Ford Bronco Sport grinding brakes problems

Filed Nov 3, 2026 · Brakes · MT

While driving, an severe and persistent rear brake resonance defect occurs during braking operations. The defect manifests as high-frequency vibration, loud grinding, and low-speed brake shudder/chatter from the rear braking system, impacting vehicle control and braking predictability under normal driving conditions. The affected component is the complete rear brake assembly, which is currently installed on the vehicle and available for inspection upon request. Safety is compromised due to diminished braking feel, driver distraction, severe auditory and tactile resonance during deceleration, and unpredictable pedal performance during low-speed maneuvers and stopping intervals. The defect has been repeatedly reproduced and formally confirmed by an authorized dealership service center over multiple repair attempts. Servicing included the execution of Technical Service Bulletin TSB 25-2438, which failed to remedy the issue. The issue was formally escalated to and evaluated by the vehicle manufacturer. The manufacturer’s Global Technical Assistance Center (GTAC) evaluated the vehicle and documented in writing that no further technical or engineering procedure exists to resolve or cure the recurring rear brake resonance. Symptoms first appeared during normal operation at approximately 17,000 miles, presenting as severe rear brake grinding and resonance without prior dashboard warning lamps or system error messages. The hardware defect remains active and unrectified.

Filed Oct 9, 2026 · Transmission · TN

Rear differential makes grinding noise. Repaired by Ford in 10/24 but grinding has returned.

Filed Oct 4, 2026 · Engine, Fuel system · NJ

On about 5 or 6 occasions over the course of one year, my brand new 2025 Ford Bronco Sport with the Big Bend trim with the VIN number in this report has completely lost engine power with severe engine hesitation with a highly rhythmic / even-patterned computer-controlled-like clicking and severe engine shaking (!!!) and a near stall while traveling from anywhere between 5 and 50 mph and the speed grinds down to a crawl, because it most often happens on an incline (maybe once on flat ground, and never downhill), and either way can be extremely dangerous! Fuel tank was full or half full on every occasion. Oil changed every 5k miles. Luckily at the higher speed, I was on a quiet hilly state highway road. I suspect it can happen at any speed though, which makes it even more dangerous! It is as if fuel stopped getting to the engine in these cases, or a computer failure in the fuel system, but I can be completely wrong about the cause. It is impossible to recreate on command obviously, being that it only happened 5 or 6 times over the course of one year, so neither myself or the dealer can recreate it on command. I complained about it to my local dealer that I bought it from, but they said they saw no codes stored, and of course couldn't recreate it. They suggested I got bad gas, but it has happened this many times. Impossible. It began happening at about 5k miles most noticeably. I currently have 12k or so on it. It's not like a throttle body or any injector or fuel system should be so dirty to cause this at the vehicle's age. No way. This is extremely dangerous. The dealer will not investigate further. Note: When this problem doesn't occur, then engine seems to run well, which leads me to think it is a fuel system / pre-engine problem, if I had to guess. I will include the first most noticeable date. I was driving much more in the first few months of the vehicle, but I let the car break in at speeds below 60 for the first 500 miles or so. I use 87 or higher octane.

Filed Sep 3, 2026 · Fuel system, Transmission · 41,000 miles · PA

The contact owns a 2022 Ford Bronco Sport. The contact received notification of the federal safety agency Campaign Number: 25V467000 (FUEL SYSTEM, GASOLINE); however, the part to do the recall repair was unavailable. The local dealer and manufacturer were contacted. 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. The contact had not experienced a failure associated with the recall. The contact stated that while turning at slow speeds and while turning while in reverse, the vehicle was vibrating and shaking abnormally with a loud grinding sound. The vehicle was taken to the local dealer and was diagnosed with rear differential failure. The contact was informed that the rear differential needed to be replaced. The vehicle was not repaired, and the contact was informed that parts were not available. The contact was concerned that the rear differential failure might cause the vehicle to become inoperable. The manufacturer was notified of the failure and confirmed that parts were not yet available. The failure mileage was 41,000.

Filed Aug 28, 2026 · Brakes · DC

Brake components showing signs of failure at 28,000 miles on both front and rear brakes. Safety placed at risk given speed and general use of vehicle which includes passengers. This includes grinding stops, increasing foot pressure used to stop car, and under certain conditions reconsidering use of vehicle. Ford dealership inspected vehicle and is aware of issue and noted TSB (T25-2438) in service visit diagnosis. No warning lights present. Signs first appear as increased brake dust covering rim and tire areas, increasingly loud grinding and squealing of brakes whether in drive or reverse. No remedy provided by Ford despite low mileage and understanding that the issue is not normal wear and tear on vehicle.

