1989 FORD BRONCO

2 recalls, 118 complaints - 31 TSBs

ELECTRICAL SYSTEM:IGNITION

Defect Description

THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.

Consequence

THIS CONDITION COULD CAUSE OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN AREA OF THE VEHICLE.

Remedy

DEALERS WILL REPLACE THE IGNITION SWITCH.

7,900,000 vehicles affected

Manufacturer: FORD MOTOR COMPANY

EQUIPMENT:OTHER:LABELS

Defect Description

TIRE RESERVE LOAD LABEL MAY NOT HAVE BEEN INSTALLED.

Consequence

VEHICLE WOULD NOT COMPLY WITH FMVSS 110.

Remedy

INSTALL PROPER LABEL.

5 vehicles affected

Manufacturer: DABRYAN COACH BUILDERS

Complaint Statistics

118 total complaints 2 crashes 19 fires 3 injuries

Top Reported Components

Component	Complaints
ELECTRICAL SYSTEM:IGNITION	10
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE	7
ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD	7
ENGINE AND ENGINE COOLING:ENGINE	6
FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY	5
SEATS	5
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP	5
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS	4
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP	4
ELECTRICAL SYSTEM:IGNITION:SWITCH	4

Incident date: Mar 22, 2010

TL*THE CONTACT OWNS A 1989 FORD BRONCO. THE CONTACT WAS UNABLE TO START THE VEHICLE BECAUSE THE KEY WOULD NOT TURN IN THE IGNITION. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING. THE DEALER REPLACED THE IGNITION SWITCH UNDER NHTSA CAMPAIGN ID NUMBER 96V071000 (ELECTRICAL SYSTEM: IGNITIO... Read more

Incident date: Jun 1, 2004

CONSUMER PARKED THE VEHICLE AT A RESTAURANT AND WENT INSIDE TO EAT. WITHIN TEN MINUTES THE CONSUMER NOTICED FIRE TRUCKS COMING INTO THE RESTAURANT'S PARKING LOT. CONSUMER WENT OUTSIDE TO INVESTIGATE WHAT WAS GOING ON, AND NOTICED THAT HIS VEHICLE WAS ON FIRE. THE FIRE DEPARTMENT EXTINGUISHED THE FI... Read more

Fire

THE FLOOR PAN UNDERNEATH THE DRIVER'S SIDE SEAT HAD THROWN. IF VEHICLE WAS INVOLVED IN AN ACCIDENT OR BRAKES HAD TO BE DEPRESSED SUDDENLY DRIVER'S SIDE SEAT BELT WOULD RIP OUT BECAUSE IT WAS ATTACHED TO THE FLOOR PAN. THERE WAS TSB/ RECALL IN ALL DATA B93900801 FOR THE FLOOR PAN REINFORCEMENT(NO... Read more

Incident date: Sep 9, 2002

VEHICLE HAD BEEN SITTING OVER NIGHT WHEN IT CAUGHT ON FIRE. FIRE DEPARTMENT STATED STEERING COLUMN AND DASH PLAYED A MAJOR PART IN FIRE. PLEASE PROVIDE ANY FURTHER INFORMATION.*AK

Fire

Incident date: May 2, 2002

WITH NO WARNING MY BRONCO DIED WHILE I WAS TRAVELING AT 45 MPH IN WORK TRAFFIC. I HAD TO PUSH THE BRONCO OUT OF TRAFFIC, AND THEN WAIT 2 HRS. FOR A TOW TRUCK TO TOW ME TO A MECHANIC, WITHA REPAIR BILL OF $184.00 TO REPLACE THE DEFECTIVE IGNITION MODULE. I WANT TO BE REIMBURSED $184.00. THIS SHOU... Read more

