NHTSA Recall Query: Underhood Fires Caused by Fuel Leak in Ford Bronco Sport (RQ24-008)

RQ24-008 at a glance

What is NHTSA investigating in the Ford Bronco Sport?

From NHTSA’s investigation summary:

On April 11, 2024, NHTSA's Office of Defects Investigation ("ODI") opened this Recall Query ("RQ") to investigate the adequacy of, including various safety concerns associated with, the remedy program in recalls 22V-859 (filed Nov. 18, 2022) and 24V-187 (filed Mar. 8, 2024).

The vehicle population associated with these recalls includes certain MY 2020-2022 Ford Escape vehicles and MY 2021-2023 Ford Bronco Sport vehicles equipped with 1.5L engines.

The safety defect in each recall involves high-pressure fuel injectors that are susceptible to cracking, allowing liquid fuel and fuel vapor to migrate onto hot surfaces within the engine compartment potentially resulting in underhood vehicle fires.

The remedy programs described in recalls 22V-859 and 24V-187 are identical and involve both a software component and a hardware component.

Specifically, Ford developed an updated engine control software designed to detect a pressure drop in the high-pressure fuel rail, provide instrument cluster messaging to the driver, invoke a strategy to disable the high-pressure fuel pump, derate the engine output, and lower the temperatures of possible ignition sources within the engine compartment.

Additionally, Ford would install a tube into the engine's cylinder head drain hole to shunt spilled liquid fuel past the various hot surfaces within the engine compartment and ultimately discard the spilled liquid fuel onto the roadway.

ODI identified various safety concerns with this remedy program, which, among other things, notably did not include repairing or replacing the defective part and potentially did include the introduction of new safety defects (like fuel spilling near the spark plugs and fuel spilling onto the public roadway).

NHTSA opened this investigation to evaluate these concerns with the remedy program, including whether the vehicles were still susceptible to underhood fires even post-remedy.

As described in more detail in the Additional Summary posted simultaneously with this resume, ODI conducted a thorough investigation that included analyzing data and other materials received in response to two Information Requests, as well as inspections of post-remedy vehicles that experienced an underhood fire.

ODI and Ford worked to identify and locate vehicles that experienced post-remedy fires and conduct joint vehicle inspections.

ODI's investigation also prompted Ford to initiate a more in-depth evaluation of the defect, including Ford's conducting component level testing of high-pressure fuel injectors.

ODI met with Ford on several occasions throughout this investigation to jointly conduct certain of these described tasks and to discuss test results.

A collateral issue surfaced as a result of this investigation: in March 2025, Ford realized that despite relevant repairs having been recorded as successfully completed, approximately 33,576 vehicles subject to recalls 22V-859 and 24V-187 did not have the software component of the remedy program installed correctly.

Thus, on March 27, 2025, Ford filed a new related recall (25V-165) for these vehicles, notifying NHTSA and the public that they were still at risk of experiencing an underhood vehicle fire due to cracked fuel injectors despite the consumer having had their vehicle remedied pursuant to one of the two earlier recalls.

In June 2025, Ford committed to implementing a new remedy program to repair the vehicles.

On July 11, 2025, Ford documented this commitment in a new recall filing (25V-467), which explains that Ford's upcoming remedy program will involve proactive replacement of all high-pressure fuel injectors within the recall population.

In view of the recall action taken by Ford, ODI is closing this Recall Query, which was opened given NHTSA's concerns that the initial remedy programs of the software to detect the pressure drop plus installation of the drain tube did not constitute an adequate repair.

The agency reserves the right to take additional action if warranted by future circumstances.

What is a recall query?

Recall Query is a review of whether an earlier recall actually fixed the problem or covered all the vehicles it should have. A recall query is opened when owners keep reporting the same failure after the recall repair.

Did this investigation lead to a recall?

Yes. NHTSA lists recall 25V467000 as the result of this investigation: 2021-2024 Ford Bronco Sport Fuel Injection System Recall (25V467).

Which vehicles are part of this investigation?

What are Ford Bronco Sport owners reporting to NHTSA?

NHTSA’s public database lists 748 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

• 2026 Ford Maverick Body Panel Recall (26V550)
• 2026 Ford Explorer Engine Recall (26V548)
• 2021-2026 Ford Bronco Sport Lower Ball Joint Recall (26V340)
• 2026 Ford Escape Park Pawl Recall (26V301)
• 2025 Ford Maverick Engine Block Heater Recall (26V239)
• 2025-2026 Ford Bronco Sport Passenger Air Bag Recall (26V201)
• 2021-2022 Ford Explorer Wiper Motor Recall (26V117)
• 2025 Ford Ranger Gas Recirculation Valve Recall (26V122)
• 2021-2022 Ford Escape Backup Camera Software Recall (26V123)
• 2025-2026 Lincoln Corsair Seat Belt Retractor Recall (25V862)

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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