Ford Bronco Sport Fuel System Problems

Fuel System complaints by model year

Which parts fail

• Delivery › Fuel pump
  2
• Fuel injection system
  2
• Storage › Evaporative emissions › Canister
  2
• Delivery › Fuel pump › Control/drive module
  1
• Delivery
  1

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

Mileage when the problem started

• Under 25k
  1931%
• 25k–50k
  2033%
• 50k–75k
  1118%
• 75k–100k
  813%
• 100k–150k
  35%
• 150k+
  00%

What owners report

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 NHTSA 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. …

Our 2024 Bronco Sport Outer Banks, 1.5 liter engine, purchased new from a Ford dealer 11/2024, serviced at the dealership and driven less than 14k miles, was destroyed by a spontaneous fire 3/22/2026. After driving 12 miles, we parked in a parking lot. Upon exiting the car we noticed a burning smell and saw small plumes of steam or smoke coming from under the car hood. Within a minute a red/orange disc of heated metal became visible on the hood surface as flames came from under the hood. Seven minutes later the fire department arrived extinguishing the fire. The car was destroyed. There were no warnings of any kind. The events suggest a cracked fuel injector. Even though 15 foot flames engulfed the car it was parked and unoccupied, there were no injuries. The results of the investigation have not been reported to us. CCTV footage was obtained from the police.

The contact owns a 2023 Ford Bronco Sport. The contact received notification of NHTSA Campaign Number: 25V467000 (Fuel System, Gasoline); however, the part to do the recall repair was unavailable. The contact stated that the manufacturer exceeded a reasonable amount of time for the recall repair. The contact stated that after filling the fuel tank and driving approximately 70 MPH, they noticed a fuel odor coming from the vehicle. After parking the vehicle for approximately 40 minutes, they returned to the vehicle that had been on fire. The fire department was contacted, which had put out the fire. The vehicle was towed and totaled. The fire had caused damage to the grounds on which the vehicle was parked. There was fuel contamination and burned areas in the yard and on the porch near where the vehicle was parked. There were no injuries. …

The contact owned a 2023 Ford Bronco Sport. The contact received a notification of NHTSA Campaign Number: 25V467000(Fuel System, Gasoline); however, the part to do the recall repair was not yet available. The contact stated that while driving approximately 73 MPH, the vehicle experienced an unknown failure 16-18 minutes later. Based on the contact's memory, the vehicle caught on fire, rolled down an embankment, crashed into a tree and came to a stop. It was unknown whether a warning light was illuminated. All the air bags deployed. The contact stated that while the vehicle was burning, the contact's legs were trapped due to the impact of the crash. The local rescue squad arrived at the scene and assisted the contact out of the vehicle. The rescue squad transported the contact to the ambulance, which transported the contact to the hospital. …

The contact owned a 2022 Ford Bronco Sport. The contact stated while driving at 70 MPH, the vehicle experienced abnormal gear shifts. Additionally, the contact noticed a gasoline odor and a burning plastic odor coming from the A/C vents. The contact stated that upon depressing the brake pedal to come to a complete stop at the stop sign, the vehicle failed to respond. The message "ABS Failure " was displayed, and several unknown warning lights were illuminated. The contact stated that he then veered to the left while there was oncoming traffic. The contact stated that he attempted to stop the vehicle by depressing the brake pedal, shifting to park (P), and engaging the electronic parking brake, but the vehicle failed to respond and was driving at 40 MPH. The contact then noticed smoke and fire coming out from underneath the hood, and the front end of the vehicle was engulfed in fire. …

The contact owned a 2022 Ford Bronco. The contact stated that while driving approximately 20 MPH, while in a line of traffic and preparing to make a right turn onto another street, the contact noticed black smoke coming from under the hood of the vehicle and spontaneously there were flames coming from under the hood. No warning light was illuminated. The contact stated that a nearby good Samaritan dialed 9-1-1 and the local Fire Department arrived on scene to extinguish the flames. A Police report was filed; however, the report was unavailable. The contact sought medical attention for minor smoke inhalation. The vehicle was towed by a towing company at the request of the Insurance provider and remained at the tow lot. The vehicle was inspected; however, the source of the fire was not identified. The vehicle was deemed a total loss by the Insurance provider. …

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.

Related recalls (6)

NHTSA investigations