1996 FORD BRONCO

2 recalls, 109 complaints - 97 TSBs

EXTERIOR LIGHTING

Defect Description

CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE D... Read more

Consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.

Remedy

PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.

61,944 vehicles affected

Manufacturer: PRO-A MOTORS, INC.

VEHICLE SPEED CONTROL

Defect Description

ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES EQUIPPED WITH SPEED CONTROL, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT, SMOKE, OR BURN.

Consequence

A FIRE AT THE SWITCH COULD OCCUR.

Remedy

BY LETTER DATED SEPTEMBER 12, 2005, OWNERS WERE INSTRUCTED TO RETURN THEIR VEHICLES TO THEIR DEALERS TO HAVE THE SPEED CONTROL DEACTIVATION SWITCH DISCONNECTED. OWNERS WHO HAVE HAD THEIR SPEED CONTROL DEACTIVATED ARE BEING NOTIFIED THAT PARTS WILL BE AVAILABLE AND ADVISED TO MAKE AN APPOINTMENT TO ... Read more

4,500,000 vehicles affected

Manufacturer: FORD MOTOR COMPANY

Complaint Statistics

109 total complaints 10 crashes 35 fires 8 injuries 3 deaths

Top Reported Components

Component	Complaints
VEHICLE SPEED CONTROL	12
VEHICLE SPEED CONTROL:CRUISE CONTROL	10
VISIBILITY:GLASS, SIDE/REAR	7
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP	6
ELECTRICAL SYSTEM	5
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS	5
POWER TRAIN:AUTOMATIC TRANSMISSION	4
VISIBILITY:POWER WINDOW DEVICES AND CONTROLS	3
SUSPENSION:FRONT	3
ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD	3

Incident date: Jan 15, 2015

TRANSMISSION JUMPS OUT OF OVERDRIVE, AFTERWARDS HARD SHIFTS IN ALL GEARS AFTER HIGH RPMS. THE FIX IS TO STOP, CUT THE ENGINE OFF AND THE TRANSMISSION RESETS FOR LACK ON A BETTER TERM. WHEN THE BRONCO IS IN OD AND IS JUST CRUSING, NOT IN A PULL, IS WHEN THE OD JUMPS OUT. LIKE ANY OTHER THING IT DO... Read more

Incident date: Feb 15, 2013

HEAD LIGHT DIMMER SWITCH/TURN SIGNAL SWITCH. AFTER HEAD LIGHTS HAVE BEEN RUNNING FOR A FEW MINUTES, THE HEAD LIGHTS WILL BEGIN TO FLASH ON/OFF IN EITHER HIGH BEAMS OR LOW BEAMS. I HAVE FOUND THE ISSUE TO BE IN THE HIGH BEAM SWITCH ITSELF. IF THIS HAD HAPPENED ON A BUSY STREET OR IN A LOCATION WHE... Read more

Incident date: May 30, 2012

TL* THE CONTACT OWNS A 1996 FORD BRONCO. WHILE PARKED, THE CONTACT NOTICED SMOKE COMING FROM UNDER THE HOOD. THE CONTACT ATTEMPTED TO EXTINGUISH THE FIRE WITH A FIRE EXTINGUISHER BUT WAS UNABLE TO CONTROL THE FIRE. THE FIRE DEPARTMENT REPORTED TO THE SCENE AND A REPORT WAS FILED. THE CONTACT REFEREN... Read more

Fire

Incident date: Oct 20, 2010

TL*THE CONTACT OWNS A 1996 FORD BRONCO WITH INDICO THORNBIRD 385* 14 * 16 TIRES(NA) DOT NUMBER KPBC80507. THE TIRES WERE VIBRATING; THEREFORE, THE CONTACT HAD THEM ROTATED. DURING THE ROTATION THE CONTACT WAS TOLD THAT THE LINING INSIDE OF ALL FOUR TIRES CURLED UP. THE MANUFACTURER INSISTED THAT THI... Read more

Incident date: Mar 26, 2010

1996 FORD BRONCO CAUGHT FIRE OVER WEEKEND WHILE MY FAMILY AND I WERE DRIVING HOME. MONDAY FORD HAD IT TOWED INTO THE LOCAL DEALERSHIP TO REPAIR AND NOW, THREE DAYS LATER THEY ARE TELLING ME THAT THEY WILL NOT REPAIR IT SINCE I KNEW ABOUT THE PROBLEM. I ARGUED THAT I HAD NO IDEA AND THEY SAY THAT T... Read more

