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severe Owners of the 2021 Ford Bronco Sport have filed 51 NHTSA complaints about the fuel system, typically surfacing around 67,830 miles at roughly $1,200 to repair (U.S. federal records, as of August 2026). Source: NHTSA Office of Defects Investigation. See fuel system across all vehicles →
| Model year | fuel system complaints |
|---|---|
| 2021 Bronco Sport (this page) | 51 |
| 2022 Bronco Sport | 45 |
| 2023 Bronco Sport | 28 |
| 2024 Bronco Sport | 9 |
Of the 4 model years of Ford Bronco Sport we track for fuel system problems, this one carries the most owner complaints on file — 51.
All 4 active fuel system recalls on this vehicle land at critical or severe — none classified moderate.
An engine stall increases the risk of a crash.
A fuel leak in the presence of an ignition source such as hot engine or exhaust components, can increase the risk of a fire.
A fuel leak in the presence of an ignition source such as hot engine or exhaust components, can increase the risk of a fire.
A fuel leak in the presence of an ignition source, such as hot engine or exhaust components, can increase the risk of a fire.
The manufacturer has issued service bulletins covering fuel system on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
This article supersedes TSB 22-2176 to increase the labor operation allowance and update the part list. Some 2020-2022 Escape/Corsair vehicles built on or before 3-Jan-2022, 2020-2022 Explorer vehicles built on or before 14-Feb-2022, 2020-2022 Aviator vehicles built on or before 07-Feb-2022 and 2021-2022 Bronco Sport vehicles built on or before 3-Dec-2021 may exhibit a slow fuel fill and/or spit back condition during refueling. This may be due to the design of the fuel tank filler pipe. To correct the condition, follow the Service Procedure to replace the fuel tank filler pipe.
full bulletin at NHTSA ↗Some 2020-2022 Escape/Corsair vehicles built on or before 3-Jan-2022, 2020-2022 Explorer vehicles built on or before 14-Feb-2022, 2020-2022 Aviator vehicles built on or before 07-Feb-2022 and 2021-2022 Bronco Sport vehicles built on or before 3-Dec-2021 may exhibit a slow fuel fill and/or spit back condition during refueling. This may be due to the design of the fuel tank filler pipe. To correct the condition, follow the Service Procedure to replace the fuel tank filler pipe.
full bulletin at NHTSA ↗Some 2020-2022 Escape/Corsair, 2021-2022 Bronco Sport, 2022 Maverick vehicles equipped with 4-wheel drive (4WD) may exhibit a grinding/rubbing noise from floor pan/underbody area. This noise will be most noticeable on tip in acceleration and may be due to a mispositioned fuel tank heat shield. To correct the condition, follow the Service Procedure to reposition the fuel tank heat shield.
full bulletin at NHTSA ↗Some 2019 MKC, 2019-2021 Edge/Nautilus/Escape/Ranger/Explorer, 2020-2021 Corsair, and 2021 Bronco Sport vehicles equipped with 2.0L and 2.3L EcoBoost engines may exhibit a light to moderate ticking type noise at idle (600-700 RPM). The noise is usually more prominent in the area of the high-pressure fuel pump, located on the top of the engine just behind the number 4 ignition coil. This noise is not detrimental to engine function and has no short or long-term effects on engine durability. This an operating characteristic of these engines and no repairs should be attempted.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The 2021 Bronco Sport shows serious fuel system problems across the 46 complaints. Early failures dominate: fuel pump quits at 1,449 miles, fuel delivery module fails at 89 miles, and vehicles stall without warning at traffic lights and during normal driving. Check engine lights are common, along with hesitation and sputtering when accelerating.
Two owner-reported engine fires stand out as the most severe—one at 30,000 miles caused injuries including a broken hip, fractured pelvis, and minor brain bleed; another at 83,000 miles destroyed the vehicle. A third fire incident also destroyed a Bronco. Fuel tank vent tubes get contaminated with water, canister purge valves fail, and EVAP systems develop small leaks.
Multiple owners report gasoline odor and grinding sounds from the engine. Many describe transmissions requiring replacement after fuel system issues surface, suggesting related drivetrain damage.
The overarching problem: Ford issued recalls (22V859000, 21V625000, 24V267000, 25V467000) for the fuel system, but parts remain unavailable for months or longer. Owners waited from November into May for repairs. Many complaints state the manufacturer exceeded a reasonable repair timeframe, leaving owners stranded with unfixed safety issues.
Same Ford Bronco Sport fuel system reports on nearby years: 2022 · 2023
Fuel pump stops working, causing complete engine stall without warning. Occurs at extremely low mileage (under 1500 miles reported). Owners describe sudden loss of power while driving in traffic.
When: As early as 1,449 miles
Symptoms owners cite: Vehicle stalls suddenly while driving; Complete loss of engine power
Repairs/costs cited: Fuel pump replacement at dealership
Recalls/TSBs owners mention: NHTSA Campaign 22V859000 (Fuel System, Gasoline); parts unavailable for extended periods
Fuel delivery module stops working, causing repeated stalling at traffic lights and during parking. Engine will not accelerate and sputters. Check engine light illuminates.
