2021-2026 Ford Bronco Sport Problems & Issues

NHTSA recall 24V267000 (Ford reference 24S24) covers 456,565 model year 2021-2024 Bronco Sport and 2022-2023 Maverick vehicles. The Body Control Module and Powertrain Control Module fail to detect 12V battery degradation, resulting in loss of motive power whenever an Auto Stop/Start event occurs or during low-speed braking. Two follow-up campaigns address inadequate initial remedies: 25S02 (NHTSA 25V019, January 2025) replaced defective Camel EFB batteries with Ford AGM units on 272,817 vehicles, and 25S26 (NHTSA 25V158, March 2025) re-fixed 48,041 vehicles previously repaired incorrectly. Dealers reflash control modules and/or replace the battery free of charge.

This recall applies to 2025 Bronco Sport vehicles that were built with a 1.5L or 2.0L MPC engine and an engine block heater. Ford reports that the block heater may overheat when the Bronco Sport is parked with the heater plugged in, and NHTSA's stated consequence is an increased risk of fire. Only the 2025 model year is listed for the Bronco Sport in this campaign. Since the hazard exists only while the heater is energized, it presents itself when the vehicle is parked and connected to power - typically overnight in cold weather. The 6,781 units NHTSA lists is the size of the whole campaign across every model included, not a Bronco Sport-specific count.

A defect in the SYNC 3 infotainment software (APIM module) on 2021-2024 Bronco Sport vehicles causes system instability. Symptoms include the display intermittently going black, failure to retain settings across ignition cycles (reverted language, erased radio presets), and inability to install updates. A separate SYNC 3 software error can leave the rearview/backup camera showing a blank image while in reverse or keep the camera image on screen after backing has ended, which is a federal rear-visibility safety concern.

A recurring and very specific electrical fault: the exterior liftgate release button stops responding to the key fob's proximity, so the gate will not open by hand even though the fob is in the owner's pocket - while the separate flip-up rear glass release keeps working normally. That split is the diagnostic signature and points at the liftgate passive-entry antenna/sensor circuit or the BCM's passive-entry strategy rather than at the latch motor itself, since the gate still opens from the fob button and the interior switch. Owners report it as intermittent at first, sometimes recoverable by cycling lock/unlock at the fob, then permanent. It is also frequently the first symptom noticed on cars that later turn out to have a weak 12V battery or a module that is not waking properly.

Certain 2021 Ford Bronco Sport vehicles were built with an inadequate amount of lubricant in the rear drive unit. Ford's recall notice states that this can cause the rear drive axle to seize. Because the Bronco Sport routes power to the rear wheels through that unit, a seizure can produce a loss of drive and/or a loss of vehicle control, increasing the risk of a crash. The campaign covers several 2020-2021 Ford and Lincoln models in addition to the Bronco Sport, and owner notification began March 12, 2021.

Bronco Sport 4WD models, including the Badlands, can overheat the 4WD driveline (reports point to the power transfer unit; only the Badlands has a liquid-cooled PTU) during sustained off-road use, towing, or spirited driving. When the driveline overheats, the system temporarily disables 4WD or derates into limp mode to protect the clutches, leaving the vehicle in front-wheel-drive only. A "Four-Wheel Drive Temporarily Disabled" or over-temperature message appears on the dash. The issue is exacerbated in hot weather, steep inclines, and deep sand or mud driving.

Owners of 1.5L three-cylinder Bronco Sports report turbocharger failures that begin with a seized or binding wastegate actuator rod (in some cases a missing actuator e-clip). Because the actuator can no longer regulate boost, the vehicle throws P0299 (underboost) and drops into limp mode. In more advanced cases the turbine wheel itself lets go and forum members have found turbine debris downstream in the catalytic converter, which turns a turbo job into a turbo-plus-cat job. Failures are commonly reported in the 60,000-80,000 mile window - just past the 60k/5-year powertrain warranty - so owners frequently pay out of pocket. A handful of threads describe the P0299 code returning shortly after a turbo replacement, suggesting oil supply and post-repair oil-feed cleaning matter to the fix.

