1991 FORD BRONCO

2 recalls, 37 complaints - 54 TSBs

TIRES:TREAD/BELT

Defect Description

THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. EQUIPMENT DESCRIPTION: FORD IS REPLACING ALL FIRESTONE WILDERNESS AT 15, 16, AND 17 INCH TIRES MOUNTED ON FORD TRUCKS AND SUVS. FORD REPORTS TREAD SEPARATION CAN... Read more

Consequence

SHOULD THE TREAD SEPARATE AT HIGHWAY SPEEDS, A VEHICLE CRASH COULD OCCUR, POSSIBLY RESULTING IN PERSONAL INJURY OR DEATH.

Remedy

THE REPLACEMENT/REIMBURSEMENT PROGRAM FOR THIS CAMPAIGN EXPIRED ON MARCH 31, 2002. HOWEVER, CUSTOMERS CAN CONTACT FORD AT 1-877-917-3673 OR GO ON-LINE TO WWW.FORD.COM FOR POSSIBLE ASSISTANCE.

13,000,000 vehicles affected

Manufacturer: FORD MOTOR COMPANY

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

Complaint Statistics

37 total complaints 1 crashes 10 fires 3 injuries 6 deaths

Top Reported Components

Component	Complaints
ELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASH	6
ELECTRICAL SYSTEM:IGNITION:SWITCH	4
FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY	3
VEHICLE SPEED CONTROL	2
SEATS:FRONT ASSEMBLY:RECLINER	2
TIRES	2
STEERING:RACK AND PINION	1
SEATS	1
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DRUM	1
ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR	1

Incident date: Apr 17, 2004

WHEN DRIVING AT AN UNDETERMINED SPEED CONSUMER NOTICED THAT STEERING COLUMN SMOKED. CONSUMER TOOK THE VEHICLE TO THE DEALERSHIP FOR INSPECTION. *AK

Incident date: Oct 24, 2003

VEHICLE GOES INTO FULL THROTTLE WITHOUT WARNING. THE ONLY WAY TO STOP THE ACCELERATION IS TO SHUT THE VEHICLE OFF. *AK

Incident date: May 22, 2003

THE CAST IRON EXHAUST MANIFOLD CRACKED, AND THE MANUFACTURE WAS NOT WILLING TO ASSIST. *JB

Incident date: Aug 27, 2002

THIS IS THE THIRD TIME I INHALED BURNT WIRE AND COULDN'T GET IT TO STOP, THAN LOSE LIGHT IN THE DARK,AND I DID ONCE HAVE FORD SERVICE TO SEE TO THE PROBLEM AND THEY ONLY FOUND BATTERY CLAMP WASN'T TIGHT BUT NO WIEING BURNING, AND I HAVE DISCOVERY A TWO YEAR LATER IT LOSED THE LIGHT AND THE PLUG OF T... Read more

1 injured 3 deaths

Incident date: Aug 27, 2002

1 injured 3 deaths

Incident date: Sep 5, 2000

THE FIRESTONE TIRES ATX P235/75R15 WERE DEFECTIVE AND THE CONSUMER HAD THEM REPLACED WITH MICHELIN TIRES. THE CONSUMER IS ASKING FOR REIMBURSMENT AND THE MANUFACTURER HAS NO INTEREST IN HONORING HIS CLAIM. *YH

THE TRANSMISSION WAS HARD TO PUT INTO GEAR AND THE TRANSMISSION IS SLIPPING WHEN DRIVING THE DEALER HAS BEEN CONTACTED. NLM

Incident date: Sep 5, 2000

Incident date: Jan 13, 2001

WHEN ATTEMPTING TO START VEHICLE BY PLACING THE KEY IN VEHICLE IGNITION KEY WILL NOT FIT IN IGNITION, CAUSING A NO START SITUATION. PLEASE PROVIDE ANY FURTHER DETAILS.*AK

