Ford Bronco Sport engine failure problems

Filed Nov 4, 2026 · Engine, Fuel system · AZ

I am filing a safety complaint regarding my 2021 Ford Bronco Sport 1.5L and Ford Motor Company's handling of recall-related repairs. Beginning October 22, 2025, I repeatedly attempted to have the applicable recall work completed through two authorized Ford dealerships. The programs involved include: • Recall 24S24 – the federal safety agency 24V267000 • Customer Satisfaction Program 22N18 – the federal safety agency ID 10233848 Despite multiple dealership visits and Multi-Point Inspections, the work was not completed until November 4, 2026. During this period, my vehicle experienced significant loss of engine power, particularly when traveling uphill and at higher elevations. Powertrain warnings also appeared, creating potentially dangerous driving conditions, especially on highways where maintaining speed is critical. The vehicle is now experiencing a failing turbocharger and other major mechanical problems. My concern is that these issues were overlooked or not properly investigated during previous dealership inspections. Had the necessary work and inspections been performed in a timely manner, these problems may have been identified before my 60,000-mile factory warranty expired. I am now facing substantial repair expenses as a result. I contacted Ford Motor Company's corporate Customer Relations department but was told they could not help. My complaint is not simply about warranty coverage or repair costs. I am concerned about the safety implications of the vehicle's loss of power, the delayed recall work, and whether the recall remedies adequately address the underlying problems. I respectfully request that the federal safety agency review the recall history, investigate the reported loss of power and engine failures, and determine whether additional safety action or investigation is warranted.

Filed Sep 9, 2026 · Driver assistance, Electrical · CA

The contact owns a 2025 Ford Bronco Sport. The contact stated that while driving downhill on the freeway with the adaptive cruise control engaged, the transmission independently shifted into neutral, the vehicle lost power, and failed to accelerate as needed. The vehicle was pulled over to the side of the road and shifted back into drive. The contact exited the freeway, and the vehicle was towed to a dealer. The contact stated that the word “CANCEL” in orange was displayed on the instrument panel, and the vehicle went into LIMP Mode. The dealer was unable to duplicate the failure. The vehicle was not repaired. The engine had seized but was operating under reduced power.

Filed Sep 3, 2026 · Engine, Transmission · 111,000 miles · AZ

The contact owns a 2024 Ford Bronco Sport. The contact stated that while driving at various speeds, the vehicle lost drive power and failed to accelerate properly. The App notified the driver of the powertrain failure. The vehicle was taken to the dealer and was diagnosed with powertrain failure. The dealer replaced the knock sensor approximately 5 - 6 times but the failure persisted. The vehicle was taken to a different dealer, Ed Morse Ford Sierra Vista (100 AZ-90, Sierra Vista, AZ 85635); to be diagnosed, and the knock sensor was replaced. The second dealer had also replaced the engine twice, but the failure reoccurred while driving approximately 70 MPH, and the vehicle was coasted to the side of the road. The vehicle was towed to a third dealer, Jim Click Ford (6244 E 22nd St Tuscan AZ 85711). The dealer diagnosed that the fuel system and computer calibration had not been completed and corrected the issue. The following day, the powertrain failure reoccurred, and the vehicle was towed back to the third dealer. The contact was informed that the knock sensors and the powertrain control module needed to be replaced; however, the vehicle was still not running properly, and the dealer replaced the engine again. The vehicle was returned to the owner, and the powertrain failure reoccurred, and the vehicle was taken to the fourth dealer, Fairway Ford (2323 Laurens Rd, Greenville, SC 29607), who replaced the same parts as the third dealer. However, shortly after retrieving the vehicle, the engine lost drive power again. The dealer was contacted, and the dealer then referred the contact to another dealer. After speaking with the manufacturer several times, the contact reached out to the dealer and was informed that the manufacturer instructed the dealer not to make any additional repairs to the vehicle even though the vehicle had an extended warranty. The manufacturer was made aware of the issue and opened a case. The failure mileage was approximately 111,000.

Filed May 21, 2026 · Fuel system · 30,000 miles · TX

The contact owns a 2023 Ford Bronco. The contact stated while driving at 50 MPH, the accelerator pedal was depressed, however the vehicle failed to accelerate as intended. The service engine warning light illuminated and the engine spuddered. The engine seized. The contact stated while attempting to start the vehicle, the vehicle did not start. The dealer was made aware of the failure, and the contact was informed that the parts were unavailable. The vehicle was towed to an independent mechanic, however the failure was not duplicated. The manufacturer was not made aware of the failure. The failure mileage was approximately 30,000.

Filed Apr 23, 2026 · Electrical, Engine · AZ

On December 13, 2025, we drove to Flagstaff, Arizona from Tucson, Arizona, where we live. As we came into town, the Bronco began to lurch and seemed to have difficulty shifting. I managed to make it to the Babbitt Ford service center’s parking lot, where it seized and died altogether. It stayed at Babbitt Ford where they worked on it until February 3, 2026. They replaced the transmission at great expense. On Feburary 3, we drove it home to Tucson. The next day, February 4, it died in the road twice, once in a major intersection. The first time it eventually resarted. The second time it died completely and required a special tow truck because we couldn't even get it into neutral to roll. It was towed to Holmes Tuttle Ford where they kept it for a week but were able to eventually restart it. They had it for 5 days, ran a diagnostic and reset the system. They drove it for over 80 miles and couldn’t recreate the problem. Then on February 25, I drove to Phoenix. While in Phoenix, it again inextricably had trouble shifting, died and wouldn’t start. I then had it towed to Camelback Ford. On March 6, Camelback Ford called and said they ran numerous tests and still can’t pinpoint the problem and the vehicle still won’t start or shift into neutral.

