Should I buy a 2023 Ford Bronco Sport with documented fuel system problems?

Depends on the price and the specific vehicle. Documented fuel system issues should be priced into the purchase — if the seller is asking full retail, negotiate down by the expected repair cost. A pre-purchase inspection from an independent shop tells you whether THIS specific vehicle has already shown the symptoms or not.

2023 Ford Bronco Sport fuel system problems

severe 26 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →

Failure mileage

Complaints

Recalls

Avg fix

$1,200

1crash

2fires

1injury

When does it fail?

Of the 26 fuel system complaints filed for the 2023 Ford Bronco Sport, here's the actual mileage breakdown — failures cluster heaviest at 0-25,000 mi.

0-25k

2 (66.7%)

25-50k

1 (33.3%)

50-75k

0 (0%)

75-100k

0 (0%)

100-125k

0 (0%)

125-150k

0 (0%)

150k+

0 (0%)

Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.

What stands out

All 2 active fuel system recalls on this vehicle land at critical or severe — none classified moderate.

Fuel system accounts for 19% of all owner complaints filed against this vehicle, across 9 categories tracked.

Related recalls

severe NHTSA 24V187000 March 8, 2024

Ford Motor Company (Ford) is recalling certain 2022-2023 Bronco Sport and 2022 Escape vehicles equipped with 1

A fuel leak in the presence of an ignition source such as hot engine or exhaust components, can increase the risk of a fire.

Fix: Dealers will update the engine control software to include fuel injector leak detection and install a drain tube, free of charge. Owner notification letters were mailed on April 24, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S16. This recall is an expansion of previous recall number 22V-859.

severe NHTSA 25V165000 March 14, 2025

Ford Motor Company (Ford) is recalling certain 2020-2022 Escape and 2021-2023 Bronco Sport vehicles previously repaired incorrectly under recall numbers 22V-859 or 24V-187

A fuel leak in the presence of an ignition source such as hot engine or exhaust components, can increase the risk of a fire.

Fix: Dealers will update the powertrain control module (PCM) software, free of charge. Owner notification letters were mailed April 22, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S21.

The failure pattern owners describe

Buyer takeaway: The 2023 Bronco Sport has a pending fuel system recall (25V467000) that remains unfixed due to parts unavailability. Actual failures range from strong fuel odors and engine stalling to two documented vehicle fires with serious injury and total loss.

A critical recall (NHTSA 25V467000, Fuel System Gasoline) has been issued for the 2023 Bronco Sport, but parts remain unavailable across most of the complaint sample. Two owners reported catastrophic fires—one at 50,000 miles while driving 73 MPH that left the vehicle completely burned and caused the driver serious injuries including fractured sternum and ribs, and a second at 50,268 miles while parked 40 minutes after refueling that spread to surrounding property. Neither vehicle was repaired before loss.

Other verified failures include strong fuel odors entering the cabin through vents (multiple reports), charcoal canister puncture from road debris at 6,000 miles, canister purge valve failure from EVAP overpressure at 36,600 miles, engine stalling and cutting out (reported across 15,000 to 98,000 miles), hesitation during acceleration, and unexpected lurch on startup. One owner reported a missing fuel cap—the tank simply opens by pushing the compartment with no locking mechanism. Dealers have not repaired most of these failures. Owners repeatedly state the manufacturer has exceeded reasonable timeframes for the recall repair, and manufacturer response has been limited to directing owners back to dealers or insurance companies.

Same Ford Bronco Sport fuel system reports on nearby years: 2021 · 2022

Failure modes owners describe

Vehicle fire and rollover

Vehicle caught fire while driving, rolled down embankment and crashed into tree. Entire vehicle burned completely; fire extended to surrounding woods.

When: 50,000 miles; vehicle stalled or failed 16-18 minutes into drive at 73 MPH

Symptoms owners cite: Vehicle caught fire; Vehicle rolled down embankment; Vehicle crashed into tree; Complete vehicle burn

Repairs/costs cited: Vehicle deemed total loss; local dealer not able to diagnose or repair. Vehicle towed for investigation.

Recalls/TSBs owners mention: NHTSA Campaign 25V467000 (Fuel System, Gasoline); recall parts not yet available at time of incident. Manufacturer referred contact to insurance company.

Strong fuel odor in cabin

Strong fuel odor entering vehicle interior through vents while driving and while parked. Odor severe enough to cause nausea.

When: 44,400 miles; 37,000 miles; 32,800 miles

Symptoms owners cite: Strong fuel odor in cabin; Fuel odor entering through air vents; Nausea from odor exposure

Repairs/costs cited: Vehicles not diagnosed or repaired. Dealer appointment scheduled but no repairs completed.

Recalls/TSBs owners mention: NHTSA Campaign 25V467000 (Fuel System, Gasoline); recall parts not yet available. Manufacturer advised contact to contact local dealer for diagnostic test.

Parked vehicle fire

Vehicle caught fire while parked approximately 40 minutes after refueling and driving at 70 MPH. Fire department extinguished fire. Caused fuel contamination and burned areas in yard and on porch.

