Ford Bronco Sport knocking problems

Filed Oct 1, 2026 · Electrical, Engine · MI

My 2022 Ford Bronco Sport exhibits severe engine knocking and low fuel pressure, which are primary symptoms of open safety recalls 24S16 and 25S76. On 9/29/26, Seelye Ford of Kalamazoo charged me $220.21 out-of-pocket for a powertrain recall system software update. They are now refusing to inspect the physical fuel injectors or complete the safety recalls unless I pay out-of-pocket to replace an unrelated push-to-start button module, holding a federal safety recall hostage. The vehicle continues to malfunction identically after their software flash, making it a severe stalling and fire hazard. It is currently stranded on the dealer's lot.

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 Jun 9, 2026 · Engine · 80,000 miles · PA

The contact owns a 2021 Ford Bronco Sport. The contact stated that while driving at an undisclosed speed on two separate occasions, the turbocharger became inoperable. The contact reported hearing a knocking sound coming from the engine at the time of the failures. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and advised the contact that the remedy was not available to complete the repair. The approximate failure mileage was 80,000.

Filed Jan 22, 2026 · Electrical, Engine · TX

Dear Texas Department of Motor Vehicles, I am submitting this letter in support of a Texas Lemon Law complaint regarding my vehicle, which has experienced repeated mechanical failures that substantially impair its use, value, and safety. The vehicle has been subject to multiple manufacturer recalls and remains in the repair shop at this time. It is available for inspection upon request. The vehicle has exhibited a persistent knocking sound from the engine or drivetrain area, intermittent loss of power, and a brake system defect in which the brakes stick unexpectedly. These conditions have continued despite multiple repair attempts by an authorized dealership, including repairs related to manufacturer recalls. These defects constitute a serious safety concern. The loss of power occurred while driving and created a hazardous situation by preventing the vehicle from accelerating as expected in traffic. The brake sticking condition impaired my ability to maintain safe control of the vehicle and increased the risk of sudden or unintended braking, endangering myself, passengers, and other motorists. The issues have been reproduced and acknowledged by the dealership, as demonstrated by repeated service visits. The vehicle has been inspected and repaired by the manufacturer’s authorized service center on multiple occasions. No inspections have been conducted by law enforcement or insurance representatives. Prior to and following recall repairs, the vehicle continued to exhibit symptoms including the knocking noise and intermittent power loss. Any warning lamps or dashboard messages are UNKNOWN. Because these defects remain unresolved after a reasonable number of repair attempts and involve safety-related systems, I believe this vehicle meets the criteria for review under the Texas Lemon Law. Sincerely, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Jan 9, 2026 · Engine, Fuel system · 23,099 miles · TX

The contact owns a 2024 Ford Bronco Sport. The contact stated that while starting the vehicle, there was a ticking sound coming from the engine compartment. There was no warning light illuminated. Additionally, while driving at an undisclosed speed, the contact smelled a fuel odor. The Mobile App indicated that the VIN was associated with the federal safety agency Campaign Number: 25V455000 (Fuel System, Gasoline); however, parts were not yet available for the recall repair. The vehicle was taken to a dealer, and a software update was performed related to the recall, but the dealer confirmed that parts were still not yet available. The dealer also informed the contact that metal shavings were found in the engine and that the engine needed to be replaced. The contact was also informed that the muffler had failed and needed to be replaced. The engine and muffler were repaired. The contact stated that the manufacturer exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the failure, and the contact was denied a buyback option for the vehicle. The approximate failure mileage was 23,099.

Filed May 7, 2025 · Electrical · 6,031 miles · OH

The contact owns a 2024 Ford Bronco Sport. The contact stated that the engine knock sensor and the oil pressure sensor failure warning lights were illuminated; however, the vehicle had not displayed any failures. The vehicle was taken to the dealer who diagnosed the vehicle and determined that the wires underneath the vehicle were defective due to bite marks. The contact stated that after the wires were repaired, the contact attempted to start the vehicle, but the vehicle failed to start. The vehicle was towed back to the dealer who determined that there were bite marks on the wires again. The contact was informed that the insulation on the wires were soy-based, and squirrels were chewing on the insulation. The wires were replaced again. The manufacturer was not informed of the failure. The failure mileage was approximately 6,031.