Incident date: Jan 1, 2001

VEHICLE HESITATED AND SMOKE COMING FROM HOOD AREA. VEHICLE BURNED TO THE GROUND.*AK

Fire

Incident date: Mar 14, 2002

WHILE DRIVING WOULD STEP ON BRAKE PEDAL TO STOP OR TO REDUCE THE SPEED OF THE VEHICLE, BUT BRAKES WILL NOT ACTIVATE ON TIME. HAD CONTACTED DEALER. PLEASE PROVIDE MORE INFORMATION.*AK

Incident date: Mar 14, 2002

WHILE DRIVING COULD HEAR A LOT OF NOISE. HAD CONTACTED DEALER, BUT THEY COULD NOT DETERMINE WHAT WAS CAUSING THE NOISE. PLEASE PROVIDE MORE INFORMATION. *AK

Incident date: Mar 14, 2002

CONSUMER EXPERIENCED SOME ELECTRICAL PROBLEMS WHICH CAUSED VEHICLE TO CATCH ON FIRE, THE FIRE DEPARTMENT COULD NOT SAY WHAT EXACTLY CAUSED THE FIRE.*AK. CONSUMER STATED VEHICLE STALLED 3 TIMES PREVIOUSLY.*JB

Fire

VEHICLE STALLS AT ANY TIME/ ANY SPEED. DEALER IS REPLACING IGNITION FOR THIRD TIME.*AK

Incident date: Dec 1, 2001

GAS TANK IS RUSTING AND LEAKING FUEL FROM THE TANK LEAVING SMALL AMOUNTS OF FUEL ON THE GROUND. PLEASE GIVE ANY FURTHER DETAILS.*AK

Incident date: Jul 5, 2000

VEHICLE STALLED WHEN ENGINE OVERHEATED. *AK

Incident date: Apr 1, 2001

TWICE THE ENGINE JUST QUIT RUNNING WITHOUT ANY WARNING, I LEFT THE VEHICLE AT MY FATHERS HOME OVER NIGHT THE FIRST TIME AND THE NEXT MORNING IT STARTED UP. I DROVE IT FOR ABOUT A WEEK K AND IT JUST QUIT RUNNING AGAIN , THIS IS VERY DANGEROUS BECAUSE THE MECHANIC COULD'T FIND A PROBLEM(IT STARTED UP ... Read more

Incident date: Apr 20, 1993

WHEN APPLYING BRAKES BRAKE LIGHTS DID NOT COME ON UNTIL CONSUMER PRESSED BRAKES A SECOND TIME. CONSUMER STATED THAT SOMEONE COULD REAR END HIM BECAUSE BRAKE LIGHTS WERE NOT COMING ON.*AK

VEHICLE STALLS INTERMITTENTLY WHILE DRIVING ESPECIALLY ON HOT DAYS, AFTER THE VEHICLE IS ALLOWED TO COOL OFF THE VEHICLE STARTS AGAIN, CONSUMER BELIEVES THIS PROBLEM IS RELATED TO A FAULTY TFI MODULE. NLM

Incident date: Nov 1, 1996

IGNITION COIL, IGNITION SWITCH,IGNITION CONTROL MODULE IN DISTRIBUTOR HAS BEEN REPLACED MANY TIMES AND CAR STILL STALLS WHEN TEMPERTURES REACH WARM DEGREES OUTSIDE.*AK

Incident date: Jul 1, 2000

SEAT JAMS DUE TO FLOOR FLEXING. THE PROBLEM WAS IDENTIFIED UNDER NHTSA ITEMS NO. SB017182, SB019336, SB019393, SB019395, SB019879, WHICH CALLED FOR FLOOR REINFORCEMENT. NO NOTIFICATION WAS PROVIDED TO OWNER. DEALER AT THE TIME OF THE SB'S WAS SALINAS VALLEY FORD, SALINAS, CA. NO RECALL NOTICE IN... Read more

