2021 Ford Bronco Sport: fuel pump failure

Filed Oct 23, 2025 · Fuel system · TX

After Ford completed Recall 25S76 on my 2021 Ford Bronco Sport (VIN [XXX] ), which involves replacing high-pressure fuel injectors due to the risk of cracking and fuel leaks, the check engine light returned immediately after the road test. The Ford dealer’s diagnostic confirmed: “After installing high-pressure fuel injectors, cleared codes, road tested and check engine light came back on, performed further P/P test, found high-pressure fuel pump with internal fault which caused a back-pressure concern and took out low-side fuel pump.” The high-pressure fuel pump and low-side fuel pump both failed immediately following the recall injector replacement, which appears to indicate a related fuel-system failure. Ford has stated these are not related issues and has only offered partial goodwill assistance, leaving a significant cost for the customer. Component/system that failed: Fuel system – high-pressure fuel pump and low-side fuel pump (available for inspection). Safety risk: A fuel-system failure can cause stalling or loss of power while driving, increasing the risk of an accident. Confirmed by dealer: Yes – documented in the Ford dealer’s diagnostic notes. Inspected by manufacturer: Yes – Ford dealer completed the diagnostic under Ford’s guidance. Warning lamps or symptoms: Check engine light returned immediately after recall work. No prior symptoms before recall repair. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Jul 13, 2025 · Electrical, Engine · FL

Since I have bought this used vehicle in September 2024, it has been shutting off completely with having to restart the engine. There was a recall for the battery in January 2025 that was finally approved to be replaced maybe in May or so. Battery was replaced but it keeps shutting off. I just took it in July 7 for the fuel pump to be replaced as they said that was the final cause. I drove it home the same day when it was finished and it has been shutting off still. It has shut off while I have been at the light, in reverse and as well as putting my vehicle into reverse by itself which could cause an accident. This situation has since be unresolved. I have taken it to the ford dealership with them many times with them saying there is nothing wrong with it.

Filed Apr 17, 2025 · OR

The vehicle sometimes ran a little rough while idle at drive thru. Then week later the push start did not work... engine turned over but not start. After 6 times it finally started and ran good on way home. Later that week, kept having traffic lights in town turn red... constant slow so stop and go. Vehicle started sputtering and stalled out in the highway and died in middle of road and would not start. Had to let it sit several minutes and it finally started. We immediately turned around and went home. Made appointment at dealership. Tried to start vehicle to drop off for appointment but would not start. Had towed in. They claim fuel pump replacement required. Drove home and ran ok. Next day power inconsistent and runs rough at start and slow speed with one push start did not work. Reporting since my spouse is in a wheelchair and can not walk. This vehicle is only one we have that my spouse can get in due to disability and I am seriously concerned if vehicle stalls out on public highway again it is likely to result in an accident and he gets seriously hurt. Never had a vehicle I felt unsafe to have my family be in before and do not think it is safe for this vehicle be on the highway.

Filed Aug 18, 2024 · Electrical, Engine · OH · fire

On 1/23/24, car was serviced for an electrical fault with the fuel pump control module which was confirmed via a vehicle alert. On 6/12/24, car was serviced for a software update recall. (I believe this was in relation to the fuel injector issue.) On 7/4/24, the car would not start but kept clicking trying to start. White smoke started coming out from under the hood. Panicked, we called the fire department and my niece's husband disconnected the battery so that the car would quit trying to start in an effort to mitigate a full fire. We could smell burning and fuel. The fire department even confirmed something smelled like it had burned but there was no active fire, so they told us to leave the battery disconnected and have it towed. I had the car towed to the dealership for $249. (Of which Ford only reimbursed me $140) My car sat for 2 weeks before Ford service confirmed the fuel injectors needed to be replaced as part of the 22N18 recall, but also said the battery was bad. Prior to this incident, I had 0 issues other than the issue in January. I had no notifications of battery issues in my app, no dimming of lights, etc. I had to pay over $300 to replace the battery so Ford could do "further testing" since I was a month out of the 36 month warranty. I picked up my car on 7/26/24 and when I started it in the bay, I smelled burning and even asked a different employee who confirmed he smelled it, and we were told by the manager that it was "old fuel burning off." He assured me the car was fine. I noticed my car being slow to start and having an odd issue whenever I turned, like a rubbing sound and it still had a burning smell even though I had to pay Ford to replace the cabin air filter. This was all new. Then, 8/18/24, my car again would not start, all the electrical lit up and the brakes were locked up. My car started smoking again under the hood as it kept trying to start. We could hear sounds like it was trying to start. Again, car is being towed to Ford.

Filed Jun 12, 2024 · Electrical, Fuel system · MN

Our 2021 Bronco just suddenly died while driving. We were in a parking lot, moving, and it just quit. The Bronco would not restart and on the display screen it said "requires a manual start". It was not the battery, and the engine sounded like it was flooded. Thankfully, we were in a parking lot and not driving very fast. While we were waiting for a tow for over an hour, and we got the car to start and were able to drive it home. We called Ford, and their only response was if it happens again to let them know. It happened again a couple weeks later. This time while driving on a road going about 30 mph. We were lucky and able to glide into a parking lot. It was very scary because it just died. We called Ford and made an appointment to have it checked out. We were charged $1117 to replace the fuel pump ($1000 was for labor). When I questioned why a fuel pump would go bad when the vehicle is only two years old. The response was "cars aren't built like they used to be". I want our experience documented as we were very lucky that we were not injured when our vehicle died while driving. Until these incidents, there was no indication that there was anything wrong with the vehicle. We have learned that this has happened to other people as well when we Googled it. It is a huge safety concern. We now have received a Ford notice about a safety recall describing the exact issues we experienced.

Filed Apr 5, 2021 · Fuel system · 1,449 miles · NY

The vehicle stalled [halted] on my daughter while in motion in moving traffic. The vehicle became inoperable and was towed to depaula ford albany ny. The vehicle stalled as a result of a faulty fuel pump and only has 1449 miles. My daughter could have been injured as a result of the vehicle disablement in flowing traffic on a busy city street. Fuel pump replacements are a "substantial defect" that impairs the car's use, value, and most important safety. This is a serious safety defect to the fuel and emission system. Fuel pump problems are typically mileage dependent issues. You typically need to have at least 60k miles on the average vehicle before the fuel pump starts to give out also, if a vehicle's fuel system is at the point where fuel pump replacement is necessary, it is 10 times likely other components are faulty: electrical connections, fuel injectors, clogged fuel filters, etc. So typically other important components are swapped out at the same time with that being said, the ford dealership advised the exhaust clamp wasn't tightening correctly so they ordered a new clamp and are putting it on tomorrow. I'm not a mechanic but I have common sense to know this is a component other than the a fuel pump. My daughter is to pick up that vehicle tomorrow and I am very concerned for her safety in this brand new vehicle under 1500 miles! We have kindly asked ford for a vehicle replacement but I also wanted to inform other avenues because I am concerned for my daughters safety in this current vehicle. The vehicle was purchased for peace of mind and right now we are unsettled! It should immediately be taken off the streets and taken back to the ford lab for assessment; if this the first ever issue like this for the 2021 bronco sport respectfully [xxx] on behalf of [xxx], owner of vehicle indian - [xxx] parts of this document have been redacted to protect personally identifiable information pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6).