2022 Ford Bronco Sport powertrain problems

Owners report complete transmission failures, incorrect gear engagement (shift to reverse goes forward, shift to drive goes backward, shift to neutral drives forward), hard/delayed shifting, stuck gears, and loss of motive power while driving. Some vehicles experience limp mode activation with powertrain malfunction codes. Failures occur at varying mileages from under warranty to 121,000 miles. Several owners were quoted $10,000-$13,000 for replacement.

When: Varies widely: some at low mileage (11K-41K miles), some at higher mileage (85K-121K miles); multiple owners report sudden onset without warning

Symptoms owners cite: Transmission shifts to wrong gear (reverse when drive selected, forward when reverse selected); Loss of motive power while driving; Vehicle stalls without warning; Hard, delayed, or jerky shifting; Vehicle stuck in gear or unable to shift; Transmission temperature excessive after short drives; Transmission fluid darker than normal at low mileage; Limp mode activation with powertrain malfunction warnings; Bearing failure with metal shards in transmission; Inability to engage gears at startup

Codes mentioned: P0868, Powertrain malfunction - reduced power, Transmission control module fault - 8th gear shift issue, Transmission clutch apply fault, Transmission solenoid fault, Transmission fluid condition deterioration

Repairs/costs cited: Torque converter replacement unsuccessful in some cases; full transmission rebuild or replacement required. Dealership quoted $10,000-$13,000; independent shops quote approximately $6,500. One owner reports bearing came loose and caused metal debris throughout transmission.

Recalls/TSBs owners mention: Ford has issued NHTSA Campaign 24V267000 (Electrical System, Power Train) which some owners report having recalled but issue persists. PCM software updates attempted on some vehicles without resolution. Some owners denied warranty coverage due to mileage or told issue not covered by active recalls.

Owners report sudden loss of motive power while driving or difficulty starting. Vehicle may shut down completely mid-drive, leaving owner stranded on highway or in traffic. Some incidents involve loss of all electrical systems including dashboard lights, brake stiffness, and inability to change gears. Issues often persist after dealer repair attempts.

When: Reported at mileages from under 1,000 miles to 55,000 miles; some owners experience multiple occurrences within months

Symptoms owners cite: Complete loss of power while driving on highway; Vehicle shuts off during idle-stop feature; Vehicle won't start (jump-start required in some cases); Loss of electrical systems (dashboard darkens, all warning lights on/off); Stiff brake pedal when power lost; Inability to shift gears when powered down; Vehicle requires hour to restart; Faded horn and lights when parked; Power loss during left-hand turns into traffic; Battery and alternator failure symptoms

Codes mentioned: Powertrain malfunction - reduced power, Charge system fault - 12 volts, Remote features disabled to preserve battery, Pre-collision assist disabled, System off to save battery

Repairs/costs cited: Dealership diagnoses include battery replacement (which failed to resolve issue in multiple cases), alternator replacement (one case), software update (ineffective in some), loosened battery wires (not repaired due to recall parts unavailable), PCM software update. Multiple dealer visits without successful resolution reported.

Recalls/TSBs owners mention: NHTSA Campaign 24V267000 (Electrical System, Power Train) and Campaign 25V019000 (Electrical System) issued. Campaign 25V019000 repair parts not yet available as of complaint dates. Manufacturer opened cases but referred owners to NHTSA Hotline. One dealership refused to perform diagnostic ($278 fee quoted).

Owners report water pump failures causing coolant leaks, overheating, and blown radiator caps. Multiple owners report repeated water pump replacements within warranty period (up to 3 replacements). Coolant levels drop despite proper maintenance. One owner reports dealership refusing warranty coverage and charging $2,700 for decontamination of coolant lines, claiming that is the root cause after three replacements.

When: Reported at 25,000-30,000 miles; one owner had 3 replacements all under warranty before being charged out-of-pocket

Symptoms owners cite: Overheating during normal driving; Blown radiator cap; Empty coolant reservoir; Coolant level dropping despite no visible leaks; Strong smell of coolant (no warning lights accompanying); Coolant leak from water pump weep hole; Engine stalling due to overheating

Repairs/costs cited: Water pump replacement performed at dealership. One owner had 3 replacements under warranty. Dealership claims decontamination of coolant lines needed ($2,700) to prevent future failures but told owner to pay out-of-pocket since replacements were under warranty. Salem Ford (NH) identified that first dealership skipped critical step during water pump replacement causing continued issue after replacement.

Recalls/TSBs owners mention: Recall 25502 referenced in one complaint regarding overheating damage inspection. Dealership declined service due to being backed up and understaffed. Ford warranty covers pump replacement but dealership refuses to cover decontamination step under warranty despite acknowledging problem awareness.

Vehicle enters limp mode (reduced power, limited acceleration) multiple times, with owners reporting 25+ occurrences in some cases. Powertrain malfunction and reduced power messages displayed. Root causes identified include fuel pump sensor failure, fuel injector defects, and canister purge valve faults. Some limp mode events accompanied by unusual odors. Issues persist despite multiple dealer repair attempts and PCM software updates.

When: Reported at various mileages; one owner reports 25 times over one year with multiple recent occurrences

Symptoms owners cite: Vehicle enters limp mode (severely reduced acceleration); Powertrain malfunction warning light and messages; Check engine light; Reduced power while driving; Vehicle stalls in traffic or at intersections; Collision assist unavailable message; Unusual smell accompanying limp mode events; Service engine soon light

Codes mentioned: Powertrain malfunction - reduced power, Collision assist unavailable, Fuel pump sensor fault, Fuel injector fault, Canister purge valve fault

Repairs/costs cited: Ford service diagnoses include fuel pump sensor replacement (not covered under recall per owner), canister purge valve replacement, spark plug replacement (later found to be incorrect), transmission fault code found, PCM/TCM/BCM replacement attempted. One owner reports Ford Corporate technician consultation and planned engineer visit that did not occur. Multiple visits to dealership without permanent resolution.

