2021 Ford Bronco Sport Engine Problems

The bronco sport was being driven, suddenly an gasoline odor was slightly noticed, it was almost dismissed because the intersection the vehicle was currently at has 4 gas stations. The SUV suddenly turned off, alerts popped up on the screen and smoke began to rise from underneath the hood. As the vehicle was exited, the gas odor was noticeable and flames began to shoot from the engine bay. Within a minute the flames had engulfed the whole front end of the vehicle into the interior.

NHTSA ID

11752828

Incident

Jul 24, 2026

The contact owns a 2021 Ford Bronco Sport. The contact stated that the check engine warning light illuminated. There was an abnormal odor of exhaust fumes inside the vehicle. Initially, the driver thought it emerged from other vehicles; however, a passenger smelled exhaust fumes, became sick, and vomited once the driver pulled over. The Ford mobile app failed to display any failure codes. The contact related the failure to NHTSA Campaign Number: 25V467000 (Fuel System, Gasoline). The vehicle was taken to a local dealer, where diagnostic trouble codes for the engine were cleared. The fuel vapor was purged, and the valve was replaced; however, the failure recurred. The vehicle was then taken to an independent mechanic shop, where it was diagnosed that the catalytic converter was fractured. The catalytic converter was replaced, and the fuel injector was serviced. The manufacturer was not contacted. The failure mileage was approximately 67,830.

NHTSA ID

11749362

Incident

Feb 25, 2026

Mileage

67,830 mi

Continuously when I am driving the vehicle, it will randomly loose acceleration and come to an almost complete stop when driving, including on major interstates.

NHTSA ID

11747377

Incident

Jun 28, 2026

Purchased a Ford Bronco Sport brand new in 2021. I received a recall notice for my bronco sport last July. I took my vehicle to the Ford dealership and they told me there was no remedy available. The recall states that my vehicle could catch on fire and crash at any time while I’m driving it. Ford still does not have a remedy almost a year later and they don’t know when they will have one. They don’t have parts even though my VIN number is affected. Ford expects me to risk my life and the life of my passengers, who happen to be my grandsons, by driving this vehicle on a daily basis. At any time, my car can catch on fire because of the fuel injector recall. I filed a claim with the Ford buyback program, but was denied because my vehicle warranty has expired. The recall didn’t even come out until after my warranty had expired. Recall info: Campaign 25S76/25V467

NHTSA ID

11743285

Incident

Jul 16, 2025

This vehicle has had the same recall for longer than a year now that Ford doesn't seem to have any kind of remedy for. They just keep "inspecting" and "reprogramming." How many fires need to happen under the hood of these vehicles before Ford is forced to either replace the fuel injectors or compensate their customers in some way? I drive around with kids in my car. Safety is not up for negotiation and this has taken far longer than it should have.

NHTSA ID

11743230

Incident

Jul 16, 2025

The contact owns a 2021 Ford Bronco Sport. The contact stated that while driving at an undisclosed speed on two separate occasions, the turbocharger became inoperable. The contact reported hearing a knocking sound coming from the engine at the time of the failures. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and advised the contact that the remedy was not available to complete the repair. The approximate failure mileage was 80,000.

NHTSA ID

11742985

Incident

Jan 21, 2026

Mileage

80,000 mi

This recall has not been handled as of yet due to unavailable parts at it has almost been a year since it was issued on 7.16.2025.

NHTSA ID

11742085

Incident

Jun 4, 2026

On December 13, 2025, we drove to Flagstaff, Arizona from Tucson, Arizona, where we live. As we came into town, the Bronco began to lurch and seemed to have difficulty shifting. I managed to make it to the Babbitt Ford service center’s parking lot, where it seized and died altogether. It stayed at Babbitt Ford where they worked on it until February 3, 2026. They replaced the transmission at great expense. On Feburary 3, we drove it home to Tucson. The next day, February 4, it died in the road twice, once in a major intersection. The first time it eventually resarted. The second time it died completely and required a special tow truck because we couldn't even get it into neutral to roll. It was towed to Holmes Tuttle Ford where they kept it for a week but were able to eventually restart it. They had it for 5 days, ran a diagnostic and reset the system. They drove it for over 80 miles and couldn’t recreate the problem. Then on February 25, I drove to Phoenix. While in Phoenix, it again inextricably had trouble shifting, died and wouldn’t start. I then had it towed to Camelback Ford. On March 6, Camelback Ford called and said they ran numerous tests and still can’t pinpoint the problem and the vehicle still won’t start or shift into neutral.

