Ford Bronco engine failure problems

Filed Jun 16, 2026 · Engine, Transmission · ID

While operating the vehicle under load, the vehicle suffered a sudden and severe loss of engine performance, followed immediately by loud metallic banging from the engine bay. The vehicle lost all power and was immediately disabled (LIMP MODE), presenting an imminent highway safety hazard.The Physical Damage: Subsequent mechanical teardown revealed deep vertical cylinder wall scoring, heavy raw fuel residue in the engine oil pan, and a blown head gasket. Relationship to Active Safety Defect: This catastrophic block failure perfectly mirrors the progressive failure profile of the federal safety agency Campaign 25V455 / Ford Safety Recall 25S75 (Low-Pressure Fuel Pump Failure). Internal component degradation in the fuel tank delivery module dropped fuel pressure to the engine. Under turbo boost, this starvation induced an extreme, instantaneous lean-out condition. The resulting low-speed pre-ignition (LSPI) exploded and shattered the internal piston rings (the metallic banging), leading to mechanical wall gouging, unburnt fuel wash into the lower crankcase, and a secondary blown head gasket. Request for Action: Ford's current VIN parameters for Recall 25S75 have not yet captured my specific vehicle despite it matching the exact production window, component setup, and catastrophic failure sequence. I am requesting that the federal safety agency log this case as clear evidence of consequential engine destruction originating from the 25V455 pump defect, and evaluate whether Ford's recall scope must be expanded to protect other consumers from highway engine failures.

Filed Jun 16, 2026 · Engine, Transmission · ID

The Incident: While operating the vehicle under high load, the driver received an explicit "Service Engine Soon" powertrain malfunction alert stating: "The powertrain control module lost communication with the vehicle active grill shutter module for a period of time." Immediately following this warning, the engine experienced a severe loss of power, followed by loud metallic banging from the engine bay. The vehicle stalled completely and lost all motive power, creating an imminent highway safety hazard.The Physical Damage: Subsequent mechanical teardown by the dealership revealed terminal block destruction, including deep vertical cylinder wall scoring, heavy unburnt liquid gasoline residue in the engine oil pan, and a blown head gasket.Relationship to Active Safety Defect: This catastrophic engine failure mirrors the progressive failure profile of the federal safety agency Campaign 25V455 / Ford Safety Recall 25S75 (Low-Pressure Fuel Pump Failure). In this EcoBoost architecture, the Active Grill Shutter (AGS) module shares critical voltage paths, grounding blocks, and wiring looms with the engine management and fuel delivery systems. The sudden network communication loss is diagnostic proof of a severe voltage drop or electrical short caused by the high-friction fuel pump degradation detailed in Recall 25S75. This circuit failure instantly starved the engine of fuel under turbo boost, inducing an extreme lean-out condition. The resulting pre-ignition forces violently shattered the internal piston rings (the loud banging), which then gouged the cylinder walls, wiped out compression, fouled the crankcase with fuel residue, and blew the head gasket.Request for Action: Ford's current VIN parameters for Recall 25S75 have not yet captured my specific vehicle despite it matching the exact production window, component setup, and catastrophic failure sequence. I am requesting that the federal safety agency log this case as definitive evidence of consequential engine destruction originating from the 25V455 fue

Filed Jun 12, 2026 · Electrical, Engine · CA

Description On your vehicle, it may be possible that one or more engine camshaft roller finger followers were not properly installed at the time of engine assembly. Safety Risk An improperly installed engine camshaft roller finger follower may result in engine failure, resulting in a no-start condition or a loss of motive power. A loss of motive power increases the risk of a crash. Your vehicle may also experience engine ticking or tapping noise, and or a low-volume oil leak due to this condition. Remedy A remedy is not yet available. Ford Motor Company is working to provide parts for this repair. When the remedy becomes available, Ford Motor Company will notify you via mail to schedule a service appointment with your dealer for repairs to be completed free of charge. The remedy is anticipated to be available 4TH quarter of 2026. Next Steps Contact your dealer for more information to schedule the free service. NOTE: Recall service not available right now. We have a remedy but parts are not available right now. We will inform you when the service is available. Or, you can contact your dealer.

Filed May 22, 2026 · Fuel system · 25,000 miles · FL

The contact owns a 2020 Ford Bronco. The contact stated while driving at an undisclosed speed, the accelerator pedal was depressed, however, the vehicle failed to accelerate as intended. The check engine warning light illuminated and the engine seized. The contact stated that while attempting to start the vehicle, the vehicle failed to start as intended. The vehicle was towed to the residence. The mobile independent mechanic came to the residence, and the vehicle was diagnosed with a failed low pressure fuel pump. The contact was informed that the low pressure fuel pump needed to be replaced. The vehicle was not repaired. The dealer was made aware of the failure. The contact was informed that the parts were unavailable. The contact received a recall notification, the federal safety agency Campaign Number: 25V455000 (Fuel System, Gasoline) however the parts were unavailable. The manufacturer was not made aware of the failure. The failure mileage was approximately 25,000.