Fire

Incident date: Mar 5, 2009

TL*THE CONTACT OWNS 1996 FORD BRONCO. THE CONTACT STATED THAT WHEN THE CRUISE CONTROL SWITCH WAS ENGAGED, THE VEHICLE BEGIN TO ACCELERATE BEYOND ITS SET SPEED. THE CONTACT WAS DRIVING 55 MPH. THE CONTACT DID NOT CALL THE MANUFACTURER. THE DEALER INFORMED THE CONTACT THAT THE CRUISE CONTROL SWITCH N... Read more

Incident date: Jul 9, 2008

TL*THE CONTACT OWNS A 1996 FORD BRONCO. SPARKS WERE DRIPPING BELOW THE DRIVER'S SIDE OF THE VEHICLE. THE CONTACT'S NEIGHBOR ATTEMPTED TO EXTINGUISH THE FIRE WITH THE GARDEN HOSE, BUT WAS UNSUCCESSFUL. EVENTUALLY, SEVERAL NEIGHBORS WERE ABLE TO EXTINGUISH THE FLAMES WITH GARDEN HOSES AND FIRE EXT... Read more

Fire

Incident date: Jul 19, 2008

TL*THE CONTACT OWNS A 1996 FORD BRONCO. WHILE THE VEHICLE WAS PARKED IN A LOT, IT SUDDENLY CAUGHT FIRE. FLAMES AND SMOKE APPEARED FROM THE HOOD OF THE VEHICLE. THE FIRE DEPARTMENT EXTINGUISHED THE FIRE AND A REPORT WAS FILED. THE VEHICLE HAS NOT YET BEEN REPAIRED. THROUGH NUMEROUS RESEARCH, THE... Read more

Fire

Incident date: Jul 9, 2008

Fire

Incident date: Nov 15, 2008

MY VEHICLE WAS PARKED IN THE YARD FOR SEVERAL HOURS, AND I WAS WORKING IN MY SHOP ABOUT 30 FEET AWAY. I STARTED SMELLING BURNING PLASTIC, AND I THOUGHT THAT THE NEIGHBORS WERE BURNING TRASH. WHEN THE ODOR BECAME STRONGER, I LOOKED OUT THE DOOR OF MY SHOP. THERE WAS SMOKE POURING OUT FROM UNDER THE H... Read more

Fire

Incident date: Nov 10, 2008

DROVE 1996 FORD BRONCO 3 BLOCKS AND PARKED IT IN CLOSED UP GARAGE. CAME BACK A FEW DAYS LATER AND FOUND IT BURNT UP. FIRE BURNT UNDER HOOD AND DASH. IT SCORCHED THE VEHICLE PARKED NEXT TO IT AND DAMAGED INSIDE OF GARAGE. *TR

Fire

Incident date: Nov 10, 2008

Fire

Incident date: Jun 20, 2008

I WAS DRIVING, CAME HOME AT 11PM, AT 11:30PM THE HORN WAS BLOWING ON MY 1996 FORD BRONCO, WENT OUTSIDE TO FIND IT HAD COMPLETELY BURNED IN A FIRE - SITTING IN MY DRIVEWAY, NOT RUNNING, KEYS OUT OF THE VEHICLE. HAD TO CALL FIRE COMPANY TO EXTINGUISH, POLICE WERE HERE ALSO - DID SOME INTERNET SEARCHIN... Read more

Fire

Incident date: Oct 26, 2007

TL*THE CONTACT OWNS A 1996 FORD BRONCO. THE VEHICLE CAUGHT FIRE AFTER BEING PARKED FOR 20 MINUTES. THE VEHICLE HAD PREVIOUSLY BEEN DRIVEN FOR 30 MINUTES AND THE CRUISE CONTROL WAS NOT ACTIVATED. THE FIRE DEPARTMENT EXTINGUISHED THE FIRE. THE VEHICLE WAS DESTROYED AND TOWED. THE FIRE DEPARTMENT ... Read more