NHTSA ID

11733302

Incident

Dec 13, 2025

I chose the engine and fuel questions as I believe these would be the issue. While driving on the I 10 east towards [XXX] there are areas on the freeway that you drive upward from a flat freeway service to (up hill). Today 04/22/2026, my bronco sport lost drive power from 65 mph to 45 mph which caused the warning lights of the engine and wrench notifications to come on. It was a little difficult and scary but I was able to get off the freeway safely and park. I looked under the hood and under the car for leaks but there were non found and after about 30 minuets, I got back on the freeway and went back home. Back in July of 2025, I believe their was a recall for the fuel injector system and I think this issue of today is based on that recall. I have not been able to confirm with Ford if this has anything to do with the 2025 recall and I have not seen any repair options. I have however, seen other's reporting the same issue. I don't know if you can doing anything but I wanted to provide my experience of today. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11733128

Incident

Apr 22, 2026

I own a 2021 Ford Bronco Sport Base (VIN: [XXX] ) equipped with the 1.5L EcoBoost 3-cylinder engine. I am experiencing a complete and repeated loss of engine coolant with no visible external leak. Upon inspection, air bubbles were observed rising through the coolant reservoir when coolant was added, indicating combustion gases are entering the cooling system through a compromised seal. On multiple occasions upon startup, sweet-smelling white smoke has been emitted from the exhaust, consistent with coolant burning in the combustion chamber. The vehicle has overheated as a result of coolant loss. These symptoms are consistent with the known 1.5L EcoBoost cracked engine block or head gasket failure defect affecting 2021 Ford Bronco Sport and 2020-2022 Ford Escape vehicles. I have been advised by a ford dealership mechanic that the vehicle is unsafe to drive due to the risk of engine failure and potential engine fire. The vehicle has been parked and is not being driven. I am filing this complaint as a safety concern given Ford’s history of engine fires related to this defect, which was the basis of recall 22S43 and ongoing federal class action litigation. I am requesting NHTSA investigate whether an expanded recall or additional consumer remedy is warranted for this vehicle. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11732849

Incident

Apr 17, 2026

The contact owns a 2021 Ford Bronco Sport. The contact stated that while driving on several occasions at various speeds, the infotainment screen went black or displayed a half-operating screen. An unknown warning light was illuminated with the message "Attention Needed - Service Engine Soon" displayed. The vehicle was taken to a dealer, and it was determined that Part Number: BE52 needed to be replaced. The vehicle was not repaired. The contact stated that while driving on several occasions at various speeds, the check engine warning light illuminated. The vehicle was taken to the same dealer where it was diagnosed, and determined that an unknown part needed to be replaced after retrieving DTC: P0496. The vehicle was not repaired. While the vehicle was parked, the vehicle hesitated while starting. The vehicle was taken to another dealer to be diagnosed, and it was determined that the battery charge was lower than 40 percent but did not need to be replaced. The vehicle was taken to another dealer where it was determined that the battery needed to be replaced. The vehicle was repaired, but within 24 hours there was an unknown warning light illuminated with an audible chime. The contact believed that the failure was associated with the body control module (BCM). The manufacturer was notified of the failure and a complaint was filed. The failure mileage was approximately 52,000.

NHTSA ID

11729950

Incident

Nov 7, 2020

Mileage

52,000 mi

While driving, the vehicle stutters during acceleration, creating hesitation and inconsistent power delivery. This occurs during normal driving conditions and has not improved after being inspected by a dealership. The issue has been reproduced multiple times and remains unresolved. The vehicle was taken in for service, but no effective repair was provided, and the condition persists. There is an active recall related to a potential fuel injector defect, which may cause fuel to accumulate on top of the engine. The recall remedy is currently unavailable. Given the ongoing stuttering and known fuel system issue, there is concern this condition is related. This creates a safety risk, particularly when merging into traffic or accelerating from a stop, as the vehicle does not respond consistently. No warning lights have consistently appeared. The issue continues despite dealership involvement and lack of available recall repair.

