2021 Ford Bronco

On July 29, 2024, the Office of Defects Investigation (ODI) opened PE24019 to investigate complaints of low-pressure fuel pump failures in MY 2021 Ford Bronco vehicles. Some consumers reported that the failure occurred without warning while driving, resulting in a complete loss of motive power with no ability to restart the engine. Ford determined that several other vehicle models contain low-pressure fuel pumps substantially similar to the 2021 Ford Bronco, including the 2022-2023 Ford Bronco, 2018-2023 Ford F-150, 2022-2023 Ford Expedition, 2019-2023 Lincoln Navigator, 2020-2023 Ford F-250-F-550, 2024 Ford Super Duty Chassis Cab, 2024-2025 Ford Ranger, 2020-2023 Ford Explorer, 2020-2023 Lincoln Aviator, and 2021-2025 Ford Mustang. ODI's investigation found that the affected vehicles may lose fuel pressure and flow from the fuel delivery module (consisting of a low-pressure fuel pump, jet pump, reservoir, and other parts) due to a low-pressure pump failure. This can cause the engine to stall while driving. The root cause is reduced internal clearance in the fuel pump, increasing friction and sensitivity to vapor lock. Fuel blockage from contamination inside the jet pump also contributed to the failure. Ford stated that the contamination source was unknown. On July 7, 2025, Ford filed recall 25V-455 for certain 2021-2023 Ford F-550 SD/F-450 SD/F-350 SD/F-250 SD, 2021-2022 Lincoln Navigator, 2021-2022 Ford Mustang, 2021-2022 Ford F-150, 2021-2023 Ford Explorer, 2022 Ford Expedition, and 2021-2023 Ford Bronco vehicles produced between July 1, 2021, and July 30, 2022. The recall also included certain 2021-2023 Lincoln Aviator produced between July 1, 2021, and December 21, 2022. Ford explained in its recall filingthat the production dates used for the recall were based on changes in the manufacturing process. Specifically, Ford determined that in June 2021, the supplier modified the jet pump manufacturing process, producing fuel pump chambers with a lower-than-specified internal clearance. In July 2022, the supplier implemented corrective actions to the manufacturing process by adding two additional vacuum pumps to reduce contamination during the production of the jet pump. ODI has identified approximately 1,000 reports involving vehicles covered in this investigation but excluded from recall 25V-455. However, even with such reports, these vehicles experienced comparatively lower failure rates than the vehicles that are subject to Recall 25V-455. Ford has explained that these vehicles were excluded from the recall population because they did not experience the manufacturing changes that prompted the recall. Specifically, according to Ford, vehicles built before July 1, 2021 (the recall production start date), were not affected by the supplier’s change to the jet pump manufacturing process. Even after closing this investigation, ODI will continue to monitor complaints for vehicles excluded from recall 25V-455 to consider whether they exhibit the same risks as the vehicles encompassed by the recall. The recall remedy is currently under development. In view of Ford’s recall action, ODI is closing this Preliminary Evaluation, but will continue to monitor the issue as a remedy is developed and implemented. ODI will 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 July 22, 2022, the Office of Defects Investigation (ODI) granted a Defect Petition (DP22001) and opened a Preliminary Evaluation (PE22007) to investigate allegations of loss of motive power in model year (MY) 2021 Ford Bronco vehicles equipped with 2.7L EcoBoost engines. Complainants were reporting sudden engine failure while driving resulting in a loss of motive power, often without the ability to restart. During PE22007, the cause of engine failure and loss of motive power in the subject vehicles was determined to be intake valve fracture, and the full scope of vehicles affected by the subject defect was identified as all MY 2021-2022 Ford and Lincoln models equipped with either the 2.7L or 3.0L EcoBoost engines, referred to as the “Nano” engine family.  If an intake valve fractures in the subject engines, it may drop into the cylinder and contact the piston, often resulting in catastrophic engine damage. On September 29, 2023, PE22007 was upgraded to an Engineering Analysis (EA23002) to further investigate the subject defect across the full scope of affected vehicles. During EA23002, ODI visited Ford facilities to review technical information related to intake valve fracture in “Nano” engines, coordinated with NHTSA’s Vehicle Research and Testing Center (VRTC), and analyzed updated field data relating the subject defect. Forensic analysis of fractured intake valves demonstrated that the defective components exhibited “grinding burn” or out of specification hardness in the area of the keeper grooves. The presence of grinding burn is evidence that during the groove grinding phase of production, the temperature of the valve became sufficiently high to alter the microstructure of the material and is indicative that the valve supplier’s manufacturing processes were not within control specifications. Grinding burn results in a hard, brittle microstructure and high residual stresses toward the surface of the valve. Through normal engine loading, a valve with grinding burn will likely fracture at the area of highest vulnerability, which is the third keeper groove. In its response to the EA23002 Information Request (IR) letter, Ford provided evidence of 396 customer complaints (including field reports), 825 warranty claims, and 936 engine exchanges. When considering both ODI and manufacturer failure report data, there have been reports representing 1066 unique vehicles within the subject vehicle population. Analysis of the failure report data demonstrates that vehicles equipped with potentially defective intake valves were built within a production “spike period” of May 2021 – October 2021. The beginning of the spike period corresponds to a ramp up in production at the valve supplier manufacturing facility, and the end of the spike period aligns with the implementation of several mid-production process improvements and the decision to change the metal alloy used to produce intake valves from “Silchrome Lite” to “Silchrome 1”. Ford began investigating the subject defect in July 2021, determined the root cause, and took corrective measures for the new production vehicles. Analysis of the failure report data demonstrates that these corrective actions were successful in eliminating the risk of intake valve fracture for subject vehicles produced after October 2021. However, Ford did not take any field action to address vehicles produced during the spike period, and in the several months following the implementation of the production changes, a significant number of field failures continued to occur. It is Ford’s assessment that not all valves produced during the spike period are defective, and that failures associated with the subject defect occur at low time in service. Analysis of the failure report data demonstrates that the vast majority of failures have occurred before 20,000 miles with over half of all reported failures occurring before 5,000 miles. The rate of reported failures related to the subject defect has steadily decreased since November 2021. ODI coordinated with NHTSA’s National Center for Statistics and Analysis (NCSA) to conduct statistical analysis and predict the number of future failures associated with the subject defect. The results of this analysis, and the trends identified through the failure report data are generally consistent with Ford’s assessment that defective intake valves will likely fail at a low time in service and indicate that the majority of subject vehicles equipped with defective valves have already experienced a failure. On August 23, 2024, Ford submitted recall 24V635 for subject vehicles equipped with “Nano” engines and built within the production spike period identified above (total population 90,736 vehicles). The remedy includes an inspection at a Ford/Lincoln dealership where the lifetime engine cycles of the vehicle will be determined. If a vehicle does not meet a threshold for lifetime engine cycles, the dealership will conduct a high RPM engine cycle accumulation procedure, which aims to identify if the vehicle is equipped with defective intake valves. Any vehicle that fails the accumulation procedure will receive an engine replacement under the recall. In addition to recall 24V635, Ford has stated that it will launch customer satisfaction campaign 24N12, which will provide extended warranty coverage to the subject vehicles through the earlier of 10 years or 150,000 miles. In view of the recall action being taken by Ford, ODI is closing this Engineering Analysis. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

