2022 Ford Bronco Sport Engine Problems

February 26, 2026, Concern: Ford Recall 25S76 / NHTSA 25V467 – No remedy available. My vehicle previously had an earlier Ford recall for fuel leakage and fire risk. The dealer installed a drain tube as an interim fix about 18 months ago. Ford has now issued a new recall 25S76 / NHTSA Recall 25V467 August 2025 for a similar hazard involving cracked fuel injectors that can cause fuel to accumulate on the engine. Ford states that parts are not available and has provided no timeline for a permanent repair. Because this is the second fire risk recall for a related issue and the prior fix did not resolve the underlying problem, I am concerned that the manufacturer has not provided a timely or effective remedy. I am requesting that NHTSA review this delay and include my case in its monitoring of this recall.

Smelling fuel strong when driving and the engine lags and almost stalls when coming to a stop and going very dangerous

Recurring Safety Defect: Powertrain Cooling System Failure causing Engine Overheating, Coolant Intrusion, and Loss of Motive Power. The vehicle has experienced three catastrophic cooling system failures within a 9-month period, posing a crash and fire risk. Incident 1 (February 2025): Water pump failure caused significant coolant loss. Diagnosed and repaired by authorized dealer under warranty. Incident 2 (June 2025): Vehicle leaked coolant and emitted visible smoke and burning odors from the exhaust. Dealer diagnosed internal turbocharger failure resulting in coolant intrusion into the engine and exhaust system. The catalytic converter was damaged by coolant burn-off and required replacement. This failure kept the vehicle out of service for 38 days. Incident 3 (November 2025): The vehicle engine overheated again while driving, triggering the "Fail-Safe" cooling mode. This resulted in a sudden reduction of motive power (limp mode), creating a collision hazard at highway speeds. The Check Engine light illuminated. Dealer diagnosis confirmed codes P1285 (Cylinder Head Overtemperature) and P05A1 (Active Grille Shutter failure). The manufacturer's dealer has confirmed the current failure but refuses to acknowledge it as part of the recurring powertrain thermal defect. The safety risk involves sudden deceleration in traffic due to overheating protection mode and potential fire risk from repeated coolant leaks onto hot engine components. The vehicle is currently at the dealer and available for inspection.

The contact owns a 2022 Ford Bronco Sport. The contact stated that on every occasion while entering the vehicle, there was a fuel odor coming through the vents. The check engine warning light illuminated briefly during one occasion. The vehicle was taken to the same dealer twice and was diagnosed with a cracked coolant pump. The dealer determined that the coolant pump and the purge valve needed to be replaced. The vehicle was repaired but the failure persisted. The vehicle was then taken to an independent mechanic, where it was diagnosed and determined that there was fluid leaking nearby the catalytic converter; however, the mechanic was unable to take the catalytic converter apart. The mechanic also determined that the fuel injectors, the exhaust clamps and gaskets, and Oxygen sensors needed to be replaced, and the turbo charger required coolant and oil feed lines replacements. The vehicle was not repaired. The manufacturer was notified of the failure and a complaint was filed. The failure mileage was 70,000.

As you may know, my Ford Bronco 2022 is under NHTSA Recall 25V467 as of July 2025. October is approaching, and so far, Ford Motor Company has not found any remedy for this problem, which can not only cause a spontaneous engine fire, but can also cause the death of those inside the vehicle or a serious accident if it occurs while driving. My vehicle is for daily use, and I have to transport my son to school every day, risking his life and mine, with the uncertainty of the vehicle catching fire. I ask that you consider requiring Ford Motor Company to collect these vehicles or exchange them for others of the same value that are not at risk.

Vehicle stutters when driving at slower speeds, usually between 22-27 MPH. After purchasing my vehicle used I have found that others have been reporting the same issue, to include in brand new Bronco Sports, and have been advised that is just how they are. Switching to sport mode does seem to help but the stutters occurs at different speeds. There has been no known part identified as causing the issue. There are no warnings displayed and no codes showing.

A manufacturer recall was issued for a defect involving the fuel system (fuel injectors), but no remedy or repair timeline has been provided. Due to the safety risk (potential fuel leakage and/or fire), I cannot reasonably use the vehicle without concern for liability if harm were to occur. Additionally, the recall must be marked as resolved in the NHTSA database before the vehicle can be returned to normal use, which is not possible without an available fix. The extended and indefinite repair timeline creates a significant burden, as the vehicle remains unusable with no clear resolution date. I have contacted both the dealer and the manufacturer, but no satisfactory resolution or timeline has been provided. No warning lights or prior symptoms were observed. The issue has not been independently reproduced, as it is a manufacturer-identified defect. The vehicle has not been repaired because no remedy is available. Overall, this represents a safety concern and loss of use, with no timeline provided for when the recall will be resolved.

A manufacturer recall was issued for a defect involving the fuel system (fuel injectors), but no remedy or repair timeline has been provided. Due to the safety risk (potential fuel leakage and/or fire), I cannot reasonably use the vehicle without concern for liability if harm were to occur. Additionally, the recall must be marked as resolved in the NHTSA database before the vehicle can be returned to normal use, which is not possible without an available fix. The extended and indefinite repair timeline creates a significant burden, as the vehicle remains unusable with no clear resolution date. I have contacted both the dealer and the manufacturer, but no satisfactory resolution or timeline has been provided. No warning lights or prior symptoms were observed. The issue has not been independently reproduced, as it is a manufacturer-identified defect. The vehicle has not been repaired because no remedy is available. Overall, this represents a safety concern and loss of use, with no timeline provided for when the recall will be resolved.