Incident date: Sep 5, 2000

FIRESTONE ATX, P235/75R15, TIRES WERE INSPECTED AND FOUND TOO DANGEROUS FOR CONTINUED USE, CONSUMER HAD TIRES REPLACED AND SENT A CLAIM FOR REIMBURSEMENT, HOWEVER HAS BEEN DENIED 6 TIMES DUE TO FAILURE TO ENCLOSE ORIGINAL DOCUMENTS WHICH CONSUMER HAD SENT ORIGINALLY. *SLC

PARKED VEHICLE, IGNITION OFF, APPROXIMATELY 20 MINUTES LATER VEHICLE ON FIRE STARTED UNDER HOOD. *AK

Fire

Incident date: May 11, 2000

FUEL TANK DEVELOPED LEAKS BETWEEN BOTTOM OF TANK AND SKID PAN. THE DESIGN AND PLACEMENT OF THE SKID PAN CONTIBUTED TO AN ACCUMULATION OF DIRT AND OTHER DEBRIS THAT CRAETED AN ENVIORONMENT THAT HASTENED THE FORMATION OF RUST, WHICH EVENTUALLY LED TO THE FORMATION OF HOLES IN THE TANK. IF NOT DETECTED... Read more

WHILE DRIVING THE VEHICLE THERE WAS A SURGE IN THE ENGINE AND VEHICLE ACCELERATED FROM 60 TO ABOUT 90MPH. KEY HAD TO BE TAKEN FROM IGNITION IN ORDER TO STOP VEHICLE. DEALER HAS NOT SEEN VEHICLE. *AK

CONSUMER KEEPS VEHICLE UNDER CAR PORT AT ALL TIMES, THEY ARE FIRST OWNERS OF VEHICLE AND THE LAST TWO-THREE YEARS VEHICLE PAINT'S BEEN PEELING, DEALERSHIP SAYS THEY ARE NOT RESPONSIBLE.

Incident date: Dec 12, 1995

OIL PAN GASKET MISSING IN SOME PLACES CAUSING OIL TO LEAK FROM CRANKCASE. MJS

Incident date: Sep 19, 1998

STEEL PLATE THAT HOLDS THE FUEL TANK, COMPLETELY RUSTED AWAY CAUSING THE FUEL TANK TO FALL OFF, THE PROBLEM WAS REPORTED TO THE DEALERSHIP,. THE FUEL TANK WILL BE REPLACED AT OWNERS EXPENSE. *AK *JB

WHILE DRIVING VEHICLE AT 20 MPH THE FUEL TANK FELL OFF, CAUSING GAS TO SPILL AND POSSIBLE FIRE HAZARD.

Incident date: Aug 21, 1997

WHILE DRIVING SMOKE CAME FROM UNDER THE DASHBOARD AND BEFORE DRIVER COULD GET OUT OF VEHICLE, VEHICLE BURST INTO FLAMES. VEHICLE HAS BEEN TOTALLED. *AK

Fire

Incident date: Nov 27, 1996

WIFE DRIVING, WENT TO PASS, THROTTLE GOT STUCK IN OPEN POSITION, COULD NOT GET GAS PEDAL TO BACK UP, VEHICLE INCREASED IN SPEED, BRAKES FAILED TO STOP VEHICLE, FINALLY TURNED OFF IGNITION, VEHICLE KEPT RUNNING FOR AWHILE, VEHICLE WAS HOT. *AK

Incident date: Nov 27, 1996

Incident date: Nov 2, 1996

FRONT SEALS ON POWER TRAIN FAILED, CAUSING FLUID TO SPRAY ONTO ENGINE, RESULTING IN VEHICLE CATCHING ON FIRE. PLEASE DEFINE IN DETAIL POWER TRAIN. *AK

Fire

Incident date: Nov 11, 1996

WHILE DRIVING SMOKE WAS COMING FROM UNDER CARRAIGE OF VEHICLE THEN THE CAR CAUGHT ON FIRE.THE REASON IS STILL UNKNOWN. *AK

