2022 Ford Bronco Sport

On January 31, 2024, The Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE24002) to investigate loss of motive power allegations in model year (MY) 2021 Ford Bronco Sport vehicles. Consumers reported a loss of engine power accompanied by complete electrical system failure either while driving or after stopping at a traffic light or stop sign. The vehicles generally could not be restarted, and the incidents were commonly diagnosed by dealerships to a failed 12-Volt (12V) battery. On April 12, 2024, Ford issued safety recall 24V-267 covering 456,565 MY 2021-2024 Ford Bronco Sport and MY 2022-2023 Ford Maverick vehicles. The recall addressed loss of motive power resulting from sudden degradation of the 12V battery during the drive cycle. The recall remedy consisted of software updates to the body control module and the powertrain control module. The updated software aimed to provide warning to consumers when the battery is failing and inhibit certain vehicle functions which can lead to loss of motive power incidents. Additionally, Ford removed the existing 12V Enhanced Flooded Battery (EFB) as both a service component for the subject vehicles and original equipment for newly built Bronco Sport vehicles (during MY 2024 production), replacing it with a more robust absorbed glass mat (AGM) battery. The same AGM battery had been incorporated into Ford Maverick production in late 2022. Following recall 24V-267, ODI received loss of motive power complaints in vehicles that had previously received Ford’s software-based remedy. Consumers reported that they did not receive warnings related to the 12V battery or the vehicle’s electrical system before the loss of power. On November 15, 2024, ODI opened Recall Query (RQ24014) to assess the effectiveness of the 24V-267 recall remedy. On January 19, 2025, Ford issued recall 25V-019 covering 272,817 MY 2021-2023 Bronco Sport and MY 2022-2023 Ford Maverick vehicles. The new recall addressed the same hazard as 24V-267 but required replacement of the existing 12V battery with an AGM battery as the remedy. Ford reported that following the opening of RQ24014, it evaluated several field-returned 12V batteries, and determined that EFBs produced by battery supplier Camel potentially contained internal manufacturing defects causing loss of motive power. Ford further concluded that the software updates provided in the 24V-267 recall remedy were unable to detect battery failures quickly enough to avoid loss of motive power. Vehicles previously within the scope of recall 24V-267, but outside of the scope of recall 25V-019, are equipped with EFBs produced by a different battery supplier (Clarios). When recall 25V-019 was issued, Ford had not identified any Clarios EFBs exhibiting the same failure mode as the Camel EFBs. In light of Ford’s recall action, ODI is closing this Recall Query. The agency will continue to monitor loss of motive power complaints in Bronco Sport vehicles equipped with Clarios EFBs and reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

On April 11, 2024, NHTSA’s Office of Defects Investigation (“ODI”) opened this Recall Query (“RQ”) to investigate the adequacy of, including various safety concerns associated with, the remedy program in recalls 22V-859 (filed Nov. 18, 2022) and 24V-187 (filed Mar. 8, 2024). The vehicle population associated with these recalls includes certain MY 2020-2022 Ford Escape vehicles and MY 2021-2023 Ford Bronco Sport vehicles equipped with 1.5L engines. The safety defect in each recall involves high-pressure fuel injectors that are susceptible to cracking, allowing liquid fuel and fuel vapor to migrate onto hot surfaces within the engine compartment potentially resulting in underhood vehicle fires. The remedy programs described in recalls 22V-859 and 24V-187 are identical and involve both a software component and a hardware component. Specifically, Ford developed an updated engine control software designed to detect a pressure drop in the high-pressure fuel rail, provide instrument cluster messaging to the driver, invoke a strategy to disable the high-pressure fuel pump, derate the engine output, and lower the temperatures of possible ignition sources within the engine compartment. Additionally, Ford would install a tube into the engine’s cylinder head drain hole to shunt spilled liquid fuel past the various hot surfaces within the engine compartment and ultimately discard the spilled liquid fuel onto the roadway. ODI identified various safety concerns with this remedy program, which, among other things, notably did not include repairing or replacing the defective part and potentially did include the introduction of new safety defects (like fuel spilling near the spark plugs and fuel spilling onto the public roadway). NHTSA opened this investigation to evaluate these concerns with the remedy program, including whether the vehicles were still susceptible to underhood fires even post-remedy. As described in more detail in the Additional Summary posted simultaneously with this resume, ODI conducted a thorough investigation that included analyzing data and other materials received in response to two Information Requests, as well as inspections of post-remedy vehicles that experienced an underhood fire. ODI and Ford worked to identify and locate vehicles that experienced post-remedy fires and conduct joint vehicle inspections. ODI’s investigation also prompted Ford to initiate a more in-depth evaluation of the defect, including Ford’s conducting component level testing of high-pressure fuel injectors. ODI met with Ford on several occasions throughout this investigation to jointly conduct certain of these described tasks and to discuss test results. A collateral issue surfaced as a result of this investigation: in March 2025, Ford realized that despite relevant repairs having been recorded as successfully completed, approximately 33,576 vehicles subject to recalls 22V-859 and 24V-187 did not have the software component of the remedy program installed correctly. Thus, on March 27, 2025, Ford filed a new related recall (25V-165) for these vehicles, notifying NHTSA and the public that they were still at risk of experiencing an underhood vehicle fire due to cracked fuel injectors despite the consumer having had their vehicle remedied pursuant to one of the two earlier recalls. In June 2025, Ford committed to implementing a new remedy program to repair the vehicles. On July 11, 2025, Ford documented this commitment in a new recall filing (25V-467), which explains that Ford’s upcoming remedy program will involve proactive replacement of all high-pressure fuel injectors within the recall population. In view of the recall action taken by Ford, ODI is closing this Recall Query, which was opened given NHTSA’s concerns that the initial remedy programs of the software to detect the pressure drop plus installation of the drain tube did not constitute an adequate repair. The agency reserves the right to take additional action if warranted by future circumstances.