Recalls/TSBs owners mention: NHTSA Campaign 24V267000 referenced; Ford refuses to cover fuel pump sensor replacement, claiming it is not recall-related. Owner reports repeat occurrence of limp mode despite active recall repair history. Ford refuses to provide rental vehicle while vehicle in repair or unsafe condition.

Owners report fuel injector defects causing cylinder misfire and check engine light. One owner's engine was blown due to bad fuel injector that dealership had cleared codes for before sale, creating fire hazard. Oil separator housing cracks causing engine oil leaks with fire risk. One owner reports engine oil leak not covered under recall despite vehicle meeting recall criteria.

When: Reported at low mileage (approximately 1-2 months after purchase in one case); oil leak at 30,000 miles

Symptoms owners cite: Check engine light; Cylinder misfire; Engine sputters when fuel added; Engine blown (loss of compression in cylinders); Oil leak in engine compartment; Burnt smell from engine; Strong coolant smell

Codes mentioned: Cylinder misfire, Bad fuel injector code, Check engine

Repairs/costs cited: Fuel injector replacement needed; one owner quoted $3,483 for new engine with Ford covering $4,457. Oil separator housing crack requires replacement; dealership wants out-of-pocket payment despite recall status.

Recalls/TSBs owners mention: NHTSA Campaign 22V191000 (Engine Oil Leak) for 2021-2022 Bronco Sport with 1.5L engines addresses oil separator housing cracks. One owner reports VIN excluded from recall. Dealership cleared critical misfire codes before customer purchase, failing to disclose defect. Owner believes issue should be covered under recall and powertrain warranty.

Automatic transmission leaking heavy amounts of fluid at low mileage. No warning lights or alerts appear before discovery. Leak creates fire risk and potential transmission failure due to fluid loss.

When: At approximately 12,000 miles

Symptoms owners cite: Heavy transmission fluid leak; Foul and burnt smell while driving with climate control on; Puddle of fluid on driveway

Repairs/costs cited: Dealer confirmed transmission leak and was waiting for parts to arrive for repair/seal work at time of complaint.

Recalls/TSBs owners mention: No response indicated in narrative.

Owners report brake failure during reversing including brake pedal becoming unresponsive and vehicle continuing to accelerate despite hard braking. One incident resulted in collision with bumper post. Parking brake also malfunctions with messages stating park is not available or parking brake cannot be engaged.

When: Reported during normal parking and reversing maneuvers; also after battery replacement in one case

Symptoms owners cite: Brake pedal becomes unresponsive during reverse; Vehicle accelerates despite hard braking; Vehicle continues backing up at increased speed despite brake application; Park mode unavailable message; Vehicle will not stay in park; Parking brake forced on automatically; Brake system warning messages

Codes mentioned: Braking system not engaged, Parking brake not available

Repairs/costs cited: One owner with $3,400 repair estimate for lift gate and rear bumper damage from brake failure incident. Owner was examined by emergency medical personnel but diagnostic testing not performed ($278 quoted for diagnostics owner could not afford). Dealership advised brakes have returned to normal after incident but owner reports temporary software malfunction.

Recalls/TSBs owners mention: Ford dealership representative could not determine cause. No manufacturer response documented.

Owners report rear differential failure including grinding, squealing, and growling noises during turning and backing. One TSB (24-2185) identified for this issue but dealership states repairs not covered under powertrain warranty. Rear differential vent hose allows road debris to enter differential, causing damage. Multiple owners report rear differential replacement needed at low mileage with parts on back order.

When: Reported at 10,000 miles to under 50,000 miles; grinding noise onset during backing or turning

Symptoms owners cite: Grinding noise when backing up at angles; Squealing and grinding from rear of vehicle; Growling noise during slow turns that progressively gets louder; Rubbing noise at rear of vehicle

Repairs/costs cited: Transaxle rebuild required in one case; dealership had vehicle for 7 weeks waiting for parts and lacking proper tools (described as fairly extensive rebuild). Rear differential replacement needed; parts on back order for extended periods (2 months or more). TSB 24-2185 exists but coverage unclear. One owner traded vehicle due to inability to repair and high costs.

Recalls/TSBs owners mention: TSB 24-2185 issued for rubbing/grinding noise but dealership states certain parts not covered under powertrain warranty. TSB 24-2185 also addresses RDU vent hose upgrade needed to prevent road debris from entering differential; owners suggest this should be a recall.

Battery failures, battery explosions, and persistent electrical issues that recur after battery replacement. One battery exploded during startup. Owners report multiple failed repairs under electrical recall campaigns with issues recurring. Loose battery connections cause powertrain warnings and starting problems.

When: Reported at 33,500 miles to 55,000 miles; some within one month of previous recall repair

Symptoms owners cite: Battery failure requiring jumpstart; Vehicle difficult to start; Battery explosion with loud popping and clicking sounds; Charge system fault messages; Remote features disabled to preserve battery; Battery warning light illuminated; Faded horn and lights when parked

Codes mentioned: Charge system fault - 12 volts, Battery warning light

Repairs/costs cited: Battery replacement performed but issue persisted. Loose battery wires identified at second dealer but repair not completed due to recall parts unavailability. Dealership requested diagnostic fee payment when unable to determine cause. Walmart battery replacement also failed to resolve issue.

Recalls/TSBs owners mention: NHTSA Campaign 24V267000 (Electrical System, Power Train) and Campaign 25V019000 (Electrical System) issued. Campaign 25V019000 repair parts not yet available. VIN tool confirms parts not available for some vehicles.