NHTSA Preliminary Evaluation: Low-pressure Fuel Pump Failure in Ford Bronco (PE24-019)

PE24-019 at a glance

What is NHTSA investigating in the Ford Bronco?

From NHTSA’s investigation summary:

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.

What is a preliminary evaluation?

Preliminary Evaluation is the first stage of a federal defect investigation. NHTSA reviews complaints, crash reports and manufacturer data to decide whether a safety defect may exist. It can close with no action, be upgraded to an engineering analysis, or end with a recall.

Did this investigation lead to a recall?

Yes. NHTSA lists recall 25V455000 as the result of this investigation: 2021-2023 Ford Bronco Fuel Pump Recall (25V455).

Which vehicles are part of this investigation?

What are Ford Bronco owners reporting to NHTSA?

NHTSA’s public database lists 1,315 owner complaints filed since 2020 for the vehicles in this investigation (all components). Complaints are unverified owner reports.

What should owners do?

1. Check your VIN at nhtsa.gov/recalls for any open recall on your vehicle.
2. If you have the problem NHTSA is investigating, take the vehicle to a dealer now and get a repair order, even if the dealer cannot find anything.
3. Keep a log of every time the problem happens: date, mileage and what happened. Photos and videos help.
4. File your own complaint at nhtsa.gov/report-a-safety-problem. Owner complaints are what start and expand investigations.
5. If the problem keeps coming back, talk to a lemon law attorney.

Recalls on the same vehicles

• 2025-2027 Ford Expedition Headlight Recall (26V606)
• 2026 Ford F-150 Rear Suspension Recall (26V577)
• 2023-2027 Ford F-150 Fuel Tank Mount Recall (26V578)
• 2026 Ford Bronco Curtain Air Bag Recall (26V580)
• 2026 Ford F-150 Differential Recall (26V576)
• 2026 Ford Maverick Body Panel Recall (26V550)
• 2026 Ford Explorer Engine Recall (26V548)
• 2021-2023 Ford F-150 Backup Camera Display Recall (26V489)
• 2021-2026 Ford Bronco Front Underhood Recall (26V468)
• 2022-2026 Ford Bronco Body Panel Recall (26V403)

Can a recall or defect investigation make my car a lemon in California?

Not by itself. What matters is whether a covered defect keeps coming back or keeps your vehicle at the dealer, and a federal investigation or recall is strong evidence that the problem is real.

Under California’s Song-Beverly Consumer Warranty Act, a manufacturer that cannot fix a warranty defect that substantially impairs a vehicle’s use, value or safety within a reasonable number of attempts may have to repurchase or replace it (Civ. Code 1793.2(d)). Within the first 18 months or 18,000 miles, the law presumes a reasonable number of attempts after two repairs of a defect likely to cause death or serious injury, four repairs of the same defect, or more than 30 days out of service (Civ. Code 1793.22(b)).

An owner who prevails can recover reasonable attorney fees and costs from the manufacturer (Civ. Code 1794(d)). You pay nothing, win or lose. We are paid only if you win, and the manufacturer pays our fees, including in settlements. If a case is lost, our firm covers the costs.

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