Fire

Incident date: Jun 16, 2005

DRIVEN 96 BRONCO TO STORE, NOTICED "SQUISHY BRAKES ON WAY HOME. PARKED VEHICLE FOR APPROX. 20-30 MIN. WHEN CAME OUTSIDE TO FIND FLAME BALLS OF DRIPPING PLASTIC; OPENED THE HOOD TO FIND MASTER CYLINDER ON FIRE & SPREADING TO AREAS BELOW. UNABLE TO QUICKLY ACCESS FIRE EXTINGUISHER; PULLED A GARDEN HOS... Read more

Fire

Incident date: Jun 15, 2005

TL*THE CONTACT OWNS A 1996 FORD BRONCO. ON JUNE 15, 2005, THE VEHICLE BEGAN TO SMOKE AND THEN CAUGHT FIRE WHILE PARKED. THE CONTACT EXTINGUISHED THE FIRE. THE MANUFACTURER CONFIRMED THAT SAFETY RECALL # 05V388000 (VEHICLE SPEED CONTROL). THE MAJORITY OF THE ENGINE COMPARTMENT SUFFERED FIRE DAMAG... Read more

Fire

Incident date: Oct 5, 2006

I BOUGHT 4 TIRES FROM SULLIVAN TIRES IN SCARBOROUGH, MAINE ON ROUTE 1. I PAID FOR THE UPGRADED QUALITY TIRES BY THEIR RECOMMENDATION. THE TIRES WERE GUARANTEED FOR 25,000 MILES. AFTER 14,000 MILES, ONE OF THE FOUR TIRES BEGAN TO HAVE IRREGULAR WEAR UNTIL ONE SIDE OF THE TIRE WAS COMPLETELY BALD. ... Read more

Incident date: Aug 22, 2005

THE FORD BRONCO WAS SITTING IN FRONT OF MY CAR. OVERNIGHT THE CAR CAUGHT FIRE AND BURNED THE FRONT CONSOLE OF THE CAR AND BELOW THE DASHBOARD. THE HOTTEST POINT OF THE FIRE WAS UNDERNEATH THE HOOD WHERE THE METAL TURNED WHITE AND DESTROYED THE PAINT. A CLAIM FILED WITH FORD WAS FILED AFTER THE RE... Read more

Fire

Incident date: Sep 1, 2005

THE CONSUMER RECEIVED A RECALL NOTICE TO HAVE 1996 FORD BRONCO CRUISE CONTROL DISCONNECTED. *TS FORD RECALL #05S28. AN ADDITIONAL THREE-MONTH DELAY WAS ISSUED BEFORE THE REPAIR COULD TAKE PLACE. THE CONSUMER FELT THAT THIS WAS IRRESPONSIBLE OF FORD. *SC

Incident date: Aug 18, 2005

1. GENERAL USE OF THE VEHICLE 2. CRUISE CONTROL STOPPED WORKING. BRAKE FLUID DARK/LEAKING OUT. BRAKE PRESSURE SWITCH CAUGHT ON FIRE AND BURNED. 3. I WILL HAVE TO GET A NEW SWITCH. *NM

Fire

Incident date: Jun 1, 2005

DT: THE CONTACT OWNED A 1996 FORD BRONCO. THE VEHICLE CAUGHT ON FIRE IN EARLY JUNE 2005. THE FIRE OCCURRED IN THE WIRE CLUSTER THAT CONNECTED INTO THE FRONT OF THE MASTER CYLINDER. THE FIRE WAS FIRST NOTICED COMING FROM THE ENGINE COMPARTMENT. THE VEHICLE WAS NOT OPERATING UNUSUALKY BEFORE THE FIRE ... Read more

Fire

Incident date: Jun 5, 2005

DT: CONSUMER STATED THAT 1996 FORD BRONCO XL CAUGHT ON FIRE AND BURNT ON JUNE 5, 2005. THE FIRE STARTED UNDER THE DRIVERS SIDE LEFT FRONT FENDER WELL RIGHT AT THE MASTER CYLINDER. THE VEHICLE HAD BEEN PARKED FOR ABOUT 20 MINUTES. THE VEHICLE HAD DRIVEN JUST FINE BEFORE THIS. CONSUMER HAS NOT CONTA... Read more

