2021 Ford Bronco Sport Engine Problems

I own a 2021 Ford Bronco Sport Base (VIN: [XXX] ) equipped with the 1.5L EcoBoost 3-cylinder engine. I am experiencing a complete and repeated loss of engine coolant with no visible external leak. Upon inspection, air bubbles were observed rising through the coolant reservoir when coolant was added, indicating combustion gases are entering the cooling system through a compromised seal. On multiple occasions upon startup, sweet-smelling white smoke has been emitted from the exhaust, consistent with coolant burning in the combustion chamber. The vehicle has overheated as a result of coolant loss. These symptoms are consistent with the known 1.5L EcoBoost cracked engine block or head gasket failure defect affecting 2021 Ford Bronco Sport and 2020-2022 Ford Escape vehicles. I have been advised by a ford dealership mechanic that the vehicle is unsafe to drive due to the risk of engine failure and potential engine fire. The vehicle has been parked and is not being driven. I am filing this complaint as a safety concern given Ford’s history of engine fires related to this defect, which was the basis of recall 22S43 and ongoing federal class action litigation. I am requesting NHTSA investigate whether an expanded recall or additional consumer remedy is warranted for this vehicle. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

While driving between [XXX] and [XXX] , the vehicle suddenly lost fuel. The estimated miles to empty started to drop rapidly from 70 miles to 50 miles within minutes. At a safe point, I pulled over, there was no pooling of fuel under the vehicle, no other warning lights were issued. I turned around to return to [XXX] , the engine stalled and ran out of gas at mile marker 18 just north of [XXX] . I left the vehicle on the side of the road and walked back to [XXX] . This stretch of road has no cell service. The vehicle was towed to Corwin Ford for inspection. I requested that Recall CSP25S76 be completed on the vehicle, and replace the fuel injectors. The response was that the fuel tank needs to be replaced. They have not provided diagnostic evidence of why. I think this falls under CSP 21S38. Additionally, the catalytic converter was replaced in January under [XXX] and the emissions warranty extension. The vehicle has high mileage, but the purge valve should not have stuck open and this is a known issue with the Ford Bronco Sports. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2021 Ford Bronco Sport. The vehicle was taken to Take 5 Oil Change for an oil change, and the contact was informed that the coolant reservoir was empty. The vehicle was taken to Ritchie Automotive, where it was diagnosed that the water pump had failed and needed to be replaced. The vehicle was not repaired. The dealer was notified of the failure and referred the contact to the NHTSA Hotline to report the failure. The manufacturer was not contacted. The failure mileage was approximately 80,000.

The contact owns a 2021 Ford Bronco Sport. The contact stated that while driving 78 MPH on the highway, the vehicle unintentionally decelerated and stalled. The vehicle was turned off, restarted, and driven as intended. No warning lights were illuminated. On another occasion, the vehicle stalled with the check engine warning light and other unknown warning lights illuminated. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 49,700.

The contact owns a 2021 Ford Bronco Sport. The contact stated that while driving 15 MPH in traffic, the accelerator pedal was depressed; however, the vehicle failed to respond as needed. The contact stated that the vehicle was in Fuel Saver Mode, and the vehicle turned off unexpectedly and failed to restart. The check engine and the battery warning lights were illuminated. The vehicle was towed to a local dealer; however, a diagnostic test was unable to be performed because the parking brake independently engaged whenever shifted into neutral(N). The vehicle was not repaired. The manufacturer was informed of the failure. The failure mileage was approximately 60,400.

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.

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.

Catastrophic engine failure. Sudden. Started my car in the morning. Engine was running rough. Drove about 1/2 mile, engine continued to get worse. Returned home. decided to get engine codes checked. Check engine lights did not come on until this incident. Couldn't keep engine running. Kept trying to restart. Heard weird noise in engine and engine seized. Car had 62,800 miles on it, just over the 5 yr/60,000 warranty. Had the car towed to local Ford dealership. They verified that the engine was seized and that I needed a new engine. They found a lot of coolant in the engine oil along with a lot of metal flakes in the oil. They called it a catastrophic failure and speculated that it could be piston or valve destruction. They did not tear down the engine to determine the cause. They wanted an additional 2,000 to do that. (I kept the old seized engine). This failure could leave the owner stranded and in a very unsafe situation. I don't know what this failure would do to the drivability of the vehicle in traffic or on the highway.

We purchased this vehicle 02/2025. The salesman stated there was a 5 point inspection and the car was good on fluids oil and brakes. We questioned the rough idle and odd sound the car made and we were told that it was normal. 07/2025 a mobile mechanic came out and repaired a recall. He stated in his notes that the car had an oil leak but he could not determine where. Fast forward to now, my car has been needing oil more than usual since we have got the car. There is a leak but it does not leak on the ground. 11/11/2025, I contacted Big Valley Ford in Stockton CA with concerns about the oil depleting rapidly and how my check engine light comes on which tells me my car has absolutely no oil. I mentioned a recall I saw online 22S21 and Greg (the man I spoke with) stated that was never a recall for my car. He saw the oil separator was replaced in 2022 but it was not for a recall. Greg then told me to make an appointment to bring the car in for a diagnostic and then an oil change. They would then mark my car where the oil is and have me come back in a few days to see how far the oil went down. I asked how much and he said 225 for the diagnostic and 135 for the oil change. Convinced he was lying to me, I called Ford in Tracy, CA and they confirmed there was a recall 22S21 for the oil separator. This car has given me so many problems and this issue clearly was never fixed and they sold me the car this way.

