What 664 owners told NHTSA about the 2021 Ford Bronco Sport Later Release

The vehicle was parked in my parking garage and rolled away causing a collision. There were no warning lights indicating an issue. The vehicle is currently sitting at a shop awaiting warranty paperwork for a transmission replacement that was done last year.

NHTSA ODI 11746222

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. Insurance company took possession of the destroyed vehicle on March 11 and is currently holding it at their location. In January the Bronco owner noticed the check engine light was on and took it to a Ford dealership in California to have it serviced. We have videos of the fire as well.

NHTSA ODI 11726002

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.

NHTSA ODI 11720708

This vehicle is subject to NHTSA Recall 25V467 involving potential fuel injector cracking and risk of fuel leaking onto the engine, creating a fire hazard. The recall status shows “Remedy Not Yet Available,” leaving the defect unresolved. While driving, the vehicle suddenly displayed an engine overheating warning and immediately entered limp mode, causing abrupt loss of power. The vehicle decelerated unexpectedly and was not able to maintain normal driving speed. This created a dangerous situation in active traffic and required a safety tow. The sudden power reduction could have resulted in a rear-end collision or loss of vehicle control. There were no prior overheating warnings immediately before this incident. The failure occurred abruptly. A warning message appeared at the time of the event, followed by limp mode activation. The vehicle had to be towed to a dealership for inspection. Given that the open recall involves fuel injector cracking and potential fuel accumulation near hot engine components, there is concern that the unresolved recall condition may be related to engine overheating and loss of power. The vehicle remains under an active fire-risk recall, yet no repair remedy is available. Owners are left operating vehicles with a known safety defect and no corrective action timeline. The defect has not been remedied because parts are not available. The vehicle was inspected by a dealership after the overheating event. The primary safety concern is the combination of an open fire-risk recall and a sudden overheating/limp mode event causing abrupt power loss in traffic, creating a serious risk of injury. Due to this open recall with no available remedy, the vehicle cannot be listed or rented on a peer-to-peer vehicle sharing platform, resulting in loss of legitimate income. The vehicle was previously eligible for use, but is now restricted solely because the safety recall remains unresolved without a repair solution. Owners are financially impacted.

NHTSA ODI 11717430

Car check engine light came on, I came home parked the car, in about 5 minutes the cars embarked in flames, the car burned down to the ground. The safety of my entire home (flames caught onto house) and neighbors home was at risk. The burning car was inspected by Fire Chief of Christiana Fire Company

NHTSA ODI 11713086

My passenger seat heater caught on fire, it was very scary but I was able to put it out with sugar after I pulled over and figured out where the smell was coming from. I took it to my dealer for an inspection but I feel as though they were just trying to cover their side of everything and said “the seat heater did not cause the fire unfortunately”. I am currently in contact with ford and my insurance company. My insurance so far just says they need to investigate more but also that my claim is closed so I’m honestly just at a loss and confused about that and will be reaching out to them again soon. There was no warning at all and I’m glad I caught it when I did because I had glasses cleaner in my passenger side door that is very flammable.

NHTSA ODI 11711488

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.

NHTSA ODI 11693691

The car seat was involved in an accident from the side where the child was sitting and inspector came out and stated child seat must be replaced for child safety.

NHTSA ODI 11667402

The contact owned a 2021 Ford Bronco Sport. The contact stated that while driving approximately 30-40 MPH and pulling out from a side street, the contact did not notice an oncoming vehicle, which crashed into the front driver's side of the vehicle, near the axle. The air bags failed to deploy. There was no warning light illuminated. The contact's vehicle contacted 911, and the emergency services arrived at the scene. The contact was transported to the hospital, where the contact was informed that she had sustained a butterfly twisted fracture of the humerus and radial nerve damage on the right hand. The contact underwent surgery. The vehicle was towed to a tow lot. The insurance company informed the contact that the vehicle would be totaled. A police report was filed. The dealer and the manufacturer were not notified of the failure. The failure mileage was approximately 65,000.

NHTSA ODI 11663043

I hit the start button on my car and it began to flicker lights and start over and over again then it started an electrical fire in the front of the vehicle. We had to quickly disconnect the battery to get it to stop trying to start. I took it to the dealer and they said it was a defective starter. If I didn’t have tools or if my car was in the garage I could have been asphyxiated or my house could have caught on fire.

