Ford · Known Issues
2025 Ford Bronco Sport Problems: 8 Known Issues
2025 model year · 920+ owner reports · Updated September 2026
2025 · All trims · All engines
Choose the year and equipment for your written issues and visual request.
2025 model year · 920+ owner reports · Updated September 2026
2025 · All trims · All engines
Choose the year and equipment for your written issues and visual request.
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According to Au7o's analysis of 920+ owner reports, the 2025 Ford Bronco Sport has 8 documented known issues, with 3 rated critical. The most serious are 2025 Bronco Sport Engine Block Heater Overheat Recall (25S52 / NHTSA 25V343000), Front Lower Control Arm Ball Joint Separation - Do Not Drive Recall and EGR Valve Failure Causing Loss of Drive Power (Recall 26S10 / NHTSA 26V122). The most commonly reported issue is 1.5L EcoBoost 3-Cylinder Engine Issues — Oil Dilution + Oil Separator + Fuel Injector (Recalls 22S21 + Injector) with 920 owner reports. Across all issues with published estimates, repair costs range from $50 to $2,000. DIY maintenance guides at au7o.io.
ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL
Ford Motor Company (Ford) is recalling certain 2025-2026 Bronco and Bronco Sport vehicles. The Instrument Panel Cluster (IPC) may fail at startup.
AIR BAGS:SENSOR:OCCUPANT CLASSIFICATION:FRONT PASSENGER
Ford Motor Company (Ford) is recalling certain 2025-2026 Bronco Sport and Maverick vehicles. The Occupant Classification Sensor (OCS) unit may fail to correctly detect the presence of an adult or child in the front passenger seat. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 208, "Occupant Crash Protection."
EQUIPMENT:ELECTRICAL:ENGINE BLOCK HEATER
Ford Motor Company (Ford) is recalling certain 2025 Maverick and 2026 Bronco Sport vehicles equipped with a 1.5L or 2.0L MPC engine and an engine block heater. The engine block heater may overheat when the vehicle is parked with the block heater plugged in.
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According to Au7o's analysis of 920+ owner reports, the 2025 Ford Bronco Sport has 8 documented issues. The most frequently reported are: 2025 Bronco Sport Engine Block Heater Overheat Recall (25S52 / NHTSA 25V343000), Front Lower Control Arm Ball Joint Separation - Do Not Drive Recall, EGR Valve Failure Causing Loss of Drive Power (Recall 26S10 / NHTSA 26V122). Of these, 3 are rated critical and should be addressed promptly.
The 2025 Ford Bronco Sport has 8 known issues documented across 920+ owner reports. 3 issues are rated critical: 2025 Bronco Sport Engine Block Heater Overheat Recall (25S52 / NHTSA 25V343000) and Front Lower Control Arm Ball Joint Separation - Do Not Drive Recall and EGR Valve Failure Causing Loss of Drive Power (Recall 26S10 / NHTSA 26V122). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
Repair costs for known Ford Bronco Sport issues range from $0 to $2,000, depending on the specific problem and whether you choose DIY or professional repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
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… Severity: high.
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 Hermo… Severity: high.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
SUSPENSION:FRONT:CONTROL ARM:LOWER BALL JOINT
Ford Motor Company (Ford) is recalling certain 2021-2026 Bronco Sport and 2022-2026 Maverick vehicles. The front lower control arm ball joints may have been incorrectly installed or incorrectly repaired at the vehicle assembly plant, allowing the control arm to disconnect from the front wheel knuckle.
ENGINE AND ENGINE COOLING:ENGINE:HARD PARTS INTERNAL/MECHANICAL
Ford Motor Company (Ford) is recalling certain 2026 Explorer, Bronco, Bronco Sport, Mustang, and Ranger vehicles. The engine piston domes may have been manufactured incorrectly, which can result in piston dome failure and lead to a loss of drive power.
+ 23 more recalls. Check all on NHTSA.gov
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On 2025 Bronco Sport models with the 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 (typically at low speeds around 15 mph or below). Ford recall… Severity: high.
2021-2025 Ford Bronco Sport with the 1.5L EcoBoost 3-cylinder engine has three overlapping documented issues: (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… Repairs typically run $50-$300. Severity: medium.
The Bronco Sport Badlands and other AWD models with the twin-clutch rear drive unit can overheat during sustained off-road use, towing, or spirited driving. When the rear differential fluid overheats, the system disengages the rear axle to protect the clutch pack, leaving the veh… Repairs typically run $0-$1,500. Severity: medium.
Bronco Sports with the panoramic sunroof experience water leaks into the cabin due to clogged drain tubes. Leaves, pollen, and debris collect in the sunroof tray and block the four drain tubes that run through the pillars to exit points near the wheel wells. When blocked, water o… Repairs typically run $0-$500. Severity: medium.
The 8-speed automatic transmission in the Bronco Sport exhibits a noticeable delay when pulling away from a stop, particularly when the vehicle has been idling for a few seconds. The driver presses the accelerator and the engine revs but the vehicle does not move for 1-2 seconds… Repairs typically run $0-$2,000. Severity: medium.
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. The issue is attributed to body flex in the unibody structure, windshield mounting stress, and the ste… Repairs typically run $300-$900. Severity: low.