Fire

Incident date: Jan 15, 2005

FIRE IN ENGINE COMPARTMENT CAUSED BY CRUISE CONTROL BRAKE SWITCH. MY FIRST INDICATION OF A PROBLEM WAS THAT MY CRUISE CONTROL DID NOT WORK. I WENT TO MY GARAGE AND FOUND THAT A FUSE HAD BLOWN. WHEN I REPLACED THE FUSE, THE SWITCH ASSEMBLY, LOCATED DIRECTLY ABOVE THE BRAKE FLUID TANK, IMMEDIATELY ... Read more

Fire

Incident date: Jun 2, 2005

DT: THE VEHICLE CAUGHT ON FIRE, THE FIRE MARSHAL SAID IT STARTED IN THE ENGINE COMPARTMENT, THE INSURANCE AGENCY CAME TO PICK UP THE VEHICLE. ALSO, THE HOUSE CAUGHT ON FIRE. *AK THE FIRE STARTED UNDER THE HOOD ON THE DRIVER'S SIDE. *SC *JB

Fire

Incident date: Mar 4, 2005

WHILE CLEANING MY 96 BRONCO I NOTICED SMOKE COMING OUT OF THE LEFT SIDE OF THE HOOD. AFTER OPENING IT, I SAW THE CRUISE CONTROL BOX TO BE SMOKING HEAVILY. I POURED WATER ON IT AND COOLED DOWN THE SUPERHEATED DEVICE. EXCEPT FOR THE CRUISE CONTROL NOT WORKING, I DID NOT ENCOUNTER ANY OTHER PROBLEMS. ... Read more

Fire

Incident date: Jun 1, 2004

CRUISE CONTROL AND BRAKE LIGHTS QUIT WORKING. REPLACED FUSE AND IT BLEW AND STILL NO BRAKE LIGHTS OR CRUISE. THE PROBLEM IS THE BRAKE PRESSURE SWITCH THAT CONTROLS THE CRUISE GOES BAD AND CAUSES FUSE TO BLOW AND CRUISE DOES NOT WORK AND BRAKE LIGHTS WILL NOT WORK. AFTER FINDING THE PROBLEM I REPL... Read more

Fire

Incident date: Mar 20, 2005

WHILE PARKED FOR TWENTY HOURS CRUISE CONTROL SWITCH IGNITIED BY ITSELF. AS A RESULT, VEHICLE CAUGHT ON FIRE. THE OWNER WAS ABLE TO SAVE THE VEHICLE.*AK

Fire

Incident date: Feb 1, 2004

IN REGAURD TO INVESTIGATION EA 05-005 HEADED UP BY BRUCE YORK; I HAVE A 1996 FORD BRONCO THAT THE SPEED CONTROL DEACTIVATION SWITCH ALSO SHORTED OUT. IT DID NOT RESULT IN A FIRE BUT THE CRUISE CONTROL DOESN'T WORK. THE WIRES ARE BURNT RIGHT NEXT TO THE SWITCH AND THE SWITCH IS FULL OF FLUID. I CURRE... Read more

Incident date: Sep 18, 2003

THE TRUCK HAD BEEN PARKED FOR ABOUT 30 MINUTES PRIOR TO THE INCIDENT. THE SPEED CONTROL SWITCH ON THE BRAKE MASTER CYLINDER OVERHEATED AND CHARRED THE AREA. REPLACED SWITCH AND CONTROL MODULE. *AK

Incident date: Jan 12, 2005

1996 FORD BRONCO, BURNED TO THE GROUND / A TOTAL LOSS. IN THE MIDDLE OF THE NIGHT. I WAS HAVING NO PROBLEMS WITH THE VEHICLE THAT I KNEW OF. I HAD A FUEL PUMP PUT IN 4 MONTHS PRIOR FROM MY MECHANIC. THE FIRE STARTED UP FRONT IN THE ENGINE COMPARTMENT, AND MOVED TOWARDS THE REAR. EVERYTHING WAS IN SO... Read more

