2025 Ford Bronco Sport Problems: 7 Known Issues

On the 2025 Ford Bronco Sport, this recall applies to 2025 Bronco Sport vehicles that were built with a 1.5L or 2.0L MPC engine and an engine block heater. Ford reports that the block heater may overheat when the Bronco Sport is parked with the heater plugged in, and NHTSA's stated consequence is an increased risk of fire. Only the 2025 model year is listed for the Bronco Sport in this campaign. Since the hazard exists only while the heater is energized, it presents itself when the vehicle is parked and connected to power - typically overnight in cold weather. The 6,781 units NHTSA lists is the size of the whole campaign across every model included, not a Bronco Sport-specific count.

On the 2025 Ford Bronco Sport, on 2025 Bronco Sport models with the 1.5L or 2.0L EcoBoost engine, the exhaust gas recirculation (EGR) valve can fail, leading to weak acceleration, engine vibration, a no-start condition, or an unexpected loss of motive power (likely at low speeds of about 20 km/h / 12 mph or below). Ford recalled roughly 12,860 Bronco Sports built 11/15/24-5/7/25 as part of a ~48,000-vehicle multi-line EcoBoost campaign and advised affected owners not to drive until repaired.

On the 2021-2026 Ford Bronco Sport, ford issued a 'Do Not Drive' safety recall for about 4,653 vehicles (roughly 2,296 of them 2021-2026 Bronco Sports) because the front lower control arm ball stud may not have been fully inserted into the front wheel knuckle (pinch bolt secured before full engagement) at the Hermosillo assembly plant, or, on vehicles built June 1, 2025 or later, a required in-plant repair may not have been completed. Partial engagement can let the lower control arm ball joint separate from the knuckle, causing sudden loss of vehicle control.

On the 2021-2025 Ford Bronco Sport, bronco Sports with the panoramic sunroof experience water leaks into the cabin due to clogged drain tubes. Leaves, pollen, and debris collect in the sunroof tray and block the four drain tubes that run through the pillars to exit points near the wheel wells. When blocked, water overflows into the headliner and can drip onto passengers, electronics, and floor areas. The front drains clog more frequently than the rear ones.

On the 2021-2025 Ford Bronco Sport, bronco Sport windshields develop stress cracks without any apparent rock chip or impact. Cracks typically start from the edges or corners of the windshield and propagate across. Ford has not identified a cause; owners suspect hidden edge chips or mounting stress. Some owners have had multiple windshield replacements. Temperature changes (hot sun to cold AC) can trigger crack propagation.

On the 2021-2025 Ford Bronco Sport 1.5L EcoBoost, 2021-2025 Ford Bronco Sport with the 1.5L EcoBoost 3-cylinder engine has three overlapping documented issues: (1) Oil separator housing cracking — NHTSA recall 22S21 covers 345,451 vehicles (2020-2022 Escape + 2021-2022 Bronco Sport) for cracked oil separator housings causing oil leaks and fire risk; dealers inspect and replace free of charge under the recall. (2) Fuel injector cracking — separate recall 22S73 (NHTSA 22V859) covers 2020-2023 Escape and 2021-2023 Bronco Sport for cracked injectors leaking fuel near hot exhaust components. (3) Oil dilution from short-trip driving — unburned fuel washes past the rings into the crankcase, causing oil level to RISE above the full mark with gasoline smell on dipstick. Ford has no published bulletin or program for oil dilution on the Bronco Sport. Owners experiencing rising oil level or fuel smell should document it through dealer service visits.

On the 2021-2025 Ford Bronco Sport, bronco Sport 4WD models, including the Badlands, can overheat the 4WD driveline (reports point to the power transfer unit; only the Badlands has a liquid-cooled PTU) during sustained off-road use, towing, or spirited driving. When the driveline overheats, the system temporarily disables 4WD or derates into limp mode to protect the clutches, leaving the vehicle in front-wheel-drive only. A "Four-Wheel Drive Temporarily Disabled" or over-temperature message appears on the dash. The issue is exacerbated in hot weather, steep inclines, and deep sand or mud driving.