NHTSA ID

11727115

Incident

Mar 21, 2026

While driving between [XXX] and [XXX] , the vehicle suddenly lost fuel. The estimated miles to empty started to drop rapidly from 70 miles to 50 miles within minutes. At a safe point, I pulled over, there was no pooling of fuel under the vehicle, no other warning lights were issued. I turned around to return to [XXX] , the engine stalled and ran out of gas at mile marker 18 just north of [XXX] . I left the vehicle on the side of the road and walked back to [XXX] . This stretch of road has no cell service. The vehicle was towed to Corwin Ford for inspection. I requested that Recall CSP25S76 be completed on the vehicle, and replace the fuel injectors. The response was that the fuel tank needs to be replaced. They have not provided diagnostic evidence of why. I think this falls under CSP 21S38. Additionally, the catalytic converter was replaced in January under [XXX] and the emissions warranty extension. The vehicle has high mileage, but the purge valve should not have stuck open and this is a known issue with the Ford Bronco Sports. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11726583

Incident

Mar 20, 2026

My car has been stalling at stops and I am unable to fill my car as it will not start so I have to put increments of 10-15.00 at a time they have told me now for over three months that parts were on back order and the recall that can catch my entire car on fire while driving cannot be fixed as their is no fix for it. Multiple issues continue to pile on when the vehicle isn’t even 5 years old

NHTSA ID

11726118

Incident

Dec 11, 2025

2921 FORD BRONCO SPORT HIGHWAY 14, Santa Clarita CA Driver noticed another car pointing to the Bronco’s hood frantically. As the Bronco slowed, the driver noticed flames coming out of the sides of the hood on both sides. Driver pulled to shoulder of highway and the driver and passenger VERY QUICKLY got out and moved approx.. 100 feet behind vehicle to safety. Flames very quickly engulfed the entire Bronco. 911 was called by driver. Santa Clarita Fire Department responds in 10 minutes. THERE WERE NO INJURIES. The fire burned for about 30 minutes and COMPLETELY DESTROYED THE VEHICLE Towing/Wrecker company was called to remove destroyed vehicle. Tow truck driver provided transportation of passengers to the Freeway Towing Company in Santa Clarita. Freeway Towing held the destroyed vehicle at their lot. Insurance company took possession of the destroyed vehicle on March 11 and is currently holding it at their location. In January the Bronco owner noticed the check engine light was on and took it to a Ford dealership in California to have it serviced. We have videos of the fire as well.

NHTSA ID

11726002

Incident

Mar 9, 2026

The contact owns a 2021 Ford Bronco Sport. The vehicle was taken to Take 5 Oil Change for an oil change, and the contact was informed that the coolant reservoir was empty. The vehicle was taken to Ritchie Automotive, where it was diagnosed that the water pump had failed and needed to be replaced. The vehicle was not repaired. The dealer was notified of the failure and referred the contact to the NHTSA Hotline to report the failure. The manufacturer was not contacted. The failure mileage was approximately 80,000.

NHTSA ID

11725042

Incident

Mar 16, 2026

Mileage

80,000 mi

The contact owns a 2021 Ford Bronco Sport. The contact stated that while driving 15 MPH in traffic, the accelerator pedal was depressed; however, the vehicle failed to respond as needed. The contact stated that the vehicle was in Fuel Saver Mode, and the vehicle turned off unexpectedly and failed to restart. The check engine and the battery warning lights were illuminated. The vehicle was towed to a local dealer; however, a diagnostic test was unable to be performed because the parking brake independently engaged whenever shifted into neutral(N). The vehicle was not repaired. The manufacturer was informed of the failure. The failure mileage was approximately 60,400.

NHTSA ID

11725037

Incident

Mar 14, 2026

Mileage

60,400 mi

The contact owns a 2021 Ford Bronco Sport. The contact stated that while driving 78 MPH on the highway, the vehicle unintentionally decelerated and stalled. The vehicle was turned off, restarted, and driven as intended. No warning lights were illuminated. On another occasion, the vehicle stalled with the check engine warning light and other unknown warning lights illuminated. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 49,700.

NHTSA ID

11724668

Incident

Mar 15, 2026

Mileage

49,700 mi

Catastrophic engine failure. Sudden. Started my car in the morning. Engine was running rough. Drove about 1/2 mile, engine continued to get worse. Returned home. decided to get engine codes checked. Check engine lights did not come on until this incident. Couldn't keep engine running. Kept trying to restart. Heard weird noise in engine and engine seized. Car had 62,800 miles on it, just over the 5 yr/60,000 warranty. Had the car towed to local Ford dealership. They verified that the engine was seized and that I needed a new engine. They found a lot of coolant in the engine oil along with a lot of metal flakes in the oil. They called it a catastrophic failure and speculated that it could be piston or valve destruction. They did not tear down the engine to determine the cause. They wanted an additional $2,000 to do that. (I kept the old seized engine). This failure could leave the owner stranded and in a very unsafe situation. I don't know what this failure would do to the drivability of the vehicle in traffic or on the highway.

