1986 FORD BRONCO

1 recalls, 43 complaints - 18 TSBs

FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS

Defect Description

SPRING LOCK FUEL LINE COUPLING MAY NOT BE PROPERLY ENGAGED.

Consequence

COUPLING COULD DISENGAGE DUE TO FUEL PRESSURE,VIBRATION, AND ENGINE MOVEMENTS; THIS WOULD CAUSE LOSS OF FUEL WHICH, INPRESENCE OF AN IGNITION SOURCE, CREATES A FIRE RISK.

Remedy

INSTALL RETAINER CLIPS OVER THE COUPLINGS TO PREVENT COUPLING SEPARATION AND FUEL LEAKAGE.

3,600,000 vehicles affected

Manufacturer: FORD MOTOR COMPANY

Complaint Statistics

43 total complaints 5 crashes 9 fires 5 injuries

Top Reported Components

Component	Complaints
ELECTRICAL SYSTEM:IGNITION	6
TIRES	4
ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR	3
SEAT BELTS:FRONT:BUCKLE ASSEMBLY	3
ELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASH	3
FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY	2
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE	2
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS	2
ELECTRICAL SYSTEM:WIRING	2
FUEL SYSTEM, GASOLINE	2

Incident date: Nov 25, 2004

WE HAVE SPEND MORE THAN 500.00 ON PART FOR THIS TRUCK IT JUST KEEP STOPPING FOR NO REASON, SHOP PEOPLE SAY ITS THE FUEL SYSTEM, IT HAS BEEN REPLACED 3 TIMES. STILL IT STOPS THEY DO NOT KNOW EXCEPT THE FUEL SYSTEM. WE HAVE BEEN STRAINED ABOUT 5 OR 6 TIMES MOST TIMES LATE AT NIGHT. HAVE BEEN TOW HOM... Read more

Incident date: May 20, 1999

RIGHT REAR TIRE HAD BEEN REPAIRED WITH FOUR STRING-PLUG ONLY REPAIRS. THERE WAS NO PATCH ON THE INNER-LINER AS RECOMMENDED BY THE RMA. *LA AS A RESULT OF THE IMPROPER PLUG-ALONE REPAIRS, AIR WAS ALLOWED TO MIGRATE INTO THE CARCASS OF THE TIRE; RESULTING ON A TREAD SEPARATION. WHILE DRIVING THE ... Read more

Crash 1 injured

Incident date: Oct 5, 2000

THE TREAD UNZIPPED FROM THE TIRE IDENTICAL TO THAT OF THE FIRESTONE DEFECT, CAUSING MY BRONCO II TO LOSE CONTROL AND FLIP THREE TIMES INTO ONCOMING TRAFFIC. *AK

Crash 1 injured

YOU BROADCASTED THE RECALL SETTLEMENT FOR FORD IGNITION MODULES,YETMY LOCAL DEALERS SEEM OBLIVIOUS TO THE RECALL ,WHAT DO I NEED TO GET ANOTHER IGNITION MODULE THAT YOU PEOPLE GOT FORD TO SETTLE ON. *AK

Incident date: Aug 12, 2001

DRIVING AT 65 MPH VEHICLE ENGINE DIED; HAVE REPLACED PART 3 TIMES IN LAST YEAR. *AK

Incident date: Oct 1, 1986

STALLED GOING ROUND CORNERS, STALLING AT STOPS. ENGINE RACED, FIXED AFTER YEARS LOW MILES. *AK

Incident date: Oct 5, 2000

THE TREAD UNZIPPED FROM THE TIRE IDENTICAL TO THAT OF THE FIRESTONE DEFECT, CAUSING MY BRONCO II TO LOSE CONTROL AND FLIP THREE TIMES INTO ONCOMING TRAFFIC.( DOT NUMBER: A3UL423186 TIRE SIZE: P205/75R15 )

Crash 1 injured

Incident date: Oct 5, 2000

Crash 1 injured

Incident date: Aug 15, 2000

GOOD MORNING! I AM WRITING TO ADD MY VOICE TO WHAT IS APPARENTLY A GROWING CHORUS OF PERSONS WHO HAVE EXPERIENCED IGNITION FAILURES ON FORD MOTOR COMPANY PRODUCTS. I HAVE BEEN UNABLE TO CONTACT FMC DIRECTLY THROUGH THEIR WEB SITE, AS THEIR OWNER REGISTRATION FORM IS, ITSELF, SUFFERING A FAILURE, AND... Read more