On January 31, 2024, the Office of Defects Investigation (ODI) opened PE24002 to investigate allegations of loss of motive power in model year (MY) 2021 Ford Bronco Sport vehicles. At that time, ODI had received 31 Vehicle Owner Questionnaires (VOQs), with consumers commonly reporting a loss of engine power accompanied by complete electrical system failure which occurred either while driving, or after coming to a stop. The investigation revealed that MY 2021-2024 Ford Bronco Sport and certain MY 2022-2023 Ford Maverick vehicles are equipped with a 12V enhanced flooded battery (EFB), which may experience an abrupt failure during a drive cycle. The failure is the result of an internal corrosion issue, which is influenced by long exposure to high under-hood temperatures. If the sudden loss of 12V battery voltage is not detected by the vehicle’s battery management sensor, the vehicle can experience a loss of power event without providing any warning to the driver. Following a loss of power due to battery failure, the vehicle may be without all 12V accessories including hazard lights and typically will not be able to be restarted. In its March 2024 response to ODI’s information request, Ford provided 367 customer complaints (including field reports, lawsuits, and legal claims) and 1005 warranty claims relating to the alleged defect. When combining ODI and manufacturer failure report data, there are 1,368 unique VINs represented across MY 2021-2023 Ford Bronco Sport vehicles. One of the VOQs submitted to NHTSA reported a minor rear-end collision resulting from a loss of power event. Included within Ford’s complaints were a reported single-vehicle collision and a vehicle fire which occurred following a loss of power event at a traffic light (fire cause and origin was not determined). Additionally, across ODI and manufacturer data, there were 12 allegations of either acid leaking from the 12V battery or smoke emitting from the battery area within the engine compartment. On April 12, 2024, Ford submitted recall 24V267 for MY 2021-2024 Ford Bronco Sport and certain MY 2022-2023 Ford Maverick vehicles (total population 456,565). The recall remedy provides updated calibrations to the body control module and powertrain control module. Ford indicated that the update will result in improved detection of 12V battery state of charge during drive cycles and will provide notification to the driver if the battery significantly degrades while driving. Additionally, Ford has replaced the EFB with an absorbed glass mat (AGM) battery as both a service component for the subject vehicles and as original equipment for Bronco Sport vehicles with production dates beginning in mid-March 2024. The warranty claim rate for peer vehicles equipped with an AGM battery is substantially lower than that for the subject vehicle population. In view of the recall action being taken by Ford, ODI is closing this Preliminary Evaluation. The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

While driving, an severe and persistent rear brake resonance defect occurs during braking operations. The defect manifests as high-frequency vibration, loud grinding, and low-speed brake shudder/chatter from the rear braking system, impacting vehicle control and braking predictability under normal driving conditions. The affected component is the complete rear brake assembly, which is currently installed on the vehicle and available for inspection upon request. Safety is compromised due to diminished braking feel, driver distraction, severe auditory and tactile resonance during deceleration, and unpredictable pedal performance during low-speed maneuvers and stopping intervals. The defect has been repeatedly reproduced and formally confirmed by an authorized dealership service center over multiple repair attempts. Servicing included the execution of Technical Service Bulletin TSB 25-2438, which failed to remedy the issue. The issue was formally escalated to and evaluated by the vehicle manufacturer. The manufacturer’s Global Technical Assistance Center (GTAC) evaluated the vehicle and documented in writing that no further technical or engineering procedure exists to resolve or cure the recurring rear brake resonance. Symptoms first appeared during normal operation at approximately 17,000 miles, presenting as severe rear brake grinding and resonance without prior dashboard warning lamps or system error messages. The hardware defect remains active and unrectified.