Filed Jul 8, 2026 · NC

All my husband purchases is mainly Fords and he has for over 20 years. The last 3 Fords we have purchases from years 2019-2025 have had the same issues. My husband had a 2019 Ford Escape that broke down on us in the mountains. Had to have transmission replaced twice before 100,000 miles. Then he got a 2020 escape and same thing plus a motor replaced..now I have a 2022 bronco sport outer banks and they claim I need transmission replaced and rear end differential. I was quoted $15,000. That is almost as much as my car is worth. I am outside the "warranty" window. The dealership was rude about it because we didnt purchase our Ford with them directly stating they are loyal to their customers who purchase with them first. We have been loyal to ford for so long and now losing faith! I can in no way possible afford that much money! I bought it because I thought it was the safe option for my daughter and for me taking her to school. This car is not safe to drive at all! I had to drive it home from dealership because I cant afford to fix it and now I am without. How am I suppose to drive my kid to school in something that is shaking and grinding like that? This is not the first ford we have had to do it but we remain loyal!

Filed Jun 12, 2026 · Suspension, Transmission · 90,000 miles · FL

The contact owns a 2021 Ford Bronco Sport. The contact stated that there was an abnormally loud grinding sound detected while driving, reversing, and turning the steering wheel. There was no warning light illuminated. The vehicle was taken to two independent mechanics, who related the failure to a recall. The mechanics referred the contact to the dealer. The contact referenced the federal safety agency Campaign Numbers: 21V011000 (Power Train), 21V074000 (Suspension) and 21V075000 (Suspension). The vehicle was taken to the local dealer, who confirmed there were no open recalls. The dealer diagnosed and determined that the rear clutch needed to be repaired. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 90,000.

Filed May 7, 2026 · Brakes · CO

The front and rear brake system has repeatedly malfunctioned across at least 7 dealer visits since 2022 on my 2021 Ford Bronco Sport (VIN: [XXX] ). Brake squealing and grinding (particularly in reverse at low speeds) have persisted despite multiple repair attempts. Ford's own SSM 52515 acknowledges engineering was working on a fix and that rotor resurfacing is "not a guaranteed fix." TSB 23-2308 was performed in March 2024 (caliper bushings/guide pins replaced). In June 2024 a dealer verbally confirmed a brake recall was coming in Oct/Nov 2024 and that rotors would be covered — that recall never materialized. Front brake pads were replaced under Recall 21C31 in September 2022 at ~8,797 miles. Front pads and rotors required full replacement again in April 2025 at ~28,833 miles — just 20,000 miles later and well below the typical 50,000–70,000 mile service life — at my out-of-pocket cost of $747. Rear brakes were documented as "in the red" in January 2026 at ~38,000 miles. The vehicle is currently at a Ford dealership. In August 2024, one dealer attributed the issue to driving habits despite Ford's own TSBs acknowledging the defect. Brake wear across both axles is abnormally premature for a [XXX] vehicle. Across brake-related and recall visits the vehicle has been out of service for approximately 30 days. Relevant: TSB 23-2308, TSB 25-2143, SSM 52515 INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed May 1, 2026 · Transmission · IL

I have 130,000 miles on my 2021 Ford Bronco sport. With no warning I'm unable to put vehicle in gear. I attempt to put the car into drive, then reverse and it will not go. The gear gets stuck in park, but unable to park, The car instructs me to intiated emergency park with many warning lights appearing. when driving it jerks , make grinding noises, and I even lost momentum. Ford said the help line states they have attempted to fix the codes and replace the parts on the inside of the transmission and no luck. Ford recommends a new transmission. I believe the 2021 Bronco sport have a faulty transmission and replacing with another will result with the same issue due to the transmission being a close system it isn't preventable. Many other owners have experienced this very same safety issue and Ford should address ot and be responsible.

Filed Apr 28, 2026 · Fuel system, Transmission · NY

Since purchasing the vehicle, I have had ongoing issues: a rattling noise when accelerating, a squeaking noise in reverse, and a fuel odor. The fuel injector recall (the federal safety agency 25V467) is still open, and Ford has not provided a remedy." Keep it simple and focused on the recurring noise and the recall.