The Office of Defects Investigation (ODI) received a petition dated March 16, 2022, requesting an investigation regarding allegations of defective intake valves in model year (MY) 2021 Ford Bronco vehicles equipped with the 2.7L Eco-boost (“Nano”) engines.  The petitioner alleged these vehicles are experiencing loss of motive power at any highway speeds with no-restart as a result of catastrophic engine failures.  To date ODI is aware of 42 submitted Vehicle Owner Questionnaires (VOQ’s) alleging a loss of motive power. On July 22, 2022, ODI opened a Preliminary Evaluation (PE22-007) to investigate allegations of stalling/loss of motive power on the subject vehicles.  Upon receiving Ford’s Information Request (IR) response, ODI learned Ford was aware of 110 consumer complaints (including field reports), 125 warranty claims and 136 engine exchanges related to the 2021 Ford Bronco.  Ford’s response indicated these failures are across the “Nano” engine family, which includes both the 2.7L and 3.0L EcoBoost engine variants with a total estimated population of 708,837 vehicles. Additionally, ODI became aware that the subject engines contained intake valves that were manufactured out of a specific alloy known as “Silchrome Lite”, which can become excessively hard and brittle if an over-temperature condition occurs during machining of the component. The overly brittle intake valve can fracture at the keeper grove causing the intake valve to freely contact the piston, resulting in catastrophic engine failure.  A design modification was implemented in October 2021, which changed the intake valve material to a different alloy known as “Silchrome 1”, that is less susceptible to over-temperature during machine grinding. ODI is upgrading this PE to an Engineering Analysis (EA23-002) to better understand the failure mechanism identified by Ford and to ascertain the complete scope.  To review the reports cited in the attached Closing Resume ODI Report Identification Number document, go to NHTSA.gov

