2021 Ford Bronco Powertrain (other) Problems

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

My drive shaft/coupling caught fire at the front transfer case. I was able to extinguish it safely. This is the same description as: NHTSA Recall No.: 26V236 Manufacturer Recall No.: 26S26 And the description “ Vehicle 1: 2021-2025 FORD BRONCO‘ includes my vehicle, however, my VIN/license plate number do not show this recall in effect.

NHTSA ID

11736856

Incident

May 6, 2026

Component or system that failed or malfunctioned: The fuel delivery system, specifically the fuel pump, which is subject to an active safety recall. The recall states that fuel pump failure can result in loss of fuel pressure and flow, leading to engine stall. The vehicle is available for inspection upon request. How safety was put at risk: A sudden engine stall while driving would result in an immediate loss of propulsion and power, creating a significant risk of collision, particularly at highway speeds or in traffic. This creates a dangerous situation for the driver, passengers, and surrounding vehicles due to the inability to accelerate or maintain speed. Has the problem been reproduced or confirmed by a dealer or service center: The defect has been confirmed by the manufacturer through an official safety recall. At this time, there is no repair remedy available. The vehicle has not yet been repaired due to lack of an available fix. Has the vehicle or component been inspected: The vehicle has not yet been physically inspected for this specific failure because the recall remedy is not available. The defect has been acknowledged by the manufacturer as part of the active recall. Warning lamps, messages, or symptoms prior to failure: At this time, there is no warning indicating when or if the fuel pump may fail. The recall states the failure may occur without warning. No prior warning lamps or messages have reliably indicated when the failure could occur. Additional information: Due to the nature of this defect and the lack of an available repair, I no longer feel the vehicle is safe to operate. The uncertainty of a sudden engine stall has created ongoing safety concerns and financial hardship, as I am responsible for a vehicle that may fail without warning.

NHTSA ID

11714757

Incident

Jul 8, 2025

The contact owns a 2021 Ford Bronco. The contact received notification of NHTSA Campaign Number: 23V069000 (Power Train) however, the part to do the recall repair was not yet available. The contact stated that the dealer had exceeded a reasonable amount of time for the recall repair. The dealer was made aware of the issue and confirmed that parts were not yet available. The manufacturer was made aware of the issue and confirmed that parts were not yet available. The contact had not experienced a failure. Parts distribution disconnect.

NHTSA ID

11561097

Incident

Mar 10, 2023

The contact owns a 2021 Ford Bronco. The contact stated that with the vehicle in park and the engine running, the vehicle inadvertently shifted into drive and accelerated up a slight incline. Upon inspection, the contact observed that the gear selector was still in park(P). No warning lights were illuminated. The vehicle was not taken to the dealer or an independent mechanic. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 23V070000 (Power Train) however, the VIN was not included. The manufacturer was notified of the failure but referred the contact to the NHTSA Hotline for assistance. The failure mileage was 12,500.

NHTSA ID

11529771

Incident

Jun 30, 2023

Mileage

12,500 mi

The Axle Tubes are held to the center differential with 3 x Plug Welds per side. The plug welds on our axle are weeping oil and do NOT appear to be properly welded. Upon online comparisons this is a known issue and is resulting in catastrophic failures. Ford claims that "weeps" are NOT covered under warranty. A weep in this location/situation means that the welding process was sub-standard and compromised.

NHTSA ID

11524757

Incident

May 29, 2023

In November 2021, I received delivery of my new Ford Bronco 4WD Badlands vehicle. I went for a road trip with my family and friends in my new car. While driving back, the car engine light appeared on the dashboard, along with the service alert, and the car began to make noise. I pulled over and tried to restart the car, but it never started. We were in the mountains, where there was no signal for more than ten miles. We were completely stranded, along with my kids, who were 13 and 16 at the time, and one of my friends' 8-year-old daughter. We were fortunate to be with our friends and he was able to take us to a near-safe area where we could contact Ford and the dealership. After 5 hours of waiting in a safe zone, we received a towing truck. I picked up the car with the towing driver and parked it at a nearly Ford dealership. We had to book a hotel room in the area, and the next morning I went to the local Ford dealership to request an appointment to see the problem, but they said they didn't have any appointments available for another three weeks and insisted I call Ford customer service again. Ford customer service arranged for the same towing company that came last night to help haul the car to my dealership, where I purchased this car. My local Towne Ford dealership was nice enough to inspect and repair the car, but after a few days, I had a similar issue and they suggested that they replace the engine with a new one. The dealership took nearly a month to ship and repair the engine replacement. A few weeks ago, as my family and I were driving from SF to LA, my car suddenly lost power. I kept getting the message, "Powertrain Malfunction/Reduced Power fault detected," and later, "Service Engine Soon warning," which states that the engine control system has determined that the turbocharger is producing less boost than normal.It was shocking because I was on vacation with my family in LA, and the kids were terrified to even be in the car. this are some experiences

NHTSA ID

11487253

Incident

Nov 11, 2021

Transmission broke at 4,884 miles reversing out of the driveway. The driveway has no grade and never sits on a hill.

NHTSA ID

11465356

Incident

Apr 14, 2022