WOULD BE DRIVING VEHICLE AT LOW SPEED & NOTICED HOW BUMPY TIRES WERE FEELING. PULLED OVER & CHECKED. TREAD WAS SEPARATING & THEY WERE OUT OF ROUND. ALSO HAD LUMPS IN THE TIRES. HAVE NOT BEEN IN TOUCH WITH FIRESTONE OR FORD. REPLACEMENT TIRES ON A 1986 FORD BRONCO. FIRESTONE RADIAL ATX 31X10.5X15 ... Read more

Incident date: Aug 29, 2000

I HAVE EXPERIENCED FOUR FAILURES OF THE TFI IGNITION MODULE OVER THE PERIOD OF TIME I HAVE OWNED THE VEHICLE, THE FIRST FAILURE OCCURRED WITHIN TWO MONTHS OF HAVING PURCHASED THE VEHICLE. EACH SUBSEQUENT FAILURE OCCURRED AT APPROXIMATELY TWO TO THREE YEAR INTERVALS. THE MOST RECENT FAILURE PROMPTED ... Read more

Incident date: Dec 24, 1998

WHILE DRIVING AN ELECTRICAL FIRE STARTED UNDER THE DASH RIGHT IN THE CENTER. VEHICLE WAS TOTALED. *AK

Fire

Incident date: Jan 23, 1999

WHILE TRYING TO STOP VEHICLE IT ACCELERATED TO HIGH AMOUNT OF SPEED, CAUSING DRIVER TO CRASH HEAD-ON INTO A UTILITY POLE. VEHICLE HAS NOT BEEN REPAIRED. *AK

Crash 1 injured

WHILE DRIVING FLAMES CAME FROM THE STEERING COLUMN AREA. CAUSE UNKNOWN. PLEASE GIVE ANY FURTHER DETAILS. *AK

Fire

Incident date: Jul 1, 1998

SEAT BELT BUCKLES FAILED.

Incident date: Jan 3, 1997

ALTERNATOR WIRING CONNECTOR MELTED AND SHORTED OUT CAUSING FIRE.

Fire

FUEL IGNITION WIRING MELTED, RESULTING IN A FIRE. *AK

Fire

Incident date: May 15, 1995

FUSES IN DASHBOARD SHORTED OUT. *SD

Incident date: May 15, 1995

INTERMITTENT STALLING. *SD

Incident date: May 15, 1995

TAILGATE CORRODED TWICE. *SD

Incident date: May 15, 1995

BRAKES FAILED. *SD

Incident date: Feb 1, 1994

ALTERNATOR REPLACED. *SD

Incident date: Feb 1, 1994

STEERING COLUMN REPLACED TWICE. *SD

Incident date: May 15, 1995

ELECTRICAL WIRING PROBLEMS, CAUSING LIGHTS ON DASHBOARD TO DIM/GO OUT

Incident date: May 7, 1995

REAR END PROBLEMS. *SD

Incident date: May 15, 1995

FUEL TANK LEAKS. *SD

Incident date: Apr 20, 1996

THE IGNITION SWITCH BURNT OUT.PLEASE DESCRIBE. *AK

Incident date: Apr 2, 1995

WHILE DRIVING, ENGINE SHUT DOWN. OWNER PULLED OVER TO RE-START ENGINE HEARD "POP" SOUND FOLLOWED BY FIRE THROUGH FIREWALL. PLEASE DESCRIBE DETAILS. *AK

Fire

Incident date: Apr 2, 1995

WHILE DRIVING, ENGINE SHUT DOWN. OWNER PULLED OVER TO RE-START ENGINE HEARD "POP" SOUND FOLLOWED BY FIRE THROUGH FIREWALL. PLEASE DESCRIBE DETAILS. *AK

