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severe Owners of the 2022 Ford Bronco Sport have filed 45 NHTSA complaints about the fuel system, typically surfacing around 47,700 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 | 51 |
| 2022 Bronco Sport (this page) | 45 |
| 2023 Bronco Sport | 28 |
| 2024 Bronco Sport | 9 |
All 6 active fuel system recalls on this vehicle land at critical or severe — none classified moderate.
No new NHTSA fuel system complaint has been filed on this vehicle in over 3 years — the issue may be aging out of the active population.
An engine stall increases the risk of a crash.
An engine stall can increase 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.
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.
2022-2023 Escape and Bronco Sport vehicles equipped with 1.5L engines should add local fuel once the vehicle arrive to the dealership to reduce the risk of driving performance issues such as: rough operation, idle quality, engine misfires, lack or loss of engine power. These conditions may occur due to different fuel specifications between manufacturing plant and final market. Make sure that the vehicles in stock have local fuel added.
full bulletin at NHTSA ↗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 ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
Owners of 2022 Ford Bronco Sports report a serious fuel system pattern affecting 40 vehicles. The most critical failures involve engine fires—one at 46,000 miles while driving 20 mph, another at 8,000 miles while parked—with flames and black smoke requiring fire department response and resulting in total losses. No warning lights preceded either fire.
Beyond fires, fuel system odors in the cabin affect multiple owners, some intense enough to cause occupants to feel ill. One driver was hospitalized for five days after fuel pump emissions entered the cabin through vents, causing loss of vehicle control and suspected carbon monoxide exposure confirmed by medical testing.
Acceleration problems appear frequently: vehicles hesitate or jerk when the pedal is depressed, sputter at 2,000 RPM, or fail to respond after restart. Engine rattle accompanies some hesitation cases. In one instance, brake failure and forward lunge occurred alongside acceleration stumble at just 549 miles.
The bulk of complaints (26 out of 40) involve parts unavailability for two fuel system recalls—campaigns 22V859000 and 25V467000. Owners have been notified of recalls but cannot get them completed because replacement components remain unavailable months or longer after notification. Dealers confirm parts aren't stocked and in some cases state they're no longer obligated to perform the work. Owners express frustration that Ford has exceeded reasonable timeframes for these repairs.
Same Ford Bronco Sport fuel system reports on nearby years: 2021 · 2023
Vehicle caught fire while driving or parked, originating from fuel filler compartment or under hood, with no warning lights. Flames and black smoke observed. Fire department required to extinguish. Vehicles declared total loss.
When: 46,000 miles; 8,000 miles
Symptoms owners cite: Black smoke from under hood; Spontaneous flames under hood while driving at low speed; Fire in fuel filler compartment while parked
Repairs/costs cited: Vehicles deemed total loss by insurance; source of fire not identified by inspection
Recalls/TSBs owners mention: Campaign 25V467000 (Fuel System, Gasoline); Campaign 22V859000 (Fuel System, Gasoline)
Owners report strong fuel smell inside cabin while driving or idling, sometimes accompanied by concern about carbon monoxide exposure. Check engine light may illuminate. Dealers unable to diagnose or detect odor on inspection.
When: 18,000 miles; 49,136 miles; 58,078 miles; unknown mileage
Symptoms owners cite: Strong fuel odor inside vehicle; Odor accompanied by check engine light; Odor strong enough to make occupant feel ill; Exhaust fumes in cabin while idling and driving
Repairs/costs cited: Dealers unable to detect odor or diagnose cause; vehicle not repaired
Recalls/TSBs owners mention: Campaign 25V467000 (Fuel System, Gasoline)
Engine hesitates when accelerator depressed, with sputtering, skipping, or lag in response. Check engine and powertrain lights may illuminate. Engine may rattle while driving. Dealers diagnose fuel injector issues but repair parts unavailable.
When: 36,000 miles; unknown mileage
Symptoms owners cite: Vehicle jerks while depressing accelerator at complete stop; Slow vehicle response when accelerating; Lag before vehicle accelerates; Engine sputters and skips at 2,000 RPM; Engine rattling sounds while driving
Codes mentioned: P0100 range suspected (fuel system)
Repairs/costs cited: Fuel injectors need replacement; dealer cleaned unknown part but failure recurred; recall parts unavailable
Recalls/TSBs owners mention: Campaign 25V467000 (Fuel System, Gasoline); Campaign 22V859000 (Fuel System, Gasoline)
Vehicle fails to respond when accelerator pedal depressed after restart, rendering it undriveable. Dealer speculated transmission involvement but actual cause not determined.
When: Unknown mileage
Symptoms owners cite: Vehicle fails to respond to accelerator pedal on restart; Loss of motive power
Repairs/costs cited: Vehicle towed to residence; not repaired
Recalls/TSBs owners mention: Campaign 25V467000 (Fuel System, Gasoline)
Brakes fail to stop vehicle immediately when pedal depressed; vehicle lunges forward while coming to complete stop. Occurs alongside hesitation and rattling noise. Dealers unable to duplicate.
When: 549 miles
Symptoms owners cite: Brakes fail to stop vehicle immediately; Vehicle lunges forward while coming to complete stop; Occurs with hesitation and engine rattle
Repairs/costs cited: Not repaired; dealers unable to duplicate failure
Recalls/TSBs owners mention: Campaign 22V859000 (Fuel System, Gasoline)
Fuel pump emissions came through vehicle vents, causing loss of vehicle control and incapacitation of driver. Occupant hospitalized for 5 days with suspected carbon monoxide exposure confirmed by medical testing.
When: Unknown mileage
Symptoms owners cite: Fuel pump emissions through vents; Loss of vehicle control; Occupant incapacitated and immobilized; Confusion/disorientation requiring hospitalization
Repairs/costs cited: Occupant required 5-day hospitalization
Synthesized from 45 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
The contact owns a 2022 Ford Bronco Sport. The contact received notification of NHTSA Campaign Number: 22V859000 (Fuel System, Gasoline) however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact stated that while driving at an undisclosed speed, the vehicle hesitated while…
It's a meaningful issue. 45 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $1,200.
Across the 10 complaints that reported odometer mileage, most fuel system failures cluster between 18,000 and 58,078 miles, with the median around 47,700. A quarter of owners report trouble before 18,000; a quarter make it past 58,078. 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 — 6 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.