2021-2026 Bronco Sport owners: 4 recalls for underhood fires, plus 3 for 12V battery failure. California lemon law may entitle you to a buyback.
Ford positioned the Bronco Sport as an affordable, rugged alternative to the compact SUV crowd, and for many buyers it delivered on that promise until the engine compartment caught fire. The 1.5L three-cylinder EcoBoost engine at the heart of every Bronco Sport has been the subject of four separate recall campaigns for a single defect: a cracked fuel injector that leaks high-pressure fuel onto hot exhaust and turbocharger surfaces, creating an underhood fire. NHTSA recall 25V467 (Ford recall 25S76), issued July 2025, consolidated all prior campaigns and covers 339,044 Bronco Sport units from model years 2021 through 2024. As of mid-2026, the final remedy, replacing the fuel injector and fuel rail assembly, has not yet been completed. An interim PCM software update and a drain tube have been installed on affected vehicles, but at least one post-remedy fire has been confirmed, prompting Ford to repurchase that owner's vehicle outright. The fire risk is only one chapter in the 2021-2026 Bronco Sport's reliability story. A separate cluster of three consecutive recall campaigns (24V267, 25V158, and 25V019) addresses a control module calibration flaw that allows the 12-volt battery to fail without warning, cutting all power to a moving vehicle. Owners have also reported widespread issues with AWD chatter, 8-speed transmission shudder, and premature water pump failure that can, in severe cases, lead to engine overheating and lasting damage. California's Song-Beverly Consumer Warranty Act exists for situations like this: multiple repair attempts for serious defects that Ford has been unable to fully correct. If your Bronco Sport has been in for any of these problems, your service records may already support a buyback or replacement claim.
The issues owners report most, ranked by severity — each one verified against a cited NHTSA source.
Fuel odor inside or outside the vehicle; check engine light; smoke or flames from engine bay; sudden drop in engine power with warning messages; instrument cluster alerts.
Sudden loss of drive power while driving; engine failure, in reported cases discovered as complete engine failure during testing; check engine light or cluster warnings may accompany the failure.
Oil burning smell from engine bay; visible oil leak on top of engine; smoke from hood; illuminated oil pressure or check engine light.
Vehicle suddenly loses power and coasts to a stop with no warning; all electrical accessories go dead; Auto Stop-Start triggers a no-restart event; battery-related warning lights appear.
Grinding, chattering, or shuddering from rear of vehicle during parking lot turns, low-speed cornering, or tight maneuvers; noise worsens when turning radius is tight.
Shudder, buck, or jerk sensation while accelerating from 0-35 mph; harsh or jerky gear changes; delayed engagement from a stop; MIL illuminated with DTC P0766 (shift solenoid D performance).
A settled Margarian Law case on this exact model, published with the actual settlement math.
Open any defect for the symptoms and why it matters for a California lemon-law claim. Each is tied to a cited NHTSA source.
Fuel odor inside or outside the vehicle; check engine light; smoke or flames from engine bay; sudden drop in engine power with warning messages; instrument cluster alerts.
Safety recall with known fire incidents — multiple repair attempts (22V859 → 24V187 → 25V165 → 25V467), remedy still incomplete as of mid-2026. Repeated repair attempts and fire risk support substantial-impairment argument. Vehicles with prior recall work that caught fire are strong lemon candidates.
Interim: PCM software update (detects pressure drop, reduces power, mitigates thermal risk) plus drain tube installation. Final remedy (fuel injector/fuel rail assembly replacement) expected July 2026.
Oil burning smell from engine bay; visible oil leak on top of engine; smoke from hood; illuminated oil pressure or check engine light.
Fire-risk recall on a sub-2-year-old vehicle. If vehicle was repaired under 22V191 and owner also experienced the fuel injector fire issue (22V859/25V467), cumulative fire-risk repairs bolster lemon claim. NHTSA documented actual fires in the population.
Inspect right-hand oil separator for leaks/damage; replace separator and seals if cracked.
Vehicle suddenly loses power and coasts to a stop with no warning; all electrical accessories go dead; Auto Stop-Start triggers a no-restart event; battery-related warning lights appear.
Three sequential recalls (24V267 → 25V158 re-repair → 25V019 battery replacement) for the same fundamental failure demonstrates inability to conform despite multiple repair attempts — classic lemon pattern. NHTSA PE24-002 was opened before Ford recalled, showing regulatory pressure.
Recalibrate BCM and PCM software (24V267 / 25V158). If battery is degraded, replace 12V battery (25V019).