Fire

Incident date: Jan 29, 1996

DRIVER'S SEAT BELT BUCKLE FAILED. *SD

Incident date: Jun 22, 1995

LEFT FRONT DISC BRAKES FAILED 3 TIMES, CAUSING VEHICLE TO PULL TO LEFT UPON BRAKING. *SKD

Incident date: Nov 13, 1995

VEHICLE EXPERIENCED AN ELECTRICAL SHORT, AND FUEL LEAKAGE. TT

Fire

Incident date: Nov 13, 1995

VEHICLE EXPERIENCED AN ELECTRICAL SHORT, AND FUEL LEAKAGE. TT

Fire

Incident date: Apr 24, 1995

LEFT REAR WHEEL CAME OFF AND WEDGED UNDER REAR FENDER. (OHIO STATE POLICE REPORT) *AK

Incident date: Jul 7, 1995

REPLACED SHOCKS. *AK

Incident date: Jul 7, 1995

BODY BOLTS ON THE PASSENGER SIDE OFTEN COMES A LOOSE. TT

THE FRONT LEFT BRAKE HAS HAD TO BE REBUILT AND IT DESTROYED ITSELF. PLEASE EXPLAIN. TT

Incident date: Jan 29, 1995

ENGINE FIRE, OHIO STATE POLICE REPORT. *TW

Fire

Incident date: Jan 1, 1993

DRIVER SIDE LAP/SHOULDER BELT BUCKLE BROKE, PLASTIC RELEASE BUTTON WILL NOT LATCH. TT

Incident date: Feb 6, 1995

IGNITION COIL FAILED.

Incident date: Feb 6, 1995

WINDSHIELD WIPER MOTOR FAILED.

Incident date: Feb 6, 1995

ALTERNATOR FAILED.

Incident date: Feb 6, 1995

GAS TANK RUSTED OUT. *AK

Technical Service Bulletins, 1986 FORD BRONCO

18 manufacturer communications from 18 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
103000 POWER TRAIN:AUTOMATIC TRANSMISSION	4
103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER	2
061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE	1
021000 SUSPENSION:FRONT	1
131000 VISIBILITY:WINDSHIELD	1
021242 SUSPENSION:FRONT:SPRINGS:LEAF SPRING ASSEMBLY:HANGER,BRACKET	1
160000 STRUCTURE	1
190000 TIRES	1

980000 UNKNOWN OR OTHER

INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS. *SLC

138600 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:HEATER CORE

SOME VEHICLES MAY EXHIBIT HEATER CORE LEAKS. *SLC

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

INFORMATION REGARDING THE NEW TRANSMISSION COOLER FLUSHER- SERVICE TIP. *MJS

114000 ELECTRICAL SYSTEM:WIRING

SUBJECT ON A WIRE HARNESS TERMINAL REPAIR KIT AVAILABLE FOR REPAIRING ELECTRICAL WIRING HARNESSES. *TT

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

INFORMATION ON IDENTIFYING NON-APPROVED / ALTERNATE REFRIGERANTS WHICH COULD CAUSE SAFETY, AND PERFORMANCE CONCERNS IF INSTALLED IN FORD A/C SYSTEMS. *TT

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

INFORMATION ON THE NEW FLUSH AND FILL TOOL AVAILABLE THROUGH ROTUNDA. *TT

110000 ELECTRICAL SYSTEM

FORD MOTOR COMPANY HAS RELEASED A NEW ELECTRICAL GREASE ( F8AZ - 19G208-AA ) TO REDUCE THE POSSIBILITY OF MOISTURE CORROSION AT THE TERMINALS. *YC

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

INFORMATION ON A NEW TRANSMISSION FLUID USAGE CHART. *YC

190000 TIRES

INFORMATION ON TIRE COMPANY TELEPHONE NUMBERS FOR CUSTOMER ASSISTANCE. *YC

063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

INFORMATION ON A BUZZING OR RATTLE NOISE FROM THE EXHAUST SYSTEM. *TT

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

FLUID- TRANSMISSION FLUID USAGE CHARTS. *JD

160000 STRUCTURE

FRAME- RIVET REPLACEMENT WITH BOLTS- SERVICE TIPS. *JD

021242 SUSPENSION:FRONT:SPRINGS:LEAF SPRING ASSEMBLY:HANGER,BRACKET

NOISE- "POPPING/CREAKING"- FRONT FRAME OR SUSPENSION BRACKETS- FRAME- "POPPING/CREAKING"- FASTENER REPLACEMENT. *JD

103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER

TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP. *TW

103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER

TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP. *TW

131000 VISIBILITY:WINDSHIELD

WINDSHIELD AND INTERIOR GLASS - FOG/FILM. *TW

021000 SUSPENSION:FRONT

UNKNOWN

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

KNOCKING NOISE ON INITIAL START-UP. *TW

NHTSA Safety Investigations, FORD BRONCO

Investigations opened by NHTSA into potential safety defects. These are separate from recalls and may or may not result in a recall.