When: 50,268 miles; fire occurred after parking for 40 minutes

Symptoms owners cite: Vehicle fire while parked; Fuel odor noticed before fire; Fuel contamination on grounds

Repairs/costs cited: Vehicle totaled and towed. Manufacturer claim filed.

Recalls/TSBs owners mention: NHTSA Campaign 25V467000 (Fuel System, Gasoline); recall parts unavailable. Manufacturer aware and claim filed.

Missing fuel cap/tank security

Vehicle lacks fuel cap or locking mechanism. Fuel tank opens by pushing open fuel tank compartment without security.

When: 28,111 miles

Symptoms owners cite: No fuel cap present; Fuel tank compartment unsecured; No locking mechanism on fuel tank

Repairs/costs cited: Dealer suggested purchasing aftermarket lock for fuel tank. No factory repair performed.

Recalls/TSBs owners mention: NHTSA Campaign 25V467000 (Fuel System, Gasoline) and 25V442000 (Back Over Prevention). No factory solution offered.

Canister purge valve failure

Canister purge valve failed due to high-pressure purge flow in EVAP system, causing engine stalling.

When: 36,600 miles; occurred while idling at stoplight

Symptoms owners cite: Vehicle stalled while idling at stoplight; Vehicle stalled twice; Check engine light illuminated

Repairs/costs cited: Dealer diagnosed canister purge valve failure and scheduled repair.

Recalls/TSBs owners mention: NHTSA Campaign 25V467000 (Fuel System, Gasoline); recall parts not yet available at time of report.

Punctured charcoal canister

Gas vaporizer (charcoal) canister punctured by road debris. Canister made of plastic with no protection from road hazards.

When: 6,000 miles

Symptoms owners cite: Emissions warning light illuminated; Canister punctured by road debris

Repairs/costs cited: Dealer diagnosed punctured gas vaporizer canister. Vehicle not repaired.

Recalls/TSBs owners mention: Manufacturer informed of failure.

Engine stalling and fuel delivery issues

Engine stalling, cutting out, and hesitation during acceleration. Check engine lights illuminated. Vehicle feels like no fuel is reaching the engine.

When: 15,000 miles; 20,000 miles; 36,600 miles; 98,000 miles

Symptoms owners cite: Check engine light illuminated; Vehicle cuts out suddenly; Engine stalling; Vehicle hesitates to accelerate uphill; Abnormal sound from engine compartment; Feels like no fuel reaching engine

Repairs/costs cited: Most vehicles not diagnosed or repaired by dealers. One repair mentioned but details not provided.

Recalls/TSBs owners mention: NHTSA Campaign 25V467000 (Fuel System, Gasoline); recall parts not yet available at time of reports.

Unexpected vehicle lurch on startup

Vehicle unexpectedly lurched forward when starting. No warning light illuminated.

When: 45,000 miles

Symptoms owners cite: Vehicle lurches forward unexpectedly during startup

Repairs/costs cited: Vehicle not diagnosed or repaired by dealer.

Recalls/TSBs owners mention: NHTSA Campaign 25V467000 (Fuel System, Gasoline); recall parts not yet available. Manufacturer unable to confirm when parts would be available and filed case.

Synthesized from 26 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.

What owners are reporting 4 most recent

fuel system · 20,000 mi · filed 11/13/2025

The contact owns a 2023 Ford Bronco Sport. The contact stated that occasionally, while driving at various speeds uphill, the vehicle hesitated to accelerate as intended while the accelerator pedal was depressed. The contact received notification of NHTSA Campaign Number: 25V467000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available. The engine temperature…

fuel system · 15,000 mi · filed 11/05/2025

The contact owns a 2023 Ford Bronco Sport. The contact stated that while driving approximately 35 MPH, the check engine warning light illuminated, and it felt as if there was no gasoline going to the engine. The contact stated that while depressing the accelerator pedal there was an abnormal sound coming from the engine compartment. The contact had not taken the vehicle to a local dealer or an…

fuel system · 37,000 mi · filed 11/05/2025

The contact wife owns a 2023 Ford Bronco Sport. The contact received notification of NHTSA Campaign Number: 25V467000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available. The contact stated that while driving at various speeds, there was an abnormal fuel odor entering the interior cabin through the air vents. No warning light was illuminated. The local dealer…

fuel system · filed 10/27/2025

The contact owns a 2023 Ford Bronco Sport. The contact was made aware of NHTSA Campaign Number: 25V467000 (Fuel System, Gasoline). The contact had not received the recall letter from the manufacturer. The contact called the local dealer and was informed that parts were not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The…

Had fuel system trouble with your 2023 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 2023 Ford Bronco Sport?

It's a meaningful issue. 26 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 17 complaints that reported odometer mileage, most fuel system failures cluster between 28,111 and 50,000 miles, with the median around 36,600. A quarter of owners report trouble before 28,111; a quarter make it past 50,000. 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?

Yes — 2 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.

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/2023/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.