Filed Apr 16, 2025 · Transmission · 4,000 miles · AZ

The contact owns a 2024 Ford Bronco Sport. The contact stated that while driving 75 MPH, the vehicle started to lose power. The WRENCH symbol warning light was illuminated with a message of a failure with the power train displayed. The vehicle was taken to a dealer however, the dealer was unable to determine the cause of the failure. The dealer replaced the knock sensors, and a software update was performed. The vehicle was repaired; however, the failure persisted while driving for long distances. On another occasion, while driving from State to State, the wrench symbol warning light illuminated with the power train failure message displayed. The contact also received a notification on his cellphone. The vehicle was repaired by another dealer; however, the contact and the dealer expected that the failure could recur. The manufacturer was made aware of the failure. The failure mileage was approximately 4,000.

Filed Jun 20, 2024 · Transmission · OH

Knocking noise from rear end reported to Chapman Ford dealership service center approximately 1 year ago, unsure of exact date. Problem was reproduced and confirmed by dealership but unknown origin. On 6/11 Chapman Ford attempted to repair by completing TSB 23-2 335 Rear Diff Drain Tube replaced with New Rear Diff Fluid Drained and filled and drain plug replaced. Drove vehicle 11 miles home from dealership. During next drive of vehicle on evening of [XXX}, while backing out of the garage the rear differential was knocking louder and more frequently. Taken back to Chapman Ford on Wednesday 6/19 as they stated Monday morning when they opened and I call that was the earliest they could inspect the vehicle. Determined the rear differential now needs completely replaced. The vehicle is available for inspection at Chapman Ford, 1255 Columbus Ave, Marysville, Ohio as it will be there for at least a week awaiting the appropriate parts. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Apr 24, 2024 · Electrical, Engine · VA

On Saturday, [XXX], my 2021 Ford Bronco Sport with approx. 33,900 miles completely shutdown and lost all power to engine and accessories while driving the vehicle in traffic. It started making a ticking sound that could not be stopped, it could not be restarted, and no accessories to include hazard lights could be turned on. I had to call the police, as my daughter and I were in the middle of traffic and cars were honking at us and I could not move the vehicle nor signal that it had died. The police arrived and since I was blocking traffic they are required to initiate a tow (which I had to pay $150 for), since they will not risk waiting hours for individual roadside assistance to arrive. The car has been towed to Ourisman Ford in Alexandria, VA, where it still presently remains as their only solution was to recommend battery replacement. There was NO warning prior to losing all power while stopped at a traffic light. I easily could have been hit while I waited for the police to arrive without any way to signal to other drivers that my car was immobilized. Ford continues to be of little assistance. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Oct 3, 2023 · Electrical, Engine · FL

Bought 2021 bronco sport in Dec 21. Since my engine has stuttered and started to die. The panel starts falling as if it is sitting off. This is not the auto engine shut off while idling at a light issue. Upon starting the engine you can hear a ticking and on every certain revelation the vehicle will sputter and start to cut off. It has died on 2 occasions in my driveway, but not yet on the road. It will stutter and start to die almost always in idle, especially in park, but it will do it and stay losing power mainly while driving low speeds or when not pressing gas pedal. I received recall and was told part was not available and didn't know when it would be available and have never been told part was available, but miraculously my recall order was closed without parts ever being replaced. This is like mist of the 8 recalls on this vehicle. 6 recalls where made before the vehicle came off of the train car. 6 recalls were still active the night I drove off the lot AFTER SERVICE WAS CLOSED. My first service was flat spots in my tires from sitting in a train car in Florida heat for 3 months, no parts were replaced, feb and March of last year the recall was closed before my car was in the shop... My dealership is clearing recalls and not reels my vehicle. They are taking advantage of my mental disabilities.