2021 Ford Bronco Sport Fuel System Problems

Which parts fail

• Delivery › Fuel pump
  1
• Delivery › Fuel pump › Control/drive module
  1
• Fuel injection system
  1
• Delivery
  1
• Storage › Evaporative emissions › Canister
  1

Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).

Mileage when the problem started

• Under 25k
  629%
• 25k–50k
  419%
• 50k–75k
  314%
• 75k–100k
  629%
• 100k–150k
  210%
• 150k+
  00%

Owner reports

Selected complaints filed with NHTSA by 2021 Ford Bronco Sport owners, lightly cleaned up (personal details are redacted by NHTSA).

The contact owns a 2021 Ford Bronco Sport. The contact stated that while her husband was driving at 60 MPH and entering the base at 15 MPH, the overheating message was displayed. The driver pulled over, and the light turned off. After exiting the vehicle, he noticed the vehicle had caught fire. The driver disconnected the battery. There were no reported injuries. Another driver stopped with a fire extinguisher to assist with putting out the fire. The fire department was able to extinguish the fire. The vehicle was towed to the local dealer, but the vehicle was not diagnosed or repaired. The contact stated that the failure was related to NHTSA Campaign Number: 25V467000 (Fuel System, Gasoline). The manufacturer was contacted, who initially was sending an inspector but changed to viewing the photos. The failure mileage was approximately 80,000.

The contact owned a 2021 Ford Bronco. The contact stated that while driving at an undisclosed speed, the contact noticed smoke coming from the front of the vehicle. After pulling to the side of the road, the contact noticed that the engine compartment had caught fire. The fire was extinguished by the Fire Department. A fire report was filed, but a fire report number was not provided. The cause of the fire had not yet been determined. A police report was not filed. The contact received notification of NHTSA Campaign Number: 25V467000 (Fuel System, Gasoline). The dealer was not contacted. The vehicle was not diagnosed or repaired. The vehicle was destroyed. The manufacturer was made aware of the failure, and a case was opened. The approximate failure mileage was 83,000.

The contact owned a 2021 Ford Bronco Sport. The contact stated that while driving at 55 MPH, the vehicle inadvertently drove off the roadway and caught fire. The fire started from the front of the vehicle. The air bags were deployed. The contact sustained a broken hip, injuries to her pelvis, left clavicle, and right rib, as well as a head injury causing a minor brain bleed. Medical attention was received. The fire department arrived on the scene and extinguished the fire. A police report was filed. The contact was unaware if a fire department report had been filed. The vehicle was towed to an unknown location, where it was deemed totaled by the insurance company. The failure mileage was approximately 30,000.

The contact owns a 2021 Ford Bronco Sport. The contact stated that the vehicle was jerking while shifting into gear, while making turns, and while coming to a complete stop. There was no warning light illuminated. Additionally, the contact stated that the vehicle rolled after shifting into park(P). The vehicle was taken to the dealer to be test-driven. The dealer informed the contact that no issues were found; however, the failure reoccurred. The contact stated that while the vehicle was at the dealer for a brake recall repair, the dealer informed her that the vehicle was experiencing transmission failure; however, the mechanic could not determine the cause of the failure. The vehicle was not repaired. The contact later received notification of NHTSA Campaign Number: 22V859000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available. …

2921 FORD BRONCO SPORT HIGHWAY 14, Santa Clarita CA Driver noticed another car pointing to the Bronco's hood frantically. As the Bronco slowed, the driver noticed flames coming out of the sides of the hood on both sides. Driver pulled to shoulder of highway and the driver and passenger VERY QUICKLY got out and moved approx.. 100 feet behind vehicle to safety. Flames very quickly engulfed the entire Bronco. 911 was called by driver. Santa Clarita Fire Department responds in 10 minutes. THERE WERE NO INJURIES. The fire burned for about 30 minutes and COMPLETELY DESTROYED THE VEHICLE Towing/Wrecker company was called to remove destroyed vehicle. Tow truck driver provided transportation of passengers to the Freeway Towing Company in Santa Clarita. Freeway Towing held the destroyed vehicle at their lot. …

The contact owns a 2021 Ford Bronco Sport. The contact stated that after refueling and starting the vehicle, the front of the vehicle was shaking abnormally. The contact stated that while driving the vehicle the shaking ceased. The local dealer was contacted, and a service tech was sent to repair the vehicle under NHTSA Campaign Number: 24V267000 (ELECTRICAL SYSTEM, POWER TRAIN) however, the abnormal shaking returned. There were no warning lights illuminated. The contact stated that the abnormal shaking persisted, and the contact waited for the shaking to cease before the vehicle was taken to the local dealer to be diagnosed. The contact was informed that the transmission needed to be replaced, and the engine needed some undisclosed repairs. The vehicle was not repaired. …

The contact owns a 2021 Ford Bronco Sport. The contact stated that the check engine warning light illuminated. There was an abnormal odor of exhaust fumes inside the vehicle. Initially, the driver thought it emerged from other vehicles; however, a passenger smelled exhaust fumes, became sick, and vomited once the driver pulled over. The Ford mobile app failed to display any failure codes. The contact related the failure to NHTSA Campaign Number: 25V467000 (Fuel System, Gasoline). The vehicle was taken to a local dealer, where diagnostic trouble codes for the engine were cleared. The fuel vapor was purged, and the valve was replaced; however, the failure recurred. The vehicle was then taken to an independent mechanic shop, where it was diagnosed that the catalytic converter was fractured. The catalytic converter was replaced, and the fuel injector was serviced. …

The contact owns a 2021 Ford Bronco. The contact received notification of the NHTSA Campaign Number: 22V859000 (Fuel System, Gasoline) however, the part to do the recall repair was not yet available. The contact stated while driving at approximately 55 MPH, several unknown warning lights were intermittently illuminated and the Back Over Prevention screen turned white. The contact stated that the vehicle communication error message was displayed. The contact was able to navigate the vehicle off the road. The contact notified Ford's AAA for towing however, the tow truck never showed up. The contact then notified the local authorities. The local authorities notified a tow truck, and the vehicle was towed back to the residence. The manufacturer was notified of the failure and confirmed that parts were unavailable. The contact was advised to continue driving the vehicle. …

The contact owns a 2021 Ford Bronco Sport. The contact stated that while driving at an undisclosed speed, the vehicle lost motive power, stalled, and then failed to restart. The loss of power train message was displayed. The vehicle was towed to the local dealer where it was diagnosed that the battery and control module needed to be reprogrammed. The vehicle was repaired. The manufacturer was not contacted. Additionally, the contact received NHTSA Campaign Number: 22V859000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available. The local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. VIN tool confirms parts not available. The failure mileage was approximately 3,500.

The contact owns a 2021 Ford Bronco Sport. The contact stated that on several occasions while attempting to start the vehicle, the vehicle failed to start-up with several unknown warning lights illuminated and flickering. The contact received notification of NHTSA Campaign Number: 25V467000 (Fuel System); however, the part to do the recall repair was not yet available. The vehicle was towed to the dealer, where it was diagnosed and determined that the fuel injector and catalytic converter had failed and needed to be replaced. The dealer confirmed that parts for the recall repair were not yet available. The vehicle was not repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the failure. The approximate failure mileage was 90,200.

Related recalls

Fuel System complaints in other Bronco Sport years