Filed Feb 18, 2026 · Engine · VA

A Safety Recall was issued on the vehicle with no remedy. The recall was in reference to the Engine Intake Valves and stated; "The engine intake valves may crack and break, which could result in loss of motive power and increase the risk of a crash". It also stated, " Prior to losing motive power, an engine malfunction indicator lamp may illuminate in the cluster and the driver may notice that the vehicle is running rough". This issue was the result of Ford manufacturing using a material that had "hardness issues". This all came out prior to the vehicle reaching the end of its warranty mileage. A test was required on the engine at the dealership at which time, the technician determined there was no need to perform the "recall test" (confirmed by video sent to us). On or around Dec. 17th, while my wife was driving the vehicle and entering a gas station, the check engine light came on, and the vehicle began losing power. She parked and immediately contacted the Ford dealership. They advised her to not drive the vehicle and have it towed to the nearest dealership (She was in Pennsylvania picking up our daughter from college). It was determined by the dealership in Pa. that compression in a cylinder was down 5% and the vehicle needed a new engine. We had the vehicle towed back to Virginia and inspected by the dealership who services the vehicle. Parts of the engine were removed for visual inspection at which time a crack intake valve was found, confirming the engine was no good. Also, confirming the issue Ford had stated in its recall. All information and pictures were sent to Ford manufacturing for determination on fixing the problem. Ford has said they will not cover the total cost to make good on their recall because the vehicle was out of warranty (miles were exceeded). How are consumers protected from manufactures taking advantage of mileage? The SAFETY recall was issued long before the warranty ran out. What if my wife had crashed w/ our daughter?

Filed Dec 17, 2025 · Engine · OK

Check engine light stayed on, constant. Code run showed cylinder 4 misfire. Bronco still under warranty so took to dealership. Mechanic said coolant was inside cylinder so he requested recommended remedy from Ford and would probably be engine replacement.

Filed Nov 25, 2025 · Brakes · AZ

The caliber seized causing the brake pad the fall and destroy the rotator. No brake indicators like turned on to advised of an issue. Ford does not want to take full responsibility for the faulty part that could have caused a major accident. Ford case# CXH06202259-S8K4B1. The vehicle is still at Ford for the repair so I don't have the repair documents yet.

Filed Aug 10, 2025 · Engine · OK · crash

Ford has issued a recall (24S55) stating the Intake valves on the ford bronco with engine2.7L and 3.0L will harden and crack or break and loss of power. I had the same issue in my 2021 Ford Bronco with the 2.3L engine while I was driving in the highway I got a check engine light then it started cutting out horribly so I slowed down to pull off the road through a metal gate that was open with a cattle guard and the engine died as I was turning in and loss power steering trying to turn the wheel back in time I didn’t and ended up side swiping the pole and knocking off my side mirror and damaging my front quarter panel along with the front door. No damage to the solid metal pole. But I took my vehicle to the local ford dealership to see what the issue was and at the time they should have gotten the recall and at least put two and two together and let ford know about the issue in the 2.3L also but they didn’t mention anything about the valve being broken but said it had no compression and the spark plug diode was broke off. I’ve never seen a diode and the diodes ground hook break off on its own it’s always been broken off from being hit by something but they said it needed a whole new engine for $13,000 so I took it to another mechanic since that’s always that dealerships go to answer for everything is it needs a new engine so the new mechanic did the same stuff and also used a bore scope but instead of just saying the cylinder was bad he seen the hole in the valve and said it just needs a new head with new valves so since I needed my ride to be able to get to work and for half the price they tore it down and sure enough the valve was cracked with a hole just as they said and just like the recall (24S55) but had that dealership paid attention to safety alerts and ran the issue up with ford and let them know the same issue had happened in the bronco with the 2.3L engines also I wouldn’t be writing this right now. I’d be putting a 5 star review on their page not a 1.

Filed Apr 18, 2025 · Electrical · 28,000 miles · PA · fire

The contact owns a 2021 Ford Bronco. The contact stated that while driving at an undisclosed speed, the electrical system and the engine seized. The contact noticed fire and smoke which exited from the engine compartment. The contact was the only occupant of the vehicle when the failure occurred. The fire department arrived and extinguished the fire. The vehicle was towed to the dealer. The vehicle was inspected and diagnosed with a faulty alternator. The contact was informed that the seized gears overheated the alternator motor, which caused the fire. The vehicle was repaired. In addition, the failure reoccurred. The contact stated that while driving at an undisclosed speed, the contact noticed smoke exiting the engine compartment. The vehicle was driven to the shoulder of the road. The contact stopped and parked the vehicle. The contact turned the vehicle off. The vehicle was started, however, the vehicle did not start. The contact stated several unknown warning lights were illuminated. The contact stated that when the failure occurred, the contact's wife and minor child were also occupants of the vehicle. The vehicle was towed to the dealer, where it was confirmed to have a failed alternator motor. The contact was informed that the alternator motor needed to be replaced again. In addition, the contact was informed that the seized gears in the alternator motor caused the fire. The vehicle was in the process of being repaired. In addition, the contact stated he was fearful of ever driving the vehicle again. The manufacturer was made aware of the failure. The contact requested a vehicle buyback. The failure mileage was approximately 28,000.

Filed Feb 24, 2025 · Fuel system · FL

While idling, the engine died. I attempted to restart several times with no luck. Battery was working, but engine would not start. Towed to Ford dealership and had to have the fuel pump replaced. Car had around 10k miles and recently went through an inspection.