Grinding, chattering, or shuddering from rear of vehicle during parking lot turns, low-speed cornering, or tight maneuvers; noise worsens when turning radius is tight.
Dealers routinely dismiss as normal AWD behavior. If fluid flush does not resolve and RDU replacement required repeatedly, or issue recurs after multiple fluid services, supports lemon-law nonconformity claim. Recall 21V011 shows Ford knew of RDU lubrication deficiency from launch.
Drain and refill RDU fluid per Ford WSM 205-02; perform 5-mile evaluation drive cycle with turns; if noise persists, replace rear drive unit assembly.
Shudder, buck, or jerk sensation while accelerating from 0-35 mph; harsh or jerky gear changes; delayed engagement from a stop; MIL illuminated with DTC P0766 (shift solenoid D performance).
If transmission shudder or hesitation persists after PCM reflash and multiple dealer visits, constitutes non-conformity to warranty. Owners report $10k-$13k transmission replacements — if repeated dealer visits failed to resolve via software, supports substantial impairment claim.
Reprogram PCM and update transmission solenoid strategy per Ford TSB 21-2268 / SSM 49930. If DTC P0766 set with MIL, additional solenoid/valve body diagnosis required.
Low coolant warning light; coolant loss with no visible external leak; overheating; white exhaust smoke; sweet smell from engine bay; engine overheats and shuts down.
If water pump fails and overheating causes engine damage (cracked head, warped block) within warranty period, constitutes substantial impairment. Multiple consecutive repairs for coolant system within warranty — especially if followed by engine damage — is a strong lemon-law fact pattern.
Flush coolant system with Motorcraft VC-1 Premium Cooling System Flush; replace water pump if leaking; repeat flush to prevent recurrence.
Windshield wipers stop working suddenly; wipers do not respond to stalk commands in any speed setting; no movement even when rain is present.
Safety-classified recall. Narrow production-date window limits population but qualifies for any vehicle with a wiper failure traceable to missing sealer. If wiper failure delayed repair (dealer backorder) leaving customer without safe vehicle in rainy conditions, supports use-impairment argument.
Inspect wiper motor; replace if inoperative.
Sudden loss of drive power while driving; engine failure, in reported cases discovered as complete engine failure during testing; check engine light or cluster warnings may accompany the failure.
A defect that can cause total engine failure and loss of drive power is a substantial safety defect under California lemon law, and the fix, a full engine long block replacement, is among the most significant repairs a new vehicle can need. With no remedy available until approximately December 2026, owners experiencing symptoms should document every repair attempt now: 4-5 documented repair attempts, dealer visits, and remedy-status communications build the record that supports a Song-Beverly claim. A first-attempt fix completed within about 30 days generally does not support a claim, so the repair history is what matters.
No fix available yet. Under recall 26V548, dealers will inspect the engine pistons and replace the engine long block as necessary, free of charge; remedy anticipated December 2026. Interim letters were mailed September 3, 2026.
interim
The engine piston domes may have been manufactured incorrectly due to a bond failure between the piston's nickel-resistant (Ni-Ring) insert and the aluminum piston body, traced to a machining collision on a supplier production line. Piston dome failure can cause engine failure and a sudden loss of drive power while driving.
open
High-pressure fuel injector may crack, allowing fuel to leak into the cylinder head; fuel travels via drain hole onto hot exhaust and turbocharger surfaces, creating underhood fire risk.
open
Vehicles that received an incorrect 24V267 remedy continue to have BCM/PCM unable to detect 12V battery state of charge changes.
open
12-volt battery may degrade and suddenly fail, causing loss of electrical accessories and/or loss of drive power.
closed
Windshield wiper motor may become inoperative due to water intrusion from missing factory sealer.
open
BCM and PCM calibrations cannot detect sudden change in 12V battery state of charge; loss of motive power may occur if alternator cannot meet electrical load demand or if Auto Stop-Start is initiated.
superseded
1.5L fuel injector may crack and leak fuel inside the engine compartment.
closed
Engine oil separator housing may crack, developing an oil leak; leaked oil can migrate to hot engine surfaces or ignition sources.
closed
Inadequate lubricant in rear drive unit may cause seizure, resulting in loss of drive and/or loss of vehicle control.
Every item below comes from this vehicle's documented defects. The more you recognize, the more a free case review is worth your time.