Filed Apr 21, 2026 · Engine · IL

I own a 2021 Ford Bronco Sport Base (VIN: [XXX] ) equipped with the 1.5L EcoBoost 3-cylinder engine. I am experiencing a complete and repeated loss of engine coolant with no visible external leak. Upon inspection, air bubbles were observed rising through the coolant reservoir when coolant was added, indicating combustion gases are entering the cooling system through a compromised seal. On multiple occasions upon startup, sweet-smelling white smoke has been emitted from the exhaust, consistent with coolant burning in the combustion chamber. The vehicle has overheated as a result of coolant loss. These symptoms are consistent with the known 1.5L EcoBoost cracked engine block or head gasket failure defect affecting 2021 Ford Bronco Sport and 2020-2022 Ford Escape vehicles. I have been advised by a ford dealership mechanic that the vehicle is unsafe to drive due to the risk of engine failure and potential engine fire. The vehicle has been parked and is not being driven. I am filing this complaint as a safety concern given Ford’s history of engine fires related to this defect, which was the basis of recall 22S43 and ongoing federal class action litigation. I am requesting the federal safety agency investigate whether an expanded recall or additional consumer remedy is warranted for this vehicle. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Mar 16, 2026 · Engine · OH

Catastrophic engine failure. Sudden. Started my car in the morning. Engine was running rough. Drove about 1/2 mile, engine continued to get worse. Returned home. decided to get engine codes checked. Check engine lights did not come on until this incident. Couldn't keep engine running. Kept trying to restart. Heard weird noise in engine and engine seized. Car had 62,800 miles on it, just over the 5 yr/60,000 warranty. Had the car towed to local Ford dealership. They verified that the engine was seized and that I needed a new engine. They found a lot of coolant in the engine oil along with a lot of metal flakes in the oil. They called it a catastrophic failure and speculated that it could be piston or valve destruction. They did not tear down the engine to determine the cause. They wanted an additional $2,000 to do that. (I kept the old seized engine). This failure could leave the owner stranded and in a very unsafe situation. I don't know what this failure would do to the drivability of the vehicle in traffic or on the highway.

Filed Feb 8, 2026 · Engine, Fuel system · MI

On 12/22/2025, my fiancé and I purchased a 2022 Ford Bronco Sport from LaFontaine Ford in Lansing, MI. During the initial purchase, we were not aware of any recalls or vehicle defects with the Bronco Sport. Roughly one month later, the check engine light came on, and after a thorough vehicle inspection, we were notified that there was a recall on the vehicle in regards to bad fuel injector(s), and that we needed to bring the vehicle back to the dealership for a computer update. After dropping the vehicle off at the dealership, we were notified that the engine was blown due to a cylinder misfire as a result of a bad fuel injector. We were also advised that the dealership had already completed the computer update prior to our purchase and cleared out the codes (critical misfire). The negligence of the dealership put my fiancé in extreme danger with selling us a vehicle with a critical fault that could cause a vehicle fire! The problem still has not been remedied as Ford is asking up to pay $3,483.00 for a new engine with them covering $4,457.00. I believe all of this should be covered under the recall and/or powertrain warranty since this issue has been well documented with Ford Bronco's prior to us purchasing the vehicle.

Filed Jan 29, 2026 · Brakes, Electrical · WA

Since my car hit 40000 miles it has had nothing but issues. I've had it in the shop at least 10 times. My brakes went out while driving with my [XXX] old, I've had loss of power, smell of exhaust in the cabin for the last 3 months and dealership says it can't be fixed, yesterday I had complete engine failure while on the freeway. Stalled and wouldn't start back up for 5 min. The dealership has never fully fixed anything but has only updated the computer system. I feel very unsafe in this vehicle. We still owe on this vehicle so trading it in is not an option since its not even worth the down payment I put down. It has a fuel injector recall that can't be fixed yet due to not having the parts available. What are we suppose to do if we can't drive the vehicle and can't buy a new one. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Dec 30, 2025 · Electrical, Transmission · 53,000 miles · TX

The contact owns a 2021 Ford Bronco Sport. The contact received notifications of the federal safety agency Campaign Numbers: 25V019000 (Electrical System) and 25V467000 (Fuel System, Gasoline). The contact stated that while stopped at a traffic light, there was an abnormal sound coming from underneath the passenger-side of the vehicle, and the vehicle stalled. No warning lights were illuminated. The contact stated that approximately a minute later, the vehicle restarted independently. The contact stated that upon shifting to drive(D) and depressing the accelerator pedal, the vehicle failed to accelerate. The contact shifted to reverse(R), and the vehicle accelerated forward unintendedly. No warning lights were illuminated. The contact test-drove the vehicle in a parking lot, and the failure persisted. The contact stated that while the hand brake was off, the brakes failed to function and seized. The vehicle was towed to the residence, where the contact test-drove the vehicle, and the vehicle operated as intended. However, the contact was concerned about the failure, and the vehicle was towed to the dealer, where the recall repair of the 12-volt battery was completed, and the PCM software update were performed. Additionally, the contact was informed that the DTC codes found indicated that the transmission had failed. The transmission was not repaired due to cost. The contact picked up the vehicle and drove the vehicle back to the residence with no issues. The contact stated that the battery failed to function as intended, and the vehicle failed to start two days later . The contact stated that upon starting the vehicle on a separate occasion, the message "Parking Not Available" was displayed. In addition, the contact stated that the vehicle briefly lost motive power before slamming into gear while driving. The contact stated that the vehicle was taken to the mechanic shop of the previous owner for inspection most recently. The previous owner repaired the rear differentials; however, the failure persisted. The check engine warning li