Incident date: Jul 1, 2000

Incident date: Sep 16, 2000

MY TRUCK STALLED ON THE FREEWAY TWICE.ONCE ON THE BAY BRIDGE,THE OTHER TIME ON I280.BOTH TIMES MY TRUCK WAS RUNNING FINE THEN ALL OF A SUDDEN IT WOULD JUST SHUT STALL.THE TIME ON THE BRIDGE WAS VERY TERRIFYING,IF TRAFFIC WAS HEAVY THERE DEFINITELY WOULD HAVE BEEN A COLLISION.I HOPE SOMEBODY DOESN'T ... Read more

Incident date: Dec 15, 1995

NO SUMMARY

TIRES WERE ANALYZED BY FIRESTONE DEALER AND THEY SAID THEY SHOULD BE REPLACED. NOT UNDER RECALL OR REPLACEMENT PROGRAM. TIRES WERE PRODUCED AT THE DECATUR, IL FACILITY WERE A MAJORITY OF THE PROBLEM TIRES WERE PRODUCED. THEY ARE DEFECTIVE AND SHOULD BE REPLACED BY THE COMPANY WHO PRODUCED THEM. ... Read more

Incident date: Aug 15, 2000

I NOTICED ABOUT A WEEK BEFORE THE TIRE BLEWOUT THAT WHILE WE WERE IDDLING THROUGH THE LOCAL WALMART PARKING LOT THE VEHICLE ROCKED BACK AND FORTH. ABOUT A WEEK LATER THE VEHICLE WAS PARKED IN THE GARAGE AND I NOTICED A BLISTER ON THE LEFT REAR TIRE IN THE TREAD SECTION. I CHECKED THE OTHER TIRES A... Read more

Incident date: Aug 25, 2000

PEOO 020; WAS TRAVELING ABOUT 57MPH ON THE HIGHWAY AND HEARD A NOISE. SHE PULL OVER TO THE SIDE OF SHOULDER. FRONT DRIVERS SIDE TIRE TREAD HAD SEPARATED. DID DAMAGE TO VEHICLE. TIRE IS FIRESTONE FIREHAWK #SS10 P215/70R15. THERE WERE NO INJURIES SHE ALSO CONTACTED FIRESTONE. *AK

Incident date: Dec 12, 1998

CONSUMER'S DAUGHTER WAS DRIVING ABOUT 55 MPH AND LEFT REAR TIRE BEGAN TO PEEL OFF AND BECAME SEPARATED FROM THE BELT. *AK

Incident date: Aug 13, 1998

IN THE SUMMER OF 1998 (JULY-AUGUST) I HAD THREE TIRE FAILURES. THE FIRST TIRE LOCATED ON THE RIGHT REAR FAILED TRAVELING 65 MILES PER HOUR ON I-75. THE TREAD SEPARATED LEAVING THE CORE INFLATED. I LOST TRACTION ON THE WHEEL AND THE VEHICLE BECAME HARD TO CONTROL AS IT WHEN OFF THE ROAD. I WAS ABL... Read more

Incident date: Feb 25, 2000

MY PAINT IS PEELING AND I WAS TOLD THAT THERE WAS A RECALL ON THIS CONCERN FOR MY TRUCK IN WHICH I WAS NEVER INFORMED NOR SENT ANY PAPERWORK- ALSO I HAVE BEEN TOLD THAT OTHERS HAVE FILED LAW SUITS DUE TO THIS AND ONE AND HAVE GOTTEN THEIR VEHICLES RE-PAINTED- IF I HAD BEEN NOTIFIED I WOULD HAVE BROU... Read more

Incident date: Jan 23, 1999

HEADLAMP SWITCH IS THE SAME AS ON T-BIRDS, STILL NO RECALL, LIGHTS WILL FLASH ON AND OFF. STEERING BOX LOCKED UP, NO LEAKS, FLOOR PAN BROKEN, NOT COVERED DUE TO THE FACT OF NOT HAVING CAPTAINS CHAIRS. SHOULD HAVE TO DO WITH THE STRENGTH OF THE FLOOR NOT THE SEAT APPLIED TO THE FLOOR, VERY... Read more