Fire

VEHICLE FUEL TANK HAS A HOLE DUE TO DESGN DEFECT DEBRIS ENTERS IN BETWEEN THE HOLDING PLATE AND TANK AND CAUSES HOLES/LEAKAGE.MFR IS AWARE OF DEFECT. *AK

Incident date: Nov 13, 1994

HIGH BACK SEATS NOT HIGH ENOUGH TO PROTECT PEOPLE IN THE FRONT SEATS FROM WHIPLASH. *DSH

THE INGNITION SWITCH NEED TO BE REPLACED, DEALER SAID IGNITION WAS BURN OUT.PLEASE DESCRIBE . *AK

Incident date: Dec 24, 1995

VEHICLE REARENDED TWO WEEKS LATER DRIVERS SEATBACK BROKE WHEN REPOSITIONED. *AK

Incident date: Apr 6, 1996

DRIVING TO STORE, NOTICED SMOKE, PULLED OVER, FIRE COMING FROM DASHBOARD ON DRIVER'S SIDE, WINDSHIELD SHATTERED. *AK

Fire

Incident date: Mar 7, 1996

WHILE PARKING THE VEHICLE CAUGHT FIRE, CAUSED BY THE IGNITION SWITCH.PLEASE DESCRIBE. *AK

Fire

Incident date: Sep 1, 1995

ELECTRICAL SYSTEM FIRE CAUSED BY WIRING HARNESS CATCHING FIRE. TT

Fire

Incident date: Nov 21, 1995

VEHICLE CAUGHT ON FIRE IN ALTERNATOR AFTER BEING PARKED. TT

Fire

Incident date: Dec 1, 1994

REAR BRAKES OVERHEATED/FAILED, CAUSING VEHICLE TO LOSE CONTROL. *AK

Incident date: Aug 16, 1995

WHILE DRIVING, SMEEL OF PLASTIC BURNING, UNDER THE DASH COMPARTMENT ELECTRICAL SHORT VEHICLE BURNED, WILL PROVIDE MORE INFORMATION. TT

Fire

Incident date: May 4, 1995

DRIVER'S SEAT BOLT AND BRACKET WHICH ANCHOR SEAT TO FLOOR HAVE RUSTED OUT. TT

Incident date: Feb 9, 1995

VEERED TO THE RIGHT TURNED WHEEL TO THE LEFT AND STEERING LOCKED UP. TT

Crash 1 injured

Incident date: Apr 29, 1995

WAS DRIVING IN AUTOMATIC OVER DRIVE IT ACELERATE HAD PULL OVER AND CUT IT OFF. TT

Incident date: Mar 1, 1995

NOTICE SMOKE COMING FROM STEERING WHEEL AND DASH BOARD AREA, POSSIBLE ELECTRICAL FIRE. TT

Fire

Technical Service Bulletins, 1991 FORD BRONCO

54 manufacturer communications from 47 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
103000 POWER TRAIN:AUTOMATIC TRANSMISSION	13
061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE	4
980000 UNKNOWN OR OTHER	4
061000 ENGINE AND ENGINE COOLING:ENGINE	3
106000 POWER TRAIN:AXLE ASSEMBLY	3
190000 TIRES	2
103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER	2
160000 STRUCTURE	2

190000 TIRES

OWNER NOTIFICATION PROGRAM SUPPLEMENT 7 REVISED INFORMATION - REGARDING REPLACEMENT OF WILDERNESS AT TIRES. *TT

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-NO 2-3 UPSHIFT. SOME VEHICLES MAY EXHIBIT A NO 2-3 UPSHIFT CONDITION. *AK

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

353400 EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC.

EXPERIENCING A WHINE / BUZZ TYPE NOISE IN THE SPEAKERS OF THE ENTERTAINMENT RADIO OR TWO-WAY RADIO ON VEHICLES WITH AN IN-TANK ELECTRIC FUEL PUMP. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

