Ford Bronco Sport fuel pump problems

Filed Jul 13, 2026 · Fuel system · CA

We were driving in the middle of nowhere between [XXX] and [XXX] and the fuel system shut down cuz the fuel pump failed with a quarter of a tank left. We are stuck on the side of a narrow highway where the speed limit was 80 mph. Very scary. Every time we tried to start the car it would sputter and fail and the fuel warning came up not for lack of fuel but for a fuel pump issue. Software update was done the day before OTA. According to recall issues, fuel pump, cracks and failures have occurred many times and there are several recalls on that, but apparently our VIN is not included. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Mar 17, 2026 · Fuel system · LA · 1 injury

Fuel pump gave of emissions that came through the vents and caused me to loose control and the smell immobilized me. The Dr said it may be carbon monoxide as they did test in hospital for 5 days I was lucky my wife was driving in front of me to get me out

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 Apr 17, 2025 · Engine, Transmission · TN

On April 8th 2025 our vehicle went into "limp mode" for the third time in 6 months. The previous incidents were part of an active recall and we're repaired by a does dealership. This time it is supposedly the failure of a fuel pump sensor causing the issue (per ford service diagnosis) which they say is NOT covered by fords recall nor is it covered under any warranty and must be paid for out of pocket. This repeat occurrence has caused our vehicle to stall in traffic not just when at stops but also just when turning or pulling onto streets or highway. This has happened while crossing busy streets putting the lives of our family at RISK MULTIPLE times. Ford refuses to pay for rental vehicles while our vehicle has been in repair for this issue and also while the vehicle is in an unsafe condition to drive. This also causes undo hardship for our family as we are not able to pay for a rental vehicle for extended amounts of time while our vehicle is in an unsafe state. I am highly concerned that Ford is trying to "wash their hands" of this vehicle and avoid true remedy the overwhelming evidence of problems of these vehicles. I have included the previous invoices for the recall repairs that caused this. I have not yet received the invoice for the repair being done currently as of 4/17/2025 .There are additional safety issues we've encountered with the "safety features" of the vehicle that i will be submitting separately.

Filed Dec 16, 2024 · Fuel system · UT

Hello, I wanted to share an issue I recently encountered with my car. After coming back from a hike, my car stalled and took long to start. When it finally did start, the engine light came on, and I was unable to go over 20 miles per hour. I read the code, which indicated a problem with the fuel injectors. I ended up being stranded for about 5 hours in a blizzard until I could get help. I took the car to the Ford dealership, and they diagnosed the issue as a faulty high-pressure fuel pump and sensor, both of which need to be replaced. I purchased this car in 2023, and I’m very surprised that these components are failing so soon. This is not what I expected from a relatively new vehicle. There is a current recal for fuel injectors for my year and model but my car is not on the list.

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 Jan 17, 2024 · Fuel system, Transmission · NC

Fuel pump loose in gas tank. Ocassional smell of fuel in cabin when starting vehicle. RPMs stick at high levels occassionally.