When: As early as 89 miles
Symptoms owners cite: Vehicle stalls at stoplight; Stalling while parking; Stalling during normal driving; Check engine light illuminated
Repairs/costs cited: Fuel delivery module diagnosed at dealer; not repaired due to warranty exclusion
Recalls/TSBs owners mention: VIN not covered under NHTSA Campaign 21V625000 (Fuel System, Gasoline)
Engine compartment ignites while driving. Two separate incidents reported. Vehicle destroyed in both cases. Fire Department extinguished fires. One incident resulted in serious owner injuries including broken hip, pelvis fracture, clavicle fracture, rib fracture, and minor brain bleed.
When: 30,000 miles and 83,000 miles
Symptoms owners cite: Smoke from engine compartment; Engine compartment fire; Vehicle engulfed in flames
Repairs/costs cited: Vehicles destroyed; not repaired
Recalls/TSBs owners mention: NHTSA Campaign 25V467000 (Fuel System, Gasoline); case opened with manufacturer
Fuel tank vent tube valve becomes contaminated with water, preventing vehicle startup. Parking brake warning light illuminates when attempting to start.
When: 40,000 miles
Symptoms owners cite: Vehicle fails to start; Parking brake warning light illuminated
Repairs/costs cited: Vent tube valve contamination diagnosed; not repaired
Recalls/TSBs owners mention: Technical Service Bulletin 23-2335 referenced; no assistance provided by manufacturer
Fuel injector and catalytic converter both fail simultaneously, preventing startup. Multiple warning lights illuminate and flicker. Occurs after several failed startup attempts.
When: 90,200 miles
Symptoms owners cite: Vehicle fails to start on multiple attempts; Unknown warning lights illuminated and flickering; Vehicle must be towed
Repairs/costs cited: Fuel injector and catalytic converter replacement needed; parts unavailable for recall repair
Recalls/TSBs owners mention: NHTSA Campaign 25V467000 (Fuel System); parts unavailable
Canister purge valve becomes defective and requires replacement. Check engine light illuminates during low-speed driving.
When: 53,700 miles
Symptoms owners cite: Check engine light illuminates; Occurs during low-speed driving
Repairs/costs cited: Canister purge valve replacement performed by dealer
Recalls/TSBs owners mention: Vehicle not covered under warranty; manufacturer notified
EVAP emission control system develops a very small leak. Vehicle shakes, hesitates during acceleration, and check engine light illuminates.
When: 83,191 miles
Symptoms owners cite: Check engine light illuminated; Vehicle shaking; Hesitation during acceleration
Codes mentioned: P0456 EVAP (Very Small Leak in EVAP Emission Control System)
Repairs/costs cited: Vehicle not repaired
Recalls/TSBs owners mention: NHTSA Campaign 25V467000 (Fuel System, Gasoline); parts unavailable
Vehicle shakes abnormally after refueling and starting. Shaking returns even after dealer repair attempt. Transmission eventually requires replacement. No warning lights initially illuminated.
When: 1,000 miles to 108,000 miles
Symptoms owners cite: Abnormal shaking at front of vehicle after refueling; Shaking persists after dealer repair; Transmission failure detected
Repairs/costs cited: Transmission replacement needed; repair not completed due to parts unavailability
Recalls/TSBs owners mention: NHTSA Campaign 22V859000 and 24V267000 referenced; parts unavailable for extended periods
Vehicle fails to accelerate normally when pedal is depressed and sputters. Occurs across multiple vehicles at various mileages.
When: Unknown to 69,398 miles
Symptoms owners cite: Accelerator pedal does not produce expected acceleration; Vehicle sputters; Hesitation after refueling
Repairs/costs cited: Scheduling issues prevent dealer diagnosis; parts unavailable
Recalls/TSBs owners mention: NHTSA Campaign 22V859000 and 25V467000 (Fuel System, Gasoline); parts unavailable
Grinding noise originates from engine compartment. No warning lights illuminated. Cause not determined.
When: 39,000 miles
Symptoms owners cite: Grinding sound from engine compartment
Repairs/costs cited: Vehicle not diagnosed or repaired; dealer confirmed parts unavailable
Recalls/TSBs owners mention: NHTSA Campaign 25V467000 (Fuel System, Gasoline); parts unavailable
Strong gasoline smell while entering and exiting vehicle. Occurs after refueling.
When: 69,398 miles
Symptoms owners cite: Gasoline odor while entering and exiting vehicle; Hesitation after fueling
Repairs/costs cited: Vehicle not diagnosed or repaired; no dealer contact made
Recalls/TSBs owners mention: NHTSA Campaign 25V467000 (Fuel System, Gasoline); parts unavailable
Synthesized from 51 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
The contact owns a 2021 Ford Bronco Sport. The contact stated while driving at an undisclosed speed, the accelerator pedal was depressed, however, the vehicle failed to accelerate as intended. Additionally, the contact stated that the vehicle sputtered. The dealer was made aware of the failure. The vehicle was scheduled for a service appointment to have the recall repairs performed. The contact…
It's a meaningful issue. 51 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $1,200.
Across the 16 complaints that reported odometer mileage, most fuel system failures cluster between 30,000 and 83,191 miles, with the median around 67,830. A quarter of owners report trouble before 30,000; a quarter make it past 83,191. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
Independent shops typically charge around $1,200 for fuel system repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Yes — 4 active recall(s) cover fuel system issues on this vehicle. Recall fixes are always free regardless of mileage or warranty status. Use the VIN decoder at the top of the page to check if your specific vehicle is affected.