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…
2021 Ford Bronco Sport fuel system problems
severe 49 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Failure mileage
Complaints
49
Recalls
0
Avg fix
$1,200
1crash
2fires
1injury
What stands out
Of the 4 model years of Ford Bronco Sport we track for fuel system problems, this one carries the most owner complaints on file — 49.
Owners have filed 49 fuel system complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
The failure pattern owners describe
Buyer takeaway: Multiple 2021 Bronco Sports report fuel system failures including stalling at very low mileage, engine fires with serious injuries, and extended recall repair delays due to parts shortages. Before buying one used, verify any open recalls are fully completed and get a full fuel system inspection.
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
Failure modes owners describe
Fuel pump failure
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 failure
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 fire
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 contamination
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 failure
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 defect
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 system small leak
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
Post-refuel shaking and transmission issues
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
Hesitation and sputtering under acceleration
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 sound from engine compartment
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
Gasoline odor from fuel system
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 49 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
Had fuel system trouble with your 2021 Ford Bronco Sport?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the fuel system problem on the 2021 Ford Bronco Sport?
It's a meaningful issue. 49 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $1,200.
At what mileage does the fuel system typically fail?
Across the 15 complaints that reported odometer mileage, most fuel system failures cluster between 25,000 and 83,191 miles, with the median around 53,700. A quarter of owners report trouble before 25,000; a quarter make it past 83,191. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
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.
Are there any recalls related to fuel system?
No active recalls currently cover fuel system issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2021/Ford/Bronco Sport.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.