NHTSA ODI 11652379

The car caught fire the morning of Dec 11, 2024 while the vehicle's owner was driving their children to school. There are photos and a fire report is being generated. The vehicle's owner and her children could have been killed. Early indications are that the fire was caused by the same faulty engine/exhaust system defect that the owner has been complaining to Ford about for years. It is assumed the fire report will confirm that. For the past two or more years the vehicle has been emitting exhaust fumes into the passenger compartment of the vehicle while driving. This has caused the vehicle's owner and her children to get sick and forced them to drive the vehicle with the windows down at all times even in cold weather. Ford's dealers have confirmed the problem several times, but either could not or refused to fix it. A summary of the vehicle's service history is included below: 35,662 miles Customer states inside of vehicle smells like exhaust. 37,431 miles Inside of vehicle smells like exhaust. 39,856 miles inside of vehicle smells like exhaust. confirmed customers concern found cat warped at mating surface to turbo replacement required. 46,832 miles Fumes getting inside the Cab, seems to be blowing in from vents. Misdiagnosed as blower motor electrical smell and missed broken catalyst. 47,300 miles Customer had car towed into shop stating car was shaking and smelled flumes inside the car. Verified concern that exhaust smell was present in car and loud noise was coming from engine, found catalytic converter had broken at flange to turbo causing exhaust leak. Recommend new catalytic converter, removed and replaced catalytic converter. Low pressure fuel injectors are leaking. Verified customer concern, found fuel seeping out of all 3 low side injectors, recommend injector replacement, remove and replaced all 3 low side fuel injectors, found no other leak at this time. Found injectors were leaking fuel. 47,829 miles Check engine light. Remove and replace purge valve.

NHTSA ODI 11631525

Since the purchase of the Bronco Sport in 2021, I have intermittently taken it in for required service. However, there have been times when I have had to take it in for hearing noise coming from when I make turns, and it sounded like my break pads were making the sound of wear. A recent report did address the break pad concern, and they were replaced. Intuitively something told me to check my fluid levels and the engine air filter, along with the cabin air filter. They both needed replacing, which I did on my own. The mechanic who put on my break asked me questions about the Bronco, I explained to him that I was having issues with take off, and have had to take it in for recalls since make the purchase. He asked me to open the hood. What he found was oil leaking around was oil leaking around my turbo. I was shocked. Because it had not been long since it was serviced. I was told to not drive it too far because there were reports of some Broncos catching on fire. When I would take it in to Town AND Country Ford, where it was purchased, they would tell me that they could not find anything wrong repeatedly, supposedly one of the recalls was fixed. Yet, I still hear the noise when I make turns. Another Ford dealership around the corner from where I live and I decided to take it there to see if I could get different results. No help. They have changed my oil I hope. Then there is Bates Ford in Lebanon, Tennessee. I have taken it there for oil change and informed them of issues. This is the last dealership who inspected the Bronco. They did not tell me about the oil leak. I drive 10 miles to work weekly. 100 miles every other month to visit elderly relatives. So, I have not put too much wear and tear on the Bronco and do not drive it hard. Please, If you are able to help in this area, it is much appreciated. I have 54,000 miles on it

NHTSA ODI 11615833

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.

NHTSA ODI 11609221

The contact owned a 2021 Ford Bronco Sport. The contact stated that while driving approximately 10 MPH the warning message "System Default, Battery" was displayed. After stopping to inspect under the hood the contact discovered smoke and flames were present coming from inside the engine compartment. The fire department was called to the scene and extinguished the fire. During the incident, the vehicle was destroyed. The vehicle was later towed to the local dealer who informed that the failure was caused by a faulty serpentine motor belt. The manufacturer was notified of the failure. A fire report was taken at the scene. The failure mileage was 142,000.

NHTSA ODI 11589602

The contact owns a 2021 Ford Bronco. The contact stated that while driving at 40 MPH during a rainstorm, the Lane Keep Assist System (LKAS) activated, after which the contact briefly lost control of the vehicle and the vehicle began to tailspin. The vehicle came to a complete stop after crashing into a barrier wall on the driver’s side. The air bags did not deploy. No warning lights were illuminated. The vehicle was not taken to the dealer or an independent mechanic. The vehicle was not repaired. A Police report was not filed. There were no injuries reported. The manufacturer was notified of the failure but provided no assistance. The failure mileage was 27,000.