SOME VEHICLES MAY EXPERIENCE AXLE WIND UP AND / OR CLUNKING, POPPING, RATCHETING TYPE NOISES WHEN MAKING CORNERING MANEUVERS ON VEHICLES EQUIPPED WITH A FOUR WHEEL DRIVE HI OR LOW RANGE MODE. *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

980000 UNKNOWN OR OTHER

INFORMATION ON VEHICLES EXHIBITING AND O/D OFF LAMP FLASHING WITH DIAGNOSTIC TROUBLE CODE 62 / 628 / 1728. *TT

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

INFORMATION ON A NEW TRANSMISSION FLUID USAGE CHART. *YC

353400 EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC.

EXPERIENCING A WHINING / BUZZING NOISE IN THE SPEAKERS OF THE ENTERTAINMENT RADIO OR TWO-WAY RADIO. *TT

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

020000 SUSPENSION

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

354600 EQUIPMENT:MECHANICAL:WRECKER AND WHEEL LIFT DEVICES

RECOMMENDED GUIDELINES FOR TOWING BEHIND RECREATIONAL VEHICLES. *TT

034500 SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC

THE USE OF PETROLEUM-BASED GREASE AS A LUBRICANT IN SERVICING DISC BRAKES IS NO LONGER ACCEPTABLE. *YC

980000 UNKNOWN OR OTHER

SOME VEHICLES MAY EXHIBIT A FLASHING TRANSMISSION CONTROL INDICATOR LAMP (TCIL) AND DIAGNOSTIC TROUBLE CODES (DTCS) 62,628, AND/OR 1728. *YC

106000 POWER TRAIN:AXLE ASSEMBLY

CONCERNS WITH AXLE WIND-UP AND / OR CLUNKING, POPPING, RATCHETING TYPE NOISES WHEN MAKING CORNERING MANEUVERS. *TT

160000 STRUCTURE

SUBJECT PERTAINING TO RED RUST STAINS ON THE EDGES OF THE BUMPER CENTER VENT AND FOG LAMP OPENINGS. *TT

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

SOME VEHICLES MAY EXHIBIT A FLASHING TRANSMISSION CONTROL INDICATOR LAMP (TCIL) AND DIAGNOSTIC TROUBLE CODES (DTCS) 62, 628, AND / OR 1728 MAY BE STORED IN MEMORY. *TT

980000 UNKNOWN OR OTHER

FUEL ECONOMY- CUSTOMER EXPECTATIONS VERSUS VEHICLE USAGE. *JD

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

106000 POWER TRAIN:AXLE ASSEMBLY

4X4 FRONT AXLES MUST USE HYPOID 4X4 GEAR OIL P/N F1TZ-19580-A & HIGH TEMP 4X4 FRONT AXLE & WHEEL BEARING GREASE WHEN SERVICING. IT IS NOT RECOMMENDED TO USE HEAVIER WEIGHT LUBES IN THESE FRONT AXLES.

036000 SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP

THE USE OF PETROLEUM-BASED GREASE AS A LUBRICANT IN SERVICING DISC BRAKES IS NO LONGER ACCEPTABLE BECAUSE IT MAY BE INCOMPATIBLE WITH THE RUBBER MATERIAL USED IN THE DISC BRAKE SYSTEM. IF PETROLEUM-BASED GREASE IS USED TO LUBRICATE ANY PAR