NHTSA ID

11775449

Incident

Mar 1, 2024

I am experiencing a fuel smell in my vehicle when I cold start it in the morning. I took it to the dealership and they could not identify the smell but claimed that if I call Ford customer service they might be able to escalate the issue. Ford customer service just said there is nothing they can do until the recall Campaign 25S76 is done but it is currently on pause even though it was issued 7/16/25 and it is currently 10/23/26. I said that these is a safety issue since Ford has identified that it can lead to the engine igniting which has happened to 8 vehicles according to Ford. They said they recommend waiting for the recall to happen despite my safety concerns on a known flaw with the vehicle. No resolution or any type of compromise provided even though I can identify the fuel smell that they say is a sign of the fuel injector issue that should be fixed under customer satisfaction program Campaign: 22N18

NHTSA ID

11773229

Incident

Oct 23, 2026

The contact owns a 2022 Ford Bronco Sport. The contact received notification of NHTSA Campaign Number: 25V467000 (Fuel System, Gasoline); however, the part to complete the recall repair was not available. The local dealer was contacted several times and confirmed that the parts were unavailable. The contact stated the manufacturer exceeded a reasonable amount of time for the recall repair. The manufacturer was notified of the issue.

NHTSA ID

11772158

Incident

Apr 1, 2024

I’m reporting that this vehicle has been under recall literally since I purchased it over 4 years ago. It has a potential fire issue with the fuel injector, which several trips to the dealership have not fixed it. Ford sends a letter out once a year and says they’ll let me know when they have a fix. I keep a fire blanket stuffed into my glovebox and I’d like to know why over 4 years isn’t long enough to fix it! NHTSA Recall #25V467 This recall used to show up in my Ford app, but they removed it some time ago. Like that would fix the problem!

NHTSA ID

11771965

Incident

Aug 29, 2022

Water is entering the vehicle and dripping onto the interior floorboards, particularly when the air conditioning is running.This has caused growth of mold and rust inside the vehicle. The vehicle has developed multiple dashboard warning lights, and the turn signals and windshield wipers have stopped functioning. Most concerning, the steering wheel has locked while the vehicle was in motion, leaving me unable to steer even though the engine remained running.This created a serious and immediate safety hazard. The vehicle has since become inoperable and will no longer start. The source of the water intrusion and the underlying causes of the electrical and steering failures have not been confirmed. However, the combination of water entering the vehicle, multiple warning lights, loss of turn signals and windshield wiper operation, loss of steering control while the engine remained running, and the subsequent failure to start raises serious concerns about the vehicle’s safety and possible electrical system damage. I took the vehicle in for an inspection to determine the cause of these problems\. I was informed that diagnostic testing would cost approximately $250 per dashboard warning light, potentially exceeding $1,000 before the underlying problems could be identified. I have not received a confirmed diagnosis of the cause of these failures. The vehicle is available for inspection upon request. Given the loss of steering control while driving, the failure of essential safety-related components, the water intrusion, and the vehicle’s current inability to start, I am requesting a thorough investigation into the cause of these failures and whether they are related to a known vehicle defect. The vehicle should not be operated until the safety issues have been properly diagnosed and corrected.

NHTSA ID

11771839

Incident

Oct 7, 2026

The rear drive unit (RDU) deteriorated at 78k miles. I began to notice a shudder during low-speed turns with high steering angle. Upon inspection, metallic flakes were discovered in the RDU’s fluid, apparently indicating mechanical degradation of the internal clutch packs. Two separate Ford dealerships recommended complete RDU assembly replacement at a significant expense. I am concerned that an important drivetrain component could deteriorate this quickly, from normal driving use. I believe this could result in wheel drag/lockup or seizure while operating the vehicle. I have not experienced it yet and I’m not sure whether a total mechanical failure would cause it either. Ford has numerous technical service bulletins on this issue, so it is known to them (TSB 26-2328). I am currently waiting for a dealership to receive parts so that the RDU may be replaced.

NHTSA ID

11771489

Incident

Sep 24, 2026

The contact owns a 2022 Ford Bronco Sport. The contact stated that while driving at approximately 35 MPH, the vehicle failed to accelerate and lost motive power. The vehicle was towed to the dealer for inspection. The contact stated that the failure was related to the powertrain control module (PCM). The dealer reportedly found a transmission failure, and the vehicle was not covered under warranty. The contact stated that there was sand and debris in the transmission. The vehicle had been driven on the beach. It was unknown whether any repairs were completed. The contact associated the failure with NHTSA Campaign Number: 24V267000 (Power Train). The manufacturer was notified by phone, and a case was filed. The failure mileage was approximately 46,580.