Fire

Incident date: Sep 8, 2004

AT APPROXIMATELY 2AM ON SEPTEMBER 8, 2004, I RECEIVED A CALL FROM MY NEIGHBOR INFORMING ME THAT MY 1996 FORD BRONCO WAS ON FIRE. WHEN I RAN OUTSIDE, THERE WERE FLAMES "SHOOTING" SEVERAL FEET INTO THE AIR. THE SOURCE OF THE FIRE WAS THE FRONT OF THE VEHICLE, IN THE ENGINE COMPARTMENT. THE FRONT TI... Read more

Fire

Incident date: May 23, 2004

THE CONSUMER COULD NOT GET VEHICLE OUT OF PARK ONE MORNING AND HAD TO REPLACE A FUSE. JUST AFTER VEHICLE STARTED SMOKE CAME FROM UNDER HOOD. THE CONSUMER OPENED THE HOOD, AND SAW A FIRE AT THE MASTER CYLINDER. THE CONSUMER PUT THE FIRE OUT WITH A BOTTLE OF WATER. *AK THE MASTER CYLINDER PRES... Read more

Fire

Incident date: Aug 3, 2004

VEHICLE WAS TAKEN TO THE SHOP FOR ROUTINE MAINTENANCE AND I ASKED THE MECHANIC TO CHECK THE ROUTE. FRONT SUSPENSION DUE TO EXCESSIVE NOISE/VIBRATION. HE CONTACTED ME LATER TO ADVISE THAT THE COIL SPRING WAS BROKEN. THE ONLY THINGS RETAINING THE SPRING WERE GRAVITY AND GOD. *AK

Incident date: Aug 3, 2004

Incident date: Mar 2, 1997

THE FOLLOWING IS A COMPLAINT ABOUT PRODUCT AND SERVICES . PRODUCT BEING 1996-97 MODEL VEHICLE FORD BRONCO VIN [XXX]. VEHICLE HAS BUILT-IN CONTROL AND ROLLOVER PROBLEMS BY DESIGN. THIS WAS A CONTRIBUTING FACTOR. WITH THE BRONCO CRASHING OFF THE MACKINAC BRIDGE MARCH 2, 1997 LOCATED IN MICHIGA... Read more

Crash 1 deaths

Incident date: Mar 2, 1997

Crash 1 deaths

Incident date: Sep 25, 2003

WHEN THE VEHICLE WAS BEING DRIVEN AT ANY SPEED THE CONSUMER NOTICED A KNOCKING NOISE COMING FROM THE FRONT END OF THE VEHICLE. THE CONSUMER STATED THAT IT SOUNDED LIKE IT WAS THE TRANSMISSION BUT HE'S NOT 100% SURE. PLEASE PROVIDE ANY FURTHER DETAILS. *NLM

Incident date: Sep 10, 2002

WHILE APPROACHING AN INTERSECTION, THE CONSUMER APPLIED THE BRAKE PEDAL, AND IT HAD GONE TO THE FLOOR. THE CONSUMER PUMPED THE BRAKES, AND VEHICLE HAD COME TO AN ABRUPT STOP. PH THE CONSUMER FOUND THAT THE BRAKE LINE HAD RUSTED AND BURST WHICH CAUSED THE BRAKING FLUID TO LEAK. SCC

Incident date: Nov 6, 2001

WHILE DRIVING VEHICLE WOULD NOT GO FORWARD. CONSUMER STATED TRANSMISSION WENT OUT. DEALER CONTACTED. *AK CRUISE CONTROL AND DOOR LOCKS ARE INOPERATIVE. EMERGENCY BRAKE LIGHT STAYS ILLUMINATED. FRONT END IS OUT OF ALIGNMENT AND PULLS TO THE LEFT. HEAD LIGHTS WILL NOT SHUT OFF. THERMOSTAT, RADIA... Read more

Fire

Incident date: Nov 6, 2001

Fire

Incident date: Nov 6, 2001

Fire

Incident date: Nov 6, 2001

Fire

Incident date: Nov 6, 2001

Fire

Incident date: Nov 6, 2001

Fire

Incident date: Nov 6, 2001

Fire

Incident date: Nov 6, 2001

Fire

Incident date: Nov 6, 2001

Fire

Incident date: Nov 6, 2001

Fire

Incident date: Nov 6, 2001

Fire

Incident date: Oct 1, 1997

AFTER TURNING ON REAR DEFOGGER, REAR WINDSHIELD SHATTERED. THIS WAS THE THIRD TIME THAT THIS INCIDENT HAD OCCURRED. DEALER NOTIFIED. *AK CONSUMER STATES THERE IS A TSB THAT STATES THE CURRENT WEATHERSTRIP CAUSED A CHEMICAL REACTION WITH THE SILVER IN THE HEATING ELEMENT AND REPLACING THE GLASS ONL... Read more

Showing 50 of 109 complaints.