PE, Closed , Model Year: 2021

Low-pressure fuel pump failure

On July 29, 2024, the Oﬃce of Defects Investigation (ODI) opened PE24019 to investigate complaints of low-pressure fuel pump failures in MY 2021 Ford Bronco vehicles. Some consumers reported that the failure occurred without warning while driving, resulting in a complete loss of motive power with ... no ability to restart the engine. Ford determined that several other vehicle models contain low-pressure fuel pumps substantially similar to the 2021 Ford Bronco, including the 2022-2023 Ford Bronco, 2018-2023 Ford F-150, 2022-2023 Ford Expedition, 2019-2023 Lincoln Navigator, 2020-2023 Ford F-250-F-550, 2024 Ford Super Duty Chassis Cab, 2024-2025 Ford Ranger, 2020-2023 Ford Explorer, 2020-2023 Lincoln Aviator, and 2021-2025 Ford Mustang. ODI's investigation found that the aﬀected vehicles may lose fuel pressure and ﬂow from the fuel delivery module (consisting of a low-pressure fuel pump, jet pump, reservoir, and other parts) due to a low-pressure pump failure. This can cause the engine to stall while driving. The root cause is reduced internal clearance in the fuel pump, increasing friction and sensitivity to vapor lock. Fuel blockage from contamination inside the jet pump also contributed to the failure. Ford stated that the contamination source was unknown. On July 7, 2025, Ford ﬁled recall 25V-455 for certain 2021-2023 Ford F-550 SD/F-450 SD/F-350 SD/F-250 SD, 2021-2022 Lincoln Navigator, 2021-2022 Ford Mustang, 2021-2022 Ford F-150, 2021-2023 Ford Explorer, 2022 Ford Expedition, and 2021-2023 Ford Bronco vehicles produced between July 1, 2021, and July 30, 2022. The recall also included certain 2021-2023 Lincoln Aviator produced between July 1, 2021, and December 21, 2022. Ford explained in its recall filingthat the production dates used for the recall were based on changes in the manufacturing process. Specifically, Ford determined that in June 2021, the supplier modified the jet pump manufacturing process, producing fuel pump chambers with a lower-than-specified internal clearance. In July 2022, the supplier implemented corrective actions to the manufacturing process by adding two additional vacuum pumps to reduce contamination during the production of the jet pump. ODI has identified approximately 1,000 reports involving vehicles covered in this investigation but excluded from recall 25V-455. However, even with such reports, these vehicles experienced comparatively lower failure rates than the vehicles that are subject to Recall 25V-455. Ford has explained that these vehicles were excluded from the recall population because they did not experience the manufacturing changes that prompted the recall. Specifically, according to Ford, vehicles built before July 1, 2021 (the recall production start date), were not affected by the supplier’s change to the jet pump manufacturing process. Even after closing this investigation, ODI will continue to monitor complaints for vehicles excluded from recall 25V-455 to consider whether they exhibit the same risks as the vehicles encompassed by the recall. The recall remedy is currently under development. In view of Ford’s recall action, ODI is closing this Preliminary Evaluation, but will continue to monitor the issue as a remedy is developed and implemented. ODI will take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identiﬁcation Number document, go to NHTSA.gov.Read more

