Ford Motor Company has issued a major safety recall affecting approximately 90,000 Bronco Sport SUVs in the United States due to a potentially dangerous fuel injector defect that could cause engine fires. The recall, announced this week, targets specific 2022-2023 model year vehicles equipped with the 1.5-liter EcoBoost engine.
Ford Bronco Sport Recall Details: What Owners Need to Know
The National Highway Traffic Safety Administration (NHTSA) report reveals that fuel injectors in affected Bronco Sport models may crack under pressure, allowing fuel to leak onto hot engine surfaces. This creates an immediate fire hazard, even when the vehicle is parked and turned off.
Ford has confirmed receiving 21 reports of under-hood fires related to this issue, though fortunately no injuries or accidents have been reported so far. The automaker first became aware of the problem through warranty claims and field reports beginning in late 2023.
Which Vehicles Are Affected?
The recall specifically covers:
- 2022 Ford Bronco Sport models built between December 1, 2020, and August 31, 2022
- 2023 Ford Bronco Sport models built between September 1, 2022, and March 3, 2023
- All affected vehicles equipped with the 1.5L EcoBoost three-cylinder turbocharged engine
The larger Bronco models with different powertrains are not included in this recall action.
What Ford Is Doing About the Fuel Injector Problem
Ford dealers will inspect and replace all three fuel injectors in affected vehicles free of charge. The company is also updating engine control software to detect fuel pressure drops that might indicate a cracked injector, which will illuminate the check engine light and trigger reduced engine power mode.
Owner notification letters are expected to be mailed starting in late May 2025. However, Ford is urging owners not to wait for the letter if they notice any warning signs.
Warning Signs Bronco Sport Owners Should Watch For
Ford advises owners to immediately contact their dealer if they experience:
- Fuel odor inside or outside the vehicle
- Visible fuel leaks in the engine compartment
- Smoke coming from under the hood
- Sudden loss of engine power or rough running conditions
As a precautionary measure, Ford recommends parking affected vehicles outdoors and away from structures until the repair is completed if any of these symptoms appear.
Industry Context: EcoBoost Engine Scrutiny Continues
This recall adds to growing concerns about Ford’s smaller EcoBoost engines, which have faced various reliability issues since their introduction. The 1.5-liter three-cylinder turbo, shared with models like the Escape and Maverick, was designed to deliver fuel efficiency without sacrificing performance.
However, the aggressive downsizing approach has led to engineering challenges. Turbocharged engines run hotter and under higher pressure than naturally aspirated units, placing greater stress on components like fuel injectors.
This isn’t Ford’s first fuel system recall in recent years. The company has previously recalled F-150 trucks and other models for fuel pump failures and fuel line issues, highlighting ongoing quality control challenges in critical powertrain components.
What Bronco Sport Owners Should Do Now
Owners can check if their vehicle is affected by visiting Ford’s recall website or the NHTSA recall page and entering their 17-digit Vehicle Identification Number (VIN). The VIN is located on the driver’s side dashboard, visible through the windshield.
Ford Customer Service can also be reached at 1-866-436-7332, referencing recall number 25S23. Dealers have been instructed to prioritize these repairs given the fire risk involved.
Owners whose vehicles have already experienced fire damage may be eligible for reimbursement for previous repairs. Ford recommends contacting their customer service department to discuss individual cases.
Looking Ahead: Impact on Ford’s Compact SUV Strategy
The Bronco Sport has been a sales success for Ford since its 2021 launch, appealing to younger buyers seeking adventure-oriented styling at an accessible price point. This recall, while serious, is unlikely to derail the model’s momentum if Ford executes the fix efficiently.
However, it does raise questions about the long-term reliability of Ford’s smallest turbocharged engines and whether the company’s downsizing strategy has pushed engineering limits too far. As Ford transitions toward electrification, ensuring quality in current gasoline powertrains remains crucial for maintaining customer trust during the critical transition period.