NHTSA ODI 11589287

I was driving and the vehicle cut off completely. Lost all power and brakes and steering while driving. I hit the vehicle in front of me. The car would not restart. It got towed to the dealer. It has no power. The hazard lights would not even turn on and car could not be put in neutral to move. I was on a busy road so it was very scary while waiting on a tow truck.

NHTSA ODI 11586229

I was involved in an accident with a deer. It impacted my driver door. The impact and physical damage were minimal to moderate. However, at least 6 airbags deployed, totaling out the vehicle. There have been some recalls on 2021 Broncos for faulty airbag sensors. There was no recall on mine. Yet, I believe these sensors were faulty as it was a minor impact to the vehicle. As I had purchased this vehicle before inflated prices and inflated interest, my financial loss is great. Had at least 6 airbags not deployed, my vehicle would not be a total loss.

NHTSA ODI 11559576

The contact's mother owns a 2021 Ford Bronco Sport. The contact stated that while the vehicle was parked with the engine turned on and the transmission shifter in the park position, the engine began to rev and the vehicle suddenly experienced unintended acceleration and crashed into a brick building. During the incident, the braking system malfunctioned and did not stop the vehicle, and only the driver's side leg air bags were deployed. No other air bags in the vehicle were deployed during the crash. The driver sustained bruising to both legs, a left leg laceration, and a neck injury. The front passenger sustained a neck injury and the rear driver's side passenger sustained a torso bruise from the seat belt. All occupants received medical treatment at the scene. A police report was taken. The vehicle was destroyed and towed away. The contact indicated that the collision avoidance system had also malfunctioned and did not prevent the crash from occurring. The manufacturer and local dealer were not notified of the failures. The failure mileage was unavailable.

NHTSA ODI 11550344

My 2021 Bronco failed our family on Friday. The Bronco failed to start upon pressing the start and brake pedal. The main console panel started flashing then cycling through all kinds of failure alerts. There was a series loud noises from the engine, the headlights flashed off and on for over 3 minutes and then the engine started smoking. The doors would not open and we were stuck inside while the engine was smoking. That smoke came through the air vents as well. Finally, I was able to get my door open though couldn’t open my son’s rear passenger side door from the outside. He was stuck inside for what seemed like forever. He was able to open it finally and I carried him inside. My son’s legs are paralyzed and he does not walk. My main concern was getting him to a safe place as I was scared to death that the engine was going to explode in that moment. The engine smoke started to ease up however the electrical burning smell was overwhelming. This all took place in my garage. The trunk would not unlock and my key fob would not engage with the vehicle at all during this time. The trunk hatch lock finally disengaged and I was finally able to get his wheelchair out. Everything failed. I could not get the Bronco into neutral at any point. The Bronco is currently at my local Ford dealer where I was told I have to wait a week before it can even be looked at. I was told "it's just the battery...." There is NO way my experience was "just the battery." As of 10/10/2023 no one from corporate or the dealer has reached out to me. Once I got to the dealer (Jarret Gordon Ford Davenport), they were so dismissive of me. The service advisor never even asked if my son or myself were OK.

NHTSA ODI 11549110

Around 08/22 backup camera failed and now there is a dent in the tailgate area. I have documentation from the dealership, finally that the backup camera was not working properly. On about May 23, 2023, I stopped at a local grocery store for just a few items. When I came back out my car would not even attempt to turn over (approx. 24,000 miles). Had to wait three hours for roadside assistance to use a jump box to get it started (would not jump-start like a normal vehicle). The next morning it was dead again, and I had to call an Uber to get my child to school, not acceptable. I took it to the dealership again, and after three days they replaced the battery.....I had not even owned the vehicle for two years, it had 6 miles on it when I bought it, and it needs a new battery? Now it is 09/22/23, the dealership has had my car since the morning of 09/13/23 and I still don't have it back. There are issues with the safety features (lane departure doesn't work, front crash assist goes off randomly, backup camera STILL doesn't work half of the time, keep hands on steering wheel alert when both hands are on steering wheel, key not detected alert after I've been driving and the key is with me, stereo still playing when I disconnect the phone and exit out of all music apps on phone it just still plays music even music that I have never listened to). There is more but I cannot remember it all at the moment, and I don't have all of my records because they are with my car that I have not had in my possession in quite a while. DON'T BUY A BRONCO! BUY A JEEP!!!! That is what I have learned from this, my first and only Ford and I can't wait to go back to Mopar products. I have truly bought a lemon!

