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

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

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

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 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

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

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 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

I started my car on 2/15. Drove about .5 miles down the street through a fast food place. Drove another .9 miles down the street. I heard a pop and pulled over immediately and the car was already on fire. The car had around 3542 miles on it. I had just leased it in September. Ford says this was the only vehicle that this has happened too. The inspection is happening with the insurance company as well as Ford Motor Company. No prior issues and no warning signs on the car before the fire.

NHTSA ODI 11454100