The Office of Defects Investigation (ODI) received three petitions on March 17, March 18, and March 29, 2022, which requested a defect investigation into an alleged defect of the valves on model year (MY) 2021 Ford Bronco vehicles equipped with the 2.7L Eco-boost engines. The petitioners alleged that MY 2021 Ford Broncos vehicles are experiencing loss of motive power at highway speeds with no-restart due to catastrophic engine failures.On May 27, 2022, ODI opened this Defect Petition to evaluate whether to grant or deny the petition.ODI has identified 26 Vehicle Owners Questionnaires (VOQs) that relate to the alleged defect in the subject vehicles. Based on ODI's review of the applicable materials, including VOQs, NHTSA has decided to grant the petition and open a Preliminary Evaluation (PE22-007) to assess the scope, frequency, and potential safety-related consequences of the alleged defect.Accordingly, this Defect Petition is closed.The ODI complaints cited above can be reviewed at NHTSA.gov under the following ODI numbers:11448171, 11448461, 11450659, 11450702, 11450737, 11450788, 11450871, 11450879, 11451158, 11451503, 11451957, 11452074, 11452692, 11453669, 11453933, 11454098, 11455294, 11456219, 11456713, 11459262,11460124, 11460125, 11461178, 11463199, 11463296, 11464516.

[XXX] notice oil leak Left side turbo [XXX] an appointment with Mavis for an oil change. Technician notify me that he sees an oil leak by the left side turbo. Maybe his technician tells me to bring him back to the dealership [XXX]. I drop it off at Ford Haley Brothers for service. [XXX] service department calls me valve cover is leaking work is perform [XXX] pick up vehicle from Healey Brothers from [XXX] through [XXX] notice a blue smoke coming from my exhaust by [XXX]. I returned back to Healey Brothers. I was consuming so much oil they notify me that one of the turbos was the cause of it the 2021 Ford bronco Badlands has 85,000 miles on it for a turbo to go bad that fast impossible. It is my daily driver. I’ve maintain all the oil changes Maintenance so far on this vehicle my concerns why so fast the turbo would go with 85,000 miles on it. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11775458

Incident

Oct 7, 2026

My car would not start. Turns out it was the fuel pump/filter low pressure recall issue. It was towed to the dealership and has been there since without a remedy from Ford, despite the recall being released over a year ago. Absolutely ridiculous that my vehicle is being held hostage because the manufacturer has not come up with a remedy.

NHTSA ID

11769227

Incident

Jul 3, 2026

I am concerned about the hard top for my Bronco. There are cracks showing above the furthest back window on the passenger side, and above the same window on the driver's side. And when it rains, it leaks in the very back, causing the carpet to get wet under the rubber mat and smell like mildew. I did request a Ford dealer to document the cracks when I had some recalls completed.

NHTSA ID

11766598

Incident

Sep 24, 2026

Loss of fuel pressure from fuel pump failure

NHTSA ID

11766132

Incident

Jul 8, 2025

The engine block may develop a coolant leak which could cause a short circuit while the engine block heater system is plugged in - increasing the risk of an underhood fire

NHTSA ID

11766130

Incident

Oct 15, 2025

The contact owns a 2021 Ford Bronco. The contact received notification of NHTSA Campaign Number: 25V455000 (FUEL SYSTEM, GASOLINE); however, the part to do the recall repair was unavailable. The local dealer was contacted, and it was confirmed that the part was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue.