Incident date: Jan 23, 1999

Incident date: Aug 1, 1995

WHEN VEHICLE IS DRIVEN FOR EXTENDED PERIODS OF TIME IN HOT CLIMATES, IT STALLS OUT AND DIES. DEALER AND MANUFACTURER HAVE BEEN NOTIFIED. *AK *JB

THIS VEHICLED HAS A RECALL ON THE FLOORBOARD, WHICH HAS STRESS CRACKS IN IT. HOWEVER WHEN I CHECKED THIS IT COMES BACK SALVAGED WITH JUNK TITLE WHICH VOIDS THE RECALL! NOW WHAT ?

Crash

RADIUS ARM BRACKET HAS CORRODED PREMATURELY.

Incident date: Jan 21, 1999

FUEL LINES RUSTED OUT CAUSING FUEL TO RUN ON THE FLOOR IN A GARAGE. FIRE POTENTAL

Incident date: Jan 21, 1999

BRAKE LINES RUST OUT AND CAUSE BRAKE FAILURE!

Incident date: Jan 21, 1999

FUEL LINES RUSTED OUT CAUSING FUEL TO RUN ON THE FLOOR IN A GARAGE. FIRE POTENTAL

PAINT IS PEELING FROM FRONT END AND IS RUSTING IN SOME SPOTS.

Incident date: Dec 7, 1998

THE CONSUMER HAS BEEN EXPERIENCING PROBLEMS WITH ALTERNATOR HARNESS. WHEN STARTED VEHICLE SMELLED SOMETHING BURNING. WHEN THE CONSUMER OPENED THE HOOD, VEHICLE WAS IN FLAMES. THE FIRE WAS PUT OUT WITH AN EXTINGUISHER. THE MANUFACTURER HAS BEEN CONTACTED. *AK

Fire

Incident date: Sep 4, 1998

CONSUMER PARKED VEHICLE IN DRIVEWAY AT APPROXIMATELY 4:30 PM AND AT APPROXIMATELY 3:06 AM CONSUMER WAS INFORMED BY NEIGHBOR OF VEHICLE BEING ON FIRE. FIRE DEPARTMENT ARRIVED TO PUT OUT THE FIRE. NINE DAYS LATER, CONSUMER RECEIVED MANUFACTURER'S. RECALL NOTICE # 95S-28 / NHTSA RECALL # 96V- 071, IGN... Read more

Fire

Incident date: Jun 1, 1998

WHEN APPLYING BRAKE PEDAL THE VEHICLE SHIFTS TO THE RIGHT. DEALER WAS NOT NOTIFIED. *AK

Incident date: Jun 1, 1998

WHILE DRIVING STEERING WHEEL WOULD LOCK UP, CAUSING THE VEHICLE TO LOSE CONTROL. DEALER WAS NOT NOTIFIED. *AK

Incident date: Aug 1, 1997

FRONT BUCKET SEATS MOUNTING STRUCTURE IS FAILING AND SEAT IS FALLING THROUGH BOTTOM OF VEHICLE.

Incident date: Jul 1, 1995

LUGS:NUTS ARE ALL LOOSE ON WHEELS.

Incident date: Apr 15, 1998

THERE WAS A RECALL LISTED ON THE IGNITION SWITCH 97V-071. BUT WHAT HAPPENED TO THIS TRUCK COULD HAVE BEEN PART OF THE RECALL. THE ALTERNATOR CAUGHT ON FIRE THAT WAS CAUSE BY THE ENGINE OVERHEATING. *AK

Fire

Incident date: Mar 3, 1994

WIRING HARNESS HAS OVERHEATED AND BURNED SEVERAL TIMES CAUSING ALTERNATOR AND OTHER COMPONENTS TO BURN AND MELT AS WELL.