Ford Bronco Sports with the 1.5L EcoBoost 3-cylinder engine have three overlapping documented issues, two of which are recalls limited to earlier model years: (1) Oil separator housing cracking — NHTSA recall 22S21 covers 345,451 vehicles (2020-2022 Escape + 2021-2022 Bronco Sport) for cracked oil separator housings causing oil leaks and fire risk; dealers inspect and replace free of charge under the recall. (2) Fuel injector cracking — separate recall 22S73 (NHTSA 22V859) covers 2020-2023 Escape and 2021-2023 Bronco Sport for cracked injectors leaking fuel near hot exhaust components. (3) Oil dilution from short-trip driving — unburned fuel washes past the rings into the crankcase, causing oil level to RISE above the full mark with gasoline smell on dipstick. Ford has no published bulletin or program for oil dilution on the Bronco Sport. Owners experiencing rising oil level or fuel smell should document it through dealer service visits.

Ford bulletin 25-2581 addresses external coolant-pump leakage on some North American 2021–2024 Bronco Sports with the 1.5L EcoBoost. Contamination in the cooling system may contribute to the leak. Belt noise, coolant residue or a low coolant level does not by itself prove the pump is leaking, so the leak source should be confirmed first.

Certain 2023 Bronco Sport vehicles (about 801, built 12/8/22-12/16/22) have an Anti-lock Brake System (ABS) module whose internal valves may have been damaged during manufacturing, causing an internal ABS module leak. The leak can produce an unexpected increase in brake pedal travel or unexpected vehicle movement during an Auto Hold event, increasing crash risk.

On 2025 Bronco Sport models with the 1.5L or 2.0L EcoBoost engine, the exhaust gas recirculation (EGR) valve can fail, leading to weak acceleration, engine vibration, a no-start condition, or an unexpected loss of motive power (likely at low speeds of about 20 km/h / 12 mph or below). Ford recalled roughly 12,860 Bronco Sports built 11/15/24-5/7/25 as part of a ~48,000-vehicle multi-line EcoBoost campaign and advised affected owners not to drive until repaired.

Ford issued a 'Do Not Drive' safety recall for about 4,653 vehicles (roughly 2,296 of them 2021-2026 Bronco Sports) because the front lower control arm ball stud may not have been fully inserted into the front wheel knuckle (pinch bolt secured before full engagement) at the Hermosillo assembly plant, or, on vehicles built June 1, 2025 or later, a required in-plant repair may not have been completed. Partial engagement can let the lower control arm ball joint separate from the knuckle, causing sudden loss of vehicle control.

AWD-equipped 2021-2024 Ford Bronco Sport models exhibit rear drive unit (RDU) chatter and shudder during low-speed turning maneuvers, particularly when backing up and turning sharply. The issue is caused by internal contamination of the rear drive unit (RDU) fluid. Ford issued SSM 49571 (Special Service Message) documenting the condition as "chatter/shudder during low speed turning events." Multiple TSBs have been released addressing the issue; the current one, TSB 26-2328 (July 2026, superseding 26-2194), prescribes an RDU vent hose replacement, RDU refill and AWD module reprogramming on 2.0L twin-clutch models, and an internal RDU clutch pack service kit plus vent hose inspection on 1.5L models. No formal NHTSA recall has been issued for this defect. BroncoSportForum.com has an extended thread specifically about new rear axle assembly replacements covered under these bulletins.

The 8F35 8-speed automatic in 2021-2022 Bronco Sport is documented in Ford bulletins to slip during acceleration from a stop when the transmission is hot, and to set DTC P0766 (shift solenoid D performance) with an illuminated MIL. TSB 21-2268 explicitly names the 2021 Bronco Sport for the P0766 condition; owners also report harsh or erratic shifting.

Bronco Sport windshields develop stress cracks without any apparent rock chip or impact. Cracks typically start from the edges or corners of the windshield and propagate across. Ford has not identified a cause; owners suspect hidden edge chips or mounting stress. Some owners have had multiple windshield replacements. Temperature changes (hot sun to cold AC) can trigger crack propagation.