NHTSA ID

11770922

Incident

May 5, 2026

Mileage

46,580 mi

misfire from fuel injectors

NHTSA ID

11770885

Incident

Oct 13, 2026

Some 2021-2024 Bronco Sport vehicles equipped with a 1.5L engine may exhibit a lack of air conditioning (A/C) cooling while at a stop and idling in ambient temperatures of 100°F (38°C) or higher. In addition, there are no diagnostic trouble codes (DTC) present related to A/C system functionality, refrigerant charge levels are to specification and the system is free of refrigerant leaks and/or A/C compressor related concerns. Customers may also report that A/C system cooling will be restored once the vehicle starts moving or placed in park/neutral. <br /><br /> The Workshop Manual (WSM), Section 412-00 Diagnosis and Testing > Pinpoint Test L "The A/C (Air Conditioning) is Inoperative - No Diagnostic Trouble Codes (DTCS)" has been updated to improve diagnostics for this condition, including the battery state of charge. If the battery state of charge is not at a sufficient level, it may result in vehicles exhibiting this concern.

For 20222026 vehicles equipped with a 8F35 transmission, a revision to the Road Testing Vehicle procedure has been made in the WSM, Section 307-01 > Diagnosis and Testing. This updated procedure improves the diagnosis of customer reported transmission concerns and aids in locating the proper root cause. During diagnosis and testing, details regarding whether the condition is more prevalent when the vehicle is hot or cold, throttle percentage at the time of occurrence, vehicle speed, the specific shift involved, and whether the issue occurs during transmission engagements (N>R, N>D, R>D, and/or D>R) should be noted in the warranty claim. Engineering requests including these detailed operating conditions that will significantly assist with root cause analysis. Diagnosis, testing, and repair should use established labor times outside this article.

This article supersedes TSB 25-2466 to add Bronco Sport, Escape, Maverick and Corsair, as well as removing Expedition and Navigator. One time use parts for Corsair and Bronco Sport were also added to the parts list. Some of the vehicles listed in the Model statement above may exhibit a headliner rattle or sagging condition around the roof opening panel. This may be due to the adhesive separating from the headliner substrate.

Some 2021-2024 Bronco Sport vehicles equipped with a 1.5L may exhibit a lack of air conditioning (A/C) cooling while at a stop and idling in ambient temperatures of 100°F (38°C) or higher. In addition, there are no diagnostic trouble codes (DTC) present related to A/C system functionality, refrigerant charge levels are to specification and system is free of refrigerant leaks and/or A/C compressor related concerns. Customers may also report that A/C system cooling will be restored once the vehicle starts moving or placed in park/neutral.<br /><br /> This condition does not affect vehicle durability and no additional diagnosis or service is required for this condition at this time. Inform customers that they can continue to drive the vehicle and engineering is currently working on a solution for this condition that is expected in Q4 2026. Replacement or reprogramming of any components will not resolve this condition. Monitor Professional Technician System (PTS) for additional information and schedule service appointments for customers once the repair becomes available.<br /><br /> If the vehicle exhibit

For Various Ford and Lincoln vehicles, if diagnostics lead to the replacement of the front seat cushion cover J-clips, lower-level service parts are now available. Use service part W709919-S901 if the J-clip is completely detached from the seat cover and W715386-S424 if the clip is still partially attached. It is not necessary to replace the seat cover if only the J-clip is separating from the cover. Refer to PTS Home > Technical Assistance > Technical Support Videos > Section 501- Body and Paint > Seat J-Clips. For claiming, use causal parts from list below and labor operations 63100A and 63100A5. Causal Parts for claiming: Bronco/Bronco Sport/Escape/Explorer/Expedition/Navigator: 7862900 or 7862901 F-150/F-Super Duty: 1562900 or 1562901 Ranger/Maverick: 6062900 or 6062901

This bulletin supersedes 26-2194. Reason for update: update the Parts list to correct a part description " Loctite 638", update the claim quantity for the drain/fill plug, update the claim quantity of the wheel hub bolts (Corsair) and limited the parts list for Edge/Nautilus to only the rear drive unit fluid. Some of the vehicles listed in the Model statement above may exhibit all of the following conditions:  Shudder chatter condition, most noticeable at low speeds turning  No relevant diagnostic trouble codes (DTCs) present This may be due to internal rear drive unit (RDU) fluid contamination.