2022 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 contact owns a 2022 Ford Bronco. The contact stated that while leaving the residence, the vehicle stalled on the highway. The driver was able to avoid a crash with a tractor-trailer. The check engine warning light illuminated intermittently, and a “Service Vehicle Soon” message was displayed. Additionally, there was a tool symbol displayed on the instrument panel. The vehicle was towed to a local dealer, and the contact was informed that the part needed to perform the recall repair of NHTSA Campaign Number: 25V455000 (Fuel System, Gasoline); was not yet available. The manufacturer was not contacted. The failure mileage was approximately 75,000.

NHTSA ID

11756185

Incident

Aug 11, 2026

Mileage

75,000 mi

The contact owns a 2022 Ford Bronco. The contact stated that the vehicle had experienced issues with hardtop roof panels. The hatch was cracked, and the forward removable panel had developed bubbles. The contact stated that the front driver’s side panel was chipped and detaching, and the underside of the roof was visible. The contact associated the failure with NHTSA Campaign Number: 26V299000 (Structure); however, the VIN was not included in the recall. The dealer was contacted regarding the failure, and the vehicle was repaired under warranty. The manufacturer was made aware of the failure and stated that the roof panel was not under warranty. The failure mileage was approximately 19,073.

NHTSA ID

11755438

Incident

May 21, 2024

Mileage

19,073 mi

The contact owns a 2022 Ford Bronco. The contact received notification of NHTSA Campaign Number: 25V455000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available. The local dealer was contacted and confirmed the part to do the recall repair was not available. 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 had not experienced a failure.

NHTSA ID

11754752

Incident

Aug 4, 2026

The contact owns a 2022 Ford Bronco. The contact received notification of NHTSA Campaign Number: 26V468000 (Engine, Electrical System); however, the part to do the recall repair was not yet available. The contact stated that while his wife was driving 70 MPH uphill, the vehicle lost drive power. Several unknown warning lights were illuminated. The driver was able to pull over to the side of the road. The vehicle was towed to the dealer, where it was diagnosed and determined that the main wiring harness had dislodged, sat across the exhaust, and was burned. The dealer determined that the main wiring harness needed to be replaced, which required the temporary removal of several components. The contact was provided a repair estimate and was advised that the failure was not covered under the recall and that the vehicle was out of warranty. The vehicle was not repaired. The contact obtained a rental vehicle out-of-pocket. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was notified of the failure and informed the contact that partial assistance might be provided. The failure mileage was approximately 60,908.

NHTSA ID

11754712

Incident

Jul 24, 2026

Mileage

60,908 mi

Safety Defect – Inadequate Warning and Insufficient Time to Respond to Alternator/Charging System Failure I am submitting this safety complaint regarding a dangerous condition in my 2022 Ford Bronco involving the charging system and alternator protection behavior. While driving, a warning related to the charging system/battery appeared. The message lacked sufficient clarity and urgency. The time from the warning until the 12-volt battery was fully depleted was extremely short—too brief to safely identify a location and pull completely out of traffic. Once the battery died: • The vehicle could not be placed in neutral, preventing it from being moved out of the travel lane. • There was insufficient power to operate the hazard lights. This occurred on a busy highway, leaving the vehicle disabled in traffic and creating a significant safety risk. I was fortunate it happened in daylight. Had it occurred at night without functioning hazard lights, the likelihood of a catastrophic accident would have been high. This aligns with known alternator/charging system issues on 2021-2022 Broncos addressed in Ford Technical Service Bulletin TSB 23-2238 (superseding TSB 22-2392). The combination of an unclear warning, inadequate response time, loss of neutral capability, and loss of hazard lights presents an unreasonable safety risk. I request that Ford investigate this condition, provide a permanent remedy, and improve the warning strategy so drivers receive clear, timely notice with enough opportunity to reach a safe location.

NHTSA ID

11754647

Incident

Jul 27, 2026

The structural fuel line located on top of the fuel tank ruptured, causing highly pressurized fuel to actively spray directly toward the hot exhaust piping on my 2022 Ford Bronco (44,657 miles). This failure created an immediate, catastrophic, and potentially fatal fire risk to myself and others. There were no warning lamps, error messages, or prior symptoms leading up to this failure; the severe leak was only discovered after a routine, short-distance trip to and from a local grocery store. The vehicle and the failed component are currently available for inspection upon request. To date, the vehicle has only been inspected by myself and a local Ford dealership. The dealership visually confirmed the leak but improperly misdiagnosed the structural line failure as "rodent damage" without providing any supporting physical evidence. However, multiple online owner forums suggest this specific fuel line failure is a known, systemic manufacturing concern. I escalated this issue to Ford Customer Service (Case #CXH-08762672-F7N2Y7), but Ford denied the warranty claim based solely on the dealership's misdiagnosis. My documented physical evidence clearly shows a component manufacturing rupture, not outside damage.

NHTSA ID

11754458

Incident

Jul 26, 2026

The hard top is cracking and letting water into the cargo area. It seems to be right outside the parameters for recall number 26S32. Talk to dealer over a month ago and have not heard back yet.

NHTSA ID

11754241

Incident

Jun 3, 2026

There is a recall on this vehicle (25S75), issued on July 8, 2025. As of the date of writing this, there is no remedy available. This is a safety issue, and the fact that it remains unresolved over a year later, is completely unacceptable. The NHTSA site says to file a complaint if the issue is not remedied in a timely manner, and this is certainly not a timely remedy.

NHTSA ID

11753797

Incident

Jul 8, 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.