EA, Closed , Model Year: 2021

Loss of Motive Power

On July 22, 2022, the Office of Defects Investigation (ODI) granted a Defect Petition (DP22001) and opened a Preliminary Evaluation (PE22007) to investigate allegations of loss of motive power in model year (MY) 2021 Ford Bronco vehicles equipped with 2.7L EcoBoost engines. Complainants were reporti... ng sudden engine failure while driving resulting in a loss of motive power, often without the ability to restart. During PE22007, the cause of engine failure and loss of motive power in the subject vehicles was determined to be intake valve fracture, and the full scope of vehicles affected by the subject defect was identified as all MY 2021-2022 Ford and Lincoln models equipped with either the 2.7L or 3.0L EcoBoost engines, referred to as the “Nano” engine family. If an intake valve fractures in the subject engines, it may drop into the cylinder and contact the piston, often resulting in catastrophic engine damage. On September 29, 2023, PE22007 was upgraded to an Engineering Analysis (EA23002) to further investigate the subject defect across the full scope of affected vehicles. During EA23002, ODI visited Ford facilities to review technical information related to intake valve fracture in “Nano” engines, coordinated with NHTSA’s Vehicle Research and Testing Center (VRTC), and analyzed updated field data relating the subject defect. Forensic analysis of fractured intake valves demonstrated that the defective components exhibited “grinding burn” or out of specification hardness in the area of the keeper grooves. The presence of grinding burn is evidence that during the groove grinding phase of production, the temperature of the valve became sufficiently high to alter the microstructure of the material and is indicative that the valve supplier’s manufacturing processes were not within control specifications. Grinding burn results in a hard, brittle microstructure and high residual stresses toward the surface of the valve. Through normal engine loading, a valve with grinding burn will likely fracture at the area of highest vulnerability, which is the third keeper groove. In its response to the EA23002 Information Request (IR) letter, Ford provided evidence of 396 customer complaints (including field reports), 825 warranty claims, and 936 engine exchanges. When considering both ODI and manufacturer failure report data, there have been reports representing 1066 unique vehicles within the subject vehicle population. Analysis of the failure report data demonstrates that vehicles equipped with potentially defective intake valves were built within a production “spike period” of May 2021 – October 2021. The beginning of the spike period corresponds to a ramp up in production at the valve supplier manufacturing facility, and the end of the spike period aligns with the implementation of several mid-production process improvements and the decision to change the metal alloy used to produce intake valves from “Silchrome Lite” to “Silchrome 1”. Ford began investigating the subject defect in July 2021, determined the root cause, and took corrective measures for the new production vehicles. Analysis of the failure report data demonstrates that these corrective actions were successful in eliminating the risk of intake valve fracture for subject vehicles produced after October 2021. However, Ford did not take any field action to address vehicles produced during the spike period, and in the several months following the implementation of the production changes, a significant number of field failures continued to occur. It is Ford’s assessment that not all valves produced during the spike period are defective, and that failures associated with the subject defect occur at low time in service. Analysis of the failure report data demonstrates that the vast majority of failures have occurred before 20,000 miles with over half of all reported failures occurring before 5,000 miles. The rate of reported failures related to the subject defect has steadily decreased since November 2021. ODI coordinated with NHTSA’s National Center for Statistics and Analysis (NCSA) to conduct statistical analysis and predict the number of future failures associated with the subject defect. The results of this analysis, and the trends identified through the failure report data are generally consistent with Ford’s assessment that defective intake valves will likely fail at a low time in service and indicate that the majority of subject vehicles equipped with defective valves have already experienced a failure. On August 23, 2024, Ford submitted recall 24V635 for subject vehicles equipped with “Nano” engines and built within the production spike period identified above (total population 90,736 vehicles). The remedy includes an inspection at a Ford/Lincoln dealership where the lifetime engine cycles of the vehicle will be determined. If a vehicle does not meet a threshold for lifetime engine cycles, the dealership will conduct a high RPM engine cycle accumulation procedure, which aims to identify if the vehicle is equipped with defective intake valves. Any vehicle that fails the accumulation procedure will receive an engine replacement under the recall. In addition to recall 24V635, Ford has stated that it will launch customer satisfaction campaign 24N12, which will provide extended warranty coverage to the subject vehicles through the earlier of 10 years or 150,000 miles. In view of the recall action being taken by Ford, ODI is closing this Engineering Analysis. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.Read more

PE, Closed , Model Year: 2021

Loss of motive power due to valve intake failure on Ford Bronco vehicles.

The Office of Defects Investigation (ODI) received a petition dated March 16, 2022, requesting an investigation regarding allegations of defective intake valves in model year (MY) 2021 Ford Bronco vehicles equipped with the 2.7L Eco-boost (“Nano”) engines. The petitioner alleged these vehicles... Read more

DP, Closed , Model Year: 2021

Loss of Motive Power

The Office of Defects Investigation (ODI) received three petitions on March 17, March 18, and March 29, 2022, which requested a defect investigation into an alleged defect of the valves on model year (MY) 2021 Ford Bronco vehicles equipped with the 2.7L Eco-boost engines. The petitioners alleged tha... Read more

EA, Closed , Model Year: 1994

ENGINE COMPARTMENT FIRES

EA05-005 IS CLOSED WITH FORD?S ACTIONS IN RECALLS 05V-017, 05V-388, AND 06V-286, RECALLING APPROXIMATELY 6.7 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).THE BRAKE SYSTEMS IN THESE RECALLED VEHICLES GENERATE A VACUUM THAT CAN POTENTIALLY CAUSE THE SCDS ... Read more

RQ, Closed , Model Year: 1992

PARKING BRAKE