The water pump began leaking somewhere around 62,000 miles, however there were no visible signs of a leak and no maintenance warnings appeared on the dashboard. I only know there was a leak because I took my Bronco Sport into the Ford dealership to have other recalls repaired and they advised me to have the water pump replaced as it was leaking. I have researched this issue and it appears to be a very common issue with Bronco Sports of all years. This issue can put others or myself at risk because it would be very easy for the engine to run out of coolant and seize up in potentially very dangerous traffic situations. Because Ford doesn't have a way for Bronco Sport drivers to come aware of this issue unless vigilantly checking coolant levels every week, it would be very easy for the engine to overheat and stall before the driver can become aware there was even an issue.

Engine coolant light came on, dial was all the way on H. Water pump ended up having a leak. This is an ongoing issue with Bronco Sports 2021-2024.

I am filing this complaint regarding a recall affecting my 2022 Ford Bronco Sport. I received a recall notice concerning the possibility of the vehicle catching fire. Despite numerous attempts to resolve the issue, Ford continues to ignore the warnings and say "we are working on fixing the issue." I feel unsafe and will not drive this vehicle until there is a resolution. Ford has taking months/years to fix this issue with no resolution in sight.

The contact owns a 2022 Ford Bronco sport. The contact stated while driving at an undisclosed speed, the O2 sensor warning light illuminated. The vehicle was taken to an independent mechanic where the failure was diagnosed with a failed O2 sensor. The contact was informed that the O2 sensor needed to be replaced. The vehicle was not repaired. The contact was informed that the O2 sensor had been ordered. The vehicle was taken to the dealer for an oil change and the contact was informed of a coolant leak. The vehicle was not repaired. The vehicle was driven to the residence. The vehicle was put up on the lift by the contact who is an independent mechanic. The contact performed an inspection of the vehicle and became aware that the coolant pump, catalytic convertor, and serpentine belt had failed. The dealer was made aware of the failure. The vehicle was taken to the dealer where the failures were confirmed. The contact was informed that the catalytic convertor, coolant pump, and serpentine belt needed to be replaced. The vehicle was being repaired. The contact was informed that the repairs were not covered under recall. The manufacturer was made aware of the failure and a case was filed. The failure mileage was approximately 67,000.

Water pump, that was just replaced in June at Ford dealership, is leaking. This is ridiculous that Ford cannot put quality products in there vehicles.

The contact owns a 2022 Ford Bronco Sport. The contact stated that after inspecting the driveway, the contact noticed an abnormal stain on the concrete driveway. The vehicle was taken to a local dealer for routine maintenance and the dealer discovered that the oil filter might have been left loose from the last service performed by the local dealer. The vehicle was repaired; however, the failure persisted. The contact's husband checked under the hood and noticed that oil was leaking onto some hoses. The vehicle was not repaired. In addition, the contact related the failure to NHTSA Campaign Number: 22V191000 (Engine and Engine Cooling); however, the VIN was not included. The manufacturer was made aware of the failure. The failure mileage was approximately 46,000.

Cabin exhaust smell = leaking catalytic converter. 4 months and 5 trips for a diagnosis/solution. Car was smelling like exhaust in the cabin. Improved with air recirculation button ON. Worse in the AM, especially with remote start on cold mornings, and when stopped/parked. Told there was no smell, changed cabin filters / ac deodorizer ($200 out of pocket), “ford doesn’t have any other complaints on exhaust smell in the cabin”, “could not replicate”. After multiple forum searches/my own research, and insisting the catalytic converter was the problem, they agreed to let me leave it overnight for a cold start in the AM. Finally diagnosed with leaking catalytic converter. They replaced it and now the smell is completely gone. There was also a small rattle on acceleration, near the gas pedal, like a tiny rock in a tin can, that I assume was related because it is gone since the replacement.

The vehicle has strong exhaust fumes inside. It has gotten so bad people at work smell it on me. I even went to the doctor because I was trying to fall asleep while driving, I am confused when I first arrive places, my lungs feel like I am inhaling fire, I have the most painful headaches, and I am nauseous around the times I drive my car. My two girls are experiencing the same problems. But if we do not drive the Bronco on the weekends, no problems. My husband put it on the life at home and there are bolts missing from the dust shield, the ones there are loose, he had to tighten the bolts on the heads, and the convertor has “hot spots” on it. I have to drive at all times with a window down. The exhaust fumes can be smelled from outside as well. I have taken it to the dealer and was told there was no smell. I am scared at this point to drive it.

The contact owns a 2022 Ford Bronco Sport. The contact stated while having the vehicle serviced at the dealer, the contact was informed that the engine was leaking coolant. The vehicle was 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. The approximate failure mileage was 60,000.

I noticed my coolant level dropping about a year ago. I would fill up the coolant reservoir and the coolant level would drop within a few days. The issue was from the water pump leaking. I replaced the water pump with an OEM ford water pump. One year later the coolant level is dropping, and I have the same issue again. Looking at some of the forums, this appears to be a common issue with this make and mode.

Water pump failed and needed to be replaced

My bronco is going through coolant very quickly. If my heat wasn't working I would likely not have checked it. There was none in the resivour. There are no leaks in the lines or radiator.