owners face uncertainty until fixes are completed. The Puma’s practical MegaBox, sporty handling, and five-star ANCAP rating remain draws, but its 90.0% reliability score and three-star ANCAP concerns for some models lag behind rivals. As Ford navigates its EV transition, addressing quality issues will be crucial to maintaining the Puma’s appeal among Australian buyers seeking value and safety.
FAQs
1. What should I do if my Ford Puma is affected by the 2025 fire risk recall?
Check your vehicle’s VIN on Ford Australia’s website or vehiclerecalls.gov.au to confirm if it’s affected. Contact your nearest Ford dealership to schedule a free inspection and repair, which involves replacing the fuel line sleeve and adding securing clips. Avoid driving unnecessarily until the repair is completed, as fuel leaks pose a fire risk.
2. How does the Puma’s fuel economy compare to competitors?
The Puma’s 1.0-liter mild-hybrid engine achieves 5.3–5.6 L/100 km, competitive with the Hyundai Kona (6.0–6.9 L/100 km) but trailing the Toyota Corolla Cross Hybrid (4.7–5.4 L/100 km). Its 42-liter fuel tank offers a range of approximately 700–800 km, suitable for urban and regional driving.
3. Is the Ford Puma still a good buy despite the recall?
The Puma offers strong value with its $30,840 starting price, practical MegaBox (456 liters), and engaging drive. However, its three-star ANCAP rating for some models and history of recalls (e.g., 2023 airbag issue, 2020 battery concerns) may concern safety-focused buyers. Its five-year warranty and free recall repairs mitigate risks, but consider rivals like the Toyota Corolla Cross for better reliability.