NHTSA ID

11765821

Incident

Sep 21, 2026

I contacted my Ford dealership, and they informed me that the recall is not currently showing as applicable to my VIN. Because my vehicle is experiencing similar issues, the dealership recommended that I contact Ford directly to have my vehicle and VIN reviewed. I would like to request that Ford review my vehicle to determine whether it may be affected by the same issue and whether my VIN could potentially be included in the affected vehicle population. My vehicle intermittently displays a “Check Brake System” warning, with the red brake warning light remaining illuminated. I have also experienced intermittent changes in braking, particularly when initially applying the brakes, where the brake pedal feels harder than normal and requires increased effort to slow or stop the vehicle. This is meaningful overlap between what I am experiencing and the recall description. Now I’m being told to reach back out to Ford, which I’ve done, or file a claim which is this

NHTSA ID

11758618

Incident

Aug 10, 2026

The contact owns a 2021 Ford Bronco. The contact stated that while driving at an undisclosed speed, the vehicle jerked and lost motive power. No warning light was illuminated. Additionally, the vehicle experienced unintended acceleration while driving. The lane departure feature also steered the vehicle in the opposite direction while there was construction on the road. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 68,000. The VIN was not available.

NHTSA ID

11758268

Incident

Jun 1, 2025

Mileage

68,000 mi

Some 2021-2026 Bronco vehicles equipped with a hard top may exhibit water leaking between the back glass and hard top. This may be due to dirt and/or debris build up between/on the liftgate window glass seal and/or back glass. To correct this condition, use an approved cleaner according to the Owner's Manual to clean the back glass and/or hard top rear cap seal and check for water leaks again. If water leaks are still present, refer to Workshop Manual (WSM), Section 501-18B for normal diagnostics and repair as necessary outside of this article. For claiming, use causal part 78205G61 and labor operation MT55301SSM up to 0.5 hours.

Some 2021-2023 Bronco vehicles equipped with a MT88 manual transmission may exhibit no 3rd gear engagement and/or a grinding noise going into 3rd and/or 4th gear. This may be due to the 3rd/4th gear shift fork. To correct this condition, replace the following parts: <br /><br /> *3rd gear (MU7Z-7101-A)<br /> *3rd/4th gear synchronizer assembly (MU7Z-7124-M)<br /> *4th gear synchronizer ring plate (MU7Z-7M157-A)<br /> *3rd/4th gear shift fork (TU7Z-7230-A)<br /> *All other one-time use parts as instructed by Workshop Manual (WSM), Section 308-03<br /><br /> Refer to WSM, Section 308-03 > Disassembly and Assembly of Subassemblies > Input Shaft, Steps 1-5. Inspect and replace any other damaged parts as needed.<br /><br /> Note: 3rd gear is part of the input shaft. The 4th gear assembly is part of the output shaft assembly and does not require replacement, unless damage is found. In this transmission, 4th gear uses a synchronizer ring to align the synchronizer assembly with the gear during shifts.<br /><br /> For access to the target components, refer to WSM, Section 308-03 > Removal > Transmission and

This bulletin supersedes 26-2297. Reason for update: Add 2022-2025 Transit vehicles. Some of the vehicles listed in the model statement above equipped with SYNC4 may experience a blank center display screen or black center display screen after welcome animation. The rear-view camera will still function when shifting the vehicle to reverse under these conditions.

Some 2021-2024 Bronco vehicles may exhibit an illuminated red brake warning indicator with diagnostic trouble code (DTC) C0049:01 stored in the anti-lock brake system (ABS) module. This may be due to pin fitment at the brake fluid level sensor connector. To resolve this concern, replace the brake fluid reservoir and replace the brake fluid level sensor electrical connector C1052 with service pigtail wiring kit 3U2Z-14S411-BXAB. For claiming, use causal part 2L210 and labor operations 2140A and 2219D45WR.

Some 2020-2026 Aviator/Explorer/F-150/Bronco/Ranger vehicles equipped with a 2.7L or 3.0L (non-diesel) engine may need the front engine cover removed and reinstalled for various reasons. The Workshop Manual (WSM), Section 303-01 Engine > Removal and Installation > Engine Front Cover service procedure has been updated to include a new essential special service tool (ESST) guide pin alignment tool (303-1790) that is used to align the engine front cover to the engine block, preventing the O-ring seal on the engine oil galley feed tube from getting damaged during installation.

This article supersedes TSB 25-2575 to update the Parts list to add the applicable body wiring harnesses and underbody shield bolts. Some vehicles listed in the Model statement above may exhibit a "Sta-bar Disconnect Service Required" message in the instrument panel cluster (IPC) with any of the following diagnostic trouble codes (DTCs) stored in the chassis control module (CHCM): C103A, C1A99, C1B03, C1B07, C1B14 and/or B1A67. This may be due to water intrusion in the stabilizer bar wiring harness connector.