My 2021 Ford Bronco Sport Big Bend 1.5L EcoBoost (VIN: [XXX] ) suffered a turbocharger failure due to oil leakage, which caused overheating and smoke from the engine bay. The vehicle became unsafe to drive due to loss of power and risk of fire from leaking oil near hot engine components. I’ve found numerous reports online of similar failures in other 2021–2022 Bronco Sport 1.5L models, suggesting a possible design or component defect. This issue poses a serious safety concern, as the engine can overheat or lose power suddenly while driving, increasing the risk of crash or fire. Please investigate this matter to determine if a recall or safety campaign should be initiated to address recurring turbocharger and oil leak failures in these vehicles. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2021 Ford Bronco Sport. The contact stated that while driving at 60 MPH, several unknown warnings lights illuminated, and the vehicle stopped independently. The local dealer was contacted. The vehicle was towed to the dealer to be diagnosed and it was determined that the water pump needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure but offered no assistance. The contact was transferred to the NHTSA Hotline to report the failure. The approximate failure mileage was 75,000.

The contact owns a 2021 Ford Bronco Sport. The contact stated while her husband was driving 15 MPH and depressing the accelerator pedal, there was an abnormal popping sound coming from the engine. The driver was able to pull into a parking lot and noticed white smoke coming from the engine while awaiting tow truck assistance. A local dealer was contacted. The vehicle was taken to the dealer to be diagnosed. The vehicle was diagnosed with engine failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified on the failure and was waiting to make a decision on what assistance to provide. The approximate failure mileage was 90,000.

The contact owns a 2021 Ford Bronco Sport. The contact stated that while her daughter was driving at an undisclosed speed, the vehicle inadvertently lost motive power and was unable to accelerate above 30 MPH. The failure persisted; however, the contact was able to drive to the intended destination. No warning lights were illuminated. The vehicle was taken to the dealer, who diagnosed a failure with turbo charger. The contact was informed that the turbo charger needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure, a case was opened, and the contact was referred to the NHTSA Hotline for assistance. The failure mileage was 70,000.

The contact owns a 2021 Ford Bronco Sport. The contact stated that while operating the vehicle, the instrument panel malfunctioned, with the message "Pull Over and Restart the Engine" displayed. The battery was replaced, and failure was resolved. Additionally, the contact stated while driving at an undisclosed speed, the vehicle suddenly lost motive power and stalled. The vehicle was towed to the local dealer who diagnosed that the engine was faulty and needed to be replaced. The engine was replaced, and the vehicle was repaired. The contact stated that later while driving at various speeds, the vehicle started jerking while changing gear. The vehicle was towed to the local dealer who diagnosed that the transmission was faulty and needed to be replaced. The transmission was replaced, and the vehicle was repaired. The contact stated that the vehicle later experienced a failure while attempting to accelerate, with the check engine warning light illuminated. The vehicle was driven to the local dealer who diagnosed that the catalytic converter was faulty and needed to be replaced. The vehicle was not yet repaired. The manufacturer was notified of the failure. The failure mileage was 5,000. The VIN was unavailable.

The water pump has been replaced twice already and the water pump needs to be replaced again at 105,000 miles. This will be the fourth water pump this vehicle has. The originally came with, two replacements, and now the one that it needs because it is leaking like the previous three. The turbo charger failed and was burning oil. That was replaced. A month later it is back at the dealership being replaced again

I took my 21 Bronco Sport Big Bend in to have a different recall fixed and also have an oil change performed. I told the service technician that my coolant level was always low but I could not find any leaks under the vehicle. The service department called me and told me that there was coolant leaking into the cylinders of my engine and I needed the long block replaced. There was no indicator light for the low coolant or any type of engine light that would alert me of an issue. I eventually got a call that they had received parts for my engine replacement. The service technician told me that they are seeing a lot of Bronco Sports have this issue, but I never received a recall notice nor can I find an open recall online for this issue. I believe my family and I were put at risk due to this issue because of the potential for engine failure or damage.

See attached document for complaint.

The evaporative emissions system failure involving the purge valve and vapor canister purge valve is a recurrent issue on this car and has been reported by hundreds if not thousand of bronco sport owners. All recall for 1.5L and I am sure the badlands have the same parks and is not included in the recall. less than 60,00o mile with a check engine light on. The safety issue that arises from this is that we are emitting more fuel vapors into the atmosphere. Please add recall to cover Badland if they contain same parks as 1.5L!!!! Also the windshield wiper pump did not work. I can not clean the windshield wen needing to see out of it. i have to pull over and clean at local gas station.

Torque converter failure at 100,000 miles. Car hesitates when it accelerates creating delay when going from stop to start.

The contact owns a 2021 Ford Bronco Sport. The contact stated while the vehicle was parked and occupied, while attempting to turn on the air condition or heating system, there was an abnormally strong fuel odor coming from the vents. The contact stated that a dealer was contacted. The vehicle was taken to Meineke Car Care Center where it was diagnosed and determined that the Oxygen sensor threads were stripped. The manufacturer was notified of the failure and informed the contact that the vehicle warranty had expired. The approximate failure mileage was 50,000.