NHTSA ID

11724559

Incident

Jan 25, 2026

The contact owns a 2021 Ford Bronco Sport. The contact stated that while her husband was driving at 60 MPH and entering the base at 15 MPH, the overheating message was displayed. The driver pulled over, and the light turned off. After exiting the vehicle, he noticed the vehicle had caught fire. The driver disconnected the battery. There were no reported injuries. Another driver stopped with a fire extinguisher to assist with putting out the fire. The fire department was able to extinguish the fire. The vehicle was towed to the local dealer, but the vehicle was not diagnosed or repaired. The contact stated that the failure was related to NHTSA Campaign Number: 25V467000 (Fuel System, Gasoline). The manufacturer was contacted, who initially was sending an inspector but changed to viewing the photos. The failure mileage was approximately 80,000.

NHTSA ID

11720708

Incident

Feb 17, 2026

Mileage

80,000 mi

This vehicle is subject to NHTSA Recall 25V467 involving potential fuel injector cracking and risk of fuel leaking onto the engine, creating a fire hazard. The recall status shows “Remedy Not Yet Available,” leaving the defect unresolved. While driving, the vehicle suddenly displayed an engine overheating warning and immediately entered limp mode, causing abrupt loss of power. The vehicle decelerated unexpectedly and was not able to maintain normal driving speed. This created a dangerous situation in active traffic and required a safety tow. The sudden power reduction could have resulted in a rear-end collision or loss of vehicle control. There were no prior overheating warnings immediately before this incident. The failure occurred abruptly. A warning message appeared at the time of the event, followed by limp mode activation. The vehicle had to be towed to a dealership for inspection. Given that the open recall involves fuel injector cracking and potential fuel accumulation near hot engine components, there is concern that the unresolved recall condition may be related to engine overheating and loss of power. The vehicle remains under an active fire-risk recall, yet no repair remedy is available. Owners are left operating vehicles with a known safety defect and no corrective action timeline. The defect has not been remedied because parts are not available. The vehicle was inspected by a dealership after the overheating event. The primary safety concern is the combination of an open fire-risk recall and a sudden overheating/limp mode event causing abrupt power loss in traffic, creating a serious risk of injury. Due to this open recall with no available remedy, the vehicle cannot be listed or rented on a peer-to-peer vehicle sharing platform, resulting in loss of legitimate income. The vehicle was previously eligible for use, but is now restricted solely because the safety recall remains unresolved without a repair solution. Owners are financially impacted.

NHTSA ID

11717430

Incident

Feb 7, 2026

Since my car hit 40000 miles it has had nothing but issues. I've had it in the shop at least 10 times. My brakes went out while driving with my [XXX] old, I've had loss of power, smell of exhaust in the cabin for the last 3 months and dealership says it can't be fixed, yesterday I had complete engine failure while on the freeway. Stalled and wouldn't start back up for 5 min. The dealership has never fully fixed anything but has only updated the computer system. I feel very unsafe in this vehicle. We still owe on this vehicle so trading it in is not an option since its not even worth the down payment I put down. It has a fuel injector recall that can't be fixed yet due to not having the parts available. What are we suppose to do if we can't drive the vehicle and can't buy a new one. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11714165

Incident

Jan 27, 2026

Car check engine light came on, I came home parked the car, in about 5 minutes the cars embarked in flames, the car burned down to the ground. The safety of my entire home (flames caught onto house) and neighbors home was at risk. The burning car was inspected by Fire Chief of Christiana Fire Company

NHTSA ID

11713086

Incident

Jan 24, 2026

The contact owns a 2021 Ford Bronco Sport. The contact received notification of NHTSA Campaign Number: 25V467000 (FUEL SYSTEM, GASOLINE); however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact stated that while operating the vehicle, the check engine warning light remained illuminated, and there was an abnormal sound coming from the vehicle while driving. The contact was unable to determine the location of the sound. The vehicle was taken to the local Auto Zone, where an undisclosed system failure had occurred. No further information was available. The failure mileage was 77,000.

NHTSA ID

11710954

Incident

Jan 13, 2026

Mileage

77,000 mi

The contact owns a 2021 Ford Bronco Sport. The contact stated that while driving approximately 45 MPH, there was a loud scraping sound coming from the engine compartment, and the vehicle jerked abnormally. The vehicle was taken to an independent mechanic, and the failure was associated with the torque converter. The manufacturer was notified of the failure. The failure mileage was 91,000.

NHTSA ID

11708392

Incident

Dec 24, 2025

Mileage

91,000 mi