Technical Service Bulletins, 1996 FORD BRONCO

97 manufacturer communications from 89 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
103000 POWER TRAIN:AUTOMATIC TRANSMISSION	10
980000 UNKNOWN OR OTHER	5
116200 ELECTRICAL SYSTEM:IGNITION:MODULE	5
061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE	4
357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER	4
106000 POWER TRAIN:AXLE ASSEMBLY	3
102000 POWER TRAIN:MANUAL TRANSMISSION	3
034000 SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS	3

110000 ELECTRICAL SYSTEM

REMOTE KEYLESS ENTRY (RKE) - SERVICE TIPS. *TT

103600 POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES

NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS. 2003 ESCORT AND SUPER DUTY F SERIES INCLUDED. *TT

125100 EXTERIOR LIGHTING:BRAKE LIGHTS:SWITCH

LAMP-BRAKE-INVADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK. *MJ

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

ENGINE OIL SYSTEM PRIMING PROCEDURES, SERVICE TIPS FOR REPORTS OF PREMATURE ENGINE FAILURE. *TT

103800 POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCH

BRAKE SHIFT INTERLOCK.*JB

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

162300 STRUCTURE:BODY:DOOR

INFORMATION ON REPLACING AND / OR REPAIRING MALFUNCTIONING (DOOR, IGNITION AND DECKLID) LOCKS. *TT

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

034000 SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS

INFORMATION FOR SERVICING AND DIAGNOSING BRAKE VIBRATION, BRAKE INSPECTION, AND BRAKE FRICTION MATERIAL REPLACEMENT. *TT

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

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

125000 EXTERIOR LIGHTING:BRAKE LIGHTS

CONDITIONS WITH THE BRAKE LAMPS INADVERTENTLY DISABLING THE BRAKE SHIFT INTERLOCK. *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

980000 UNKNOWN OR OTHER

FORD MOTOR COMPANY HAS RELEASED A PRIVATE LABELED MATERIAL TO BE USED FOR IRON PARTICLE / ACID RAIN SERVICE REPAIRS. *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

162300 STRUCTURE:BODY:DOOR

SUBJECT REGARDING DOOR TRIM PANEL REPLACEMENT - SERVICE TIP. *TT

116200 ELECTRICAL SYSTEM:IGNITION:MODULE

INFORMATION REGARDING REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS). *TT

100000 POWER TRAIN

INFORMATION REGARDING REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS). *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

063100 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL

MASS AIR FLOW (MAF)- SENSOR CONTAMINATION- SERVICE TIP. *AK

162000 STRUCTURE:BODY

INFORMATION REGARDING REPLACEMENT AND / OR REPAIRS ON ANY LOCK COMPONENT. *YC

063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

EXPERIENCING A " BUZZING " OR " RATTLING " NOISE FROM THE EXHAUST SYSTEM. *YC

162300 STRUCTURE:BODY:DOOR

LOCKS FAILED. YD

980000 UNKNOWN OR OTHER

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

138000 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM

PERFORMANCE ENHANCEMENT FOR DEFROSTER. *YC

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

036400 SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:ABS WARNING LIGHT

CONCERNS WITH FALSE ABS ACTIVATION WHILE LIGHT BRAKING AT LOW SPEEDS. *YC

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

CONCERNS WITH FALSE ABS ACTIVATION WHILE LIGHT BRAKING AT LOW SPEEDS. *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

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

354600 EQUIPMENT:MECHANICAL:WRECKER AND WHEEL LIFT DEVICES

RECOMMENDED GUIDELINES FOR TOWING BEHIND RECREATIONAL VEHICLES. *TT

034000 SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS

SERVICE TIP INFORMATION REGARDING ELIMINATION OF SANDING ROTORS AND DRUMS. *YC

034530 SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR

HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT FROM ROTUNDA IS NOW APPROVED FOR WARRANTY AND SERVICE USE. *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