California's Song-Beverly Consumer Warranty Act gives you the right to a repurchase or replacement vehicle when a manufacturer cannot fix a covered defect after a reasonable number of attempts during the warranty period. The law creates a presumption that you may qualify when: two or more repair attempts were made for a defect that could cause death or serious injury — such as an underhood fire or sudden loss of drive power while moving — or four or more repair attempts for any other substantial defect, or the vehicle was out of service cumulatively for 30 or more calendar days during the warranty period. For Bronco Sport owners, the fuel injector fire defect alone has generated four recall campaigns since 2022, with no permanent remedy completed as of mid-2026. Owners who had their vehicles in for any of those recall appointments, plus additional visits for the same symptom, may already have a qualifying pattern. The same is true for owners who experienced repeated sudden power-loss events across the BCM/PCM recall sequence. Days waiting for backordered recall parts count toward the 30-day out-of-service threshold. If you qualify, Ford must either repurchase the vehicle at the price you paid (minus a reasonable mileage offset) or replace it with a comparable vehicle. Ford also pays your attorney fees if you prevail. The above is general information only and is not legal advice; your eligibility depends on your specific facts and repair history.
“Could not duplicate” doesn't mean the defect isn't real. Here's exactly what to do to protect a potential California lemon-law claim.
Document the moment it happens. Photos, video, and screenshots of any warning lights — with the date and the mileage.
Get a repair order every visit — even “found nothing.” That paperwork is the foundation of a claim.
Check your VIN at nhtsa.gov/recalls. Note any recall that has no available remedy yet.
Track your out-of-service days. California law counts the cumulative days your vehicle spends in the shop.
Keep loaner & rental records. Alternate-transport paperwork during long repairs matters.
Save everything in one place. Symptoms, dates, repair orders, and every repeat visit — the intermittent ones especially.
Ford dealers frequently return Bronco Sport owners with a 'no trouble found' (NTF) verdict — particularly for the AWD chatter (dealers often say 'all AWDs do this'), intermittent power-loss events, and fuel smell that is not present when the vehicle arrives at the shop. Here is how to protect your record: 1. Document everything before the visit. Write the exact date, time, mileage, outside temperature, and a precise description: 'I smelled fuel inside the cabin at highway speed on June 15 at 3:00 PM.' Photos of any instrument cluster warnings are very helpful. 2. Request the Diagnostic Trouble Codes in writing — including stored and pending codes — even if the dealer says the problem is gone. A PCM log of a fuel pressure drop or battery voltage event is documented evidence even after the symptom clears. 3. Ask whether the relevant recall remedy has been applied to your VIN. For the fuel injector fire recall, confirm whether the interim PCM update and drain tube were installed, and ask when the final injector replacement remedy will be available. An open safety recall with only an interim fix is itself a documented failure to permanently repair. 4. For AWD chatter: cite TSBs SSM 49571 and SSM 51823 by name. Both bulletins confirm that chatter during low-speed turns is a known defect — not a normal characteristic. If the dealer has not performed the RDU drain-and-refill procedure described in those TSBs, the acknowledged fix has not been attempted. 5. Keep every repair order, including UTD visits. Under California law, a UTD repair visit still counts as a repair attempt. The pattern matters more than any single outcome.
Four recall campaigns for the same fuel injector fire defect — with an interim remedy confirmed to be insufficient after a post-remedy vehicle caught fire — is an extraordinary admission by any standard. Add three sequential recalls for sudden power loss from a battery detection flaw that dealers repeatedly failed to fix correctly, and the Bronco Sport's first-generation reliability record is one of the most recall-dense in Ford's modern lineup. If your Bronco Sport has been in for any of these issues during the warranty period, we encourage you to gather your service records now — before the warranty clock runs out — and speak with a California lemon law attorney. The consultation costs nothing.
— The Margarian Law team
Has your Bronco Sport been in for the fuel injector fire recall, a sudden loss of power, a transmission shudder that software updates did not fix, or an engine overheating problem? If your vehicle is a 2021-2024 model and has had more than one dealer visit for any of the issues described above, your service records may already support a California lemon law claim. The consultation is free — find out whether Ford owes you a buyback.
Likely yes, if you own a 2021-2024 Bronco Sport. NHTSA recall 25V467 (Ford recall 25S76, issued July 2025) covers 339,044 Ford Bronco Sport vehicles from model years 2021 through 2024, all equipped with the 1.5L three-cylinder EcoBoost engine. The defect: the high-pressure fuel injector can crack, allowing fuel to leak at a high rate onto the cylinder head and from there onto hot exhaust and turbocharger surfaces, where it can ignite. This recall supersedes and consolidates three earlier campaigns — 22V859 (2022), 24V187 (2024), and 25V165 (2025) — that addressed the same underlying problem with interim remedies that proved insufficient. As of mid-2026, the final remedy (fuel injector and fuel rail replacement) was anticipated for July 2026 but had not been completed on all affected vehicles. You can check your VIN status at nhtsa.gov.