Fire

Incident date: Dec 4, 1997

HAD RECEIVED RECALL NOTICE (#96V071000) IN THE MAIL. HAD CALLED DEALER FOR APPOINTMENT & TOOK VEHICLE IN. DEALER DID NOT REPAIR VEHICLE AT ALL. NOT SATISFIED. *AK

Incident date: Jul 13, 1997

VEHICLE ROLLED OVER IN COLLISION.

2 injured

REAR VIEW MIRRORS DO NOT REMAIN STABLE WHILE TRAVELING AT 35 MPH OR MORE.

GAS TANK RUSTED OUT AND NEEDED REPLACEMENT.

Incident date: Aug 5, 1997

VEHICLE'S LEGS TO SEAT TRACKS GETS STRESS CRACKS AND SEAT COMES LOOSE FROM FLOOR. *AK

Showing 50 of 118 complaints.

Technical Service Bulletins, 1989 FORD BRONCO

31 manufacturer communications from 31 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
103000 POWER TRAIN:AUTOMATIC TRANSMISSION	10
061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE	2
103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER	2
103600 POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES	2
061000 ENGINE AND ENGINE COOLING:ENGINE	1
021000 SUSPENSION:FRONT	1
131000 VISIBILITY:WINDSHIELD	1
021242 SUSPENSION:FRONT:SPRINGS:LEAF SPRING ASSEMBLY:HANGER,BRACKET	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

103600 POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES

SUBJECT REGARDING CONTAMINATION FROM PRIOR TRANSMISSION CONCERNS OR EXCESS WEAR MAY BE TRAPPED IN THE TRANSMISSION FLUID COOLING SYSTEM. *TT

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

TRANSMISSION- E40D/4R100-1989-99-MAIN CONTROLS, SEPARATOR PLATES AND SEPARATOR PLATE GASKETS USAGE CHART. YD

103600 POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES

VEHICLES MAY EXPERIENCE SOLID PARTICLE CONTAMINANTS FROM PRIOR TRANSMISSION CONCERNS OR EXCESS WEAR, MAY BE TRAPPED IN THE TRANSMISSION FLUID COOLING SYSTEM IS NOT PROPERLY FLUSHED, FLUID IN-LINE FILTER KIT. *MJS

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

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

FORD MOTOR COMPANY NOW RECOMMENDS SAE 5W-30 VISCOSITY GRADE FOR SERVICING ANY FORD GASOLINE-POWERED VEHICLE REGARDLESS OF MODEL YEAR. *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

354600 EQUIPMENT:MECHANICAL:WRECKER AND WHEEL LIFT DEVICES

RECOMMENDED GUIDELINES FOR TOWING BEHIND RECREATIONAL VEHICLES. *TT

020000 SUSPENSION

SOME VEHICLES MAY EXHIBIT A DRIFT OR PULL TO THE LEFT WHILE BRAKING. *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

101000 POWER TRAIN:CLUTCH ASSEMBLY

SERVICE TIP INFORMATION REGARDING THE REVERSE CLUTCH PISTON AND PISTON SEAL USAGE. *TT

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

DELAYED FORWARD ENGAGEMENT AND/OR HEAT STAINED FORWARD CLUTCH PLATES AFTER INSTALLING CENTER SUPPORT SERVICE. *TW

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

REVISED DESIGN TRANSMISSION REAR CASE BUSHING. *TW

021000 SUSPENSION:FRONT

UNKNOWN

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

KNOCKING NOISE ON INITIAL START-UP. *TW

061000 ENGINE AND ENGINE COOLING:ENGINE

NEW TORQUE-TO-YIELD CYLINDER HEAD BOLT KIT. *TW

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

VEHICLES MAY EXHIBIT A SHIFT CONCERN. *TW

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

TRANSMISSION OVERHEATING, CONVERTER COVER DISCOLORATION, CLUTCHES BURNED AND BURNT FLUID *TW

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

UPGRADE KIT FOR THE E40D TRANSMISSION. *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