045300 SERVICE BRAKES, AIR:DISC:ROTOR

AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT. *YC

106000 POWER TRAIN:AXLE ASSEMBLY

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

160000 STRUCTURE

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

034530 SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR

SUBJECT REGARDING THE AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT. *TT

102000 POWER TRAIN:MANUAL TRANSMISSION

SOME VEHICLES MAY STALL WHEN THE TRANSMISSION IS PLACED INTO GEAR. *YC

980000 UNKNOWN OR OTHER

AUTHORIZED WARRANTY PART REPLACEMENT OF BRAKE PADS TO CORRECT EXCESSIVE BRAKE NOISE. *TW

102000 POWER TRAIN:MANUAL TRANSMISSION

NEW CLUTCH SLAVE CYLINDER WITH A REDESIGNED LIP SEAL. *TW

121000 EXTERIOR LIGHTING:HEADLIGHTS

HEADLAMP- HEADLAMP HOUSING MELTS- AMBULANCE AND EMERGENCY VEHICLES ONLY. *JD

980000 UNKNOWN OR OTHER

FUEL ECONOMY- CUSTOMER EXPECTATIONS VERSUS VEHICLE USAGE. *JD

021700 SUSPENSION:FRONT:HUB

NOISE- "RATCHETING"- FRONT AXLE- 4X4- SELF-ENGAGEMENT OF AUTOMATIC HUB LOCKS- BRONCO, F-150 AND F-250 UNDER 8500# GVW. *JD

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

FLUID- TRANSMISSION FLUID USAGE CHARTS. *JD

160000 STRUCTURE

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

101100 POWER TRAIN:CLUTCH ASSEMBLY:PEDAL/HAND LEVER(MOTORCYCLE)

THE CLUTCH MAY BE HARD TO DEPRESS DUE TO DUST/CONTAMINATION ENTERING THE SLAVE CYLINDER. *TW

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

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

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

AIR CONDITIONING- R-134A TRACER DYE INSTALLED IN A/C SYSTEM AND THREE O-RING SPRING LOCK COUPLERS- SERVICE TIP. *JD

141100 AIR BAGS:FRONTAL:SENSOR/CONTROL MODULE

AIR BAG LAMP FLASH-OUT CODE 33 ON VEHICLES EQUIPED WITH A PASSENGER SIDE AIR BAG. *JD

104000 POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE)

SOME 1995 AND ALL 1996 AND 1997 VEHICLES WITH E4OD TRANSMISSIONS HAVE BEEN BUILT WITH A REUSABLE ELASTOMERIC TRANSMISSION FLUID PAN GASKET. *JD

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

VEHICLES WITH E4OD TRANSMISSIONS HAVE BEEN BUILT WITH A REUSABLE ELASTOMERIC TRANSMISSION FLUID PAN GASKET. *JD

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

SOME 1995 AND ALL 1996 AND 1997 VEHICLES WITH E40D TRANSMISSIONS HAVE BEEN BUILT WITH A REUSABLE ELASTOMERIC TRANSMISSION FLUID PAN GASKET. *JD

103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER

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

116200 ELECTRICAL SYSTEM:IGNITION:MODULE

MALFUNCTION INDICATOR LAMP (MIL) - DIAGNOSTIC TROUBLE CODES (DTCS) P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, AND/OR P0308 STORED IN MEMORY. *TW

107000 POWER TRAIN:AXLE HUBS

NOISE - RATCHETING - FRONT AXLE - 4X4 - SELF ENGAGEMENT OF AUTOMATIC HUB LOCKS. *TW

011000 STEERING: STEERING WHEEL/HANDLE BAR

STEERING - CLUNK NOISE FROM STEERING COLUMN ON ACCELERATING AND BRAKING. *TW

116200 ELECTRICAL SYSTEM:IGNITION:MODULE

POWERTRAIN CONTROL MODULE -REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP. *TW

116200 ELECTRICAL SYSTEM:IGNITION:MODULE

MALFUNCTION INDICATOR LAMP (MIL) - DIAGNOSTIC TROUBLE CODES (DTCS) P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307 AND/OR P0308 STORED IN MEMORY. *TW

