1997 FORD BRONCO

1 recalls, 1 complaints - 9 TSBs

EXTERIOR LIGHTING:HEADLIGHTS

Defect Description

CERTAIN POLI-AUTO COMBINATION HEADLAMP ASSEMBLIES, P/NOS. 11-728, 11-728D, 11-710, 11-419, 11-713, 11-703, 11-704, 11-708P, 11-735, 11-725, 11-726, 11-716 (P&C), 11-721-1, 11-733, 11-729, 11-730, AND 11-732, SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES. SOME COMBINATION LAMPS THA... Read more

Consequence

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

Remedy

POLI-AUTO WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE HEADLAMPS AT ITS ORIGINAL PURCHASE PRICE. THE RECALL IS EXPECTED TO BEGIN DURING APRIL 2006. OWNERS MAY CONTACT POLI-AUTO AT 305-477-1356.

1,450 vehicles affected

Manufacturer: POLI-AUTO, INC.

Complaint Statistics

1 total complaints

Top Reported Components

Component	Complaints
FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY	1

Incident date: Dec 28, 1996

GAS TANK RUSTED THROUGH A SKID PLATE UNDERNEATH TANK WHERE A PAD FIT BETWEEN TANK & PLATE. WATER OR MOISTURE GETS BETWEEN GAS TANK & SKID PLATE & STAYS THERE, EVENTUALLY RUST OCCURS & GAS LEAKS OUT & DRAINS ON EXHAUST PIPE. *AK CONSUMER STATES THAT THE GAS TANK RUSTED THROUGH DUE TO A DEFECTIVE DES... Read more

Technical Service Bulletins, 1997 FORD BRONCO

9 manufacturer communications from 9 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
106000 POWER TRAIN:AXLE ASSEMBLY	3
102000 POWER TRAIN:MANUAL TRANSMISSION	2
103000 POWER TRAIN:AUTOMATIC TRANSMISSION	2
190000 TIRES	1
104000 POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE)	1

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

106000 POWER TRAIN:AXLE ASSEMBLY

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

102000 POWER TRAIN:MANUAL TRANSMISSION

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

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

SOME 1995 AND ALL 1996 AND 1997 VEHICLES WITH E40D 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

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

190000 TIRES

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

106000 POWER TRAIN:AXLE ASSEMBLY

SOME VEHICLES EQUIPPED W/ AN AX4S TRANSAXLE MAY HAVE BEEN SHIPPED W/ A LOW TRANSAXLE FLUID LEVEL. *TT

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