NHTSA ODI 11546110

When trying to start the vehicle, it would not crank. Instead, all dash indicator lights, interior lights, and exterior lights began flashing. Numerous random error messages began flashing on the dashboard screen. Then a large plume of smoke began coming out from under the hood and there was an acrid burning smell. No flames were visible so the fire department would not respond when called and advised to have it towed. After much difficulty loading onto a tow truck (the parking brake would not disengage--dash indicated a parking brake fault as one of the many errors--so it had to be dragged onto the flatbed tow truck) the vehicle was towed to the local dealership in Dothan, AL. Per the dealership, there was an underhood fire involving the starter and battery. We are unable to inspect the damaged components. They stated they are unable to remedy the smoke smell that has permeated the vehicle despite the disabling lung conditions of one of our family members. We have tried numerous times over the last 9 months to get the dealership to perform service required by NHTSA Recall # 22V859, but they keep stating the parts are unavailable. They will not say whether this underhood fire is directly related to the recall already in effect.

NHTSA ODI 11544366

After spending Sunday preparing for the week at my small business, I was driving home on the highway just before 10:00PM at approximately 55 miles per hour. As I traveled toward a T intersection there was a sedan that had been stopped at their respective stop sign; I quickly approached and the vehicle pulled out abruptly in an attempt to cross both eastbound lanes and travel westbound on the four-lane divided highway. Though all attempts were made on my part to prevent it, the broadside collision occurred in the right eastbound lane at a high rate of speed; driver's side front end damage to my vehicle and rear driver's side damage to the sedan. Angled in the middle of both eastbound lanes of traffic, my vehicle became disabled due to the deployment of the driver's knee airbag. However, the chest airbag did NOT deploy and resulted in a severe whiplash injury. 1. What component or system failed or malfunctioned, and is it available for inspection upon request? Driver's Air Bag. Yes, original is still installed in vehicle. 2. How was your safety or the safety of others put at risk? I personally sustained a severe whiplash injury due to the chest air bag NOT deploying. To this day I do not feel 100% safe driving the vehicle as the original airbag is still installed; if it didn't deploy the first time and I sustained debilitating injuries, how can I, or the next owner, be confident it will ever deploy?! 3. Has the problem been reproduced or confirmed by a dealer or independent service center? Unknown. Airbag didn't deploy. 4. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? Yes. Knee airbag was replaced and all other repairs were completed. 5. Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? NO. I had just purchased this vehicle brand new, off the lot several months prior to the collision and it had less than 10,000 miles.

NHTSA ODI 11538645

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.

NHTSA ODI 11502250

After I turned on the car, unbeknownst to me, the Ford Bronco stayed revved up and it did not slow down. I then switched from park to reverse and the Bronco went so fast (>4000rpm) that I ended up hitting the tree so hard that the tree was uprooted. The car was not driveable and it had to be towed. This is under progressive insurance claim: 22-3913700. The insurance company would not check the "inside" of the car (etc...transmission, electrical, etc...) as they say this is prior to the accident. I have called the Ford dealership for assistance several times to report this and for them to take a look at the inside of the car, but they have not returned my messages.

NHTSA ODI 11481418

Within seconds of parking and turning off my vehicle I heard a loud pop and saw gray smoke billowing out from under the hood of my 2021 Ford Bronco Sport. Within 10 minutes the entire vehicle was engulfed in flames and destroyed two other vehicles and did additional property damage. The fire investigator stated that the fire started in the lower right front of the engine compartment but many of the parts were now incinerated including the aluminum wheels that melted into a puddle. No warning lamps or other indicators were present. Insurance representatives are currently inspecting the vehicle.

NHTSA ODI 11478717