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.

- POTENTIAL FUEL PUMP FAILURE WHILE DRIVING - MAJOR CONCERN WHILE OPERATING VEHICLE FOR MYSELF AND FOR CHILDREN AND ELDERLY PASSENGERS - YES - YES BUT NO SOLUTION AVAILABLE - NO

NHTSA ID

11755232

Incident

Aug 6, 2026

There is multiple anti lock braking faults that pop up while driving and then go away the next time the vehicle is used. Brake fluid, pads, rotors and calipers all seem to spec and are working at the moment, but major concerns with the software or possible release and reengagement of the emergency brake.

NHTSA ID

11754883

Incident

Aug 5, 2026

Fuel pump.has low pressure therefore making vehicle stop running completely. Has happened twice , once while driving on highway. This is extremly dangerous to have your vehicle just come to complete dead stop in middle.of road. FORD has no remedy to fix and now i am without a car I am paying for since it wont start now.

NHTSA ID

11754851

Incident

Aug 3, 2026

Corrosion of the entire spare tire carrier mount

NHTSA ID

11753780

Incident

Jul 30, 2026

Persistent highway-speed vibration (45 to 82 mph) present since July 2022, documented at five Ford dealerships between 21,000 and 100,000 miles, and still unresolved and undiagnosed after four years. It is a whole-vehicle shake felt primarily through the seat and from the rear of the vehicle at highway speed, occurring on highways nationwide (documented in [XXX], [XXX], and [XXX]). Wheel and tire causes were controlled for and eliminated: three complete wheel-and-tire set swaps (two on factory stock sets) did not change the vibration; a dealer road-force balance (08/2024) did not resolve it; it persists while coasting in neutral. On XXX an independent facility (Heritage Auto Solutions, [XXX]) road-tested and lift-inspected the vehicle and identified objective anomalies at the rear driveshaft: an abnormal welded balance-weight cluster and visible play at the slip yoke; the facility recommended replacement. The shaft is currently at an independent driveline facility for balance testing; the root cause of the vibration has NOT been definitively confirmed by any facility. That is the safety concern: a sustained, unresolved vibration consistent with a driveline-area defect at 70+ mph, present for four years, with no dealer ever performing an instrumented driveline diagnosis. A driveline component failing at highway speed is a loss-of-control hazard. Ford has issued driveline field actions on this platform (Customer Satisfaction Program 22B27, front driveshaft, noise/vibration; Recall 26V236, transfer-case misalignment, possible loss of drive power). The manufacturer was formally notified in writing of the independent findings on XXX (Ford case XXX) and has not responded as of XXX. Attached: the independent facility's written report and driveshaft photographs. The vehicle is currently out of service. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11751184

Incident

Jun 26, 2026

Component or system that failed/malfunctioning:Climate Control System / Rear Passenger Cabin Ventilation.Is the component available for inspection?Yes, the vehicle and the climate control system are completely intact, unaltered, and available for physical inspection upon request.Description of Incident & Safety Risks:There is little to no airflow reaching the rear passenger seating area of the vehicle. The 4-Door 2021 Ford Bronco relies entirely on hidden, under-seat floor ducts to regulate back-seat temperatures, as it lacks center console or upper B-pillar vents. Under normal operation, the air reaching the back row is severely restricted, leaving the rear cabin isolated from proper climate regulation. My safety and the safety of others have been severely put at risk during travel. Because of the near-zero airflow, the rear passenger compartment quickly traps extreme ambient heat or freezing cold. This environment is highly unsafe for vulnerable occupants riding in the back seat—specifically young children, elderly family members, and animals—who cannot properly regulate their body temperatures and face an immediate risk of heat exhaustion, heatstroke, or hypothermia. Additionally, the lack of air circulation creates a critical safety hazard by causing severe fogging on the rear side windows, obstructing driver blind-spot visibility and increasing crash risks.Dealer/Service Confirmation & Manufacturer Inspection:The problem has not yet been confirmed by a Ford dealer or independent service center, nor has the vehicle or system been inspected by the manufacturer, police, insurance representatives or others. The vehicle remains exactly as it was when the issue was identified.Warning Lamps, Messages, or Prior Symptoms:There were absolutely no dashboard warning lamps, digital error messages, or physical symptoms prior to this issue. The lack of adequate airflow is a continuous condition.