171100 LATCHES/LOCKS/LINKAGES:DOORS:LATCH

LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - SERVICE TIP. *TW

141000 AIR BAGS:FRONTAL

WHEN DIAGNOSING AN AIR BAG LAMP FLASH-OUT CODE 33 (PASSENGER SIDE AIR BAG HIGH RESISTANCE OR OPEN) ON A 1994-1996 F150 OR BRONCO THAT IS NOT EQUIPPED WITH A PASSENGER SIDE AIR BAG, CHECK FOR PROPER GROUND FROM PIN 7, CIRCUIT 629, AT THE AIR

103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER

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

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

TRANSMISSION - E40D - REVISED DESIGN FORWARD PLANET THRUST WASHER - SERVICE TIP. *TW

011000 STEERING: STEERING WHEEL/HANDLE BAR

A "CLUNK" NOISE HEARD/FELT THROUGH THE STEERING COLUMN WHEN MANEUVERING IN PARKING LOTS, DRIVING IN STOP AND GO TRAFFIC OR DRIVING OVER BUMPS. *TW

116200 ELECTRICAL SYSTEM:IGNITION:MODULE

CHECK ENGINE LIGHT, CODE P030X, WITH NO DRIVEABILITY COMPLAINT. *TW

011000 STEERING: STEERING WHEEL/HANDLE BAR

A 'CLUNK' NOISE MAY BE HEARD/FELT THROUGH THE STEERING COLUMN WHEN MANEUVERING IN PARKING LOTS, DRIVING IN STOP AND GO TRAFFIC OR DRIVING OVER BUMPS. *TW

141000 AIR BAGS:FRONTAL

DIAGNOSING AN AIR BAG LAMP FLASH-OUT CODE 33 (PASSENGER SIDE AIR BAG HIGH RESISTANCE OR OPEN)

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

AIR CONDITIONING - COMPRESSOR FAILURE - INSUFFICIENT AMOUNT OF REFRIGERANT OIL. *TW

131000 VISIBILITY:WINDSHIELD

WINDSHIELD AND INTERIOR GLASS - FOG/FILM. *TW

034000 SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS

BRAKES - ELIMINATION OF SANDING ROTORS AND DRUMS - SERVICE TIP. *TW

185000 VEHICLE SPEED CONTROL:CRUISE CONTROL

LONG CRANK - STICKING IDLE AIR CONTROL (IAC) VALVE - VEHICLES BUILT FROM 11/1/94 THROUGH 3/30/96 -STALL - AFTER STARTING WHEN ENGINE ALLOWED TO SOAK FROM 1-4 HOURS - STICKING IDLE AIR CONTROL (IAC) VALVE. *TW

075000 FUEL SYSTEM, GASOLINE:CARBURETOR SYSTEM

MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP. *TW

102000 POWER TRAIN:MANUAL TRANSMISSION

E4OD TRANS MAY EMIT A TICK/RATTLE NOISE WHEN DRIVING AT LIGHT LOADS IN 1ST GEAR AT 1100 TO 1800 RPM RPM. *TT

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

FOR CONCERNS OF STALLING, REFLASH PCM W/ 1996 CALIBRATION (R11 LEVEL). *TT

190000 TIRES

FIRESTONE P235 TIRES MAY EXHIBIT A HIGH FREQUENCY VIBRATION AT 65-75 MPH. *TT

353000 EQUIPMENT:ELECTRICAL

INFORMATION FOR WHEN DIAGNOSING CONCERNS W/ FACTORY INSTALLED CELLULAR PHONES. *TT

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

EXPERIENCING A KNOCKING NOISE WHEN THE ENGINE IS COLD AND UNDER ACCELERATION. *TT

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

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

UNKNOWN

162200 STRUCTURE:BODY:BUMPERS

UNKNOWN

138000 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM

UNKNOWN

114100 ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD

UNKNOWN

062000 ENGINE AND ENGINE COOLING:COOLING SYSTEM

UNKNOWN

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

UNKNOWN

061000 ENGINE AND ENGINE COOLING:ENGINE

UNKNOWN

062000 ENGINE AND ENGINE COOLING:COOLING SYSTEM

COOLING SYSTEM - LEAKING RADIATOR HOSE - UPGRADED HOSE CLAMPS. *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