Yes. Sudden, complete loss of drive power in the Bronco Sport is the subject of three linked recall campaigns. NHTSA recall 24V267 (Ford 24S24, April 2024) covers 456,565 vehicles including 2021-2024 Bronco Sports, addressing a flaw in the body and powertrain control module calibrations that prevents the vehicle from detecting a sudden drop in 12-volt battery charge — causing the vehicle to lose all electrical power and drive capability without warning. Because the initial calibration fix was applied incorrectly on some vehicles, Ford issued a second repair recall (NHTSA 25V158, March 2025) requiring recalibration. A third recall (NHTSA 25V019, January 2025) addressed vehicles where the 12-volt battery itself had physically degraded and needed replacement. If your Bronco Sport stalled without warning and you have already had one recall repair, check your VIN at nhtsa.gov — the subsequent 25V158 or 25V019 recalls may still be open on your vehicle.
This is a documented defect in the rear drive unit (RDU), not normal AWD behavior. Ford has issued two successive Technical Service Bulletins — SSM 49571 (2021, covering MY2021) and SSM 51823 (2022-2023, expanded to 2021-2023 Bronco Sport) — that confirm the chatter or shudder during low-speed turns is caused by contamination in the RDU limited-slip clutch pack fluid. The fix is a RDU fluid drain and refill; if the noise persists, the RDU assembly may need replacement. The same underlying RDU system was also the subject of recall 21V011 issued at launch (January 2021) for inadequate lubrication. If a dealer has told you the noise is normal or dismissed your complaint without performing the TSB procedure, ask them specifically to reference SSM 51823. Multiple visits for the same unresolved AWD issue can contribute to a lemon law repair count.
Coolant loss and water pump failure on the 1.5L EcoBoost engine are documented issues covered by Ford Technical Service Bulletins SSM 52949 (September 2024) and TSB 25-2063 (February 2025), both of which apply to 2021-2024 Bronco Sports. The cause is premature failure of the electric water pump due to coolant system contamination. The initial fix is a coolant flush with Motorcraft VC-1 fluid; if the pump is already leaking, it must be replaced. Because this is addressed by a TSB rather than a safety recall, Ford should cover the repair under the powertrain warranty if your vehicle is still within the factory warranty period. If the water pump failure led to engine overheating and caused additional damage — cracked head, warped block, or turbocharger failure — that secondary engine damage is also potentially warranty-eligible. Repeated coolant system repairs within the warranty period, especially if followed by engine damage, can support a lemon law claim for substantial impairment.
It may, depending on your repair history. California's Song-Beverly Consumer Warranty Act presumes a vehicle may qualify as a lemon when: two or more repair attempts were made for a defect that poses a risk of death or serious injury — such as an underhood fire or sudden loss of drive power — or four or more attempts for any other substantial defect, or the vehicle was out of service for a cumulative total of 30 or more calendar days during the warranty period. For Bronco Sport owners, the fuel injector fire recall alone has generated four campaigns since 2022, with a post-remedy fire confirmed. Owners who have visited the dealer under any combination of those campaigns — or for repeated power-loss events across the BCM recall sequence — may already be at or past the threshold. Days your vehicle sat at the dealer waiting for recall parts count toward the 30-day out-of-service total. If your Bronco Sport qualifies, Ford must repurchase it at the price you paid (minus a mileage offset) or replace it with a comparable vehicle, and Ford pays your attorney fees. The above is general information only and is not legal advice; every case depends on its specific facts and dates.
The interim remedy issued with recall 25V467 — a PCM software update to detect fuel pressure drops and reduce engine power, plus installation of a drain tube — is not the permanent fix. Ford's own communications state that the final remedy, physical replacement of the fuel injector and fuel rail assembly, was anticipated for July 2026. Ford has acknowledged that at least one vehicle caught fire after receiving the interim software-and-drain-tube remedy, and that vehicle was repurchased. If you have received only the interim remedy and have not yet received a fuel injector replacement, your vehicle still carries the risk described in recall 25V467. Check your VIN at nhtsa.gov and contact your dealer to ask specifically whether the final injector replacement remedy is available for your vehicle. Document the date you inquired and the dealer's response. A vehicle with an open safety recall and no available permanent fix can support a claim of substantial impairment of use or value under California law.
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