NHTSA ID

11750401

Incident

Jul 12, 2026

It has now been 1 year since the recall 25V455 was issued for my 2021 Ford Bronco. I use my Bronco for business but due to the recall, it has been unable to be used due to legal reasons in my state. I have lost thousands of dollars from the vehicle sitting and Ford continues to fail to provide a timely remedy. The date of the recall being issued has been pushed back over a dozen times and now shows "no eta". They have no communication with their dealers as to what the delay is and Ford Customer Service will not disclose anything other then "we will notify you when it becomes available". This delay, lack of communication and constant failure to uphold recall release dates are causing undue financial burden on my business and Ford displays a glaring lack of caring to get this issue resolved. Dealerships are likewise frustrated as they are bearing the front of peoples questions and anger regarding the recall fix but Ford does not communicate anything with them. I am formally demanding that Ford be held accountable toward being transparent with their customers. Provide timely and transparent updates on the progress toward the recall fix and ensure that progress is actually happening. In addition, I have in my possession a 2023 Bronco's fuel pump that is a newer design that Ford has been installing in their 2023+ Bronco's. This new design is not affected by the recall and fits into my 2021 Bronco without modification. Ford has proven that they have a fix as they are installing it in new Bronco's from 2023+. When I ask if I can install a unaffected fuel pump into my 2021 Bronco to get the recall cleared, I am denied. That is unacceptable.

NHTSA ID

11748607

Incident

Jul 8, 2025

Ford has failed to remedy RECALL 25V455 issued OVER 1 YEAR AGO !!!!!!!! My fuel pump failed in August of 2025 and left me (single female) stranded on side of interstate highway in 100' heat. Dealer confirmed in-tank fuel pump failed and replaced with another recalled pump. There was no warning that failure was happening until vehicle stopped in traffic. Had over 1/4 tank of gas at the time. Afraid to drive vehicle out of town because it could strand me again. Can not trade in vehicle because open recall reduces value of vehicle

NHTSA ID

11747918

Incident

Aug 22, 2025

Some 2021-2026 Bronco vehicles may require the removal and installation of the transfer case for various reasons. Installation requires Loctite® 243 adhesive applied to the mounting bolt threads in the transmission. Make sure that the mating faces are clean and dry. Tightening the mounting bolts also requires an updated two-stage tightening sequence. Workshop Manual (WSM), Sections 307-07C/D and 308-07C/D Installation > Transfer Case have been updated to reflect this change.

Some 2021-2026 Ford/Lincoln vehicles may exhibit various symptoms including but not limited to the auto start/stop system not operating as intended with a "Check Charging System" message in the instrument panel cluster (IPC) while the charging system is operating properly with no charging related diagnostic trouble codes (DTC) stored. This may be due to someone using an aftermarket programmer to change the body control module (BCM) configuration to disable the auto start/stop system or perform other unsupported programming modifications. To correct this condition on F-150 and Bronco vehicles, download and run the Ford Diagnosis and Repair System (FDRS) application titled "BCM-Charging System Configuration Correction". Running this application will determine if the BCM configuration was modified by the customer and if so, provide the option to return the configuration back to factory settings. For other vehicle models exhibiting concerns related to unsupported aftermarket BCM programming, submit a Technical Support Request (TSR) requesting support to revert the BCM configuration

Some 2021-2024 Ford and Lincoln vehicles may exhibit an "Updating SYNC" message on the vehicle center display screen after an over the air (OTA) update. The message can be cleared from the center display screen and SYNC can be used normally, but it will re-appear at every subsequent ignition cycle. Inform customers that engineering is currently working on a software update solution for this condition to be delivered OTA expected in late Q3 2026. Software will update automatically if vehicle connectivity is enabled in the vehicles settings. Monitor Professional Technician System (PTS) for additional information.

Some 2021-2026 Bronco vehicles may exhibit a "Park Brake Limited Function Service Required" message in the instrument panel cluster (IPC). This may be due to an issue with the driver door harness connector after removing and installing the removeable doors. If diagnostic trouble code (DTC) B1625:29 is stored in the driver door module (DDM), inspect connector C322C between the upper and lower door hinges that attaches to the body for proper installation and/or pin fitment. Repair as necessary. If the condition was caused by improper door installation, do not submit a claim for this condition. If no concerns are found with the connector, refer to Workshop Manual (WSM), Section 501-11 > Diagnosis and Testing for normal diagnostics.

NEW VEHICLE DELIVERY HOLD - Emissions Recall 26E04 Certain 2021-2025 Model Year F-150, Maverick, Mustang, Ranger, Expedition, Bronco Sport, Explorer, Bronco, Navigator, and Aviator Vehicles Powertrain Control Module Software Update

This article supersedes 25-2551. Reason for update: to correct the descriptions for the liftgate glass weather seals. Some of the vehicles listed in the model statement above may exhibit paint wearing along on the top inner edge of the tailgate where the rear window weather strip contacts the tailgate. This may be due to the accumulation of dirt between the rear window seal and tailgate.