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

VEHICLES EXPERIENCING OCCASIONAL HARSH REVERSE ENGAGEMENT CONCERNS. *TW

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

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

UNKNOWN

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

KNOCKING NOISE ON INITIAL START-UP. *TW

162200 STRUCTURE:BODY:BUMPERS

UNKNOWN

061000 ENGINE AND ENGINE COOLING:ENGINE

UNKNOWN

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

UNKNOWN

062000 ENGINE AND ENGINE COOLING:COOLING SYSTEM

UNKNOWN

114100 ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD

UNKNOWN

138000 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM

UNKNOWN

061000 ENGINE AND ENGINE COOLING:ENGINE

REVISED OIL PAN GASKET. *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

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

ENGINE HESITATION/SURGE DURING LIGHT ACCELERATION. *TW

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

UPGRADE KIT FOR THE E40D TRANSMISSION. *TW

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

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

There is no summary currently available

EA, Closed , Model Year: 1991

IDLE AIR SPD CTRL VLV MALF

There is no summary currently available

EA, Closed , Model Year: 1992

PARKING BRAKE FAILURE

There is no summary currently available

PE, Closed , Model Year: 1991

IDLE AIR SPD CTRL VLV MALF

There is no summary currently available

EA, Closed , Model Year: 1990

FUEL EXPULSION

There is no summary currently available

PE, Closed , Model Year: 1990

FUEL EXPULSION

There is no summary currently available

EA, Closed , Model Year: 1990

FRONT SEAT BACK FAILURE

There is no summary currently available

PE, Closed , Model Year: 1990

FNT RECLNING SEAT BCK FAIL

There is no summary currently available

PE, Closed , Model Year: 1988

FORD TRUCK INCONSISTENT VEHICLE CONTROL.

SEE CLOSE RESUME

PE, Closed , Model Year: 1986

FUEL TANK CORROSION

There is no summary currently available

PE, Closed , Model Year: 1989

FLOORBOARD FRACTURE

There is no summary currently available

PE, Closed , Model Year: 1981

FRONT BRK CALIPER SEIZURE

ANALYSIS:ALLEGEDLY, DURING BRAKE APPLICATION THE DISC BRAKE CALIPERSSEIZE, RESULTING IN EXCESSIVE PULL AND/OR FRONT BRAKE LOCK-UP.SOMEREPORTS CITE A COMPLETE LOSS OF VEHICLE CONTROL RESULTING IN UNFOREWARNEDAND UNAVOIDABLE TRAVEL INTO OPPOSING TRAFFIC LANES.CONSUMERS CLAIM THATSERVICE PERSONNEL HAVE... Read more

FORD BRONCO - All Years Overview

Complete safety history for the FORD BRONCO across all model years (1967, 2026).

168 Total Recalls

2,194 Total Complaints

17 Investigations

104 Reported Crashes

192 Reported Fires

132 Reported Deaths

FORD BRONCO - Year by Year

Compare recalls and complaints across model years. Click any year to see full details.

Year	Recalls	Complaints
2026	7	9	View
2025	19	74	View
2024	16	111	View
2023	18	266	View
2022	23	508	View
2021	20	303	View
1999	0	5	View
1998	0	2	View
1997	1	1	View
1996	2	109	View
1995	2	131	View
1994	5	114	View
1993	7	45	View
1992	4	56	View
1991 (current)	2	37
1990	1	77	View
1989	2	118	View
1988	1	68	View
1987	1	61	View
1986	1	43	View
1985	1	24	View
1984	4	11	View
1983	2	4	View
1982	1	1	View
1981	1	2	View
1980	4	0	View
1979	6	2	View
1978	6	0	View
1977	2	1	View
1976	2	0	View
1975	2	0	View
1972	1	0	View
1971	1	0	View
1970	1	0	View
1969	0	1	View
1967	2	2	View

Other FORD Models

Model	Recalls	Complaints
MUSTANG	1,104	11,600	View
RANGER	928	10,371	View
F-350 SD	776	2,363	View
F-450 SD	692	624	View
F-150	692	46,142	View
F-250 SD	638	3,635	View
EXPLORER	624	42,549	View
F-550 SD	578	603	View

Vehicle Safety

Consumer Safety

Infrastructure

Public Health

1991 FORD BRONCO

Complaint Statistics

Top Reported Components

Technical Service Bulletins, 1991 FORD BRONCO

Most Affected Components

NHTSA Safety Investigations, FORD BRONCO

FORD BRONCO - All Years Overview

FORD BRONCO - Year by Year

Other FORD Models